I need to add some length to some 10 gauge solar panel wiring.
The wiring will be INSIDE the RV.
I need to pull the wire through a channel that will not allow for solar connectors (MC4) to pass through.
I will be adding 10 gauge PV wire that will terminate at a fuse block ( same wire at both ends of the connection).
Each wire will be carrying either 300v or 365v (The panels are all parallel wired.)
What would be the best method to join the two wires?
I soldered and shrink wrapped all the wires this spring, but what do I know?
Just did what I could with what I had and what I know.
It has been working just fine this summer.
I did put 7.5 amp fuses in line on ALL the lines.
Again, what do I know? It is working and the coach hasn't caught fire-----YET.
Oh, after reading Scott's post I must add to mine. Obviously the aviation industry MUST have more stringent requirements and stresses than a ground vehicle.
I fastened the wires so that they would never be under stress or hang free so they could vibrate. Zero load, anchored, slack where important, all factors that should be taken into consideration when wiring in a moving, vibrating, shaking coach (not a Foretravel).
So for what its worth in the aviation community wires are rarely soldered anymore do to becoming more acceptable to breaking at the solder joint. The goal is to attain over 100% strength at all connections. Using matching splices and crimping and tools is there answer. These are two piece splices with a crimp barrel using a matching crimp tool and a shrink wrap with adhesive inside to prevent moisture from entering and provide a strain relief beyond the crimp barrel. On our coaches with the lower vibration and much less usage I see no problem with soldering and quality heat shrink with internal adhesive. At home I always by hand pull test every connection prior to heat shrink. If you can pull it apart it wasn't together. Always amazed on battery cables how different the ends feel when crimped correctly and the wire end becomes stiff at connector.
You can sometimes solder up the connection without letting solder wick to the area that may need to be flexible .
Vise grip heat sink the end. Solder follows the heat.
Scott, I love your saying:"If you are going to be dumb you have to be tough."
Here is what I believe, when doing wiring:" Because I am ignorant, I have to double down on safety."
Works for me on a lot of things, like if one nail is enough, two nails are even better. Build it to last, not just good enough.
Lon,
How are you getting 300 to 365 volts out of panels 36 or 48 volts if in a parallel wiring format?
How about a roll of #10 solar wire so you don't need to splice in a piece?
Posting a diagram along with the number of panels, panel specs, location of your controller, batteries, etc would be good.
Pierce
Google "non insulated butt wire connectors" to see lots of choices. Use a proper crimping tool. Combine with good marine grade adhesive lined shrink tubing in appropriate color. An example linked below:
RockDIG 100 Sets AWG 12-10 Separated Heat Shrink Butt Connectors (100PCS... (https://www.amazon.com/RockDIG-360Pcs-22-10-Splices-Terminals/dp/B09GFTZCB9/ref=sr_1_20?qid=1661177929&refinements=p_n_feature_four_browse-bin%3A18945768011%2Cp_n_feature_nine_browse-bin%3A18644575011&rnid=18644573011&s=industrial&sr=1-20&th=1)
Thanks Chuck, I ordered the 12-10 connectors you suggested.
That is very similar. I'll be ordering in all three sizes. I'm confident my crimper for bare connections will work perfect on those👍👍
Thanks Scott
RockDIG 180 Sets AWG 22-16/16-14/12-10 Separated Heat Shrink/Butt Connectors... (https://www.amazon.com/gp/product/B081BH3VRL/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1)
Not sure why you don't just put a MC4 before and after the channel.
I have (for some strange reason) several different wire stripping/crimping tools but attached is my favorite and oldest one.
It is a Vacco Model 1800 with the crimping features on the end opposite the handles.
When crimping a 14/16 gauge wire with a 14/16 gauge butt splice or any 14/16 gauge connector, I use the 16/22 crimp feature, with the connector wire seam in the crimp pocket and the crimp protrusion opposite the seam. Always one size down for the crimp works for me.
Either my crimping tool I have had for years has worn oversize or the surgery on my thumb, or (God forbid) I am just getting weak as I age.
Don't know, but my crimps this way stay crimped.
Your killing me, little self control. So I went back to Amazon and ordered the assortment and then searched for the same kit and couldn't find on my own. They are listed under "separated" Also found a separated ring lug assortment that I want. Please restrain from making me spend my money on stuff I want, but dont need today. 8)
RockDIG 540PCS Separated Heat Shrink Wire Connectors Assortment Kit, 270PCS... (https://www.amazon.com/RockDIG-Separated-Terminals-Electrical-Connectors/dp/B09FPQJWS8/ref=sr_1_1_sspa?crid=35C18ZBHLEE17&keywords=rock%2Bdig%2Bseparated&qid=1661188291&s=industrial&sprefix=rockdig%2Bseperated%2Cindustrial%2C172&sr=1-1-spons&spLa=ZW5jcnlwdGVkUXVhbGlmaWVyPUE3SzNZWDBDSFdCUDYmZW5jcnlwdGVkSWQ9QTA4MjYzMjBQSU1aOFk5UDdZRlImZW5jcnlwdGVkQWRJZD1BMDc1NDM4NzFYOTlYV1NFTUpKVUUmd2lkZ2V0TmFtZT1zcF9hdGYmYWN0aW9uPWNsaWNrUmVkaXJlY3QmZG9Ob3RMb2dDbGljaz10cnVl&th=1)
I can't help it. With me, it's been a life long obsession. Been there - got the cap.
Most of my wire crimping tools
Good collection. I love my hydraulic crimper. Think it's the same as yours. Wish it did small crimps. I like to use the hand tool that pushes up in one spot on the backside of the small crimping terminals instead of squashing the whole thing.
Arrow T-25 and T-50 staplers are great tools also. The installers at CTV of SB gave me a set to take home on my first job out of HS right after I made a $25K mistake. Didn't get fired as there was a lot of $$ for designing the CTV system in 1962
Pierce
Pierce, take a look at the crimping tool I posted. Exactly what you described and my absolute all around favorite for the type of crimping I do.
Could not open it on my phone but just looked at it on the desktop and big screen. Excellent and perfect for crimping so the wire cannot pull out. +++
Pierce