Skip to main content ↑ ↓
Topic: splicing solar panel wires (Read 483 times) previous topic - next topic

splicing solar panel wires

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?
1995 U320C SE 40'
Jeep 4x4 Commander - Limited - Hemi
"The Pack"  Yogi and Diesel our Airedales -  Charlie our Boxer/Akita mix. Gone but NEVER forgotten Jake our yellow Lab.
NRA Law Enforcement Firearms instructor - Handgun/shotgun
Regional Firearms instructor for national Armored Transp. Co.

Re: splicing solar panel wires

Reply #1 –
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).
Nitehawk,  Demolition Lady, & our NEW master, Zippy the speeding BB cat.
1989 Grand Villa 36' ORED
Oshkosh chassis, 8.2 DD V8
2006 Saturn Vue AWD

Re: splicing solar panel wires

Reply #2 –
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.

Re: splicing solar panel wires

Reply #3 –
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.

Re: splicing solar panel wires

Reply #4 –
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.
Nitehawk,  Demolition Lady, & our NEW master, Zippy the speeding BB cat.
1989 Grand Villa 36' ORED
Oshkosh chassis, 8.2 DD V8
2006 Saturn Vue AWD

Re: splicing solar panel wires

Reply #5 –
Quote from: Lon and Cheryl –
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?
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
Pierce and Gaylie Stewart
'93 U300/36 WTBI
Detroit 6V-92TA Jake
1140 watts on the roof
SBFD (ret)

Re: splicing solar panel wires

Reply #6 –
Quote from: dsd –
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.
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...

As an Amazon Associate Foretravel Owners' Forum earns from qualifying purchases.
1993 U280 SE 40' WTBI, Build: 4359
C8.3 300hp, 6-Speed, Exhaust Brake
960 watts on the roof (6 x 160)
Sorento (or BOLT) on a Kar Kaddy SS
"Nature abhors a vacuum"

Re: splicing solar panel wires

Reply #7 –
Quote from: Chuck & Jeannie –
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...


Thanks Chuck, I ordered the 12-10 connectors you suggested.
As an Amazon Associate Foretravel Owners' Forum earns from qualifying purchases.
1995 U320C SE 40'
Jeep 4x4 Commander - Limited - Hemi
"The Pack"  Yogi and Diesel our Airedales -  Charlie our Boxer/Akita mix. Gone but NEVER forgotten Jake our yellow Lab.
NRA Law Enforcement Firearms instructor - Handgun/shotgun
Regional Firearms instructor for national Armored Transp. Co.

Re: splicing solar panel wires

Reply #8 –
Quote from: Chuck & Jeannie –
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...


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...
As an Amazon Associate Foretravel Owners' Forum earns from qualifying purchases.

Re: splicing solar panel wires

Reply #9 –
Not sure why you don't just put a MC4 before and after the channel.
1999 40 ft. U-320 wtfe build 5563 Chuck & Lynda's "Rollin' Inn"  2030 watts solar
prev. mh's 71 GMC 5 yrs. 73 Pace Setter 1 yr. 78 Vogue 5 yrs 81 FTX 40ft all electric 18 yrs. 1996 Monaco Signature 3 yrs.
2014 Grand Cherokee Overland
Dream as if you will live forever. Live as if you will die today.  James Dean

Re: splicing solar panel wires

Reply #10 –
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.
Nitehawk,  Demolition Lady, & our NEW master, Zippy the speeding BB cat.
1989 Grand Villa 36' ORED
Oshkosh chassis, 8.2 DD V8
2006 Saturn Vue AWD

Re: splicing solar panel wires

Reply #11 –
Quote from: Chuck & Jeannie –
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...



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...
As an Amazon Associate Foretravel Owners' Forum earns from qualifying purchases.

Re: splicing solar panel wires

Reply #12 –
Quote from: dsd –
Please refrain from making me spend my money on stuff I want, but don't need today.
I can't help it.  With me, it's been a life long obsession.  Been there - got the cap.

1993 U280 SE 40' WTBI, Build: 4359
C8.3 300hp, 6-Speed, Exhaust Brake
960 watts on the roof (6 x 160)
Sorento (or BOLT) on a Kar Kaddy SS
"Nature abhors a vacuum"

Re: splicing solar panel wires

Reply #13 –
Most of my wire crimping tools

Re: splicing solar panel wires

Reply #14 –
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 and Gaylie Stewart
'93 U300/36 WTBI
Detroit 6V-92TA Jake
1140 watts on the roof
SBFD (ret)

Re: splicing solar panel wires

Reply #15 –
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.
Nitehawk,  Demolition Lady, & our NEW master, Zippy the speeding BB cat.
1989 Grand Villa 36' ORED
Oshkosh chassis, 8.2 DD V8
2006 Saturn Vue AWD
 

Re: splicing solar panel wires

Reply #16 –
Quote from: nitehawk –
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
Pierce and Gaylie Stewart
'93 U300/36 WTBI
Detroit 6V-92TA Jake
1140 watts on the roof
SBFD (ret)