classic 150 blue +pv-in connector

[daloniga]

I'm feeling not-a-little foolish right now.  I read the manual and it says the blue I/O block with 4 connectors will accept 4 gauge wire.  I've tried to insert 4 gauge into the PV+ connector for 15 minutes -- even removed the screw entirely and the dog-on thing simply will not insert and seat. 

Should I try tinning the wire or is there some other technique to do this??

[dRdoS7]

Hi,

I soldered the ends of my cables (battery cables only, as the solar ones were slightly smaller and had stiffer wires), then filed it down to fit. Filed a flat on the top for the grub screw to locate.

dRdoS7

[Vic]

Hi daloniga,  welcome to the Forum.

The USA standard building wire  --  THHN #4 AWG (19 strand)  cable fits very easily into the Classic PV/battery terminal block.

The end of the cable should be cleanly cut,  and not mashed by diagonal cutters.

Do NOT use fine-stranded able,  as it is larger in diameter than is common 19-strand cable.  The connectors of the blue terminal block are not designed for fine-strand cable,  and problems can arise from using fine stranded cable.

Personally,  would NOT tin the cable end.  With the correct cable (THHN/THWN/THW-2/MTW) it is not necessary,  even with #4 AWG,  and the blue block connectors are designed for copper 19 strand cable,  not for cable with soldered ends.

If you are using 19 stand #4 AWG cable,  and having trouble inserting the stripped cable end,  then probably,   the cut of the cable end is not a clean cut  --   perhaps mashed from cutting the cable.   A good cable cutter (the Bypass type)  will help.   In a pinch one could use a Hacksaw,  with the cable gently clamped to a bench or table.

IMO,   Vic

[daloniga]

I am using THHN wire.  If I use the end cut at Lowes, and don't bend the wire (as if routing for install), it slides easily into the connector.  When I use my cutters, or bend the wire to install, the wires distort from a perfect circle cross-section.   This is gonna take some thought .... and maybe a new wire cutter.

Thanks for the info folks.

[Vic]

Hi daloniga,

Thanks for the info on the cable that you are using.

Even if you are using diagonal cutters,  you can massage the stripped end of the cable,  gently,  with Lineman's pliers,  or even needle nose pliers.   Just gently squish the stripped area,  going around the circumference of the cable.   When done with that,  you might use a shop rag,  and try to rotate the stripped area in the same direction as the normal twist of the individual strands of the cable.

When making your cable bends on these large cables,  you might also use the Lineman's pliers to hold the cable,  and make the bend.

You should get better and better at cutting and forming larger cables,  and getting them to easily fit into the connector block on Classics.

Some people use a short hank of #6 AWG cable from the terminal to a box (like one that contains the PV and battery breakers,  a splice box,  gutter,  etc,  and make the transition from #6 to #4,  or larger cable,  there,  for simplicity.

FWIW,   Vic

[daloniga]

I went to the big-box home-improvement store today and picked up some cable cutters and some 9" lineman's pliers (60 mile round trip).  I'll grind down the lineman's plier jaws to get a smooth surface for bending.  Hopefully, I can work up a technique suitable to this task.

I previously tried every trick in the book to re-true the circular cross section but no joy.  I feel for any installer that is out in the boonies and encounters a similiar problem.  If I can't make this happen in a half hour, I'll tinn and file until I get a useable cross section.  Bad scene.   :-(

[tecnodave]

Dalognia,

Klein tools make a very nice bypass wire shear that cuts 4 gauge cable easily....a pit pricey at $38.00 USD or so but well worth the cost for the high quality cuts it does and not needing to trim to fit.
My local Home Depot carries these.

David