[RE-wrenches] Buchanan Crimp in 1000v Applications and the NEC

Tue Nov 11 17:07:21 PST 2025

Jason,

Back to your comment about Wagos. First of all, I have had some
jurisdictions in NY complain about them in 3R boxes. Even after I got it in
writing from Wago that while not approved for wet locations, they are ok in
a 3R box. Squirting some no-ox has helped the jurisdiction with that. It's
not a big deal to do, so I've given up fighting that. But I figured I'd
share in case others run into that issue.

But to your point about PV wire fitting in. I have noticed that the 600v PV
wire I get does just barely fit into the 221-612 wago nuts. The 1000v PV
wire definitely will not.

Cheers,
Dave

On Tue, Nov 11, 2025, 7:49 PM Chris Sparadeo via RE-wrenches <
re-wrenches at lists.re-wrenches.org> wrote:

>
> https://www.staubli.com/content/dam/ecs/technical-documentation/assembly-instructions/RE/PV_MA231-en.pdf
>
> Page 4 states:
> “Thermal stress
> Ensure that the connector is not exposed to excessive thermal stress.
> • Install the connector in such a way that sufficient heat dissipation is
> ensured.
> • Installation in areas that restrict the air flow (e.g. in large bundles,
> in split looms or other housings) is not permitted.
> • Direct burial of the connector is not permitted.”
>
> I think a junction box would be considered a housing that restricts air
> flow.
>
>
> On Tue, Nov 11, 2025 at 7:31 PM Jason Szumlanski via RE-wrenches <
> re-wrenches at lists.re-wrenches.org> wrote:
>
>> We're talking about inside a junction box (NEMA 3R or 4, for example),
>> not an "outdoor environment." Wagos (and other connectors like wire nuts,
>> Polaris Taps, power distribution blocks, terminal blocks, etc) are allowed
>> inside of a rooftop junction box, just like they are allowed in various
>> switch boxes, enclosures, and cabinets that are suitable for the
>> environment outdoors.
>>
>> For the same reason you can put circuit breakers inside of a NEMA 3R load
>> center outdoors, you can use splice connectors of many kinds inside of a
>> NEMA 3R enclosure. They do not need to be listed for "outdoors" because it
>> is not outdoors. It's enclosed and adequately protected from the
>> environment.
>>
>> In other words, any AHJ that challenges me on this, I just ask them to
>> show me a circuit breaker that's listed for use in a wet location. That's
>> usually enough to shut them down.
>>
>>
>> Jason Szumlanski
>> Principal Solar Designer | Florida Solar Design Group
>> NABCEP Certified Solar Professional (PVIP)
>> Florida State Certified Solar Contractor CVC56956
>> Florida Certified Electrical Contractor EC13013208
>>
>> On Tue, Nov 11, 2025, 7:11 PM Glenn <glenn.burt at glbcc.com> wrote:
>>
>>> I have not found a listing for Wagos in an outdoor environment.
>>>
>>> -Glenn
>>>
>>> On Nov 11, 2025 18:01, Jason Szumlanski via RE-wrenches <
>>> re-wrenches at lists.re-wrenches.org> wrote:
>>>
>>> We have had terrific success using Wagos in rooftop junction boxes for
>>> splicing #12 Enphase cable to #10 home run THWN. We have no issues
>>> whatsoever with these.
>>>
>>> Unfortunately, the #10 PV wire insulation is too large for the Wago
>>> 221-6XX series. We have been buying #14-#4 Polaris taps and it's getting
>>> very expensive. I would like an alternative.
>>>
>>> For a while we were using the King Innovation AlumiConn purple
>>> "suitcase" connectors for Enphase, but they are only 300V rated and I don't
>>> think the PV Wire insulation fits in those, either, for <300V applications.
>>>
>>> I have seen people using MC4 connectors in rooftop junction boxes like
>>> Blake suggested, but I wasn't sure if that is acceptable practice to use
>>> them this way (in an enclosure), and it does require a pretty large
>>> junction box. We prefer to use the EZ Solar JB-# series of boxes. The rail
>>> mount ones (JB-3) are pretty small, but the tile roof JB-2 is huge, and the
>>> shingle JB-1 is sizable as well. I guess if there is no prohibition against
>>> using them in an enclosure, then it should be allowed. I do like the
>>> watertight nature of this solution.
>>>
>>> I have seen some clowns using MC4 connectors with #10 THHN wire to make
>>> these splices. That's obviously no bueno. Crazy stuff...
>>>
>>>
>>> Jason Szumlanski
>>> Principal Solar Designer | Florida Solar Design Group
>>> NABCEP Certified Solar Professional (PVIP)
>>> Florida State Certified Solar Contractor CVC56956
>>> Florida Certified Electrical Contractor EC13013208
>>>
>>>
>>> On Tue, Nov 11, 2025 at 4:44 PM Dave Tedeyan via RE-wrenches <
>>> re-wrenches at lists.re-wrenches.org> wrote:
>>>
>>> Hi Adam,
>>> This response is just to you. Is NYSERDA the inspection agency you are
>>> talking about? Cause they have given me issues about using Wago Nuts inside
>>> a 3R box, even after I got a statement from Wago saying that it is okay to
>>> put it inside a 3R box. But squirting a bit of No-Ox in there seems to make
>>> them happy about it. The one time we put one inside a 3R panel board to
>>> extend a short wire and forgot to put No-Ox on that one, they gave us a 2
>>> out of 5 on the inspection, even though that was the only thing noted in
>>> the entire inspection report! But I would be curious if the point you make
>>> above will work with NYSERDA?
>>>
>>> Cheers,
>>> Dave
>>>
>>> On Tue, Nov 11, 2025 at 4:16 PM AE Solar via RE-wrenches <
>>> re-wrenches at lists.re-wrenches.org> wrote:
>>>
>>> We had an inspection agency that was giving us a hard time about using
>>> buchanan crimps in junction boxes because they aren't rated for
>>> outdoor/damp locations. The point was made (on this listserve) that "*if
>>> the inside of a 3R enclosure isn't considered dry enough for a buchanan
>>> crimp/cap, then there's millions of 3R panels with breakers and busbars in
>>> them that would have the same problem*". The inspection agency finally
>>> relented. We put a little No-Alox in the cap. I know that's not what your
>>> initial post was about, but tossing that in for consideration just in
>>> case...
>>>
>>> Adam Katzman (he/him)
>>> Autonomous Energies | Owner/Operator
>>> www.AutonomousEnergies.com <http://www.autonomousenergies.com>
>>> (518) 567-1468
>>>
>>>
>>>
>>>
>>> On Tue, Nov 11, 2025 at 3:51 PM Jay via RE-wrenches <
>>> re-wrenches at lists.re-wrenches.org> wrote:
>>>
>>> Hi Sam
>>>
>>> I can’t imagine being just copper it would matter, the AHJ might have a
>>> different opinion however
>>>
>>> Question.
>>> How are you insulating them?
>>>
>>> Jay
>>>
>>>
>>> On Nov 11, 2025, at 11:15 AM, Sam Haraldson via RE-wrenches <
>>> re-wrenches at lists.re-wrenches.org> wrote:
>>>
>>> 
>>> Wrenches,
>>>
>>> On the attached product spec sheet for Ideal Copper Crimps (aka Buchanan
>>> crimps) you'll see that max voltage for the crimp is rated at 600V but an
>>> asterisk indicates up to 1000V when "in fixtures and signs".  In our
>>> application this is a 1000v system and we are joining pairs of #10 PV
>>> wires.  The junctions are made in a rail-mounted, plastic j-box.  We could
>>> not find the definition of "fixture" as it might pertain to this situation
>>> in the NEC and as such are interested to learn more about using Buchanan
>>> crimps for 1000V applications.
>>>
>>> <image.png>
>>>
>>>
>>> Cheers,
>>> Sam
>>>
>>> [image: OnSite Energy] <https://onsiteenergyinc.com/>
>>>
>>> Sam Haraldson
>>> Operations Specialist
>>> (406) 551-6135
>>> 1515 N. Rouse Ave Bozeman, MT 59715
>>> <https://www.google.com/maps/search/1515+N.+Rouse+Ave+Bozeman,+MT+59715?entry=gmail&source=g>
>>> Locally owned and operated since 2012
>>> [image: B Corporation] <https://onsiteenergyinc.com/bcorp>
>>> <IDEALIndustries-Crimp Connectors.pdf>
>>> _______________________________________________
>>> List sponsored by Redwood Alliance
>>>
>>> Pay optional member dues here: http://re-wrenches.org
>>>
>>> List Address: RE-wrenches at lists.re-wrenches.org
>>>
>>> Change listserver email address & settings:
>>> http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org
>>>
>>> There are two list archives for searching. When one doesn't work, try
>>> the other:
>>> https://www.mail-archive.com/re-wrenches@lists.re-wrenches.org/
>>> http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org
>>>
>>> List rules & etiquette:
>>> http://www.re-wrenches.org/etiquette.htm
>>>
>>> Check out or update participant bios:
>>> http://www.members.re-wrenches.org
>>>
>>> _______________________________________________
>>> List sponsored by Redwood Alliance
>>>
>>> Pay optional member dues here: http://re-wrenches.org
>>>
>>> List Address: RE-wrenches at lists.re-wrenches.org
>>>
>>> Change listserver email address & settings:
>>> http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org
>>>
>>> There are two list archives for searching. When one doesn't work, try
>>> the other:
>>> https://www.mail-archive.com/re-wrenches@lists.re-wrenches.org/
>>> http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org
>>>
>>> List rules & etiquette:
>>> http://www.re-wrenches.org/etiquette.htm
>>>
>>> Check out or update participant bios:
>>> http://www.members.re-wrenches.org
>>>
>>> _______________________________________________
>>> List sponsored by Redwood Alliance
>>>
>>> Pay optional member dues here: http://re-wrenches.org
>>>
>>> List Address: RE-wrenches at lists.re-wrenches.org
>>>
>>> Change listserver email address & settings:
>>> http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org
>>>
>>> There are two list archives for searching. When one doesn't work, try
>>> the other:
>>> https://www.mail-archive.com/re-wrenches@lists.re-wrenches.org/
>>> http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org
>>>
>>> List rules & etiquette:
>>> http://www.re-wrenches.org/etiquette.htm
>>>
>>> Check out or update participant bios:
>>> http://www.members.re-wrenches.org
>>>
>>> _______________________________________________
>>> List sponsored by Redwood Alliance
>>>
>>> Pay optional member dues here: http://re-wrenches.org
>>>
>>> List Address: RE-wrenches at lists.re-wrenches.org
>>>
>>> Change listserver email address & settings:
>>> http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org
>>>
>>> There are two list archives for searching. When one doesn't work, try
>>> the other:
>>> https://www.mail-archive.com/re-wrenches@lists.re-wrenches.org/
>>> http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org
>>>
>>> List rules & etiquette:
>>> http://www.re-wrenches.org/etiquette.htm
>>>
>>> Check out or update participant bios:
>>> http://www.members.re-wrenches.org
>>>
>>>
>>> _______________________________________________
>> List sponsored by Redwood Alliance
>>
>> Pay optional member dues here: http://re-wrenches.org
>>
>> List Address: RE-wrenches at lists.re-wrenches.org
>>
>> Change listserver email address & settings:
>> http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org
>>
>> There are two list archives for searching. When one doesn't work, try the
>> other:
>> https://www.mail-archive.com/re-wrenches@lists.re-wrenches.org/
>> http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org
>>
>> List rules & etiquette:
>> http://www.re-wrenches.org/etiquette.htm
>>
>> Check out or update participant bios:
>> http://www.members.re-wrenches.org
>>
>> _______________________________________________
> List sponsored by Redwood Alliance
>
> Pay optional member dues here: http://re-wrenches.org
>
> List Address: RE-wrenches at lists.re-wrenches.org
>
> Change listserver email address & settings:
> http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org
>
> There are two list archives for searching. When one doesn't work, try the
> other:
> https://www.mail-archive.com/re-wrenches@lists.re-wrenches.org/
> http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org
>
> List rules & etiquette:
> http://www.re-wrenches.org/etiquette.htm
>
> Check out or update participant bios:
> http://www.members.re-wrenches.org
>
>
-------------- next part --------------
An HTML attachment was scrubbed...
URL: <http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org/attachments/20251111/0e325396/attachment.htm>