[RE-wrenches] Ferrules for large fine-stranded wire.

[Kirk Herander]

William, All,

I was at a workshop on the (sort of) new Fortress battery product the other
day. I brought up this very
issue of the terminal lugs of the Envy not accepting a 4/0 ferrule, even
though 4/0 cable with ferrules are recommended in the manual. The
instructor had no comment, except to imply that maybe one should use 3/0
max. Huh?

Anyway these Greaves pin adapters are by far the best I've found for
working with the 4/0 terminal block.
The pin diameter matches 4/0 cable and thus fits great. Preferable IMO to a
reduced 4/0 barrel to 2/0 pin of AL or AL-clad others. And the barrel has a
generous flange which makes it quite easy to insert high-strand flex cable.
#PT 222FX40. But @ $50 ea, not cheap.

[image: image.png]

On Wed, Sep 3, 2025 at 7:10 PM William Miller via RE-wrenches <
re-wrenches at lists.re-wrenches.org> wrote:

> Friends:
>
>
>
> My understanding is if the lug has a set-screw that contacts the strands,
> fine strands can wind around the set screw, get into the threads and not
> tighten adequately.  If you are crimping fine strands inside of some type
> of barrel your connection should be OK.
>
>
>
> I had been using Outback until they imploded and all of the battery
> connections were via studs or bolts that required crimped-on rings.  Now I
> am back to set screw lugs and fine stranding became an issue again.
>
>
>
> I did try another experiment: I took a 4/0 ferrule that would not fit into
> the Envy lugs and snipped a section out of it.  I curled it into a slightly
> smaller diameter and it fit into the lug.  I suppose one could cut the
> ferrule in half longitudinally and insert a portion of the ferrule between
> the set screw and the strands.
>
>
>
> I am pleased with the copper sheeting wrapped around the fine strands.
> That will be my SOP.
>
>
>
> William
>
>
>
> Miller Solar
>
> 17395 Oak Road, Atascadero, CA 93422
>
> 805-438-5600
>
> www.millersolar.com
>
> CA Lic. 773985
>
>
>
>
>
> *From:* RE-wrenches [mailto:re-wrenches-bounces at lists.re-wrenches.org] *On
> Behalf Of *Ray Walters via RE-wrenches
> *Sent:* Wednesday, September 3, 2025 1:40 PM
> *To:* re-wrenches at lists.re-wrenches.org
> *Cc:* Ray Walters
> *Subject:* Re: [RE-wrenches] Ferrules for large fine-stranded wire.
>
>
>
> I've got to ask: Are none of the lugs on these Chinese inverters approved
> for fine strand cable?  I just have not had a problem with that, but I've
> mostly used Magnum, Midnite, and Outback equipment over the years.   What
> were the lugs on the old Trace DC 250 boxes?  Were they fine strand rated?
> They sure were tough to get 4/0 into, as William mentioned.
>
> Ray
> Remote Solar
>
> On 9/3/2025 12:57 PM, Kent via RE-wrenches wrote:
>
> William,
>
> If the only reason the ferrule wouldn't fit after using the hex crimper
> was the ridge left where the dies meet, you could rotate the cable 120
> degrees and crimp the ferrule again.
>
> I doubt that the indenter crimper will do a decent job with large ferrules.
>
> I do like your thin piece of copper solution. Not UL approved but I dare
> say wrench approved.
>
> Kent Osterberg
> Blue Mountain Solar
>
>
>
> On 9/2/2025 8:55 PM, William Miller via RE-wrenches wrote:
>
> Friends:
>
>
>
> Thank you for all of your input on this question.  I feel it only right I
> report back how this turned out
>
>
>
> I tried a crimper like this:
>
>
>
>
>
>
>
> It left a jagged ridge on both sides of the ferrule where the dies met.
>
>
>
> The crimper below was suggested but I have not tried it:
>
>
>
> This was suggested but I have not tried it either:
>
>
>
>
>
> _______________________________________________
> 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
>
>

-- 


*Kirk Herander / **kirkh at vermont.solar <kirkh at vermont.solar>*

*Owner|Principal, VT Solar, LLC*

*Celebrating our 35th Anniversary 1991-2026!!*

dba Vermont Solar Engineering

802.559.1225
-------------- next part --------------
An HTML attachment was scrubbed...
URL: <http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org/attachments/20260123/6c56e74d/attachment-0001.htm>
-------------- next part --------------
A non-text attachment was scrubbed...
Name: image.png
Type: image/png
Size: 268372 bytes
Desc: not available
URL: <http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org/attachments/20260123/6c56e74d/attachment-0001.png>