<html><head><meta http-equiv="content-type" content="text/html; charset=utf-8"></head><body dir="auto"><div dir="ltr"></div><div dir="ltr">I got curious about ferrules. </div><div dir="ltr"><br></div><div dir="ltr">Turns out they come in different physical sizes for the same wire size. </div><div dir="ltr"><br></div><div dir="ltr">I’ve found .63” and .69” OD for 4/0 wire. </div><div dir="ltr"><br></div><div dir="ltr">With .69 being more normal and. .64 called small diameter </div><div dir="ltr"><br></div><div dir="ltr">Try measuring what you’ve got. Or the actual diameter in the inverter. </div><div dir="ltr"><br></div><div dir="ltr">I’m mean no excuse for the rep being clueless </div><div dir="ltr"><br></div><div dir="ltr">Jay</div><div dir="ltr"><br></div><div dir="ltr"><br></div><div dir="ltr"><br><blockquote type="cite">On Jan 23, 2026, at 10:46 AM, Kirk Herander via RE-wrenches <re-wrenches@lists.re-wrenches.org> wrote:<br><br></blockquote></div><blockquote type="cite"><div dir="ltr"><div dir="ltr"><div dir="ltr"><div class="gmail_default" style="font-size:large">William, All,</div><div class="gmail_default" style="font-size:large"><br></div><div class="gmail_default" style="font-size:large">I was at a workshop on the (sort of) new Fortress battery product the other day. I brought up this very</div><div class="gmail_default" style="font-size:large">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?</div><div class="gmail_default" style="font-size:large"><br></div><div class="gmail_default" style="font-size:large">Anyway these Greaves pin adapters are by far the best I've found for working with the 4/0 terminal block.</div><div class="gmail_default" style="font-size:large">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. </div><div class="gmail_default" style="font-size:large">#<span class="gmail_default" style="color:rgb(10,38,60);font-family:Anton"></span><font size="4" style="color:rgb(10,38,60);font-family:Anton">PT 222FX40. But @ $50 ea, not cheap.</font></div><div class="gmail_default" style="font-size:large"><br></div><div class="gmail_default" style="font-size:large"><div><image.png></div><br></div></div><br><div class="gmail_quote"><div dir="ltr" class="gmail_attr">On Wed, Sep 3, 2025 at 7:10 PM William Miller via RE-wrenches <<a href="mailto:re-wrenches@lists.re-wrenches.org" target="_blank">re-wrenches@lists.re-wrenches.org</a>> wrote:<br></div><blockquote class="gmail_quote" style="margin:0px 0px 0px 0.8ex;border-left:1px solid rgb(204,204,204);padding-left:1ex"><div><div lang="EN-US"><div><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)">Friends:</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)"> </span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)">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. </span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)"> </span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)">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.</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)"> </span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)">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.</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)"> </span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)">I am pleased with the copper sheeting wrapped around the fine strands. That will be my SOP.</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)"> </span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)">William</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)"> </span></p><div><p class="MsoNormal"><span style="font-size:12pt;font-family:Arial,"sans-serif";color:rgb(31,73,125)">Miller Solar</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Arial,"sans-serif";color:rgb(31,73,125)">17395 Oak Road, Atascadero, CA 93422</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Arial,"sans-serif";color:rgb(31,73,125)">805-438-5600</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Arial,"sans-serif";color:rgb(31,73,125)"><a href="http://www.millersolar.com/" target="_blank"><span style="color:blue">www.millersolar.com</span></a></span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Arial,"sans-serif";color:rgb(31,73,125)">CA Lic. 773985</span></p><p class="MsoNormal"><span style="color:rgb(31,73,125)"> </span></p></div><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif";color:rgb(31,73,125)"> </span></p><div><div style="border-right:none;border-bottom:none;border-left:none;border-top:1pt solid rgb(181,196,223);padding:3pt 0in 0in"><p class="MsoNormal"><b><span style="font-size:10pt;font-family:Tahoma,"sans-serif"">From:</span></b><span style="font-size:10pt;font-family:Tahoma,"sans-serif""> RE-wrenches [mailto:<a href="mailto:re-wrenches-bounces@lists.re-wrenches.org" target="_blank">re-wrenches-bounces@lists.re-wrenches.org</a>] <b>On Behalf Of </b>Ray Walters via RE-wrenches<br><b>Sent:</b> Wednesday, September 3, 2025 1:40 PM<br><b>To:</b> <a href="mailto:re-wrenches@lists.re-wrenches.org" target="_blank">re-wrenches@lists.re-wrenches.org</a><br><b>Cc:</b> Ray Walters<br><b>Subject:</b> Re: [RE-wrenches] Ferrules for large fine-stranded wire.</span></p></div></div><p class="MsoNormal"> </p><p>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. </p><p>Ray <br>Remote Solar</p><div><p class="MsoNormal">On 9/3/2025 12:57 PM, Kent via RE-wrenches wrote:</p></div><blockquote style="margin-top:5pt;margin-bottom:5pt"><p>William,</p><p>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.</p><p>I doubt that the indenter crimper will do a decent job with large ferrules.</p><p>I do like your thin piece of copper solution. Not UL approved but I dare say wrench approved.</p><p class="MsoNormal">Kent Osterberg<br>Blue Mountain Solar </p><p> </p><div><p class="MsoNormal">On 9/2/2025 8:55 PM, William Miller via RE-wrenches wrote:</p></div><blockquote style="margin-top:5pt;margin-bottom:5pt"><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif"">Friends:</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif""> </span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif"">Thank you for all of your input on this question. I feel it only right I report back how this turned out</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif""> </span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif"">I tried a crimper like this:</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif""> </span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif""> </span></p><p class="MsoNormal"> </p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif"">It left a jagged ridge on both sides of the ferrule where the dies met.</span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif""> </span></p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif"">The crimper below was suggested but I have not tried it:</span></p><p class="MsoNormal"> </p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif"">This was suggested but I have not tried it either:</span></p><p class="MsoNormal"> </p><p class="MsoNormal"><span style="font-size:12pt;font-family:Verdana,"sans-serif""> </span></p></blockquote></blockquote></div></div>
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