oversized wiring to charge controller

Controller with #6 terminals sounds like something at least 30-35A. With that much solar people (usually) run panels in series and use MPPT controller, then wire to controller can be thinner.

Wire to battery is another thing.

Or what is a proper controller that can handle the larger wire?

What is your planned solar array?

Consider larger voltage.

Almot wrote:
With that much solar people (usually) run panels in series and use MPPT controller, then wire to controller can be thinner.

x2

Well... Yes. Panels in series = higher voltage to controller = thinner cable. And higher voltage on battery bank, 24V or 48V. This is what people with solar homes do - big bank with 48V (or more).

Keep in mind the typical 120WATT Solar Panel we see alot of on the RV's only produce around 5-6 AMPS DC CURRENT which doesn't require the larger cable sizes between the panel and the solar controller. Makes it much easier to dress up the cables around the roof as well.

Like said above when you connect the solar panel controller which may have three or four 120WATT Solar panels feeding it then you would want the connection to be a larger 4AWG or so size between the solar controller and the battery connections...

Roy Ken

I use a Bogart sc2030 30 amp controller along with a Trimetric. I was able to get 4 gauge wire in it. It has to be twisted tight. I have 520 watts charging four 6 gc

rjxj wrote:
I was able to get 4 gauge wire in it {Bogart}.

You had to, because Bogart is PWM and can't accept series wiring. If it were MPPT, a #10 wire in series would suffice, on the panels side.

OP, if you still want a thick cable, you can use Splicer Reducer AWG 2-14. Wrap an insulation tape around it. But I would rather run higher voltage and avoided the problem altogether.

A step-down pin terminal is what you need. I don't have a good link.

Maybe this one #4 to #6


But honestly I would use #6 and not worry.

Almot wrote:

rjxj wrote:
I was able to get 4 gauge wire in it {Bogart}.

You had to, because Bogart is PWM and can't accept series wiring. If it were MPPT, a #10 wire in series would suffice, on the panels side.

I didn't have to use 4 gauge but it keeps the losses very low. 6 would work. The price difference between 12 feet of 6 g vs 10 g is not much. $120 controller and using the extra money for more inexpensive wattage works well. That's what Hensley bet on when developing the sc2030. He bet that wattage would keep getting cheaper and it is. A person can put together a decent pwm system for the same amount that people used to pay for a panel years ago.

Morningstar PWM 30 amp $140
2- 150 watt panels with shipping $330
Wire, combiner box etc $100 to $150
$600 for 300 watts on the roof aint bad at all and would serve most people very well. Priced for a DIY person of course. :)


Cheap

I used AWG 4 from the combiner box on the roof to the controller. The controller only accepted #6 termination. I used a 4 AWG spade connector I bought at an online auto sound website. They were around $5 for four pieces (gold plated, also).

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