Forum Discussion

hedge's avatar
hedge
Explorer
Jul 28, 2016

How to fit 4gauge wire in 6gauge terminals?

I'm adding another solar panel and upgrading the wire on my solar install. I have quite a bit of 4gauge wire that I was planning on running to the roof but now I notice my controller only accepts 6gauge wire.

I'd rather run the 4gauge once had have a level of future proofing if I decide to upgrade the controller. Is there a way of fitting the 4gauge wire in there that I haven't thought of?

Ideas I've had so far, none seem that great.

-crimp on a terminal and folding it over and then flatten it out
-just cut some of the wire out of the bundle? leaving enough slack to cut off a fresh end
  • enblethen's avatar
    enblethen
    Nomad
    Jul 28, 2016
    Use high stranded wire from a automotive audio shop or marine supply.
  • Ductape's avatar
    Ductape
    Explorer
    Jul 28, 2016
    Nothing wrong with your second option. Clearly you don't need the full capacity of the 4 for your system. And a few mm length of reduced diameter has negligible effect on resistance anyway.
  • Golden_HVAC's avatar
    Golden_HVAC
    Explorer
    Jul 28, 2016
    Are you using solid #4 wire? File it down with a grinder.

    If it is stranded, then cut off a couple of strands, until it fits. Unless you are actually running more than 40 amps through the wire, it is possible to cut it down to #8 size with no voltage loss.

    Good luck,

    Fred.
  • SCVJeff's avatar
    SCVJeff
    Explorer
    Jul 28, 2016
    hedge wrote:
    I'm adding another solar panel and upgrading the wire on my solar install. I have quite a bit of 4gauge wire that I was planning on running to the roof but now I notice my controller only accepts 6gauge wire.

    I'd rather run the 4gauge once had have a level of future proofing if I decide to upgrade the controller. Is there a way of fitting the 4gauge wire in there that I haven't thought of?

    Ideas I've had so far, none seem that great.

    -crimp on a terminal and folding it over and then flatten it out
    -just cut some of the wire out of the bundle? leaving enough slack to cut off a fresh end
    Keep cutting wire until it fits. You are after reducing the line losses, the terminals will be fine.

    You could also build a pair of 4 > 6 ga. pigtails crimped into some crimp barrels
  • hedge's avatar
    hedge
    Explorer
    Jul 28, 2016
    ok, thanks for the ideas. I think I'll just cut out a few strands until it fits.
  • Matt_Colie's avatar
    Matt_Colie
    Explorer II
    Jul 28, 2016
    Hedge,

    Before you do anything rash, try just cleaning up the end of the 4AWG and see if you can fit it in the terminal lug. For the lug to be able to accept 6AWG as cut by ordin commonary people, it will have to be large enough to accept a 4 that has been dressed properly.

    I have had to do this a lot in the boat work that I did before the depression killed that.

    Matt

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