Firstascent
Solar Enthusiast
- Joined
- Mar 7, 2020
- Messages
- 265
I did some quick testing tonight as I was noticing some interesting things preparing to crimp various wires for my solar build.
I started with UL listed components thinking that would give me a better chance at the right fit for each item.
Wire - 2/0 Ancor UL listed wire
Lug connector - Pandit LCA2/0-38, UL listed
The first thing I noticed was that with this exact config, it is a VERY tight fit, before crimping. meaning it's difficult to get the lug over all the fine strands without damaging them or a single strand falling out. It can be done, but it take some time
I did some quick crimp test with different setups and also crimp tools and was also able to borrow a VERY fancy automatic crimper.
The attached photo shows 4 crimps, in order from Left to Right, here are the info/results from each. All wire is the same 2/0 wire.
1. 2/0 copper lug, Crimped using Milwaukee battery powered crimper with 2/0 die set.
2. 3/0 copper lug, Crimped using Milwaukee battery powered crimper with 3/0 die set.
3. Same 2/0 copper lug as #1 above, but crimped using a manual Greenlee crimper, set to the 2/0 adjustable die.
4. This is actually a 2/0 lug, but it's similar in size to a 3/0. I'm not sure why, it's not a manufacturing error, and I checked it against the specs on Panduit's website. This is an LCAX instead of LCA model, Not sure the purpose or reasoning behind it but they felt a need for it for some reason.
I think next I'll cut in half #1 and #3 to see if I notice any difference in the crimp on the wire itself, but I'm betting they will look fairly identical.
Anyway, just thought I would post up my little test, I was bored tonight so if anything, I had fun haha.
I started with UL listed components thinking that would give me a better chance at the right fit for each item.
Wire - 2/0 Ancor UL listed wire
Lug connector - Pandit LCA2/0-38, UL listed
The first thing I noticed was that with this exact config, it is a VERY tight fit, before crimping. meaning it's difficult to get the lug over all the fine strands without damaging them or a single strand falling out. It can be done, but it take some time
I did some quick crimp test with different setups and also crimp tools and was also able to borrow a VERY fancy automatic crimper.
The attached photo shows 4 crimps, in order from Left to Right, here are the info/results from each. All wire is the same 2/0 wire.
1. 2/0 copper lug, Crimped using Milwaukee battery powered crimper with 2/0 die set.
Perfect results. As long as you can get the lug over the wire without damaging the fine strands
2. 3/0 copper lug, Crimped using Milwaukee battery powered crimper with 3/0 die set.
I tried this thinking I could see someone sizing up due to the tight fitment of the lug. This "looked" great, but with a little elbow grease I was finally able to pull the lug off of the wire.
Not too surprising since the die is meant for a larger 3/0 wire. But could be dangerous, I bet someone out there has done this.
3. Same 2/0 copper lug as #1 above, but crimped using a manual Greenlee crimper, set to the 2/0 adjustable die.
Perfect results as well, but similarly as long as you can get the lug over the wire without damaging the fine strands
4. This is actually a 2/0 lug, but it's similar in size to a 3/0. I'm not sure why, it's not a manufacturing error, and I checked it against the specs on Panduit's website. This is an LCAX instead of LCA model, Not sure the purpose or reasoning behind it but they felt a need for it for some reason.
In any case, I used the 2/0 die from the Milwaukee crimper. I think it crimped ok for the wires internally, but you can see the extra flange/tab material on the side from the crimp, this is due to the lug being physically larger in size so the extra material gets pushed out
I think next I'll cut in half #1 and #3 to see if I notice any difference in the crimp on the wire itself, but I'm betting they will look fairly identical.
Anyway, just thought I would post up my little test, I was bored tonight so if anything, I had fun haha.