diy solar

diy solar

Buchanan Splice Caps and other novel splicing methods.

I used a wire nut in my combiner box for one of my arrays to splice 10 (from panels), 8 (to inside) and 14 (SPD) gauge wires together:

20240412-11-03.15.png

I'm pretty particular about things as well, but what sold me on using a wire nut versus other methods was watching this Youtube video on splicing larger gauge wires:
 
Wago's are just fine for high current AC or DC applications. They are rated to 32 amps and just for fun I've ran them for hours at over 50 amps without any issues. I've loaned my FLIR to a buddy or I'd take a picture of the below set up and show you. I'm cycle testing some batteries at 30 amps. The batteries are warmer than the Wago's.

We use them all the time and have never had a problem. People say they are fire hazards but there's not any evidence to support that. "Pictures or it didn't' happen". I get it, it's fun to be in the "I'm an old school electrician" tribe (30+ year master electrician here) but I'm using WAGO's on chillers motors in $30 million dollar surgery centers and I sleep just fine. Life and death sort of stuff which I take very seriously.

Hands down the best wire connector out there is an appropriately rated safety switch. You can splice together wires of large size differences in a weatherproof enclosure and you get a free disconnect while you're at it. I've picked up dozens of them on eBay for pennies on the dollar.

1712970624994.png
 
The one issue with the wagos is the tendency to have one of the levers catch onto another wire and lift it up half way but I always take electrical tape and wrap the levers so they don’t have a chance flip up. I feel completely safe using them, especially when stranded thhn is involved.
 
Hedges said:
What's wrong with such outlet type boxes?
I've mounted them on the end of rigid conduit, spliced wires to PC wire in them, put a gasketed cover on front.
Click to expand...
Nothing wrong with the box, you are misunderstanding the context.

The box pictured doesn't lend itself well to mounting a junction block as mentioned in this post.

It helps to read the posts ahead of the responses. :)

I know what I would do if I was the OP and have in fact done it. I gave options according to what he wants, nothing more.
 
OzSolar said:
Wago's are just fine for high current AC or DC applications. They are rated to 32 amps and just for fun I've ran them for hours at over 50 amps without any issues. I've loaned my FLIR to a buddy or I'd take a picture of the below set up and show you. I'm cycle testing some batteries at 30 amps. The batteries are warmer than the Wago's.

We use them all the time and have never had a problem. People say they are fire hazards but there's not any evidence to support that. "Pictures or it didn't' happen". I get it, it's fun to be in the "I'm an old school electrician" tribe (30+ year master electrician here) but I'm using WAGO's on chillers motors in $30 million dollar surgery centers and I sleep just fine. Life and death sort of stuff which I take very seriously.

Hands down the best wire connector out there is an appropriately rated safety switch. You can splice together wires of large size differences in a weatherproof enclosure and you get a free disconnect while you're at it. I've picked up dozens of them on eBay for pennies on the dollar.

View attachment 209044
Click to expand...
In defense of such push in type/locking lever type connections, the NHX Hybrid inverters sold by Watts247 (made by Megarevo) uses this type of connection.

This inverter I'm still considering but the electrical connections do give me some pause. My biggest concern with any connection is whether the connection can dissipate heat as there is always some slight resistance at the connection.
 
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