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Ferrule Crimping Larger Wires

Henderson

Solar Enthusiast
Joined
Jan 9, 2022
Messages
398
Hi all. I have some 2/0 AWG cables that I would like to ferrule but I am not seeing any ferrule crimping tools that can crimp cables that size. I have the actual ferrules just need the crimping tool and my searching online on Amazon hasn't yielded anything fruitful. What tools are you guys using to crimp ferrules for those larger sized wires? Was looking to see if my hydraulic crimper used for battery lugs would work but I'm doubtful of that given that ferrules is a much softer material than those battery lugs.

Thanks in advance.
 
What kind of connection are you going to use this ferruled 2/0 with?
The purpose of the ferrule is really just to keep all the wires together, so if the connector can apply enough force to deform the ferrule, that's really all you should need. If you want to use something like a lug crimper to gently deform part of the ferrule so it stays put while you install it, go ahead.
 
What kind of connection are you going to use this ferruled 2/0 with?
The purpose of the ferrule is really just to keep all the wires together, so if the connector can apply enough force to deform the ferrule, that's really all you should need. If you want to use something like a lug crimper to gently deform part of the ferrule so it stays put while you install it, go ahead.
Good point. Using it to connect into an inverter on the battery terminals (18KPV). So one end will be ferruled into the inverter and the other end will be a regular battery lug. They are quite tight now without the ferrules but wanted to clean up my setup a bit.
 
Good point. Using it to connect into an inverter on the battery terminals (18KPV). So one end will be ferruled into the inverter and the other end will be a regular battery lug. They are quite tight now without the ferrules but wanted to clean up my setup a bit.
The inverter doesn't have ring terminals for the battery connection?
 
The inverter doesn't have ring terminals for the battery connection?
No. The 18KPV has those terminals where you insert the cables into the ring and there's a nut you screw down to hold the cable in place.
 
Good point. Using it to connect into an inverter on the battery terminals (18KPV). So one end will be ferruled into the inverter and the other end will be a regular battery lug. They are quite tight now without the ferrules but wanted to clean up my setup a bit.
Do use the ferrules, don't worry about crimping them before installing. Just tighten down the hex nut, it'll deform the ferrules for you.
 
The 18KPV has wire lugs, not ring terminals. The manual also does not say to use ferrules. The manual does specify ferrules for the PV inputs. I'm assuming this means do not use ferrules for the battery cables.

I'm installing mine currently. I went 4/0 welding cable, no ferrules.
 
The 18KPV has wire lugs, not ring terminals. The manual also does not say to use ferrules. The manual does specify ferrules for the PV inputs. I'm assuming this means do not use ferrules for the battery cables.

I'm installing mine currently. I went 4/0 welding cable, no ferrules.
Ok. Yeah I currently have mine like that. Ferruled on the PV cables and bare copper on the battery side. Figured it would've made a more secure connection if the battery cables were ferruled.
 
Make sure to buy ferrules that are the correct depth. A lot of the ones sold on amazon are the short type that won't let you fully insert the cable into the terminal. Use a set of calipers to measure the depth of the hole.

And almost all ferrules on Amazon are metric verse AWG so they don't fit the wire properly. The ones below let you choose the correct depth in the right AWG.


They also have ferrule crimpers that go to 4/0 and beyond.

Also if you do get a crimper make sure to get the right shape for your terminal block. This usually means square or sometimes hex depending on the shape as they compress.
 
The 18KPV has wire lugs, not ring terminals. The manual also does not say to use ferrules. The manual does specify ferrules for the PV inputs. I'm assuming this means do not use ferrules for the battery cables.

I'm installing mine currently. I went 4/0 welding cable, no ferrules.
In general, don't use fine-stranded cable without ferrules in terminals where you're twisting something down onto the cable. The 18kpv terminals twist a hex nut onto the cable, and it'll make a mess of the strands if there isn't a ferrule.
 
Make sure to buy ferrules that are the correct depth. A lot of the ones sold on amazon are the short type that won't let you fully insert the cable into the terminal. Use a set of calipers to measure the depth of the hole.

And almost all ferrules on Amazon are metric verse AWG so they don't fit the wire properly. The ones below let you choose the correct depth in the right AWG.


They also have ferrule crimpers that go to 4/0 and beyond.

Also if you do get a crimper make sure to get the right shape for your terminal block. This usually means square or sometimes hex depending on the shape as they compress.
You are a link machine! You always have the best and most appropriate links.
 
With the 4/0 there isn't room to twist the strands. I'm not sure I can fit a ferrule of any type in there. I had to use the zip tie trick to get initial insertion.
 
With the 4/0 there isn't room to twist the strands. I'm not sure I can fit a ferrule of any type in there. I had to use the zip tie trick to get initial insertion.
You're still putting a lot of shear stress on the strands in contact with the nut when you tighten it down. I personally wouldn't do it.
The 18kpv manual claims a single 250 kcmil is also an option, so I'm inclined to think a 4/0 with a ferrule should fit. A tight ferrule wouldn't be much different than the zip-tie; it would probably be easier to get the cable in with the ferrule than without.

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I have had issues with #4 on the EG4 3k inverters and breakers. Some I wouldn't have known about without close inspection.

I will never use stranded heavy gauge wires without some type of lug or feral ever again. If I had torqued them down any more it would have broke the screw. Heat, humidity, & oxidation is a killer.

Been doing high current DC commercially for many years and have never seen an issue come up. I follow instructions on a DIY solar install and this happens. Absently and totally not acceptable.

I upgraded all the wire to #2, Switched to Commercial bullet breakers, put lugs and ferrules on everything.


I can now sleep at night

1736897683736.png1736897784990.png
 

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+1 for sourcing both ferrules and crimpers from FerrulesDirect.com. They are my go-to supplier for both of those items. I started buying smaller crimp ring terminals, closed end connectors and strain relief bushings from there also.

Their longer ferrules come in very handy for certain terminals like the relay terminals on the Cerbo GX. The short ferrules will NOT work.
 
With the 4/0 there isn't room to twist the strands. I'm not sure I can fit a ferrule of any type in there. I had to use the zip tie trick to get initial insertion.

You don't twist the wire before putting a ferrule on. You want the strands to go straight through past the end. Then crimp it and cut the ends off.
 

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