Connecting Solar Panels

[Bushwanderer]

Hi All,
I suspect that I'm going to show everyone that I'm a bit thick.

I've bought a solar panel (80-85W), a regulator, & the cabling bits. Now I need to hook it together.

The cabling & connectors I have bought from Jaycar, while the rest I've bought on ebay.

It's connecting the cabling to the connectors that is the problem. The cabling is double insulated, multi-strand, single core (2.5mm^2).

Am I right in believing that the connectors should be crimped to the multi-strand cable, rather than the inner insulator, or both in two different positions?

Should the two insulators be separated in the connector, or just trim them at the same point?

The crimper that I have specifies AWG. The only table that I have shows that 14 AWG is "about" 2mm^2. Does this mean that I should use the 00-14AWG crimp position (it seems a bit arbitrary to me)?

Any & all replies appreciated,
Peter

[fraser130]

Hello there!
Without seeing the type of connectors you have, If you have those dodgy automotive crimp connectors, I would remove the plastic insulation on them, crimp them, then solder them, making sure the solder soaks right inside the fitting, then cover with heatshrink tubing. You may end up with 7 amps continuous going through them, and they may get warm, or just loosen up over time.

2.5mm2 is on the lower end of cabling for 80w solar, but will be fine for a shorter run.

Fraser

[barney]

what you're after is a good electrical connection, strip the double insulated cable down to the copper cores, give them a nice neat twist, (if it looks like a bird's nest, cut it and do it again).

then insert all of the strands into the lug and crimp it.

if you have a look at the lug, it has an outer coloured sleeve, if you are using 2.5mm cable, it should be blue. yellow is for 4 - 6mm and red is for 1.5mm. if you look at the shape of the lug, there should be one side of the lug which will allow the lug to sit relatively flat on a flat surface, this is the bottom.the lug is designed to be crimped from the top.
now, looking at your crimpers, the profile of the jaws should show a semi circle on one side and a tongue on the other side that will fit into the semi circle when the jaws are together.
the top of the lug will mate with the tongue and the bottom will sit in the half circle.
squeeze the jaws together really hard, the tighter the crimp, the better electrical connection will be attained.

hope this helps without being too condescending.

[Bushwanderer]

Hi Guys,
Thanks for your replies.

Jaycar rate the cable (cat NO. WH3120) to 30A, but I take your point.

The connectors are the waterproof round "PV" connectors (Cat Nos. PS-5100 & PP5102).

They can be seen here (browse "Connectors" & "Solar Connectors"):

www.jaycar.com.au/productResults.asp?FORM=CAT

I apologise for not including this info up front.

Best Wishes,
Peter
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[BigTim]

G'day Peter,

Those connectors are the MC3 type commonly used in the solar industry.

Correct assembly is as follows:
1) strip both outer and inner sheaths from cable at approximately the same point leaving around 10mm of the multistranded core sticking out.

2) twist the strands of the core together into a nice firm column.

3) slide the outer gland cover (screws on to main body later), the conical seal compressor and the rubber seal onto the cable.

4) place the twisted core of the cable into the U shaped end of the pin which has two small upright tabs on it and then crimp the two tabs down firmly onto the cable - if you don't have the correct tool a pair of long nosed pliers work quite well - taking care not to squeeze the cable out from under the first tab as you crimp it.

5) optional - at this point some people like to solder the connection as well but it's really not necessary if you've done a decent crimp.

6) IMPORTANT - make SURE everything is right so far because this next step is not reversible - insert the pin and cable into the main body of the plug / socket and press in firmly until it seats in firmly with a click.

7) slide the rubber seal up and into the base of the main body, slide the seal compressor over the seal and then tighten into place by screwing the outer gland cover into place.

Repeat for the other plug / socket. Also important - don't get the pins mixed up between the plug and the socket or you will eventually wind up bending them when disconnecting / connecting. If you have trouble let me know and I'll post a couple of pics.

[Bushwanderer]

Hi BigTim,
I think that even I can do that.
Many Thanks,
Peter