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Old 02-26-2017, 07:11 AM   #15
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The contactor connection problem is more likely the wire cold forming under the screw. I learned about it 40 some years ago from a building inspector then followed it with a couple of sales engineers for connectors and blocks. It's a known issue that a screw terminal will tighten against the wire or wire bundle with stranded then the wire will deform from the pressure resulting in a loose connection. The answer is to retighten after a week or so.

Pressure crimp type splices don't have a problem because the deform the bundle enough during crimping to form a solid. Crimp type rings or forks have a good connection at the wire bond but still have a problem with the screw end.

FWIW There may be yet another issue at play with materials. Back when we were younger and the US dominated the market quality manufacturers worked to match materials in wire, terminals and screws for temperature expansion. That was from lessons learned way back when electricity was being commercialized. The influx of cheap foreign competition flooded the market with product designs based solely on cost. The result is a lot of product with materials that do not play so well together.
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