Need to butt #6 welding wire.

[davidceder]

Hey Guys and Gals

Is there a safe means of butting together two lengths of #6 welding wire? I need to extend a wire to a circuit breaker box and install a circuit breaker. The CB needs to be 30AMP 150 VDC and I do not want the butt to be the weak link. This circuit will disconnect my solar controller from a straight run to my house batteries. When the controller was installed they did indeed put in a similar circuit to isolate the panels from the controller but the controller continues to draw off the batteries even with the house battery switch turned off. (makes sense to me) but they should have a switch for the controller as I am under cover so solar system is in-op. You would think the manufacturer of the controller (Morningstar) would have a switch on the unit but that is not the case. This is on my 2017 Bay Star 3401 recently purchased used.

Thanks

[redbaron73]

This is one method, a Morris connector

https://amzn.to/2H0pVnP

[KiteSquid]

Some type of terminal block.

[arcaguy]

I'd go to the local welding supply and see what they have. Whatever you do make it water tight so it doesn't corrode. A corroded connection will get hot and might start a fire.

[Johninar]

I'm not a fan of aluminum splices.
https://www.arc-zone.com/Heavy-Duty-...RoCuHgQAvD_BwE

[TJ]

Originally Posted by Johninar

I'm not a fan of aluminum splices.
https://www.arc-zone.com/Heavy-Duty-...RoCuHgQAvD_BwE

Me either! Go with the ones Johninar suggests.

TJ

[stang37]

There are a lot of different butt splice devices available. Just Goggle #6 AWG copper wire splices. You can get compression or screw type connections. They will require some type insulation to be place on the splice after installed. More search and you might find some that are already insulated. Good luck

[Stuart W]

A junction box with a insulated stud and lugs on both wires

[rarebear.nm]

I have used both screw and compression type butt connectors. You will want/need to insulate the splice to make it safe and keep moisture away from it. In most cases I use double wall adhesive lined heat shrink tubing. Perhaps a couple of layers. A good quality electrical tape may insulate just fine with several wraps, but I prefer the heat shrink option.

If you use a crimp type you need to use a quality compression tool at that gauge of wire. I use a pair of 10 ton crimpers: IMO- the hammer driven crimpers do not get a good uniform crimp around the entire connector.

https://www.amazon.com/PENSON-CAYQK0...gateway&sr=8-1

[10 fan]

Home Depot sells insulated splice connectors, good quality.

[BMGM37]

I prefer this style of connector, simple, solid and insulated and filled with an anti-oxidant.

https://www.amazon.com/Morris-97017-...a-490797089427

[ptw]

Originally Posted by rarebear.nm

If you use a crimp type you need to use a quality compression tool at that gauge of wire. I use a pair of 10 ton crimpers: IMO- the hammer driven crimpers do not get a good uniform crimp around the entire connector.

https://www.amazon.com/PENSON-CAYQK0...gateway&sr=8-1

Attachment 244781

I worked 35 years in electrical power distribution. The hydraulic crimp is the best way to go. Our hydraulic crimpers started at around $2000. So, how well does a $35 crimper work? I may have to buy one for home.

[BCam]

I have a question: Why are you using welding wire? Is there some advantage to using it over copper electrical wire?

[10 fan]

Very flexible and because of the high strand count usually has a higher ampacity.