Hi, Before investing in the Greaves adapters, I previously bought both normal and narrow 4/0 ferrules. Neither fit the 4/0 max terminal block of the Fortress Envy.
On Sat, Jan 24, 2026 at 8:36 AM Jay via RE-wrenches < [email protected]> wrote: > I got curious about ferrules. > > Turns out they come in different physical sizes for the same wire size. > > I’ve found .63” and .69” OD for 4/0 wire. > > With .69 being more normal and. .64 called small diameter > > Try measuring what you’ve got. Or the actual diameter in the inverter. > > I’m mean no excuse for the rep being clueless > > Jay > > > > On Jan 23, 2026, at 10:46 AM, Kirk Herander via RE-wrenches < > [email protected]> wrote: > > > William, All, > > I was at a workshop on the (sort of) new Fortress battery product the > other day. I brought up this very > issue of the terminal lugs of the Envy not accepting a 4/0 ferrule, even > though 4/0 cable with ferrules are recommended in the manual. The > instructor had no comment, except to imply that maybe one should use 3/0 > max. Huh? > > Anyway these Greaves pin adapters are by far the best I've found for > working with the 4/0 terminal block. > The pin diameter matches 4/0 cable and thus fits great. Preferable IMO to > a reduced 4/0 barrel to 2/0 pin of AL or AL-clad others. And the barrel has > a generous flange which makes it quite easy to insert high-strand flex > cable. > #PT 222FX40. But @ $50 ea, not cheap. > > <image.png> > > > On Wed, Sep 3, 2025 at 7:10 PM William Miller via RE-wrenches < > [email protected]> wrote: > >> Friends: >> >> >> >> My understanding is if the lug has a set-screw that contacts the strands, >> fine strands can wind around the set screw, get into the threads and not >> tighten adequately. If you are crimping fine strands inside of some type >> of barrel your connection should be OK. >> >> >> >> I had been using Outback until they imploded and all of the battery >> connections were via studs or bolts that required crimped-on rings. Now I >> am back to set screw lugs and fine stranding became an issue again. >> >> >> >> I did try another experiment: I took a 4/0 ferrule that would not fit >> into the Envy lugs and snipped a section out of it. I curled it into a >> slightly smaller diameter and it fit into the lug. I suppose one could cut >> the ferrule in half longitudinally and insert a portion of the ferrule >> between the set screw and the strands. >> >> >> >> I am pleased with the copper sheeting wrapped around the fine strands. >> That will be my SOP. >> >> >> >> William >> >> >> >> Miller Solar >> >> 17395 Oak Road, Atascadero, CA 93422 >> >> 805-438-5600 >> >> www.millersolar.com >> >> CA Lic. 773985 >> >> >> >> >> >> *From:* RE-wrenches [mailto:[email protected]] *On >> Behalf Of *Ray Walters via RE-wrenches >> *Sent:* Wednesday, September 3, 2025 1:40 PM >> *To:* [email protected] >> *Cc:* Ray Walters >> *Subject:* Re: [RE-wrenches] Ferrules for large fine-stranded wire. >> >> >> >> I've got to ask: Are none of the lugs on these Chinese inverters approved >> for fine strand cable? I just have not had a problem with that, but I've >> mostly used Magnum, Midnite, and Outback equipment over the years. What >> were the lugs on the old Trace DC 250 boxes? Were they fine strand rated? >> They sure were tough to get 4/0 into, as William mentioned. >> >> Ray >> Remote Solar >> >> On 9/3/2025 12:57 PM, Kent via RE-wrenches wrote: >> >> William, >> >> If the only reason the ferrule wouldn't fit after using the hex crimper >> was the ridge left where the dies meet, you could rotate the cable 120 >> degrees and crimp the ferrule again. >> >> I doubt that the indenter crimper will do a decent job with large >> ferrules. >> >> I do like your thin piece of copper solution. Not UL approved but I dare >> say wrench approved. >> >> Kent Osterberg >> Blue Mountain Solar >> >> >> >> On 9/2/2025 8:55 PM, William Miller via RE-wrenches wrote: >> >> Friends: >> >> >> >> Thank you for all of your input on this question. I feel it only right I >> report back how this turned out >> >> >> >> I tried a crimper like this: >> >> >> >> >> >> >> >> It left a jagged ridge on both sides of the ferrule where the dies met. >> >> >> >> The crimper below was suggested but I have not tried it: >> >> >> >> This was suggested but I have not tried it either: >> >> >> >> >> >> _______________________________________________ >> List sponsored by Redwood Alliance >> >> Pay optional member dues here: http://re-wrenches.org >> >> List Address: [email protected] >> >> Change listserver email address & settings: >> http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org >> >> There are two list archives for searching. When one doesn't work, try the >> other: >> https://www.mail-archive.com/[email protected]/ >> http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org >> >> List rules & etiquette: >> http://www.re-wrenches.org/etiquette.htm >> >> Check out or update participant bios: >> http://www.members.re-wrenches.org >> >> > > -- > > > *Kirk Herander / **[email protected] <[email protected]>* > > *Owner|Principal, VT Solar, LLC* > > *Celebrating our 35th Anniversary 1991-2026!!* > > dba Vermont Solar Engineering > > 802.559.1225 > _______________________________________________ > List sponsored by Redwood Alliance > > Pay optional member dues here: http://re-wrenches.org > > List Address: [email protected] > > Change listserver email address & settings: > http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org > > There are two list archives for searching. When one doesn't work, try the > other: > https://www.mail-archive.com/[email protected]/ > http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org > > List rules & etiquette: > http://www.re-wrenches.org/etiquette.htm > > Check out or update participant bios: > http://www.members.re-wrenches.org > > _______________________________________________ > List sponsored by Redwood Alliance > > Pay optional member dues here: http://re-wrenches.org > > List Address: [email protected] > > Change listserver email address & settings: > http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org > > There are two list archives for searching. When one doesn't work, try the > other: > https://www.mail-archive.com/[email protected]/ > http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org > > List rules & etiquette: > http://www.re-wrenches.org/etiquette.htm > > Check out or update participant bios: > http://www.members.re-wrenches.org > > -- *Kirk Herander / **[email protected] <[email protected]>* *Owner|Principal, VT Solar, LLC* *Celebrating our 35th Anniversary 1991-2026!!* dba Vermont Solar Engineering 802.559.1225
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