How to Crimp Cables and Introduction to the Toolbox

The process of crimping photovoltaic cables generally refers to the procedure of connecting the wires of photovoltaic modules with connectors or terminals through a crimping process. This ensures that the current flows efficiently and safely from the photovoltaic modules to the inverter and can withstand long-term outdoor environmental conditions. The quality of crimping directly affects the performance and stability of the system.

Here are the basic steps of the photovoltaic cable crimping process:

1. Preparation

• Tool Preparation: Common tools include crimping pliers (manual or electric), crimping dies, wire strippers, insulating tape, etc.
• Material Inspection: Ensure that the photovoltaic cables, connectors, and terminals meet relevant standards and are free of damage or corrosion.
• Personal Protection: Wear appropriate protective equipment to ensure safety during operation.

2. Stripping the Cable Outer Insulation

• Use wire strippers to remove the outer insulation of the photovoltaic cable to expose the internal conductor. The length to strip should be based on the connector’s requirements, generally leaving enough length to ensure a good contact.
• When stripping, avoid damaging the internal conductor.

3. Check Cable and Terminal Compatibility

• Select the appropriate terminal based on the specifications of the photovoltaic cable. Ensure that the terminal fits the cable size and can securely enclose the conductor.
• If the terminal and cable are mismatched, it will lead to poor contact, affecting electrical performance.

4. Insert the Cable into the Terminal

• Insert the stripped cable conductor into the terminal, ensuring that the conductor is fully seated inside the terminal and not exposed outside.

5. Crimping with Crimping Pliers

• Use crimping pliers to crimp the terminal according to its specifications. The pressure and number of crimps should be adjusted based on the material and size of the cable and terminal. Typically, the crimping process should form a flat, tight contact area.
• Different crimping dies are used for different terminal shapes, so match the appropriate one.

6. Inspect Crimping Quality

• After crimping, visually inspect the crimp to ensure there are no visible defects such as deformation, cracks, or looseness.
• You can also use a crimping quality tester to check the electrical connection and ensure the crimp is good.

7. Insulation Treatment

• If necessary, apply insulating tape to the crimped area, or use heat shrink tubing to protect the joint from external environmental factors and improve its weather resistance.

8. Testing

• After crimping, conduct an electrical test to ensure the connection is good, and current flows smoothly.

Key Considerations:

• Crimping Force Control: Too much or too little crimping force will affect the quality of the joint. Excessive force can damage the cable, while insufficient force may not form a good electrical connection.
• Cleanliness: Ensure the cable and terminal are free from oil, dirt, or corrosion before crimping.
• Environmental Considerations: Since photovoltaic systems are usually exposed to outdoor conditions, the crimped connection must be water-resistant and corrosion-resistant.

This process ensures reliable electrical connections for photovoltaic cables, preventing failures caused by poor contact and improving the overall performance and lifespan of the photovoltaic system.