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Tesla Universal Wall Connector - Wires Fanning Out Under Terminal Screw - Safe?

L

Lightning McQueen

Member
Location
United States
Occupation
N/A
The Gen 2 Tesla Wall Connector specifically stated that ferrules were safe to use. The new Gen 3 doesn’t mention anything about ferrules, so I assume they’re not approved.

When installing #8 THHN on a 50A Breaker (40A Charge rate) I notice the wires will NOT land perfectly flush under the terminal screw.

No matter how much they’re twisted and centered, the wires start to fan out when torquing to the required spec.

https://imgur.com/a/kNNJm1v

They’ve been torqued to spec, pulled on, and torqued to speed again. Will this cause any issues?
 
L

Lightning McQueen

Member
Location
United States
Occupation
N/A
infinity said:
No. You're using the terminal as designed and it is installed according to its instructions so you're good to go.

Welcome to the Forum. :)
Click to expand...
I didn’t realize I had a typo, I meant “They’ve been torqued to spec, pulled on, and torqued to spec again.”

Glad to hear there aren’t any issues with the wire slightly fanning away from the screw and that this looks good and installed to spec! Thanks for having me in the forum (y)
 
L

Lightning McQueen

Member
Location
United States
Occupation
N/A
infinity said:
No. You're using the terminal as designed and it is installed according to its instructions so you're good to go.

Welcome to the Forum. :)
Click to expand...
LarryFine said:
View attachment 2574954
Click to expand...
One more question…

Here’s a close up of L1 - You can see that this one wire fans out, but landed under the terminal screw.

https://imgur.com/a/UVDUzJY

If that wire ever touches the black plastic next to it (while still secured under the terminal screw) could that cause any issues like melting or heat build up?

I’m 99% sure it wouldn’t cause any issues, but wanted to ask. Thanks again!
 
R

retirede

Senior Member
Location
Illinois
electrofelon said:
A little aside but related to your concern. I am not pleased with many/most set screw terminals and often see strands not clamped well and even just floating in mid air. I am skeptical much actual testing is done with these things. In general I think a clamp type of termination would be better and wish that was the standard.
Click to expand...

Agreed. Set screw terminals without a non-rotating clamping surface should be limited to solid wire.
 
L

Lightning McQueen

Member
Location
United States
Occupation
N/A
electrofelon said:
A little aside but related to your concern. I am not pleased with many/most set screw terminals and often see strands not clamped well and even just floating in mid air. I am skeptical much actual testing is done with these things. In general I think a clamp type of termination would be better and wish that was the standard.
Click to expand...
retirede said:
Agreed. Set screw terminals without a non-rotating clamping surface should be limited to solid wire.
Click to expand...
Agreed. A clamp type termination would be best!

I had one more question if you wouldn’t mind taking a look and providing feedback when you have a moment. Thanks
 
W

winnie

Senior Member
Location
Springfield, MA, USA
Occupation
Electric motor research
electrofelon said:
A little aside but related to your concern. I am not pleased with many/most set screw terminals and often see strands not clamped well and even just floating in mid air. I am skeptical much actual testing is done with these things. In general I think a clamp type of termination would be better and wish that was the standard.
Click to expand...
It appears that the set screws twist right against the wires with no sort of saddle or intermediate protector.

IMHO these sort of connectors should always require (or at least permit) the use of ferrules.

I wonder if twisting the wires in the opposite direction would make them tighten up when the set screw twists against them.
 
M

MD Automation

Senior Member
Location
Maryland
Occupation
Engineer
electrofelon said:
In general I think a clamp type of termination would be better and wish that was the standard.
Click to expand...
winnie said:
It appears that the set screws twist right against the wires with no sort of saddle or intermediate protector.
Click to expand...
Agreed, a saddle type clamp where the screw does not bear directly on the wire is a much better connection, particularly for stranded wires.

This is a view of the redesigned Leviton 14-50R, showing exactly that type of connection. The Allen screw brings up the lower saddle to squeeze the entire wire - solid or stranded - against the fixed top plate.

IMG_3203.jpg
 
electrofelon

electrofelon

Senior Member
Location
Cherry Valley NY, Seattle, WA
winnie said:
It appears that the set screws twist right against the wires with no sort of saddle or intermediate protector.

IMHO these sort of connectors should always require (or at least permit) the use of ferrules.

I wonder if twisting the wires in the opposite direction would make them tighten up when the set screw twists against them.
Click to expand...
Yeah what is with ferrules anyway? They don't really seem to be a thing here in the states like they are in the rest of the world.
 
roger

roger

Moderator
Staff member
Location
Fl
Occupation
Retired Electrician
Lightning McQueen said:
The Gen 2 Tesla Wall Connector specifically stated that ferrules were safe to use. The new Gen 3 doesn’t mention anything about ferrules, so I assume they’re not approved.

When installing #8 THHN on a 50A Breaker (40A Charge rate) I notice the wires will NOT land perfectly flush under the terminal screw.

No matter how much they’re twisted and centered, the wires start to fan out when torquing to the required spec.

https://imgur.com/a/kNNJm1v

They’ve been torqued to spec, pulled on, and torqued to speed again. Will this cause any issues?
Click to expand...
So assuming you made this termination what did your supervisor say? The members here are only viewing pictures, your supervisor is on site and would undoubtedly be able to critique better than we can.
 
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