How to Connect 6awg SOOW Wire to AC Busbars

I'm using 6 Awg SOOW cable for my AC electrical connections in my mobile cargo trailer build. Was going to use MC, but I thought the SOOW looked clearer.

Problem I'm having is connecting the fine stranded 6 awg wire to busbars and screw terminals. When the screw bites, some of the the wires spread out from under the screw.

Solutions?

What is the correct North American way to connect SOOW in this way? Seems ferrules might work, but is that correct for NA? And if it is correct, Im guessing I'd need a crimper? Square? Or multi sided?

Not sure if you already found out (search engines are fairly clever about spellings) but they are wire ferrules.

I believe some of them are designed to simply deform under the pressure of the screw. I dont know much about various types of ferrules. But i might after enough other people drop in here and educate us. ?

Ferrules or pin terminals.
If the mechanical lug is square use a square or coupon crimper.
If its a round mechanical lug with a big set screw let the lug deform the ferrule.

Switch to 6AWG romex, problem solved. Stop trying to use DC wiring practices on your AC system where they create unnecessary problems.

This works ok for 6 awg.

Lilikoi_Heavy_Industries said:

Switch to 6AWG romex, problem solved. Stop trying to use DC wiring practices on your AC system where they create unnecessary problems.

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Sounds to me like he was seeking a certain ‘finished’ look without having to install a separate conduit. I could understand that as a motivation if you’re trying to make something look good to make you happy and the thought of cutting/forming/assembling rigid conduit, or pulling wire through flexible conduit, does not seem like a fun way to accomplish it. ?‍

Vigo said:

Sounds to me like he was seeking a certain ‘finished’ look without having to install a separate conduit. I could understand that as a motivation if you’re trying to make something look good to make you happy and the thought of cutting/forming/assembling rigid conduit, or pulling wire through flexible conduit, does not seem like a fun way to accomplish it. ?‍

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How much better does it really look? The black jacket on 6/3 NM-B looks just about the same as the wire in the picture.


Check out the recent youtube video from current connected, installing into a MultiplusII spring terminal block with 6AWG wire. He runs the black outer jacket of the wire all the way up to where a traditional conduit/nipple connection would end so that you never see the individual AC wires when the inverter wiring cover panel is installed. It's a different inverter but an example of the wire that I'd recommend.

You’re right. When you said Romex my mind went straight to the hideous yellow stuff im most used to seeing (12/2, 14/3 etc) and i totally overlooked the fact that you can also get larger multi-conductor with the same sort of black jacketing.

Vigo said:

You’re right. When you said Romex my mind went straight to the hideous yellow stuff im most used to seeing (12/2, 14/3 etc) and i totally overlooked the fact that you can also get larger multi-conductor with the same sort of black jacketing.

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I think we've all seen somebody try to use some 12ga romex in the worst possible way, I totally get it!

Correctly sized romex for AC wiring, inside the house? Right tool for the job! Can go UF if needing to handle burial and UV exposure, it has similar stranding but more durable insulation. UF is harder to find at the store.

EDIT: I probably deserve to be called out for this "inside the house" statement, the poster gave more "mobile" details. If somebody has clearly written requirements that have your *AC* connections switch over to finely stranded/ferrule connections in a mobile environment, that's cool... But it should be documented if so, and each lug in the system and each ferrule should be listed compatible with that usage, either by manufacturer or independent testing. As it is, we just do very robust and durable AC wiring in trailers and motorhomes, extra precautions against vibration wear, etc. So much respect if you can provide all of that clearly written documentation!

Since ferrules are cheaper than replacing all my conductors, I went with ferrules. Kit should be here Monday.

I'll redo all connections under screw terminals and busbars, but I think the wires that terminate in breaker cage style connectors are fine as they are not directly pushed by a screw but rather pulled togetger by the cage.

Lilikoi_Heavy_Industries said:

Switch to 6AWG romex, problem solved. Stop trying to use DC wiring practices on your AC system where they create unnecessary problems.

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Your right. I finally got the SOOW installed but it was a pain ish.

That said, it did start a new love affair with ferrules . Man I LOVE THOSE THINGS. Just got a set yesterday.

I think the wires that terminate in breaker cage style connectors are fine as they are not directly pushed by a screw but rather pulled togetger by the cage.

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I don't know much terminology for different connection types. Took me a minute on google to figure out if i was thinking about the same thing you were.. found this:
Cage Clamp pdf

Which is definitely 'suitable' for stranded although it may or may not be someone's preference. To me it seems to be the same thing as the 'push to connect' option on a lot of household 5-15r receptacles which i have personally found to be the cause of many problems over time. But.. on solid wire, not stranded. Not sure i've ever used something like the above on stranded wire, except perhaps on speaker enclosure terminals? If this is considered the same type of connection that's on those Wago lever-nuts, i trust those quite a lot. Video testing common AC connectors

But i was actually thinking about a different style.. what is it called when the screw is pulling up a 'box' or 'wall' from the bottom until it pinches the wire to the top? I like those a lot. Don't know the name..

Vigo said:

But i was actually thinking about a different style.. what is it called when the screw is pulling up a 'box' or 'wall' from the bottom until it pinches the wire to the top? I like those a lot. Don't know the name..

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That is what all my Breakers are.