[RE-wrenches] Flexible stranded Connectors

[Glenn Burt]

Hi Ray,

I've had good success with the Cobra X Flex cables for the battery runs,
then using a Greaves Shoo-Pin adapter to transition from fine stranded to
regular stranding. I think the design of the SI lugs has changed, but they
used to have two terminals per battery pole - so what I have done is in the
trough below the SI's I brought the x-Flex near the vertical conduit into
the SI, crimped on a Shoo-Pin adapter (I can send you cut sheets directly
along with other pictures if you like), used a 3 position Polaris splice
with two lengths of THWN running up into the conduit to the SI terminals.

I had them special ordered through GEXPRO - a local distributor here.

-Glenn

-----Original Message-----
From: re-wrenches-bounces at lists.re-wrenches.org
[mailto:re-wrenches-bounces at lists.re-wrenches.org] On Behalf Of Ray Walters
Sent: Wednesday, April 30, 2014 1:48 AM
To: RE-wrenches
Subject: [RE-wrenches] Flexible stranded Connectors

Hi All;

In order to avoid any of my work showing up in someone's slideshow of
horrors, I'm trying to find the correct way to wire 3 Sunny Islands with
Cobra X flex cable.
While it doesn't actually mention it in the SMA manual, a call to SMA tech
support confirmed my suspicions: the DC lugs in the inverter are NOT rated
for flex or fine stranded cable.
Both SMA and CED recommended I try Grainger's for crimp on adapters.  
Grainger had no clue, and nothing came up in searches there.
 From a trade show, I have an ILSCO lug book, that shows a crimp on pigtail
adapter.  It does not mention whether its flex rated though on the crimp
side of the adapter, as the adapter is used primarily to land over sized
cables into smaller lugs.  (2/0 to #1, for instance) The best I've found so
far, is NSI, which makes sleeves, that are installed around the wire, right
in the connection:
http://www.nsiindustries.com/products/electrical/connectors/compression-conn
ectors/copper-compression/fsflex-cable-sleeve.aspx
I also found a Schneider white paper recommending sleeves with their lugs:
http://static.schneider-electric.us/docs/Circuit%20Protection/0515DB0301.pdf

So who has used these sleeves, and where do I get them?
The sleeves seem like a decent compromise, whilst the ILSCO pigtail adapters
are coming in at $40/ ea...... (ouch)

On the internet, I'm seeing several examples of X flex used directly (no
adapters) with the Sunny Islands, so are folks just blowing off articles
690.31(F) and 110.14, that specify the connector be rated for flex cable?
And finally, couldn't SMA use a lug that was flex rated?
For example, Marathon makes Class K rated mechanical Lugs: 
http://www.marathonsp.com/NewRatings.html
I'd use THHN, but I really don't feel good about wiring the Heineman
breakers with that stiff a wire.  I've cracked breaker cases
before......that's why the X flex is industry standard for off grid DC.

Thanks for your help,

--
R.Ray Walters
CTO, Solarray, Inc
Nabcep Certified PV Installer,
Licensed Master Electrician
Solar Design Engineer
303 505-8760

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