Is this wiring termination safe?

[Nalgene]

I’m finishing up my wiring for my T6 conversion and have 25mm^2 wire for my Orion XS 12 | 12 50A. Its a really tight squeeze and in the end I’ve had to snip a few frayed strands where they just wouldn't go into the terminal. Does this look safe? Obviously I want my wiring to be safe but also not looking forward to the prospect of having to rip these out and replace with 16mm^2 if that’s the only alternative!

 

[Rioja John]

I would use something like these but insulated.

ET25B | SUPERLEC | 25mm Uninsulated Crimp Blade | Crimp Blade Terminal | Electrical Cable Ends -Superlec Direct

duckduckgo.com

 

[tommy_t6.1]

Not really, you want as little of the copper core exposed as possible.

 

[Pewt]

Use wire ferrules.

 

[Nalgene]

Thanks all so far.
@Rioja John These look decent, just slightly worried about the connection they'll make with the screw terminal as the blade won't have the same 'give' as wire so worried it'll wriggle loose. Am I overthinking it?
@tommy_t6.1 By that do you mean the issue is mainly that I've stripped too much insulation back?
@Pewt I did try to use normal uninsulated bootlace ferrules but they don't fit in the Orion XS with 25mm wire

 

[TallPaul_S]

I wouldn't be happy with that, 16mm wire is still fairly tight in the XS 50a. I'd do them again, just making sure the screws are fully wound out. Also, make sure the strain relief cover sits correctly and that the cable outer diameter is big enough. On 16mm you need extra heatshrink.

 

[Nalgene]

I wouldn't be happy with that, 16mm wire is still fairly tight in the XS 50a. I'd do them again, just making sure the screws are fully wound out. Also, make sure the strain relief cover sits correctly and that the cable outer diameter is big enough. On 16mm you need extra heatshrink.

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Thanks for the reply. with the 25mm wire its just so difficult to get the wire in the terminal - it seems the terminal itself is 25mm so getting stranded wire to fit into it exactly is proving a nigh on impossible task! Thanks for the comment on strain relief too - on the wire I'm using it is completely filling the hole so no extra heatshrink needed there by the look of it. Unless I give up and switch to 16mm I guess!

 

[Dellmassive]

Just finish them off with some heat shrink. (To control some of those stray ends,)

Add extras layers of heatsinks if needed to bulk out the thickness for the cable clamp bracket.

And make sure you use the correct screw driver to screw the terminals up as per spec... Ie super tight..

If not the terminal will burn and melt.!!!

 

[Howzat]

Slide on some heat shrinks then snip away a % of the strands until the ends fit without any strays then push up the shrink to the terms.

 

[Samiguel]

Slide on some heat shrinks then snip away a % of the strands until the ends fit without any strays then push up the shrink to the terms.

I solved a similar issue with 16mm cable on a Victron MPPT.

Once you have stripped back the insulation, slide some heat shrink down the cable and then use a Stanley knife to cut another "ring" of insulation about 3-4mm long by rolling the cable around along the blade.
Slide this ring up the copper until it is flush with the tips of the wires. Offer this up to the connector and then push in - the ring of insulation keeps all the conductors together and slides back down them as you push in. Tighten screw on the connector and then slide the heat shrink up tightly to the terminal and shrink it.

Low tech solution, but worked well for me!

 

[sparkywig]

As previously mentioned, use crimp pin ferrules and heat shrink. You can get different size pins for smaller terminals.
It's just bad practice to trim conductors to fit terminals