Wiring The Charging Device - intervolt DCC Pro Installation & Operation Manual

Wiring the Charging Device

Using the correct cable gauge size for the task is paramount to performance
and safety. Please refer the table below for the minimum recommended cable
size (cross section) required in order to prevent Voltage drop.
Cable Run Length
1-5 Metres
5-9 Metres
All cable lugs must be properly terminated using appropriate tooling in
order to prevent poor contact which can result in overheating of the stud.
An example of the correct method of termination is depicted below.
COPPER LUG FOR
POWER TERMINATION
The DCC Pro is fully protected electronically against catastrophic failure. It is
mandatory however that inline fuses are tted to protect the wiring in the event
of an external short circuit. The fuse rating should not be less than the
continuous current rating of the wiring. The table below details the
recommended fuse size for all required wiring.
Main
Fuse rating 40A minimum
There are four large power terminals, one each for the main and auxiliary
batteries, one for the solar panel and one for the negative connection. A lug
with a 6mm diameter hole should be used for terminating these four cables.
There is a single, smaller control terminal which is used when Ignition Control
mode is implemented. Spring washers are not required.
DO NOT USE POWER TOOLS TO FASTEN TERMINAL SCREWS
All terminals should be fastened with hand tools and care should be taken not
to over-torque the screws. The torque settings are detailed in the table below.
Maximum torque rating
Minimum Conductor Size
6 mm²
10 mm²
Solar
To solar panel spec.
Main/Auxiliary/Solar/Negative
5.0 Nm
Recommended SAE Equivalent
8 B&S/AWG (7.91mm²)
6 B&S/AWG (13.56mm²)
CRIMP LUGS FOR
IGNITION TERMINATION
Auxiliary
30A minimum
Ignition
1.5 Nm
17