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Step 6: Connecting the DC Cables
NOTICE
REVERSE POLARITY
Check cable polarity at both the battery and the Freedom
n
EX 4000 before making the final DC connection. Positive
must be connected to positive; negative must be
connected to negative.
Reversing the positive and negative battery cables will
n
blow a fuse in the Freedom EX 4000 and void your
warranty.
Failure to follow these instructions can result in equipment
damage.
WARNING
FIRE HAZARD
Use only stranded, copper wire rated minimum 75 °C (105 °C for
marine installations). Make sure all DC connections are tight to a
torque of 71–80 in-lb (8–9 Nm) of force. Loose connections will
overheat.
Failure to follow these instructions can result in death, serious
injury, or equipment damage.
Follow the procedure given below to connect the battery leads
to the terminals on the DC end. The cables should be as short
as possible and large enough to handle the required current, in
accordance with the electrical codes or regulations applicable to
your installation. Table 1 specifies the minimum DC cable size
and maximum fuse size for the Freedom EX 4000.
If at all possible, minimize routing your DC cables through an
electrical distribution panel, battery isolator, or other device that
will cause additional voltage drops which can degrade the
inverter/charger/converter's ability to operate the loads.
Figure 17 48V DC connections
1 2
1
captive nut panel screw
2
negative (–)
3
positive (+)
975-0998-01-01
3
To make the 48V DC connections:
1. Make sure the inverter/charger/converter is off and no AC
or DC is connected to the unit.
2. Remove the wiring compartment cover by loosening the
captive nut panel screw.
NOTE:
Use a screwdriver to loosen the captive nut panel screw.
3. Loosen the DC terminal nuts from the terminal bolts and
set them aside for later.
4. Strip ½" (13 mm) to ¾" (19 mm) insulation from one end of
each cable. The amount stripped off will depend on the
terminals chosen.
5. Attach the connectors that will secure the cables to the
battery, to the disconnect/battery selector switch, and the
fuse block. The connectors you use must create a
permanent, low-resistance connection. It is recommended
to use approved and certified cable ring lugs. Use the tool
recommended by the terminal manufacturer. Make sure no
stray wires protrude from the lug or terminal.
NOTE: You may find it more convenient to have the cable
lugs attached by the company that sells you the cable
and/or connectors.
6. Strip ½" (13 mm) to ¾" (19 mm) of insulation from each
cable end that will be connected to the
inverter/charger/converter. The amount stripped off will
depend on the terminals chosen.
7. Attach the cable ring lug that will join the cable to the
inverter/charger/converter DC terminal. Cover the lug
stem with heat shrink insulation (see Step 6: Connecting
the DC Cables) to ensure that the lug does not touch the
enclosure.
8. Install a fuse and fuse holder in the cable that will be used
for the positive side of the DC circuit. The fuse must:
a. be as close to the battery positive terminal as
possible
b. be rated for 48V DC circuits
c. have an Ampere Interrupting Capacity (AIC) that
exceeds the short-circuit current available from the
battery (that is, Class T fuse)
9. To prevent sparking when making the connection, ensure
the disconnect/battery selector switch is off.
10. Route the positive cable through the right side strain relief
clamp and attach the cable lug on the positive cable to the
positive 48V DC terminal on the
inverter/charger/converter.
11. Fasten the DC terminal nut (set aside earlier) to the
terminal bolt. Tighten the nut to a torque of 8–9 N-m (71–
80 in-lb ) of force. Do not overtighten. Make the connection
snug enough so the cable lug does not move around on the
DC terminal. Center it through the DC knockout hole and
do not let it touch the edge. See Step 6: Connecting the
DC Cables on page 31.
Basic Installation Procedures
31
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