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3. Installation
3.1. Mounting
• Mount vertically on a non-flammable surface, with the power terminals facing downwards.
• For optimum performance, a minimum of 10cm space should be kept free around the product for cooling. With limited
cooling, e.g. due to insufficient ventilation, the charging current will be reduced sooner than at the specified maximum ambient
temperature. With improved airflow (e.g. forced airflow), the performance will greatly improve.
• With limited cooling or extreme ambient temperature, the charger can become hot (especially the bottom plate). Due to internal
temperature control, the bottom plate will never get warmer than 90 °C; this is no problem for the charger. Make sure that the
mounting surface can withstand this temperature.
• Mount close to the battery but never directly above the battery (to prevent damage from gassing of the battery).
3.2. Cable type recommendations
For correct connection of a cable to the input/output screw terminals, stranded wires with flexible and very flexible cores can be
used according to:
• IEC 60228 - Class 2 (stranded), Class 5 (flexible), Class 6 (very flexible)
• UL486A-B - Class B/C (stranded), Class I (flexible), Class K (very flexible)
Cables with twisted cores are very stiff, which means that they are rarely used in practice. The table below provides an overview
of how to recognise the different wire classes.
Nominal cross section
Class 5 (IEC)
2
10mm
0.4mm
6AWG
-
2
16mm
0.4mm
4AWG
-
2
25mm
0.4mm
The use of ferrules is not required for cables from the above table. If an even thinner cable is used, a ferrule can help to bundle
the loose wires. However, it is up to the installer to make sure that the cable is properly secured. The connecting cable, with or
without a ferrule, should be adequately clamped to ensure low contact resistance.
Preparation for correct mounting of fine-strand wires in the screw terminal block
1.
Cut the cable straight with no loose or staggered threads. Using wire cutters will result in a straight cut.
2.
Make sure no fine wires are cut when stripping the insulation.
3.
Open the screw on the screw terminal block completely to prevent fine wires from getting caught behind the screw and
bunching up. Pay particular attention to this when using the maximum wire diameter.
4.
Tighten the screw with the correct torque; see
less than the recommended torque.
5.
Hold the recommended torque for at least 5 seconds; this will give the screw time to settle to the set torque. This maximises
the force on the wire, thereby maintaining a gas-tight contact pattern during heating and cooling cycles over time. Take the
time to do it right. This is important. This is a UL486 test requirement and a requirement for all factory and field installations.
Page 5
Manual - Orion XS 12/12-50A DC-DC battery charger
Single wire diameter in the bundle
Class 6 (IEC)
0.2mm
-
0.2mm
-
0.2mm
Recommended torque [6]
Class I (UL)
Class K (UL)
-
-
24 AWG
30 AWG
-
-
24 AWG
30 AWG
-
-
and note the wire size and wire class. Never apply
Installation
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