CTEK SMARTPASS 120 Installation Procedure

SMARTPASS 120/120S LAYOUT
+IN
SMARTPASS 120S
CABLE AND FUSE REQUIREMENTS
CONNECTION
Negative Cable (black)
Connector Plate **
* Max current rating for SMARTPASS 120/120S is 50A. During installation, a fuse rated up to 50A should be installed. When connecting multiple consumers, individual fuses
should be used with the sum of max load not exceeding 50A.
** If the D250SE and SMARTPASS 120/120S are installed in different locations and the accompanying connector plate is not used, please follow the recommendations in
the table.
INSTALLATION INSTRUCTIONS
Installation must be carried out by a person suitably qualified or experienced in automotive installations.
Incorrect installation can cause harm to the user, vehicle, connected devices, D250SE and SMARTPASS 120/120S.
1
Identify a suitable smooth, stable and non-combustible surface where
the device(s) (D250SE and/or SMARTPASS 120/120S) can be firmly
secured and ventilated without exposure to fuel, oil or dirt. This selected
area must allow 100mm spacing around the device(s) for heat dissipa-
tion.
Do not install the device(s) upside down.
NOTE: If a non-combustible surface is not available, use the included
metal bracket in between the mounting surface and device.
2
If using D250SE together with SMARTPASS 120/120S, fit the two units
together with the included connector plate before mounting them to the
identified surface.
3
Torque-tighten the device(s) with M4 or ST4.2 screws to 2Nm/18 lb-in
each corner.
!
Before proceeding to the next steps, ensure the service battery and starter
battery are disconnected.
4
Connect the INPUT and OUTPUT cables to the device by securing screws
(M8).
Ensure the cables are fixed to the underlying surface closely to the
D250SE and/or SMARTPASS 120/120S using cable ties or alternative
fixing methods to prevent loosening of connection terminals due to
vibrations and force applied to the cables.
Torque-tighten the screws after attaching the ring terminals to
8-14Nm/71-124 lb-in.
NOTE: Maximum ring terminal thickness is 6mm. Check the torque of
the screws on a regular basis to avoid overheating and short circuiting
connections.
MAINTENANCE WORK
!
Before carrying out any service work in the electrical system, disconnect the Negative cable (black) connection to SMARTPASS120/120S. Reconnect ground cable as
the final step after batteries are connected again, see below.
Disconnect BOTH batteries in the dual battery system when replacing or need to disconnect one of the batteries due to service or reparation. Keeping one of the batteries
connected can cause severe damage to SMARTPASS 120/120S and other electronics.
!
Check status of SMARTPASS 120/120S and D250SE after completion of installation or service work. Refer to D250SE AND SMARTPASS 120/120S INDICATORS section
in the manuals for further information
SMARTPASS 120/120S MANUAL AMENDMENT
CABLE AND FUSE REQUIREMENTS & INSTALLATION PROCEDURE
+OUT
+OUT
0.5m/2ft
35mm /AWG2 35mm
2
35mm /AWG2 35mm
2
16mm /AWG5 16mm
2
4mm /AWG12 6mm
2
.
NO DESCRIPTION
1 SMARTPASS 120S- Smart alternator cable (red)
2 Negative cable (black)
1
3 Temperature sensor
TERMINAL SCREW CONNECTIONS (M8)
2
SYMBOL DESCRIPTION
Input - Alternator
3
Output - Service Battery
Output - Consumers
MIN CABLE SIZES
1m/3ft 2m/6ft
/AWG2 35mm /AWG2
2 2
/AWG2 35mm /AWG2
2 2
/AWG5 16mm /AWG5
2 2
/AWG10 10mm /AWG8
2 2
5
Connect the smart alternator cable, if this feature is required.
6
Use tape to secure the temperature cable to a clean, flat surface on top
of the service battery. Position the sensor as close to the positive termi-
nal post as possible.
7
Connect the service and starter batteries to the system.
8
Connect the SMARTPASS 120/120S Negative cable (black) to the ground.
NOTE: Negative cable (black) must be fused in accordance with the
CABLE AND FUSE REQUIREMENTS table.
9
Check the status of D250SE and SMARTPASS 120/120S after com-
pleting the installation. Refer to D250SE AND SMARTPASS 120/120S
INDICATORS section in the manual for further information.
10
Add the included warning tag to the positive battery terminals of both,
the start and service batteries.
WARNING!
The D250SE and SMARTPASS
120/120S are not protected against
reverse polarity and short circuit.
Disconnect the battery terminal posts
from the batteries before installation.
5m/15ft 10m/30ft
50mm /AWG1 50mm /AWG1
2 2
10mm /AWG8 10mm /AWG8
2 2
The D250SE and SMARTPASS
120/120S are not spark free.
Ensure good ventilation
50028855A
LENGTH
0.2m/0.6ft
0.2m/0.6ft
0.2m/0.6ft
CONNECTED TO-
Starter Battery
D250SE input-Alternator
Service Battery
D250SE Output - Service
Battery
Non-critical Consumers
FUSE
300A
300A
50A*
2A
WARNING!