User Manual

5
CABLE SIZING
Cabling should be proportionate to the amperage of your system. The following table
notes the maximum current carrying capacity based on cable gauge. Battery cables
should be selected allowing a maximum voltage drop of 2% or less across the entire
length of the cable. Interconnection cables (battery to battery) should also be sized
at the same gauge and of equal length between connections. When choosing
interconnect cables or custom bus bars, size to allow adequate spacing between
batteries for airflow as outlined above.
WARNING
The charger cabling should be insulated and free of damage. The cable connectors should
b
e clean and properly mated with the battery terminals to ensure a snug connection.
Loose or overtightened connections may cause high resistance. The result is an
unwanted voltage drop as well as excessive terminal heating, causing the terminal to
melt or even catch fire. To limit the possibility of damage or fire, use a torque wrench
to properly adjust terminal connections during your regular maintenance schedule.
Undertorqued connections may become loose as the terminal warms & cools causing
possible arching and risk of spark. Over-torqued connections may indent, crack or
bend the terminal and/or washers or terminal connectors. Terminal damage from
overtorque is often irreparable. The use of an Infrared (IR temperature) sensor may
assist in identifying poor connections when testing under load or during charge.
Using an Infrared (IR) temperature sensor may assist in identifying poor connections
when testing under load or during charge.
Connections which have overheated and/or developed problems will often be welded
to the terminal. Visual inspections may not always detect poor connections. It is
recommended that terminal connections are disconnected, cleaned and re-torqued
periodically as part of the regular maintenance routine.
TERMINALS
Inspection of battery terminal connections is also important. Loose connections
may result in ignition of hydrogen gases or cause a short, melting the terminals.
It is important to inspect, disconnect, clean and properly torque these connections
on a regular basis. Use a proper torque wrench, noting the required torque setting
for the particular terminal.
TABLE 1: Wire gauge sizing by amperage