User manual

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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.
TERMINALS & CABLE CONNECTIONS
All cable connections should be adequately sized, insulated and free of damage. The
cable connectors should be clean and properly mated with the battery terminals to ensure
a snug connection.
Electrolyte spills and corrosion buildup will damage cable connectors and terminals. It is
recommended that terminal connections are disconnected, cleaned and re-torqued
periodically as part of the regular maintenance routine. This also applies to connections
using bus bars. Check and recalibrate the torque wrench for accuracy before use.
Visual inspections may not always detect poor connections. The use of 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. Loose connections may result in ignition of hydrogen gas
during charging or cause a short, melting the terminals.
Loose or overtightened connections may also cause high resistance. The result is an
unwanted voltage drop as well as excessive terminal heating which causes 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.
As batteries are cycled and heat up during charge, under-torqued connections may
become loose over time as the terminals heat & cool, causing possible arching and a
risk of spark. Over-torqued connections may indent, crack or bend the terminal and/or
washers or terminal connectors.
Damage to terminals and/or batteries caused by under/over-torque is often
unrepairable and is not covered under manufacturer warranty. Follow the
recommended torque settings for each terminal type. Battery distributors or dealers
may offer replacement or repair, where possible, at the customer's expense.
TABLE 1: Wire gauge sizing by amperage