2 INSTALLATION
2.1 Wiring
The heavy gauge wires on the BCDC1240-LV unit carry peak currents of up to 50
Amps, and it is important to make a good, low resistance, electrical connection
that will not degrade over time. Failure to make a good, reliable contact may
result in breakdown of the wire insulation and cause a short circuit, or worst case
a fi re. We recommend that this activity be undertaken by an appropriately trained
person.
Redarc recommends using a soldered butt splice crimp connection that is covered
with heatshrink. The process should be to feed the heatshrink over the wires,
crimp the wires into the butt splice, then solder the wires on the butt splice, and
fi nally heat the heatshrink. Do not solder the wire before crimping.
Redarc does not recommend using standard red/ blue/yellow blade connections
as they are not rated for either the current or gauge of wire supplied on the unit.
The appropriate sized butt splice should be selected: for example if 8AWG wires
are used to connect the unit then an 8AWG butt splice should be used. If the wire
gauge brought up to the unit is larger than the 8AWG, then it is recommended to
use a butt splice that has two different size entrys, each matching the respective
wire size. Various butt splices are available from auto electrical suppliers.
Crimping provides good mechanical connection, soldering provides a long lasting
electrical connection and forming of the heatshrink will prevent any shorting/
contact with your vehicle chassis.
The term ‘crimping’ refers to a method of fi rmly attaching a terminal or contact
to the end of an electrical conductor by pressure forming or reshaping a metal
barrel onto the connector. The forming of a satisfactory crimp is dependent upon
the correct combination of conductor, crimp barrel and crimping tool. When
the correct combination of equipment is employed, a crimp that has both good
electrical and mechanical characteristics will be formed.
Butt splices are used to dress and terminate multiple conductors of the same or
different gauges in an end-to-end or series confi guration.
8
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