Orion-Tr Smart DC-DC Charger Non-Isolated 4. Installation 4.1. Mounting Mount vertically on a non-flammable surface, with the power terminals facing downwards. Mount close to the battery, but never directly above the battery to prevent damage due to gassing of the battery. Observe a minimum clearance of 10 cm under and above the product for optimal cooling. Please see the Appendix [31] of this manual for the dimension drawing; this drawing also indicates the mounting holes. 4.2. Cable and fuse recommendations Use flexible multi-stranded copper cables for the battery connections.
The diameter of the individual strand of the cable used should not exceed 0.4mm (0.016 inch) or have a surface area exceeding 0.125mmІ (AWG26). The maximum operating temperature is 90°C (194°F). A 16mmІ cable, for example, should have at least 122 strands (class 5 or higher stranding according to VDE 0295, IEC 60228 and BS6360). Example of suitable cable: class 5 “Tri-rated” cable (it has three approvals: American (UL), Canadian (CSA) and British (BS)). In the case of thicker strands, the contact area will be too small, and the resulting high contact resistance will cause severe overheating, eventually resulting in fire. See the below figure for examples of what cable to use and not to use.
Cable type recommendation 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.
Page 4 Installation Single wire diameter in the bundle Nominal cross-section Class 5 (IEC) Class 6 (IEC) Class I (UL) Class K (UL) 9AWG 24AWG 30AWG 6mm2 0.3mm 0.2mm 7AWG 24AWG 30AWG 10mm2 0.4mm 0.2mm - - 6AWG - - 24AWG 30AWG 16mm2 0.4mm 0.2mm - - 4AWG - - 24AWG 30AWG