14 | Installation
3.2.3 WHAT YOU WILL NEED
TOOLS
In the following sections of this manual, guidance is given on the installation of the BCDC Core
which may require common automotive electrical tools such as:
• Screwdriver set
• Spanner set
• Socket set
• Pliers
• Side cutters
• Cable cutters
• Ratcheting or Hydraulic crimping tool
• Soldering Iron
CONSUMABLES
To mount, connect and manage wiring of the BCDC Core Battery Charger, installers use
a range of materials including:
• Cabling
• Cable connectors, lugs and terminals
• Fuses
• Electrical tape
• Heat Shrink
• Cable ties
• Conduit / Split tubing
• Wires
• Fasteners
Depending on your setup, additional fixings (nuts, bolts and self-tapping screws) and battery
post clamps may be required.
3.3 Cable sizing
The heavy gauge cables on BCDC Core 25 and Core 40 carry peak currents of up to 35 / 55 A
respectively. To carry this current effectively, the wire gauge required when extending this cables
depends on the length of cable run required.
"Table 3.3.1: Cable and Lug Sizing" (page 14)
for cable thickness requirements
for the following cables:
Brown*
Output Cable
Red
Vehicle Input Cable
Black
Ground Cable
Yellow
Solar Input Cable
*NOTE:
The Brown Output cable should be at maximum 1m in length.
Before making any connections run and layout the cables and wires required for your setup; trim
any excess if needed using side or cable cutters.
Table 3.3.1:
Cable and Lug Sizing
Part Number
Cable Install
Length
Cross
Sectional Area
Nearest Equivalent
B&S, BAE, AWG
Lug Cable
Size
BCDCN1225
1 – 5 m
3' – 16'
≥ 7.7 mm²
8
8 B&S / 10 mm²
5 – 9 m
16' – 30'
≥ 13.6 mm²
6
6 B&S / 16 mm²
BCDCN1240
1 – 5 m
3' – 16'
≥ 13.6 mm²
6
6 B&S / 16 mm²
5 – 9 m
16' – 30'
≥ 20.3 mm²
4
4 B&S / 25 mm²
Summary of Contents for BCDCN1225
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