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2.4 CHARACTERISTICS OF FUSES AND FUSE HOLDERS PROVIDED
WITH THE KITS
DC-1000-KIT, DC-2000-KIT and DC-2500-KIT are provided with 100A, 200A and 300A
fuses respectively (Fig. 3.3). These fuses are Marine Rated Battery Fuses (MRBF-XXX
Series) made by Cooper Bussmann. The MRBF Fuse provides easy, practical weatherproof
and economical circuit protection in tight space constraints. The fuse is installed
between the Positive Battery Terminal Stud and the Positive Battery Cable with the help
of a special Clamping Fixture. The Clamping Fixture consists of the following:
• Clamping Fixture Bar (CFBAR), Fig. 3.4. Has a base plate for connecting to the
battery stud (with a hole to accommodate battery stud of up to stud size 3/8” /
M10) and a stud (size M-8) for connecting the MRBF fuse and the battery cable.
• Stainless Steel nut (thread size M8, will require ½” or 13 mm wrench for
tightening), Flat Washer and Spring Washer, Fig. 3.5.
• An Insulating Cap, Fig. 3.6. It slides over the base plate of CFBAR and is used to
insulate the exposed stud and the nut of the CFBAR.
DC-3500-KIT is provided with 400A, Class-T Fuse Assembly.
2.5 SIZING OF CABLES TO REDUCE VOLTAGE DROP, HEATING AND
POWER LOSS
Flow of electric current in a conductor is opposed by the resistance of the conductor.
The resistance of the conductor increases linearly as the length of the conductor is
increased and decreases as the cross-section (thickness) of the conductor is increased.
Flow of current through the resistance of the conductor produces voltage drop and
power loss due to heating. Voltage drop due to resistance of the conductor increases
linearly as the current increases.
Power loss because of heating due to resistance of the conductor increases by the
square of the increase in the current - e.g. if the current increases 2 times, the heating
/ power loss increases 4 times. Thus, it is desirable that thicker and shorter conductors
be used to reduce the undesirable effects of voltage drop, heating and power loss.
The size (thickness / cross-section) of the conductors is designated by AWG (American Wire
Gauge). Please note that a smaller AWG # denotes a thicker size of the conductor up to
AWG #1. Wires thicker than AWG #1 are designated AWG #1/0, AWG #2/0,
AWG #3/0 and so on. In this case, increasing AWG # X/0 denotes thicker wire.
DC input circuit of an inverter is required to handle very large DC currents. Cables and
connectors from the battery to the inverter should be properly sized to ensure minimum
voltage drop, minimum heating and minimum power loss between the battery and the
inverter. Thinner cables and loose connections will result in larger voltage drop, increased
loss of power and consequent reduction in efciency, poor inverter performance and will
produce abnormal heating that may lead to risk of insulation melt down and re.
SECTION 2 | General Information