How to make a cable step down assembly for the Manager Alpha

To allow the Manager Alpha to carry the expected current, a step down assembly may be required for the lug to fit to the Main Unit in order to use the correct cable gauge.

The Manager Alpha terminals can accommodate lug sizes with up to 25 mm² (4 AWG) cable entry with an M6 stud hole. If a cable size larger than 25 mm² (4 AWG) is required, a step down assembly needs to be implemented and must be as close as possible to the Main Unit terminals (within 0.5 m (1'6") of cable length).

REDARC recommend that any 25 mm² (4 AWG) extension cables used are XLPE insulated to withstand high temperature environments and can safely conduct any fault currents.

The following demonstrate different methods of implementing a step down in cable gauge. Ensure to crimp all connections with good quality crimp tools and apply heatshrink on top to insulate the connection

To allow for the larger cable to fit into the 25 mm² (4 AWG) cable lug, strip back the cable enough for the strands to fit into a parallel splice and cable lug hole. Insert the cable into the parallel splice and trim down the remaining strands enough to fit into the 25 mm² cable lug.

Source a butt splice that is suitable for both cable sizes and assemble by stripping back both cables enough for the strands to fit into the butt splice. 

Source a butt splice suitable for the larger cable size. To assemble, strip back the 25 mm² (4 AWG) cable enough to fold back and insert the strands into the butt splice, then strip back the larger cable enough to fit into the other side of the butt splice.  

Assemble the smaller and larger cable with suitably sized lugs and secure both with an insulated terminal stud. Fit an insulated terminal boot over the stud and lugs to protect the connection from shorting.

NOTE: The lugs mounted to the bolt or fuse holder must have the same stud hole and are sized to suit the bolt or fuse holder size.