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Wiring: power, logic*

Summary: Sections, protections, routing, connectors, grounding.

1) Sizing of sections and protections (48–51.2 V / 24 V)

  • Cable section: to be determined according to direct current, round-trip length, allowable voltage drop, environment (temperature, installation). Use the 48 V / 24 V charts (http://clubphotosa.free.fr/van/abaque.php?volt=48&tension_saisie=&energy=intensite&energy_value=200&longueur=2&resistivite=0.021&temperature=20) as a starting point.
  • Voltage drop: aim for ≤ 3% on power, ≤ 5% acceptable on short harnesses.
  • Protections: DC fuses calibrated on direct current with margin; place the fuse close to the + battery terminal; accessible main switch.

2) Power connections: crimping and torques

  • Crimping: use approved lugs and tools; check quality (pull test, visual inspection); heat shrink with adhesive if in harsh environment.
  • Torque values: adhere to manufacturer values (batteries, terminals, bars); recheck after 50 hours of service then periodically.
  • Heating: any warm/hot point under load indicates a bad contact (tighten/replace); risk of arcing and fire.

3) Routing and separation of harnesses

  • Separate power and logic; cross at 90° if necessary; avoid large power loops.
  • Mechanical protection: sleeves, grommets, ties; respect bending radius; avoid friction and hard points.
  • Grounding/chassis: single grounding point (star) on battery/controller side; avoid ground loops.

4) Logic and bus wiring (CAN)

  • CAN: shielded twisted pair, 120 Ω termination at each end; avoid long branches; clean reference grounds.
  • Connectors: lockable, IP suited to the environment (dust/mud/water); keying and colour codes.
  • EMC: twist pairs (Hall/encoder), shield if necessary; keep away from power cables; ground shielding on one side only (as applicable).

5) Marking, identification and documentation

  • Labelling: voltage, polarity, cable ID, bus direction; durable printing (oil/water/UV).
  • Schematics: update immediately (versions, revisions); include torque values, sections and connector references.
  • Traceability: record installation date, torque values, checks performed.

6) Checks and tests before powering up

  1. Complete visual check: sections, sleeves, fixings, IP, markings.
  2. Continuity and short-circuit test (multimeter) without power.
  3. Check torque values on battery, controller, terminals.
  4. Progressive power-up: limited power supply/provisional fuse; monitor voltage/current; check for hot spots.

7) Specific best practices (workshop/farm)

  • Avoid 'flying leads'; prefer cable paths; protect from splashes and high-pressure cleaning.
  • Allow slack for maintenance without stress on connectors; plan for unclipping ties for intervention.
  • Take photos and record measurements (voltage drop, currents) during commissioning.

Quick checklist

  • Sections/charts validated; voltage drop controlled
  • Fuses/main switch in place; polarities identified
  • Crimping compliant; torque values checked
  • Power/logic separation; shielding/CAN terminations OK
  • Continuity/short-circuit tests performed; no hot spots


*: The technical information presented in this article is provided for guidance only. It does not replace the official manuals of the manufacturers. Before any installation, handling or use, please consult the product documentation and follow the safety instructions. The Torque.works site cannot be held responsible for inappropriate use or incorrect interpretation of the information provided.