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Page6
Installation Tools
#6 or # 8 MOUNTING SCREWS - SCREWDRIVER - SOLDER & SOLDERING IRON
(NON GROUNDED MODEL) - TAPE or HEAT SHRINK TUBING –RTV SEALER - SMALL
CRESCENT WRENCH FOR BATTERY TERMINALS - HOOKUP WIRE
IMPORTANT
When installing the system wiring, make sure all wire connections are making good electrical and
mechanical connection. Splice connections should be soldered. The use of crimp connectors should
be avoided if possible. Connections that are not made with screw tightened terminals should have an
anti-oxygen / anti-corrosion coatings applied to the connections before inserting the wires.
Note: Step numbers correspond to the numbers in the installation schematics.
1. Choose a good mounting location no more than 10 wired feet from the battery you are
charging. Although these controllers have been designed for mounting in semi-harsh locations,
mounting them in a more protected environment will help to extend the operational life.
2. Splice a #14 too #10 AWG black wire to the BLACK BAT- WIRE on the controller, and connect
it to the BATTERY BANK’S negative (-) terminal and/or the system's negative battery bus. If
you are using a smart battery fuel meter that measurers total Input to Output Amp/Hours, it will
usually have a shunt in the (-) connection to the battery. Connect the (-) wire from the controller to
the same terminal as the other loads on the shunt as shown in the meter’s manual.
3. Splice a #14 too #10 AWG black wire to the BLACK PV- WIRE on the controller, to the SOLAR
PANEL’S negative (-) terminal(s).
4. Splice a #14 too #10 AWG red wire to the RED BAT+ WIRE on the controller, and connect it to
the BATTERY BANK’S positive (+) terminal and/or the system's Positive battery bus. In dual
bank systems the Red wire connects to the Primary House Battery bank. For single battery
banks systems, a fuse should be installed in the red positive wire. It should be located as
close to the battery as possible for the best protection. The Bat+ Fuse is rated at 8A for the
PV7 and 15A for the PV14.
5. Splice a #14 too #10 AWG orange wire to the ORANGE PV+ WIRE on the controller, and
connect it to the combined positive (+) output of all the SOLAR PANELS. For added protection
and ease of maintenance, we highly recommend that you install a fuse somewhere in the orange
PV+ wire. It will provide protection against its accidental connection to a high current source and
fully protect the controller. It also will serve as a convenient place to disconnect the charging source
from the controller when the battery is removed from the system while the charging source remains
active.
FlexchargeTM USA
INSTALLATION INSTRUCTIONS
PV7/24, PV7D & PV14 CHARGE CONTROLLERS
