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After seeing that you are putting on 2 screw down DC terminals on the front of the switches! We have had problems with this type of power connection over the last 20+ years at radio site. The terminals get loose after a period of time (intermittent connections), and with vibration from fans helping that. Also have the exposed cut wire ends sticking out of the side of the terminal, that can come in contact with other objects (usually grounding them) and short !

Might I suggest to use some old CB type Microphone Plugs and Jacks instead. These are the round metal ones with screw down rings on them. You can get them with 3,4,5,6 and 8 pins in them. The 3 pin one would be perfect! That would give you a metal chassis jack (Male) and a metal Female cable plug. The pins are thick, and will hold quite a few amps of power. A lot heavier than the usual single pin DC power jack, and it screws down and secures.

Makes it easier to use in the "Radio Site" environment. Quick change in and out, if you need to swap out the unit for some reason?
Cost on them should be just a little bit more, but worth paying for it!

Wayne

You should use crimped RING or eyelet lugs/ends not bare wires under the thumb nuts then you do not have stray wires nor will they loosen up.
You can also use a lock star washer if you are really concerned.

wtm wrote:Also have the exposed cut wire ends sticking out of the side of the terminal, that can come in contact with other objects...

I agree with Chris about soldering on lugs or at least tinning the ends of the leads if they are stranded to prevent fraying.

Chris, do the posts have a through hole to stick the wire through or do they need to be wrapped around the post?

you can inset banana type plugs, or a ring connector, & they have holes for inserting up to a 12AWG wire I believe.

But personally I would not use 12 AWG, you should be using at least 10 AWG.

Always put a lug on your wire ends.

MY BAD - 12AWG is heavy enough!!!!!!!! - DUH

opps, looks like Chris went of the deep end with that comment...

we have a 25 amp fuse on the dc-dc board, so we will never use more than that, and a 12 AWG wire internally from the binding post input connector to the DC-DC board.

the 12 AWG wire can take several times that amount of current.

12 AWG will be more than sufficient, but of course the user can hook up to their hearts content!

dave is going over this stuff!

Any reason you guys didn't use these style connectors?

That said, banana plugs are a nice solution to that type of connector on the switch.

Because if we put that connector on most people would not have those connectors and would complain.

Have you seen the inside of the average WISP's cabinets?

Ahem... as the vendor you're suppose to provide the piece that snaps in :)