EGON DC-Hub Dual Installation Guide

Video Installation Guides

Watch step-by-step instructions to get the most out of your EGON DC-Hub DUAL:

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EGON DC-Hub Dual Bracket Assembly Instructions

All critical distribution logic—fusing locations, current paths, and connection grouping—has been engineered into the board. Your job is to size cables correctly, install appropriate fuses, and follow the clearly labelled terminals. Used correctly, the DC‑Hub Dual will:

Dramatically reduce wiring complexity.
Eliminate many common causes of electrical failure.
Make installations easier to understand, inspect, and
service.
Provide a professional, repeatable outcome even for DIY installers.

SAFETY

2.1 Read before installing.
DC power systems store and transfer significant energy.
Incorrect installation can result in fire, damage to equipment,
or serious personal injury. Take your time, read this manual
fully, and do not proceed if you are unsure about any step.

2.2 General Safety Rules

Always disconnect all batteries, chargers, and solar inputs before starting work.
Never work on live circuits. Confirm circuits are de‑energized with a multimeter.
Wear eye protection and remove rings, watches, and metal jewelery.
Secure all cabling to prevent vibration damage in high vibration conditions.
Never exceed the rated current of connectors, cables, or fuses.

2.3 Fusing rules (critical)

All batteries must be externally fused as close to the battery as possible (within 30 cm).
Fuses on the DC‑Hub DUAL do NOT replace battery protection fuses.
Fuse size must always protect the cable first, then the device.
Never install a fuse with a higher rating than the cable can safely carry.

Product Overview

3.1 Brief

The EGON DC‑Hub Dual is designed for dual dc/dc charger systems that demand professional‑grade distribution, clear fault‑finding, and long‑term reliability.

3.2 The DC-Hub DUAL provides:

A centralised connection point for start battery, auxiliary battery, solar, and DC‑DC chargers.
Three high‑current 80A fused input/output circuits.
Ten 25A fused accessory circuits that can be used as inputs or outputs.
Two independent start battery inputs.
Two independent solar inputs
Two independent DC-DC charger connections All load distribution, fault indication, and protection philosophy remains unchanged.

4. Specifications

System voltage: 12 V / 24 V DC
Auxiliary (house) battery input: 150 A max (external Mega fuse
required)
High-current I/O circuits: 3 Å~ 80 A max
General-purpose I/O circuits: 10 Å~ 25 A max
DC-DC charger inputs: 2 Å~ 80 A max
Solar inputs: 2 Å~ 60 A max
Fuse types: MIDI (high-current), standard blade (25 A circuits)

5. Environmental

Intended for automotive and mobile applications
Install in a dry, protected location away from extreme heat, direct water (including splashes) and extreme dust exposure

Connection Overview

P1. High-current input/output - 80 A max. Fused by FM1 (MIDI fuse)

P2. High-current input/output - 80 A max - Fused by FM2 (MIDI fuse)

P3. High-current input/output - 80 A max - Fused by FM2 (MIDI fuse)

P4. Auxiliary / house battery input - 150 A max - MUST be externally fused with a Mega fuse within 30 cm of the battery

P5. General-purpose inputs/outputs (circuits 1–5) - 25 A max per circuit - Uses blade fuses F1–F5 - Five positive/negative in/output pairs

P6 General-purpose inputs/outputs - 25 A max per circuit - Uses blade fuses F6–F10- Five positive/ negative output pairs - Five positive/negative in/output pairs

DC-DC Charger #1 connections:

P7. DC-DC charger output and ground - 80 A max - Fused by FM4 (MIDI fuse)

P8. Solar input for DC-DC charger #1 - 60 A max - Fused by FM5 (MIDI fuse)

P9. Solar and start battery connection for DC-DC charger #1

P10. Start battery #1 input for DC-DC #1 - 80 A max - MUST be externally fused within 30 cm of the start battery (MIDI fuse).

DC-DC Charger #2connections:

P11. DC-DC charger output and ground - 80 A max - Fused by FM6 (MIDI fuse)

P12. Solar input for DC-DC charger #2 - 60 A max - Fused by FM7 (MIDI fuse)

P13. Solar and start battery connection for DC-DC charger #2

P14. Start battery 2 input for DC-DC charger #2 - 80 A max - MUST be externally fused within 30 cm of the ,start battery (MIDI fuse).

Solar Configurations

Unregulated solar (DC‑DC charger with MPPT)

For DC-DC charger with in-built MPPT (e.g Redarc BC-DC)
Solar connects directly to DC‑DC charger via P8 or P12.
DC‑DC solar input cable connects via P9 or P13 “SLR IN”.
Fuse FM5 or FM7 must NOT be installed.

Regulated solar (external MPPT):

Solar connect to an external MPPT regulator.
MPPT output connects to P8 or P12.
Fuse FM5 or FM7 must be installed.

6.2 Ground Connections

All ground (negative) connections return to the common negative bus on the DC‑Hub.
(This operates as a in-built negative bus bar) 6.2 Ground Connections
Ensure all high‑current devices have an appropriately sized negative cable back to the Hub or to a properly engineered common ground point tied into the Hub’s ground.

Installation Steps. In this order

Mount spacers in the bracket with screws inserted from the back. Do not over-tighten the screws. Just a firm hand will do.
Mount the bracket in a dry and easily accessible location. (DC-Hub DUAL is not suited to under-bonnet installations.)
Place external battery fuses near each battery but do NOT insert fuses until installation is complete, or near completion (safety).
Route and secure all cabling for chargers, solar, batteries and loads.
Connect loads, chargers, batteries and solar inputs as planned to the Dc-Hub.
Use cable ties to secure the cables to the T-bars on the mounting bracket. This is IMPORTANT as it reduces vibration wearing the cables loose.
Verify polarity and connector torques, and then energize the system by installing the battery fuse/s. A small white LED on the board will indicate that the board is energized.
Insert each fuse step by step and check system behavior at every step. As each fuse is inserted, a red LED that indicated an open but connected circuit, will go out. If one stays on, check the fuse. (the LED will only illuminate if there is an accessory connected).
Double check the tightness of ALL the connectors on the Dc-Hub. THIS IS A VITAL FINAL STEP. DO NOT SKIP IT!

A word from the makers

Please don’t skip any of these steps, especially the last one. We’ve built the DC-Hub from the best components we can find anywhere in the world. We assemble them in Western Australia and everyone who has a part in them is proud of this amazing product. 1000’s of DC-Hubs are working faultlessly all over the world, and the reliability is already legendary. So please make sure you read all this boring stuff. Hey, that means you, bloke with a beer in hand. We understand. Truly we do! Get it right, and it’ll serve you right year after year after year.

8. Troubleshooting and Maintenance

If a circuit stops working:

Check the relevant fuse and LED indicator. •
Inspect wiring and terminations.
Confirm the load itself is functioning correctly.
Maintenance: Inspect the system periodically, especially after rough travel. Check terminal tightness, fuse condition, and cable routing. Early inspection prevents small issues becoming major failures.

Warranty and Support

The EGON DC‑Hub Dual is covered by EGON’s standard warranty against defects in materials and workmanship when installed correctly. Damage caused by incorrect installation or misuse is not covered.

For support, installation guidance, and updates, contact EGON through the EGON website. Refer to EGON’s video installation guides and wiring examples for further help.

DC-Hub Dual Connection Examples

DC Hub Dual Next Gen with Victron

DC Hub Dual Next Gen with Redarc Manager Alpha 100 or 75

DC Hub Dual Next Gen with Redarc BCDC Alpha 50

DC Hub Dual Next Gen with Enerdrive and Simarine

Tightening Torque Settings and Connector Maintenance

It is extremely important to tighten the screw terminals on the DC-Hub and the DC-Hub Dual connectors properly.

Please use the following torque settings to tighten the connectors:

150A connector: 3Nm
80A/40A connectors: 1.8Nm
25A connectors: 0.8Nm

Take Note: Ensure all unused clamps are tightened to prevent rattling from the circuit board. In high-vibration applications, make sure to regularly check screw tensions.

Cable Ratings and Fuses

Use the below guide for choosing the right cable size, lug and heat shrink size for your application.

Never exceed the amp rating for a cable.
Always use a fuse that is smaller or equal to the maximum current-carrying capability of the cable.
Never exceed the manufacturer's recommended fuse rating for the appliance you are connecting. It’s there for a reason.

Cable ratings and fuses guide

Final Words

All batteries MUST be fused as close to the battery as possible. Do not rely on the fuses built into the DC-Hub or DC-Hub Dual for this. Read that again. Now.
Cables that are too thin can cause heat build-up and reduce the efficiency of chargers and accessories. That’s no fun for anyone!
We’ve made connecting cables extremely easy! But you can still get them wrong. After all, we’re only human. The copper must be clean and enter into the connection cleanly and the screw tightened firmly. (See torque settings for guides).
Fuses protect the cables from burning in case of a short-circuit. So fuses must be capable of handling the current required to run the accessory, but NOT MORE THAN 25% of that. Accessory manufacturers recommend fuse sizes for a reason. Cue: “We didn’t start the fire” by Billy Joel.

Fuses

The DC-Hub Dual is not supplied with any fuses.

Support

For further assistance:

Email us: support@egon.com.au
Watch our tutorials on YouTube

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EGON DC-Hub Dual Installation Guide