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Offline motoman

Wiring fuse block
« on: June 16, 2018, 12:58:30 PM »
I have 2 batteries installed. I want to put a fuse block on the second battery to run my lights and a couple additional usb plugs. I have 4, 60 watt lights. 2 for the front and 2 for the back. The usb plugs would be used for my phone, gps and camera. I am mounting the fuse block above the drivers' seat on the inside of the roof. To power the fuse block, what gauge wire should I run from the second battery, (under the seat) to the fuse block. There are 4 30 amp slots in the fuse block. 1 will be for the front lights, 1 for the rear lights and the other 2 for the usb devices.

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Offline NMKawierider

Re: Wiring fuse block
« Reply #1 on: June 16, 2018, 01:39:50 PM »
First- I needed to move your topic as it wsn't instructional but rather asked a question. As for what size to wire to the block -if there was no limits you would add-up all the load's amps or watts and convert the watts to total amps of load, then measure the distance from the battery to the block, then use one of the many wire size calculators that can be found on the web. However..if you expect not to max out the charging system all the time and expect it to keep both batteries charged, the there is a cap of about 15 amps you can add to the system. 12-13 is better. For that #10g wire and ground will be enough for around 6-8 feet. You can play it safe and just get some #8g, Black or Red for positive and one white for the negative and you will be good to go for anything. I would do the load calcs though so you know what you are dealing with. Stators and rectifiers don't come cheap these days. If it's any relief, most of what you are saying you will be running is well less then 15 amps...more like 8-9. The LED lights alone will use half of the amps that a converter shows. My 24" light bar was supposed to use 9 amps but actually only uses 4.6.   
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Offline EZ Rider

Re: Wiring fuse block
« Reply #2 on: July 31, 2018, 12:06:54 AM »
Motoman,  It sounds like you are doing (or have already done) almost exactly what I am preparing to do.  If finished, did you have any issues or have any suggestions for mounting the Fuse/Relay box above the driver seat?

I thought about each individual part of this mod for about 9 or 10 days before deciding on that location.  That night I read your post.

I have my second battery installed, but still waiting on the battery isolator to arrive so I can continue with the electrical.  I don't know exactly what your lights will pull, but my front light bar is 270 watts, and I am told the draw works out to be about 10 amps.  Looking at the pigtail that comes on the light, it looks to be about a 14 or even a 16 gauge wire.  If it indeed pulls 10 amps, that wire is going to get very warm, so I am guessing it to actually pull less than 5 amps.  Going to do a temporary hook up tomorrow and actually measure the amperage.  Will post that later.

Calculating for my circuit (roughly 500 watts total if everything is on at the same time), lights, USB power outlets, Stereo and a little extra I may need for something else I may want to add down the road, I am planning on using a 6 or 8 gauge wire to feed the block and then just fuse it at a lower point until I need more power to that block.  If you haven't already finished your project, I would assume you could go with a lighter wire, possibly even a 10 gauge.  If you have a multi-meter, you could do like I am going to do and do a temporary hook up one of your lights to a power source and measure the draw.  That will tell you your minimum requirements.

Lauren
2017 Zforce 800 Trail
RazorBackOffroad accessories: Doors, Rock Sliders, Sherpa Rack and Spare Tire Mount

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Offline EZ Rider

Re: Wiring fuse block
« Reply #3 on: July 31, 2018, 11:34:16 AM »
I got a chance this morning to hook up and measure the power draw on my 127 Watt light bar.
Although my calculations show almost 20 Amps (I must be doing it wrong), and the forum where I purchased it says just over 10 Amps, my actual measurement was just over 4.8 Amps.  That sounds more reasonable for an 18 gauge pigtail that came with it.
Lauren
2017 Zforce 800 Trail
RazorBackOffroad accessories: Doors, Rock Sliders, Sherpa Rack and Spare Tire Mount

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Offline EZ Rider

Re: Wiring fuse block
« Reply #4 on: July 31, 2018, 11:50:33 AM »
While tracing out wires in the harness, I came across yet another connector under the dash.  I verified that the 2 white connectors do indeed go to the connectors on each side for the front lights, but can anyone tell me what this red one is for?

The white ones are identical in color code and pin-out with 5 wires.
The red one has 6 pins/wires and color code is (clockwise from ground): Green/Black - Brown/White - Violet/Black - Orange/Black - Black/Brown - Brown

Lauren
2017 Zforce 800 Trail
RazorBackOffroad accessories: Doors, Rock Sliders, Sherpa Rack and Spare Tire Mount

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Offline motoman

Re: Wiring fuse block
« Reply #5 on: August 26, 2018, 08:46:57 PM »
Well it's been a few months since the mod. Everything works good. Just used 3m 2 sided mounting tape for the fuse block. That's solid.