Accessorizing Your Accessorizing Your Electrical SystemElectrical System

Paul DuffyBob Kiessel

A Seminar for MI Squadron of MSTA

OutlineOutline

Key TermsKey Terms Typical Electrical LoadsTypical Electrical Loads Sources of Electrical PowerSources of Electrical Power Two items requiring attention:Two items requiring attention:

• System CapacitySystem Capacity• Wiring it TogetherWiring it Together

Who Are We?Who Are We?

Paul Duffy has 30 years experience with Paul Duffy has 30 years experience with Ford Motor in Electrical Engineering and Ford Motor in Electrical Engineering and Manufacturing. He presently heads Manufacturing. He presently heads Electronic/Electrical Engineering for a fuel Electronic/Electrical Engineering for a fuel cell manufacturer.cell manufacturer.

Bob Kiessel has 30 years experience with Bob Kiessel has 30 years experience with Ford Motor. He retired as Chief Electrical Ford Motor. He retired as Chief Electrical Engineer and presently is COO of a small Engineer and presently is COO of a small software company.software company.

Key TermsKey Terms Electrical Potential (EMF or Voltage)Electrical Potential (EMF or Voltage)

• VoltsVolts• Measure of the force causing electricity to flow Measure of the force causing electricity to flow

in a conductorin a conductor Electrical CurrentElectrical Current

• AmpsAmps• Measure of the amount of electricity flowing in Measure of the amount of electricity flowing in

a conductora conductor Electrical PowerElectrical Power

• Power (Watts) = Voltage (volts) x Current Power (Watts) = Voltage (volts) x Current (amps)(amps)

• Energy per time - the rate that energy is usedEnergy per time - the rate that energy is used• 745 watts = 1 hp745 watts = 1 hp

The WaterThe Water AnalogyAnalogy A Battery provides current (amps) at a specified A Battery provides current (amps) at a specified

“pressure” (volts).“pressure” (volts). The accessory load determines how much current is The accessory load determines how much current is

drawn from the battery based on its resistance. drawn from the battery based on its resistance. • I (amps) = V (volts) / R (ohms) I (amps) = V (volts) / R (ohms) • Amount of water= Pressure/resistance of pipeAmount of water= Pressure/resistance of pipe

A wire carries the current like a pipe in a water A wire carries the current like a pipe in a water system. system. • If too thin or too long, you get a pressure drop If too thin or too long, you get a pressure drop

(voltage drop) and… (voltage drop) and… • The accessory may not be able to operate properly.The accessory may not be able to operate properly.• With electricity, you also can burn up the thin pipe!With electricity, you also can burn up the thin pipe!

Typical MC Electrical LoadsTypical MC Electrical Loads LightingLighting

• HeadlightsHeadlights• TaillightsTaillights• Marker lightsMarker lights• Instrument Cluster & Turn Indicator lightsInstrument Cluster & Turn Indicator lights• Turn/Brake SignalsTurn/Brake Signals

Electric Cooling FanElectric Cooling Fan Engine Control/Ignition SystemEngine Control/Ignition System EFI (on some bikes)EFI (on some bikes)

In order to determine whether your charging system In order to determine whether your charging system has enough capacity for your accessory, it’s important has enough capacity for your accessory, it’s important to know the duty cycle of a load.to know the duty cycle of a load.

Typical Electrical LoadsTypical Electrical LoadsConstant LoadsConstant Loads WattsWatts AmpsAmps

HeadlampsHeadlamps 120120 8.68.6

Tail lampsTail lamps 1010 0.70.7

Front markersFront markers 1616 1.11.1

Instrument ClusterInstrument Cluster 44 0.30.3

Indicator LightsIndicator Lights 77 0.50.5

Engine Cooling FanEngine Cooling Fan 7070 5.05.0

Ignition System (non EFI)Ignition System (non EFI) 3030 2.12.1

TotalTotal 257257 18.418.4

Intermittent Loads Intermittent Loads

Brake lampsBrake lamps 4242 3.03.0

Front turn signalFront turn signal 2727 1.91.9

Rear turn signalRear turn signal 2727 1.91.9

HornHorn 7070 5.05.0

Sources of Electrical PowerSources of Electrical Power BatteryBattery

• Limited capacity – typically sized for startingLimited capacity – typically sized for starting AlternatorAlternator

• Converts mechanical energy into electrical Converts mechanical energy into electrical energyenergy

• Limited Output – based on size of alternator Limited Output – based on size of alternator and rpm of engineand rpm of engine

• Sized based on average load in worst case Sized based on average load in worst case conditions (with more or less margin).conditions (with more or less margin).

Information in owner’s manual – FZ1Information in owner’s manual – FZ1• Battery – 12 Ah (amp-hours)Battery – 12 Ah (amp-hours)• Alternator – 365w @ 14 volts > 26 amps peakAlternator – 365w @ 14 volts > 26 amps peak

Typical Motorcycle Alternator Output

0

5

10

15

20

25

30

0 1000 2000 3000 4000 5000 6000

RPM

Am

ps Output

Base Load

Battery is discharging in this region!

Battery is charging in this region!

Finding the Crossover PointFinding the Crossover Point

Vout vs RPM

12

12.2

12.4

12.6

12.8

13

13.2

13.4

13.6

0 500 1000 1500 2000 2500 3000 3500

RPM

Vo

lts

Battery Voltage

Heated GearHeated Gear

WattsWatts AmpsAmps

Heated GripsHeated Grips 3636 2.62.6

Heated GlovesHeated Gloves 2424 1.71.7

Heated VestHeated Vest 5252 3.73.7

Heated Jacket Heated Jacket LinerLiner 7575 5.45.4

Heated ChapsHeated Chaps 4343 3.13.1

Change in Crossover PointChange in Crossover PointTypical Motorcycle Alternator Output

0

5

10

15

20

25

30

0 1000 2000 3000 4000 5000 6000

RPM

Am

ps

Output

Base Load

Base + Full Gear

Base + 30% Gear

What Can You Do When Power Is What Can You Do When Power Is Limited?Limited?

ConserveConserve—energy diet! Manage loads wisely.—energy diet! Manage loads wisely. Shut off one headlampShut off one headlamp Use PWM controllers for heated gearUse PWM controllers for heated gear Use LED’s for some lighting loadsUse LED’s for some lighting loads Raise idle speed a few hundred rpm or rev at Raise idle speed a few hundred rpm or rev at

stoplightsstoplights Shift down a gear if at low speedShift down a gear if at low speed

Please note: increasing battery size only delays Please note: increasing battery size only delays the inevitable; alternator upgrade is very the inevitable; alternator upgrade is very expensive and may affect regulatorexpensive and may affect regulator

Wiring AccessoriesWiring Accessories

I will present how to approach a wiring I will present how to approach a wiring project—installation of an accessory. project—installation of an accessory.

I’ll provide some guidelines on “Best I’ll provide some guidelines on “Best Practices” -- reasons behind these are Practices” -- reasons behind these are from a lifetime of scars.from a lifetime of scars.

For power distribution, we’ll suggest that you use:For power distribution, we’ll suggest that you use:

A “star” architecture for power and grounds (a common A “star” architecture for power and grounds (a common point of origin for all power leads and all ground leads). point of origin for all power leads and all ground leads). This minimizes the risk of system interactions.This minimizes the risk of system interactions.

Always use a return ground wireAlways use a return ground wire — —i.e., don’t rely on chassis or i.e., don’t rely on chassis or frame ground.frame ground.

Separate signal & power grounds Separate signal & power grounds when you have sensors in a system. Don’t ever tap into a when you have sensors in a system. Don’t ever tap into a

sensor ground.sensor ground.

Wiring AccessoriesWiring Accessories

A wiring system has a capacity just like a charging A wiring system has a capacity just like a charging system. To size it:system. To size it:

• First figure out the accessory load First figure out the accessory load in amps [or if you have power:in amps [or if you have power:

I (amps) = P (watts) / V (volts)]I (amps) = P (watts) / V (volts)]• Next choose the wire gage to Next choose the wire gage to

handle the total current expected in handle the total current expected in the wire.the wire.

• Fuse the wire to prevent the smoke Fuse the wire to prevent the smoke from leaking out—a fuse is used to from leaking out—a fuse is used to protect the wiring from fire.protect the wiring from fire.

• Smaller fuse is OK (eg, 20 amp for Smaller fuse is OK (eg, 20 amp for 14g)14g)

• Ensure return ground wire gage is Ensure return ground wire gage is sized for sum of all return currentssized for sum of all return currents

AWGAWGgaugegauge

MaxMaxCurrentCurrent

MaxMax FuseFuse

(amps)(amps) (amps)(amps)

1212 4141 4040

1414 3232 3030

1616 2222 2020

1818 1616 1515

2020 1111 1010

2222 77 55

2424 3.53.5 2.52.5

Power Always OnPower Always On

•This is the simplest way of adding an accessory.•Attach a fused wire to the battery and use the accessory’s switch to turn power on and off. But:

•You can run down your battery if you forget to turn it off. The Ignition key does not shut it off.•A variant is to add a switch external to the accessory, but you still have to remember to turn it off.

Using The Ignition SwitchUsing The Ignition Switch

You can ensure that an accessory is shut You can ensure that an accessory is shut off by wiring the accessory downstream of off by wiring the accessory downstream of the ignition switchthe ignition switch. . Then turning off key Then turning off key shuts off the power.shuts off the power.

Unfortunately, you can exceed the current Unfortunately, you can exceed the current rating of the ignition switch – an rating of the ignition switch – an expensive repair.expensive repair.

To prevent this failure, use a relay to To prevent this failure, use a relay to handle the current.handle the current.

Using a Switched RelayUsing a Switched Relay

Above is shown a wiring diagram of how to attach a relay to Above is shown a wiring diagram of how to attach a relay to power your accessories.power your accessories.

A relay has an electromagnetic coil and a switch inside. A relay has an electromagnetic coil and a switch inside. When the electromagnet is energized, the switch closes. When the electromagnet is energized, the switch closes.

Ignition-keyed power is used to energize the coil (uses 0.1 Ignition-keyed power is used to energize the coil (uses 0.1 amp), and the relay contacts switch the high current amp), and the relay contacts switch the high current (typically up to 10 - 30 amp capacity) directly from the (typically up to 10 - 30 amp capacity) directly from the battery.battery.

And for Multiple AccessoriesAnd for Multiple Accessories

Combine Relay with Star circuits.Combine Relay with Star circuits. Use fused heavy gage wire (sum of all currents) to Star near batteryUse fused heavy gage wire (sum of all currents) to Star near battery Use light gage to accessory—each device must be fused separately because Use light gage to accessory—each device must be fused separately because

gage changesgage changes With heavy gage wire to accessories, added fuses are not required.With heavy gage wire to accessories, added fuses are not required. Ground/return wire gages are same as power wires.Ground/return wire gages are same as power wires.

Connector typesConnector types

When connections in the wiring are When connections in the wiring are required (most times), one must choose required (most times), one must choose a proper connector based on:a proper connector based on:

1.1. Current LoadsCurrent Loads2.2. Environmental factors (water, heat, salt, Environmental factors (water, heat, salt,

vibration)vibration)3.3. Ease of useEase of use4.4. Frequency of use (some connectors fatigue Frequency of use (some connectors fatigue

quickly)quickly) The connector is usually the weakest The connector is usually the weakest

point in the system.point in the system.

Connector typesConnector types

Some sample connectors will be available at Some sample connectors will be available at the meeting.the meeting.

You can buy connectors at Radio Shack, You can buy connectors at Radio Shack, hardware and auto parts stores.hardware and auto parts stores.

Another source is to buy a “donor” Another source is to buy a “donor” motorcycle harness from a parted out bike motorcycle harness from a parted out bike and “cut and splice” connectors. Also the and “cut and splice” connectors. Also the harness is a good source of appropriately harness is a good source of appropriately colored wires so you can figure out what’s colored wires so you can figure out what’s what after a year.what after a year.

CautionsCautions Solder any wiring connections to terminals or pins Solder any wiring connections to terminals or pins

(or even in-line splices). Crimp terminals are not (or even in-line splices). Crimp terminals are not reliable—the wires pull out. Solder after crimping.reliable—the wires pull out. Solder after crimping.

Never twist and tape. Extremely unreliable.Never twist and tape. Extremely unreliable. Always tie strap wiring & connectors to limit Always tie strap wiring & connectors to limit

movement. The vibration experienced in normal movement. The vibration experienced in normal use will destroy the terminals of connectors and use will destroy the terminals of connectors and fatigue copper wire over time if left to flop fatigue copper wire over time if left to flop around.around.

Never use solid copper wire—always stranded. Never use solid copper wire—always stranded. Solid fatigues very quickly.Solid fatigues very quickly.

CautionsCautions Never cut into lighting circuits!! Too many ways to Never cut into lighting circuits!! Too many ways to

cause failure & you don’t want these at night.cause failure & you don’t want these at night. Wiring is very susceptible to corrosion, so always seal Wiring is very susceptible to corrosion, so always seal

connections exposed to elements.connections exposed to elements.• Electrical tape is not a good seal – Liquid Tape is.Electrical tape is not a good seal – Liquid Tape is.• For splices, sealant works well if used under heat shrink.For splices, sealant works well if used under heat shrink.• Wiring will wick moisture and transport it to other areas, Wiring will wick moisture and transport it to other areas,

corroding the wire internally.corroding the wire internally.• Always try to keep splices and connectors in drier areas of the Always try to keep splices and connectors in drier areas of the

bike. Grease can be used as a moisture barrier on connectors bike. Grease can be used as a moisture barrier on connectors (but grease washes off and attracts conductive dirt).(but grease washes off and attracts conductive dirt).

Always fuse close to the battery. Always fuse close to the battery. Look for abrasion sources and protect the wiring with Look for abrasion sources and protect the wiring with

convolute (ribbed, hard plastic casing you can buy at convolute (ribbed, hard plastic casing you can buy at Radio Shack.)Radio Shack.)

Sneak CircuitsSneak Circuits

So you’ve wired in your new LED turn So you’ve wired in your new LED turn signals and now the turn indicator is signals and now the turn indicator is always lit---you’ve created a sneak circuit.always lit---you’ve created a sneak circuit.

A sneak circuit is an unintended A sneak circuit is an unintended interaction of various circuits.interaction of various circuits.

When this happens, get an expert When this happens, get an expert involved!involved!

THE ENDTHE END

Questions?Questions?

Future clinicsFuture clinics• Training in splicing and soldering?Training in splicing and soldering?• Any projects?Any projects?