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Old 07-26-2015, 09:44 AM   #1
JaxPilot
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Default 99 TXT reducer/buss/fuse location?

So, I've had my box from ScottyB sitting on the desk for several days now. I've been researching the forum on where everyone is placing their voltage reducer, fuse box, and buss bar. In the future, I'm planning to add two more batteries, one on each side of the cart to make it 48v. If I'm reserving that location for new batteries, where's the best place to put all of this? Can I put it on the rear wheel well on the driver side, and still have room for a battery over there?

If not there, is there room under the dash somewhere that is reasonably accessible for the fuse box, and the bus bar so that I can make new connections? Any other ideas are welcome.

Also, is 12 or 14 gauge wire sufficient for the +36(soon 48 ) volts in to the reducer, and for the ground to the buss bar and reducer?
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Old 07-27-2015, 10:52 AM   #2
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Default Re: 99 TXT reducer/buss/fuse location?

On my '98 series, I found room for the reducer, fuse block, and second battery on the driver's side.
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Old 07-27-2015, 11:12 AM   #3
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Default Re: 99 TXT reducer/buss/fuse location?

http://www.buggiesgonewild.com/elect...r-install.html
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Old 07-27-2015, 11:47 AM   #4
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Default Re: 99 TXT reducer/buss/fuse location?

Thanks Yurtle! My search criteria must of been too narrow. Is 14 gage wire sufficient to run as power and ground between the reducer and fuse box?
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Old 07-27-2015, 01:16 PM   #5
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Default Re: 99 TXT reducer/buss/fuse location?

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--------------
Is 14 gage wire sufficient to run as power and ground between the reducer and fuse box?
Maybe. It depends on how many amps your 12V accessories draw and the distance between the reducer and the fuse block.

You also had a question about what gauge wire to feed the reducer with. Since the pack voltage is stepped down by the reducer, the input amps will be the max output amps of the reducer times the output voltage divided by the input voltage. IE: The input amps for a 30A 12V reducer feed by 36V will be 10A and if feed by 48V, it will be 7.5V. Add about 25% to those Amps since the reducer is less than 100% efficient.

Here is a Amp vs Length vs Gauge chart for boat wiring, but your wires will be less than 20 feet long, so you can problem get away with dropping a gauge or so. If the wire get hot with everything on, it is too small.
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Old 07-27-2015, 11:28 PM   #6
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Default Re: 99 TXT reducer/buss/fuse location?

Thanks, JohnnieB, this is exactly the education I was looking for! Now, let's see if I have learned my lessons. And, since I already have 100' each of green, red, and black, 14 AWG wire, let's see if I can put it to good use.


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... It depends on how many amps your 12V accessories draw and the distance between the reducer and the fuse block.
1. If the MAX input amperage to the reducer is 15A (10A calculated ((30*12)/36), rounded up 50% for a wide margin of error), and the reducer is 4' from the Battery Pack, then the chart says 14 AWG should be more than sufficient from the BP to reducer for power in. Correct?

2. This would mean that the ground wire from BP to reducer could (should?) also be 14 AWG, even though it could go down to 16 AWG, if I read some of the rest of ABYC E-11 correctly. Correct?

3. For the Reducer to the Fuse block 2' away, if I consider that the max output should not exceed 30A, then I believe the chart is telling me to use 10 AWG for that run. Correct?

4. Each individual power run from the fuse block to the accessory rocker switches will be about 6' in length and carry 3 to 10 amps, so again 14 AWG should be plenty big, as only 16 AWG is called for. Correct?

5. Each ground run from rocker switch to grounding buss bar also could be 16 AWG, but 14 AWG will provide a greater Margin of Error. I also think that 14 AWG will be sufficient from the BP to the grounding buss bar 4' away. Correct?

I have calculated that I should be able to stay well within the maximum output amperage of the ScottyB reducer, and worse case still be about 13% under. The MAX single amperage device I would have would be a radio, at 8A, if I ever add one. The combined initial max Amp draw would be nominally 12A {12v Fan @ 3A, TecScan lights @ 3A, LED light bar @ 6A}, and worse case 26A. That would be if I added a rear facing LED light bar @ 6A and the 8A stereo.

Looking at the wiring on ScottyB's reducer, I believe the green wire is 10 AWG, and the black and yellow are either 10 or 12. The red is smaller, so it could be 14. Measured diameter of the adapter wires, including insulation, are listed. I can't get to actual conductor, as there are already Molex ends crimped on them.

Red = .086"
Yellow = .100
Black = .116
Green = .122 - 10 AWG?

Bottom line, I think I am more than safe using 14 AWG for all connections EXCEPT the 12V/30A output from the reducer to the fuse block, where 10 AWG is recommended. Does that sound like a reasonable conclusion?
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Old 07-28-2015, 07:31 AM   #7
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Default Re: 99 TXT reducer/buss/fuse location?

The only red flag waving at me is #2. The ground wire (Black) is common to both input and output, so it carries both input and output amps and should be at least as heavy as the +12V output wire (Green).

Since you have a supply of 14Ga wire, I'd use it for everything except the yellow wire (Remote On/Off) to the keyswitch which doesn't carry any amps to speak of and anything 20Ga or thicker would suffice.

For the "Ground" wire, I'd connect two 14Ga wires to the black wire in the pigtail, one going to the battery pack's main negative terminal and the other to the -12V distribution block.

If any wire got more than warm in operation, I double it up with a parallel run of 14Ga, which would effectively be an 11Ga conductor.
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Old 07-28-2015, 03:52 PM   #8
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Default Re: 99 TXT reducer/buss/fuse location?

Make sure your switches that carry 10 amps are rated for that.
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Old 07-28-2015, 04:11 PM   #9
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Default Re: 99 TXT reducer/buss/fuse location?

I used 10AWG to feed the 30 amp reducer, with a 3 position key switch feeding the "on" for the reducer. I used 14 for all of my loads, as I didn't want different size wires for each load. My biggest load was 2 55 watt headlights, which is around 10 amps.

I used industrial "tubular" wire labels. Make a wiring chart to identify which wire goes where.
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Old 07-28-2015, 08:56 PM   #10
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Default Re: 99 TXT reducer/buss/fuse location?

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Originally Posted by yurtle View Post
Make sure your switches that carry 10 amps are rated for that.
I did. They are all 12V / 20A.

Thanks,
Paul
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