 | Home > Puma (Tdci) > BlueSea Heavy Duty ON/OFF battery switch with AFD |
 
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| Simon.pl Member Since: 15 Mar 2016 Location: Warsaw Posts: 98   
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Ok - as the investigation continues I wanted to ask how do you guys protect your alternator's diodes (or think you will protect) in case of emergency shut off using the kill switch?
I'm talking about the situation when for instance under heavy load the winch solenoid fries that makes permanent contact inside and you are not able to stop the winch. The only way is to cut the power off, but that would kill the alternator hence the need for AFD. In case there is voltage regulator build in is turning the engine off before cutting the power off the only solution that could save the alternator? |
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8th Aug 2017 8:15pm |
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| davew Member Since: 02 Jan 2012 Location: North Yorkshire Posts: 888  
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The usual way is a high power, low resistance resistor that you connect between the ignition live and earth when the switch is activated. For the few seconds that the engine is still turning it keeps the alternator honest by giving it a load. It also protects the various electronic parts of the vehicle from experiencing high voltage spikes during this time.
The normal FIA switches are supplied with such a resistor. An alternative to the above is to run the alternator output directly to the battery so that it is still connected to the batter when you disconnect everything else. It does leave you open to issues if you get a problem with the alternator cable though ! http://www.yorkshireoffroadclub.net/ |
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8th Aug 2017 8:31pm |
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| Simon.pl Member Since: 15 Mar 2016 Location: Warsaw Posts: 98
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This was my original idea. Even bought such FIA switch. Than moved to the "nicer" solution that BlueSea delivers, but had not done my homework before and just after buying the switch found out that the alternator had the VR build in.
Will see if I'd be able to use the resistor with this switch. Thanks  |
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8th Aug 2017 8:53pm |
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| MadTom Member Since: 10 Sep 2013 Location: Olomouc Posts: 572  
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In "standard" LR I have additional high current switch just for the winch. With remote control from the drivers place. It is also good to disconnect the power from the winch, when the winch is not in use. "Drobek" = The Small One - Discovery 2, "BlufĂnek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo
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9th Aug 2017 7:10am |
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| Simon.pl Member Since: 15 Mar 2016 Location: Warsaw Posts: 98
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I also plan to have on/off switch in the cabin. Please have a look on the attached piece of my electric drawing. But in fact the switch will control the current on the cable remote socket so it is "dead" until activated inside. This will not eliminate the problem when the relay fries as the high current is constantly present on the relay.
 Click image to enlarge |
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9th Aug 2017 11:13am |
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| MadTom Member Since: 10 Sep 2013 Location: Olomouc Posts: 572
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The high current switch/relay/solenoid is there primary for disconnect the high power wire from winch. In case of a crash, there is lower risk of short circuit and possible fire.
When the winch is in use, it is controlled by its own solenoids, and in case of stuck solenoid = winch is running out of control, I can kill it by the high current switch. The high power switch is just next to the battery, so it is in good protected place. I´m using some DC contactor originally designed for use in a tank T72, with pure silver contact with 11mm diameter. It is rated for continuous current of 200A without time limit. Much more rugged, than standard winch solenoids. To control it, I have a small switch on board, with red LED indicator. And last but not least - I have seen several winches damaged by water - they have suffered from electrolytic corrosion, because of DC voltage continuously presented on the winch/solenoids. This is also eliminated by the additional switch. "Drobek" = The Small One - Discovery 2, "BlufĂnek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo |
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9th Aug 2017 11:48am |
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| Simon.pl Member Since: 15 Mar 2016 Location: Warsaw Posts: 98
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Isn't the relay (with solenoids inside) responsible for delivering the high power to the winch?
It just feeds field contactors when the remote gives power on low current pins and only in such situation the high power is on the winch.. But there is on the solenoids indeed. I don't want to multiply switches. I just want to have one for the front winch that cuts the alternator as well, and the other one for the rear winch (as it will be fed from different battery). Maybe simple warning next to the switch like "turn the engine off before use" should be enough |
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9th Aug 2017 11:58pm |
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| MadTom Member Since: 10 Sep 2013 Location: Olomouc Posts: 572
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In my setup I have battery - high power relay/contactor - winch solenoids - winch. Alternator is directly connected to the battery.
High power relay is there for cutting power to the winch, when not in use, and as s security switch for case of jammed winch solenoid. It is placed just next to the battery. Resistance of the high power relay is comparable to good 500A fuse with fuse holder. "Drobek" = The Small One - Discovery 2, "BlufĂnek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo |
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10th Aug 2017 7:24am |
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| TopQ1967 Member Since: 14 Feb 2012 Location: Veghel Posts: 226  
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Hi, Your electric drawing looks nice. I am very interrested in the whole thing? |
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18th Aug 2017 8:04pm |
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| Simon.pl Member Since: 15 Mar 2016 Location: Warsaw Posts: 98
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Thanks TopQ1967
It's still not ready - there are some relays missing here and there, wires are not numbered, and some other details missing, but if you are interested at this stage - here it is! 
I have my build thread here as well although it hasn't been updated for a while, so this drawing is not there yet. Will work on it when I find time
Click image to enlarge |
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19th Aug 2017 5:17pm |
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| MadTom Member Since: 10 Sep 2013 Location: Olomouc Posts: 572
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What software do you use for drawing this schematics? It looks like simple to understand also for non-electricians. "Drobek" = The Small One - Discovery 2, "BlufĂnek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo
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19th Aug 2017 5:32pm |
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| Simon.pl Member Since: 15 Mar 2016 Location: Warsaw Posts: 98
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Yeah - combining block and detailed diagrams makes the drawing easier to read.
I use VISIO to draw - just import thumbnails and connect it with wires. |
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19th Aug 2017 5:45pm |
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