Minneapolis, MN, July 2014, - Waytek, Inc., a leading distributor of electrical wiring supplies, connectors, and relays for the mobile equipment market, is pleased to announce the addition of Blue Sea Systems products to its broad, in-stock offering of Original Equipment Manufacturer (OEM) electrical components.

Blue Sea Systems designs and manufactures AC and DC electrical system equipment engineered to withstand the demanding applications in marine and specialty emergency vehicles, industrial machinery, construction machinery, and agricultural equipment markets. Blue Sea System is an industry leader with a reputation for quality.

“More than 75 percent of Blue Sea Systems products are hand assembled in Bellingham, Wash. and backed with a satisfaction guarantee,” said Jim Keister, marketing manager at Waytek, Inc. “Blue Sea Systems stand behind their products because they’re built to last; they stand behind them for as long as you own them.”

OEM customers and retailers can purchase Blue Sea System’s products on the Waytek website. Bulk pricing is available for large order OEM customers. For retail customers, retail packaging is available and designed to be hung in-store on J-hooks for the most efficient use of space. The Waytek website conveniently provides all the mechanical information and specifications necessary to help customers make an appropriate, informed purchase.

The Waytek website features a broad selection of Blue Sea System’s most popular products. Photos, technical and data sheets, and application guides accompany detailed product descriptions. Waytek also has knowledgeable customer service representatives available to answer product questions at 800-328-2724.
Blue Sea

About Waytek

Since 1970, Waytek has been providing electrical wiring supplies to OEMs in the truck body and trailer, construction machinery and equipment, agricultural equipment, and emergency vehicle markets. Waytek maintains a large inventory of more than 10,000 different electrical supplies. Waytek prides itself on having the “Right Parts, In Stock, to be delivered On Time.” To view the Blue Sea System’s products, visit the Waytek website at www.waytekwire.com

About Blue Sea Systems

Blue Sea Systems was founded in 1992 based on a commitment to create innovative, high-quality marine electrical products to improve the safety, simplicity and reliability of boating. Blue Sea Systems employees are active boaters who apply their passion to designing, developing and building products that enhance the experience of boaters. For specific product information and to learn more about Blue Sea Systems, visit www.bluesea.com.

How to Choose the Right Time Delay Relay


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Time delay relays are designed to control an event based on time. Work trucks, buses, emergency vehicles and other mobile equipment require delayed circuit operation for several applications. The solid state design of time delay relays withstands the electrical environments typically found in on and off-road vehicles and equipment. The key is selecting the right time delay relay for your application.

When designing circuits using time delay relays, you should consider the following questions:

  1. What initiates a time delay relay?
  2. Does the timing start with the application or release of voltage?
  3. When is the output relay energized?

Three industry standard time delay relay functions are available: On-Delay, Off-Delay and One-Shot.

On-delay timer relays are used when one circuit function must activate a time delay after another function. For example, you want to start an air compressor five seconds after the PTO is activated. The circuit that activates the PTO would be connected to the on-delay timer relay’s timer input. The timer’s output would operate the compressor’s start circuit. When the PTO is activated the timer starts. Five seconds later the timer’s output would start the compressor, and would stay on until the timer’s input is removed.

Off-delay timer relays are used when one function must start a second function and the second function must stay on for a time period after the first function is deactivated. For example, a school bus has an egress light that must be started when the door is opened, and must stay on for 10 seconds after the door closes. The door open switch is connected the off-delay timer relay’s timer input and the egress light is connected the timer’s output. When the door is opened the timer’s output is activated, turning on the light. When the door switch indicates the door is closed the timer starts. After 10 seconds the timer’s output is deactivated, turning off the light.

One-shot timer relays are used when one function must start a second function and the second function must stay on for a fixed time period. For example, a rear view mirror heater must only operate for 15 minutes to prevent damage to the mirror. The mirror heater switch is connected to the one-shot timer’s input and the timer’s output operates the mirror heater. When the switch is turned on the timer starts and its output is activated, turning on the mirror heater. After 15 minutes the timer’s output turns off regardless of if the switch is on or off.

For more information on time delay relays, call 800.328.2724.

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Waytek Partners with ITS to Help Reduce Fuel Usage Among Fleet Operators with New E-COPILOT Technology

Minneapolis, MN, June 2014, - Waytek, Inc., a leading distributor of electrical wiring supplies, connectors, and relays for the mobile equipment market, now distributes the E-COPILOT by ITS, a device for automating the reduction of fuel consumption and emissions that can result in fuel savings of 10 percent or more.

The E-COPILOT device is a small box that commonly mounts behind a fleet vehicle’s dash panel. By monitoring a number of data points within the vehicle’s ECMs, the E-COPILOT manages the driver’s access to engine power to optimize fuel economy and performance.

“Companies are currently spending millions of dollars attempting to correct inefficient driver behavior. In an economy that’s working on tight budgets, this task becomes even more critical,” said Jim Keister, marketing manager at Waytek, Inc. “E-COPILOT provides intelligent power management of both horsepower and acceleration that can save fleets 10 percent or more in fuel savings,” added Keister.

Waytek is excited to have this fleet-proven technology in stock and ready to assist fleet managers with their cost savings initiatives. The E-COPILOT installs in less than two hours, meets Department of Transportation safety regulations, reduces maintenance costs, meets or exceeds all government standards, and does not affect manufacturer’s warranty.

In addition to fuel savings, E-COPILOT eliminates aggressive acceleration without sacrificing necessary power. E-COPILOT reduces maintenance costs, fuel costs and decreases premature tire wear.

“As fleet managers look for ways to save money with tightened budgets, the E-COPILOT is a great tool for immediate fuel savings,” said Keister. “With the cost of fuel and the number of hours that fleet vehicles log, this is an easy place to see an immediate impact in cost reduction.”

The E-COPILOT can be installed in new or retrofitted into existing trucks. It requires no maintenance, works with all engine models of class 7 and 8 trucks, requires no permanent modifications to the vehicle, and the device stays with the vehicle as it’s transferred to the next fleet.

To purchase E-COPILOT or to learn more, visit www.waytekwire.com.

Waytek E-copilot

About Waytek: Since 1970, Waytek has been providing electrical wiring supplies to OEMs in the truck body & trailer, construction machinery & equipment, agricultural equipment, and emergency vehicle markets. Waytek maintains a large inventory of over 10,000 different electrical supplies. Waytek prides itself on having the “Right Parts, In Stock, to be delivered On Time.” To view the E-COPILOT in Waytek’s product line, go to www.waytekwire.com

About ITS: Intelligent Transportation Solutions provides intelligent automation that is focused on reducing fuel consumption, harmful emissions, maintenance costs and improving safety. ITS is headquartered in Minneapolis, Minn. and has multiple years of experience in business, marketing, and vehicle engineering.

How To Manage Power in Dual Voltage Systems

DC Power Converters

DC Converters Manage Battery Power in Dual Voltage Systems

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When the voltage required to power your motor is much higher than the voltage required to power your auxiliary devices, the electrical system is referred to as dual voltage.  If not properly supported, dual voltage systems can suffer from excessive current overload or rapid battery discharge, which significantly reduces the life of batteries. DC to DC Converters take high voltage power from battery packs and provide regulated and clean 12 volt output power for standard auxiliary devices and accessories.

A very common instance of dual voltage systems is electric utility vehicles and mobile equipment.  They are made with 48 volt or higher traction packs in order to power the motor, however, their auxiliary systems, like head lights, radios, communication accessories, computers, wipers and tailgates only require 12 volt power. The 48 volt motor power needs to be converted down to 12 volt power in order to supply the accessories safely. DC to DC converters provide steady energy for 12 volt accessories from battery systems where nominal voltage is much higher and make the output electrically isolated from the input.

DC Converters are designed to withstand reverse battery, over-temperature, over-current, and short circuiting without damage to the unit.They also offer protection from under-voltage and over-voltage on the input. If the input is too high or too low, the converter will shut off to protect itself. Under-voltage protection incorporates a delay so that momentary battery sags do not turn off the converter, and the operating temperature is constantly monitored. If the unit becomes too hot, it will fold back to protect itself. The converter uses current-mode control topology. This topology allows for cycle-by-cycle current limiting during short circuits or overloads. Converters are small, light, silent, and have no moving parts to wear-out, making them very low maintenance.

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Electrical Terminal Blocks: Convenient, Space Saving Solution for Connecting Several Wires

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Electrical terminal blocks provide a convenient way to connect individual electrical wires. Also known as terminal boards or terminal strips, terminal blocks are available in several electrical terminal configurations. The following terminal blocks offer different advantages depending upon your needs.

Double row termterminal blockinal blocks are used for general purpose electronic or electrical work. They help eliminate splicing and can conserve panel space when used to construct high density circuitry. The exact dimensions of the terminal block will vary depending on the number of positions, amps, and voltage. Designed in numerous combinations of amp and volt configurations, ours are available in 20, 30, & 75 amp models with 150, 300, or 600 volt styles and can offer anywhere from 2 to 12 positions.

Single-Row Terminal Strip

Our standard single row terminal strips are rated up to 600 volts and available in 20, 27, or 45 amp models. They can withstand temperatures ranging from 185° to 86° Fahrenheit (or 85° to 30° Celsius). Sold with and without a wire guard, typical wire range will vary and can be anywhere from 10-20 depending on the model you choose.

7-Terminal Junction BoxOur 7-Terminal Junction Box is a stud-type junction block that provides a convenient way to connect wires between trailer and towing vehicles. It has a black ABS Plastic cover and base includes five open rubber grommets, five closed rubber grommets, and #10/32 threaded studs that are spaced ¾ “ apart. Though equipped with barriers to prevent shorting and mounting hardware, nuts and washers are not included. Its glass-filled nylon construction enables it to withstand a maximum temperature of 200° Fahrenheit (or 105° Celsius).

Whether you want to conserve panel space, customize your terminal block, or connect wires between two vehicles, there is a block that will offer the ideal solution for your electrical terminal needs.

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Heavy Duty Welding Cable Alternative to Battery Cable


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Welding cable was originally designed and intended for connecting welding equipment and grounds. It is a high voltage cable built for flexibility so the welder doesn’t have to drag a heavy, stiff cable while working. The transportation, vehicle and heavy equipment industries have recognized the benefits of welding cable’s high flexibility, high voltage, and high heat capabilities and are using it as an alternative to battery cable.

Vehicle and equipment manufacturers are designing with space, weight and fuel savings in mind. Compartments and components are getting smaller and lighter. Welding cable is very easy to work with in small spaces because it is constructed with highly flexible Class K stranding of SAE compliant 30 Ga. copper conductors, and high grade RoHS compliant EPDM insulation. Its extreme flexibility allows tighter diameter bends, so you are able to do more with less cable, making it a cost effective choice. Welding cable offers a more efficient and cost effective method for routing wires. The EPDM jacket resists cuts, tears, abrasion, grease, oil, water and flame for optimal durability. Welding cable withstands the extreme temperatures up to 105°C and remains flexible in -50°C. Capable of high-power applications up to 600 volts.

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What to do When Deutsch Connectors are Difficult to Source?

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Deutsch connectors are in high demand and can be difficult to source due to manufacturer lead times. You see Deutsch connectors everywhere on trucks, construction equipment, Ag equipment, almost any piece of mobile equipment. However, you can’t afford to slow your equipment production to wait for a connector lead time.  Waytek has partnered with Amphenol, Delphi and Molex to make Deutsch compatible connectors in stock, ready to ship as soon as your order is placed. Amphenol, Delphi and Molex have spent countless hours testing and perfecting the Deutsch compatible connector lines to make them a reliable replacement.

Deutsch Compatible Connector

Deutsch Compatible Connector Lines: Amphenol ATP, Amphenol AT, Delphi HES, Molex XRC.

Deutsch DT Compatible – Amphenol AT Connectors: A high performance, cost effective system with wedge locks, durable thermoplastic housings and nickel plated contacts to ensure reliable electrical connections, and withstand harsh environments.

Deutsch HDP Compatible – Molex XRC Connectors: Extra rugged circular connectors are IP67 sealed for protection against dust and water. Their reverse terminal genders allow for custom polarization, and the housing construction with a collar offers easy gripping and efficient installation for decreased labor time and costs.

Deutsch HD Compatible – Amphenol AHD Connectors: Offered in either a smooth Diagnostic Grade housing for non-sealed controlled applications, or Military Style housing with a silicone elastomer seal and threaded constructions for protection against environmental ingress.

Deutsch HDP Compatible – Delphi HES Connectors: Harsh environment series connectors with a rugged construction and IP67 rating. They provide a high current capability, improved sealing, and higher terminal retention with significant cost advantage compared to standard pin-and-sleeve systems.

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How to Protect Electrical Connections from Corrosion, Pull-out and High Repair Costs

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Reducing recurring electrical problems and repair costs is always on the minds of fleet owners. Electrical connectors must operate in adverse conditions like extreme heat, extreme cold, vibration, strain, snow, rain, moisture and chemicals. These conditions cause electrical connector corrosion and wires to pull-out, resulting in equipment downtime and high repair costs.

Electrical-Connector-CorrosionCorrosion damage is estimated at over $23.4 billion in the transportation sector. Wiring and lighting is the most frequent corrosion problem in maintaining fleets. These issues often stem from faulty electrical connections. Equipment downtime often results in hundreds to thousands of dollars in violations, repair costs and lost opportunities.

Heat-shrink-electrical-connectorsUsing a high quality sealed electrical connector can protect against moisture and contaminant causing corrosion. The simplest way to prevent corrosion damage is to use heat shrink terminals and electrical wire connectors in place of non-insulated, vinyl or nylon insulated options. Heat shrink electrical connectors are constructed with adhesive lined polyolefin heat shrink tubing to seal-out moisture. Their initial cost is a little higher than non-insulated, nylon or vinyl electrical connectors, but they offer strong environmental protection, easy installation and durability, making them an extremely valuable selection.

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New Online Quick Order Tool

Waytekwire Quick OrderThe online quick order tool was created for the busy purchasing and engineering professionals that knows what they need to order and wants the order placed quickly so they can move-on to their next project on the list. It allows you to quickly enter purchase orders, or a list of items you want to order, by entering quantities and waytek stock numbers into an online form. The quick order tool is located in the top right corner of the home page at www.waytekwire.com. There are 5 line item entries on the home page form, but if you need more, simply click the “Add to cart button” for a larger quick order form with 20 line item entries.

How to use the Quick Order Tool

Quick-Order-Tool1. Type the quantity and waytek part numbers into the fields provided. If you have more than 5 line items to enter, before entering any information in the fields, click the “Add to Cart” button for a larger quick order form with 20 line items

2. Click the “Add to Cart” or “Add to Order” button once you’ve finished adding items to the quick order form.

Quick-Order-Tool23. Review your quick order form, then click the “Add to Current Order” button.

4. After clicking the “Add to Current Order” button, you will be linked to the home page where you will see your shopping cart with items in it in the upper right hand corner. Click on the shopping cart icon.

Quick Order Tool5. Review your cart. You can make changes to quantities, line items and more. If everything looks good in your cart, click the “Proceed with Checkout” button.

You will be directed to login to your account or register for an account if you don’t already have one. Registering is a simple and secure form that asks you to create a userid and password, enter a billing address, company name, shipping address, email address, etc. It takes about 1 minute to complete registration.

Quick-Order-Checkout6. After logging-in or registering for an account, you can whiz through the check-out process. Upon placing your order, you will receive an order confirmation email.

If you have any questions on how to use the quick order tool, or any other questions, comments or suggestions about waytekwire.com, email us or call 800.328.2724.


How To Extend the Life of Your Anderson Connectors

Anderson-MultipoleAnderson Power Products (APP) suggests a series of procedures for maintaining and extending the performance life of Anderson Connectors. Following these installation tips, preventative maintenance and corrective procedures can result in lower connector operating costs, greater efficiency and productivity.

Connector Installation Tips

  1. Reference Assembly Instructions specific to the connector. Assembly instructions for a connector can be obtained from APP or a distributor.
  2. Use proper assembly tools.
  3. Reference all applicable electrical standards requirements such as NEC, UL, CSA, etc.
  4. Perform a sample assembly of a few pieces for assembly verification testing. Test these samples for proper crimp dimensions, crimp tightness, crimp resistance and operating temperature.
  5. Perform periodic assembly verification testing to assure assembly process and tooling are performing correctly.  Typically, crimp dimensions are checked at short intervals and crimp resistance and secureness are checked at longer intervals.  The changes in the wire gauge, wire stranding, wire coatings, contact crimp tools, crimp dies and crimp dimensions will affect the quality characteristics of the crimp.  Verification testing should be performed when any of these change.

Connector Crimping and Soldering

Proper crimping and cleaning of the wire is essential for optimizing connector service.  A proper crimp that is performed on oxidized wire may have high resistance and could result in excess heat.  Cutting back cable to a non-oxidized area and / or cleaning the wire with a wire brush or 3M Scotch Bright ™ is recommended.

improper-stripped-wire1. Stripping Cable Insulation: Problems with cable harness and connector systems often begin with improper or accidental cutting of wire strands while stripping cable insulation.  Each strand is important, and all of them must be included in the contact barrel to avoid unnecessary hot spots during operation.  When removing insulation, position a sharp blade at  a right angle and apply steady, controlled pressure, cutting only the cable insulation, not the copper wire.  Strip cable to the proper length for the contact being crimped.  Proper lengths are listed in the instruction sheet with each APP connector.

2. Cleaning Copper Wire

Cleaning Copper WireAged and badly tarnished copper should be thoroughly scraped with a stiff wire brush that penetrates the entire bundle cleaning every strand. The wires will then be ready for insertion into the contact barrel when they are brushed to their original bright copper finish. Contact barrels are lined with silver or tin plating to assure consistent conductivity, which will be reduced if the barrel is crimped around aged or tarnished wire.

3. Crimping


The best preparation will be defeated if inadequate tools or improper crimping procedures are performed.  Never use a hammer and chisel or the “squeeze-in-a-vise” method.  They won’t do the job and will result in substantial reduction in connector life.

Use an APP crimp tool.  Make sure the stripped cable is inserted all the way into the barrel of the contact and that the contact point is centered in the crimp tool.  A crimp tool will effectively compress the contact barrel tightly around the cable strands, allowing them to be pressed tightly against each other and against the inside wall of the contact barrel.

When the crimp has been completed, check the appearance of the contact.  A properly crimped contact barrel is compacted tightly with the outer strands.  The outer strands on an improperly crimped barrel will be loose and will not have adequate clamping force.  Test for low pull-out force.  If the cable can be loosened, recrimp until it is tight.






4. Soldering

The alternative to crimping is to solder all cable strands within the contact barrel.   When using an open flame, make sure that you are not in an area where explosive gasses are present.  The right proportion of solder is essential if this procedure is employed.   Use a quality 60/40 solder (60 percent tin, 40 percent lead) in wire form with a rosin flux core.  Cable strands should be separately fluxed with rosin paste, and the contact should be held in a vise with the barrel end facing up.  Apply heat to the outside of the barrel while the solder flows in beside the wire strands.

Here are some things to avoid when soldering:

A.  Don’t use too much solder, to the point that it flows out of the contact barrel.

B.  Don’t allow flux or solder on the outside of the contact.  This will interfere with contact mounting within the installation or with the contact connection to a mating connector.

C.  Don’t overheat and cause excessive solder to “wick” up into the cable and stiffen it.  This could interfere with contact flexibility when connectors are mated.

D.  Don’t solder when contact is in the connector housing.  Solder away from the housing and then insert the contact into the housing.

NOTE: Underwriters Laboratories (UL) requires the use of a cable clamp for soldered connections to unsupported leads.

5.  Inserting Contact into Housing

Contacts should never be forced into housing.  If the contact does not fit easily, check the contact barrel for distortion.  Replace the barrel if it is distorted or shows signs of wear or damage.


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