Waytek Introduces New Line of Power Distribution Modules for CAN-BUS Focused Manufacturers

Waytek_InfinityWaytek, a leading distributor of electrical wiring supplies, connectors, and relays, for the mobile equipment industry is proud to announce the addition of Infinitybox, to its broad, in-stock offering of OEM manufacturing electrical components.

Staying ahead of the demand, Waytek added the premier manufacturer of CAN-BUS for power management and mobile equipment products, Infinitybox, to its product line. This progressive line of power distribution modules (PDMs) complements the Waytek line by offering exciting new technology that’s easier to program, install and use.

The Infinitybox J1939 POWERCELL PDM is designed for the commercial vehicle. It provides 10 outputs per each POWERCELL, solid-state MOSFET outputs, internal fuses for harness protection, standard automotive connectors for simple harnessing, and up to six POWERCELLs on one Infinity J1939 network. A variety of connection kits are also available.

They provide a customizable, modular power distribution platform that can be added to existing CAN-based wiring harnesses or they can replace traditional wired relay panels.

The Infinitybox inMOTION Motor Controller includes 5 H-bridge relay pairs for polarity reversing, internal current sensors for monitoring output load, integrated fuses for harness protection, standard automotive connectors for simple harnessing, and output configuration set by CAN messages sent from the Infinity J1939 input device.

Infinitybox J1939 PDMs are targeted toward the commercial vehicle manufacturer market. They provide a customizable, modular power distribution platform that can be added to existing CAN-based wiring harnesses or they can replace traditional wired relay panels.

The Infinitybox product line offers easy integration into existing Infinitybox J1939 networks, labor savings compared to building customer relay panels, and flexible solutions allow vehicle customization on production line. The Infinitybox J1939 PDM offers integrated output LEDs for status and diagnostics, and are field configurable and addressable.

The off-the-shelf system is completely customizable. Customers add the Infinitybox hardware necessary for the complexity of their vehicle. The behavior of the PDMs can be controlled by configuring the software on your J1939 input device. This flexibility allows changes to be made before, during and after installation; providing unprecedented control over your vehicles electrical system.

A wide range of Infinitybox products are kept in stock at Waytek. The Company offers customers a simple migration path from traditional switches and relays to Infinitybox J1939 switches and power distribution modules.

Infinitybox PDMs provide a complete electrical management solution for low-volume prototypes or high-volume, serial production. Its multiplexed architecture streamlines and has the capability to integrate functions of external electronics modules including timers, delays, dimmers, alarms and other control systems. It also features a built-in Infinitybox J1939 gateway that allows integration to other systems in the vehicle.

Originally designed for harsh-duty and off-highway equipment, Infinitybox products have crossed over to a broad range of commercial, emergency vehicle and motorsports applications. These power systems have been designed and tested to thrive in the harshest off-highway applications.

Infinitybox products are designed to provide vehicle manufacturers with the right tools to quickly engineer custom solutions for their power distribution systems.

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 more than 10,000 different electrical supplies. Waytek prides itself on having the “Right Parts, In Stock, and delivered On Time.” To view Infinitybox products in Waytek’s product line, go to www.waytekwire.com.

About Infinitybox LLC: The Infinitybox team brings decades of power distribution, circuit protection and electrical architecture design experience to our customers. In addition to providing off-the-shelf electrical distribution building blocks, our team can engineer custom solutions for your unique application. These modular systems allow vehicle manufacturers of any size to quickly engineer their power distribution system using these standard PDM building blocks.

IP Code

The IP Code, International Protection Marking, IEC standard 60529, sometimes interpreted as Ingress Protection Marking, classifies and rates the degree of protection provided against intrusion, dust, accidental contact, and water by mechanical casings and electrical enclosures.

The standard aims to provide users more detailed information than vague marketing terms such as waterproof. Two numbers indicate protection against solid bodies, first digit, and against liquids, second digit, in accordance with the charts below.

Ingress Protection Rating Guide

First Number | Effective Against

0
  • No protection (Sometimes X)
1
  • Protected against solid objects up to 50mm3
2
  • Protected against solid objects up to 12mm3
3
  • Protected against solid objects up to 2.5mm3
4
  • Protected against solid objects up to 1mm3
5
  • Protected against dust, limited ingress (no harmful deposit)
6
  • Totally protected against dust

Second Number | Effective Against

0
  • No protection (Sometimes X)
1
  • Protection against vertically falling drops of water (e.g. condensation)
2
  • Protection against direct sprays of water up to 15 degrees from vertical
3
  • Protection against direct sprays of water up to 60 degrees from vertical
4
  • Protection against water sprayed from all directions – limited ingress permitted
5
  • Protected against low pressure jets of water from all directions – limited ingress permitted
6
  • Protected against low pressure jets of water, limited ingress permitted (e.g. ship deck)
7
  • Protected against the effect of immersion between 15cm and 1m
8
  • Protected against long periods of immersion under pressure

Ingress Protection Rating Guide

Overcurrent – Primary Hazards

When considering the generic application for circuit protection within the confines of appliance or equipment design, there are three significant categories of consideration.

They are:

1) Avoidance of hazardous conditions for operating personnel and others indirectly involved.

2) Any reduction in size of current-carrying conductors.

3) Isolating a faulted function—leaving the normally operating functions able to continue.

The safety issue is undoubtedly the most important of these three. The primary safety focus is to eliminate two types of hazards:

1) Electrical shock

2) Smoke and fire

The safety consideration manifests itself most often in the primary-input circuit protector. In this application, power enters the appliance and is immediately met by a protector that is ready to take the system off-line when required.

The matter of current reduction is really a traditional definition for circuit protection application. Anywhere there is a reduction in the size of a current-carrying medium; the potential exists for a fault to exceed the limits of that medium. For example, wire is designed to carry 20 amps, and is protected accordingly. If a branch circuit is taken from this 20-amp circuit utilizing wire (which, depending upon insulation, is rated to carry 3 amps), then a dangerous overload in the 3-amp circuit (say, 15 amps or a 500% overload) would not be noticed by the 20-amp circuit. (Figure 1)

Figure 1

Figure 1

The third issue involves the design of fault-tolerant equipment and relates to the case illustrated above involving distributed power through branch circuits (Figure 1). If the low-amp branch circuits are independent functions, a fault in one circuit should not take the whole system down. By inserting a circuit breaker in each of the branches, the fault is isolated to the least-affected circuit, leaving the others to function normally.

Types of Abnormal Conditions

In the discussion of circuit protection, it is convenient to separate fault conditions into two types. They are distinguished by virtue of their magnitude, but also by their cause-and effect relationship. The two are overload and short circuit. MP_Circuit Breaker Group

An overload is a condition where, for various reasons, the current level within an electric circuit exceeds its specified limits but continues along its designed path. An excellent example is a stalled motor. This situation, at least initially, exceeds the normally specified steady-state condition. Overload will occur at start-up, or if the rotation of the motor is impeded in some way.

This overload will generally be in the area of 300–700% of the rated current level of the device. Start-up conditions are allowed for within most circuit designs. Other extended overload conditions must be protected.

Short circuits, on the other hand, are conditions that occur when the current path to the load is bypassed with a very low or negligible resistance path. Under this condition, excessively high current flows, which represent a significant hazard both to the appliance and attendant personnel.

In general, an overload is defined by a magnitude of 200–800% of normal rating, and a short circuit is anything greater than this. Because of its limited impedance/resistance path, however, a short circuit is usually considerably higher than 1000% of normal rating. A short circuit involves circuit damage. An overload may or may not involve circuit damage and many times is easily eliminated without repair, even though sustained overloads result in short circuits over time if not protected.

Product Spotlight: Blue Sea Systems m-Series Battery Switch

Many people associate “heavy-duty” with size. But heavy duty doesn’t always mean heavy weight. Waytek stocks the Blue Sea Systems m-series battery switch in a “mini” compact size, with heavy-duty current capacity and harsh environment specifications.

The m-Series Battery Switch from Blue Sea Systems is a great choice for on-road, off-road and boating equipment. Its “mini” size, flexible mounting options, and current-carrying capacity make this battery switch versatile to meet just about any battery switch application for small and medium-size vehicles and equipment. It is very compact, measuring less than 3″ by 3″ (7.6cm X 7.6cm), making it ideal for installations where there are size and space constraints. In spite of its size, its current-carrying capacity exceeds many standard-size switches.

The Blue Sea Systems m-Series Battery Switch is available at Waytek in three models:

The latest innovation in battery switches, Blue Sea Systems’ Dual Circuit Plus™ Battery Switches provide Engine and Start circuit isolation. Dual Circuit Plus™ Battery Switches turn the House and Start batteries on at the same time, but isolates them from each other. Battery isolation protects the Start battery from being discharged from House loads like refrigerators, stereos, and lights, preserving it for starting the engine. Battery isolation also protects sensitive electronics from voltage spikes and sags that may occur during engine starting. In addition, when coupled with an automatic charging relay (ACR) or battery isolator, both battery banks are automatically charged.

Current and Voltage Ratings

The mini size of Blue Sea Systems m-Series battery switches is deceiving. These switches are capable of 300 Amperes continuous rating and 500/450 Amperes intermittent rating. The Single Circuit and Selector models are rated at 48V; the Dual Circuit Plus™ is rated at 32 V. Furthermore, the Dual Circuit Plus™ model is rated at 300 Amperes per circuit so that they have a total current-carrying capacity of 600 Amperes. And, because these switches are UL Listed, you can be confident that they safely handle these high amperages. (See: Technical Brief: UL Marine Listed, Battery Switch Testing)

Case Material

The m-Series Battery Switch case is manufactured using two glass-reinforced plastic variations with properties specific to their application in the switch:

  • The front case, knob, snap-on rear cover plate, and removable isolator covers are made from glass-reinforced polycarbonate, a highly impact resistant material.
  • The switch back plate to which the terminal studs are connected is polybutylene terephthalate (PBT) polymer. PBT is a high heat-rating material not affected by the heat that can be generated by the terminals when operating with high current.

Terminal Stud and Electrical Contact Material

The m-Series battery switch is manufactured with copper contacts and tin-plated copper terminal studs. The bare copper contacts provide the best conductivity and therefore the least amount of heating. The 3/8″ (M10) tin-plated copper studs provide maximum conductivity and corrosion resistance. The 7/8″ (22.2mm) long stud length accepts multiple-cable terminals.

On the Dual Circuit™ and Selector models, the terminal studs are cold pressed into the copper contacts; On the Single Circuit model, the heads of the studs serve as the electrical contacts. Both techniques provide a very strong mechanical and ideal electrical connection. This technique is better than using a nut to fasten the stud to the bus or backplate-a practice used by most battery switches on the market today. A nut may loosen with vibration or during installation of battery cables. When the one-piece stud is pressed into place, it remains tightly fastened thereby eliminating the risk of overheating and switch failure.

Mounting Options

The m-Series battery switch can be mounted in any one of three convenient ways to meet just about any installation need:

  • Surface mounting

  • Front panel, through hole mounting, this option is self-trimming, for up to 3/4″ (19mm) panel thickness

  • Rear-panel, through-hole mounting, for up to 1/8″ (3.175mm) panel thickness

  • Rear case installed

The rear cover plate can be attached in all of the mounting configurations. The removable rear cover plate and side isolator covers protect terminal studs. Remove only the side isolator cover required for you to make connections.

The knob can be removed when the switch is in the off position to provide lockout for servicing. This prevents power from being turned on while the electrical system is being serviced. The knob is positively retained in other positions.

Additional Features

In addition to its compact size, multiple models, and current-carrying capacity, the m-Series Battery Switch also has additional features that make it a desirable choice for many boating needs:

  • Ignition protected-Safe for installation in on-road and off-road vehicles and equipment
  • Accepts up to 4/0 AWG battery cables

 

WAYTEK NAMED NEW DISTRIBUTOR OF BLUE SEA SYSTEMS HEAVY DUTY ELECTRICAL PRODUCTS

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

80030fl

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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

Waytek-Welding-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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