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Bobs Ten
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Date:  1-29-2020
Number of Hours:  3.20
Manual Reference:  
Brief Description:  Install Instrument Panel

1530 - 1842

Last week, I looked over the backbone wiring again and compared it to what is wired in the panel. I found a small issue that I was not satisfied with. The secondary bus is there to primarily power the essential bus, which powers all of the engine electrics. As such, the secondary voltage regulatorr should receive secondary bus voltage for the field and sense leads. This is where the mismatch occured. The essential bus is powered by two separate sources through the bus manager, which is a diode bridge. The panel wiring used essential bus power to feed the secondary voltage regulator. A potential problem occurs with this scenario as the voltage regulator would be sensing TWO power sources at the essential bus, and the inevitable voltage drop[ across the diode bridge. This voltage would be incorrect for the secondary system, i.e. if the secondary battery was at a lower voltage and required charging, the essential bus would still be at normal voltage, being powered by both the primary AND secondary system. This would cause no increase in secondary alternator output due to seeing an incorrect bus voltage.

The solution was fairly simple in concept but consumed quite some time to implement.

Removed circuit breaker panel and disconnected all wiring.

Routed and connected a 16 awg and a 20 awg wire from the secondary firewall power bushing to the circuit breaker panel area. This required work from the footwells...

Terminated the field power and sense wire using ring terminals.

Next, it was necessary to shorten the copper bus bar that was attached to the line side of the circuit breakers. The bus bar was shortened, shaped, bent, and finished as required. It was then reinstalled on the ECU 1, ECU 2, and injector power circuit breakers.

I then reinstalled the wiring on the circuit breakers, including the new secondary bus and sense wires.

The panel was the reinstalled and all connections verified for fit and interference. The main bus wire needed to be rerouted slightly.

I then worked on
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