Electrical Best Practices Page |1 - GM Upfitter

Electrical Best Practices

Page |1

Contents Scope ...........................................................................................................................................................................................................................9

Common Electrical Problems ......................................................................................................................................................................................10

GENERAL INFORMATION ........................................................................................................................................................................................10

FAILURE MODES .....................................................................................................................................................................................................10

Short Circuit........................................................................................................................................................................................................10

Open Circuit........................................................................................................................................................................................................10

Intermittent Circuit.............................................................................................................................................................................................11

Sources of Electrical Problems ............................................................................................................................................................................12

OEM and Auxiliary Battery Guidelines ........................................................................................................................................................................17

OEM BATTERY GUIDELINES.....................................................................................................................................................................................17

General Information ...........................................................................................................................................................................................17

Discharge Prevention..........................................................................................................................................................................................18

Charging Procedures...........................................................................................................................................................................................19

OEM BATTERY RELOCATION GUIDELINES ............................................................................................................................................................20

Location .............................................................................................................................................................................................................. 20

Vibration: ...........................................................................................................................................................................................................20

Accessibility ........................................................................................................................................................................................................20

Tilt Angles...........................................................................................................................................................................................................21

Temperature ......................................................................................................................................................................................................21

AUXILIARY BATTERY GUIDELINES ............................................................................................................................................................................21

General Information ...........................................................................................................................................................................................21

Location .............................................................................................................................................................................................................. 21

Venting ............................................................................................................................................................................................................... 22

Mounting and Fastening .....................................................................................................................................................................................22

Connecting and Grounding .................................................................................................................................................................................22

Best Practices ? Electrical 2018

Revised Date: 09/30/2017

Electrical Best Practices

Page |2

Cable Sizing.........................................................................................................................................................................................................22 BATTERY DISCHARGE LIMITER GUIDELINES .........................................................................................................................................................23 Electrical System Interfacing ? New Circuit Guidelines ................................................................................................................................................25 NEW CIRCUIT GUIDELINES ..................................................................................................................................................................................25 Interfacing to the OEM Electrical System ............................................................................................................................................................25 Body Builder Junction Block/Connector ..............................................................................................................................................................26 EXTENDING OEM CIRCUIT GUIDELINES ...............................................................................................................................................................26 Electrical System Interfacing ? Design Guidelines........................................................................................................................................................28 Design Guidelines ...................................................................................................................................................................................................28 Cable (Wire) Selection Guidelines .......................................................................................................................................................................28 Cable Ampacity...................................................................................................................................................................................................28 Design Recommendations ..................................................................................................................................................................................28 Cable (Wire) Types..................................................................................................................................................................................................29 ? Passenger compartment ..................................................................................................................................................................................29 ? Engine compartment .......................................................................................................................................................................................29 Typical Calculation Example ................................................................................................................................................................................32 WIRE HARNESS ASSEMBLY GUIDELINES ..................................................................................................................................................................33 Design Recommendations ..................................................................................................................................................................................33 CONNECTING GUIDELINES ......................................................................................................................................................................................33 Design Recommendations ..................................................................................................................................................................................33 CONNECTOR TYPES.................................................................................................................................................................................................35 Unsealed Connectors..........................................................................................................................................................................................35 Sealed Connectors ..............................................................................................................................................................................................35 HOW TO CHOOSE A CONNECTION SYSTEM .............................................................................................................................................................36 Terminals ............................................................................................................................................................................................................ 36

Best Practices ? Electrical 2018

Revised Date: 09/30/2017

Electrical Best Practices

Page |3

Terminal Characteristics .....................................................................................................................................................................................37 ASSEMBLING CONNECTION SYSTEMS .................................................................................................................................................................39 Terminating a Wire (Hand Crimped)....................................................................................................................................................................39 SOLDERING GUIDELINES .........................................................................................................................................................................................42 Soldering Procedures..........................................................................................................................................................................................42 Seating Terminals ...............................................................................................................................................................................................43 Adding secondary or TPA locks ...........................................................................................................................................................................44 Hinged Secondary Locks......................................................................................................................................................................................45 MATING TWO CONNECTORS TOGETHER .............................................................................................................................................................45 DISASSEMBLING CONNECTION SYSTEMS ................................................................................................................................................................46 Removing TPA or Secondary Locks ......................................................................................................................................................................46 TERMINAL REMOVAL ..........................................................................................................................................................................................47 Splicing Guidelines..................................................................................................................................................................................................48 Splicing Two Wires..............................................................................................................................................................................................48 Splicing Multiple Wires .......................................................................................................................................................................................51 Recommended splicing procedure: .....................................................................................................................................................................51 Soldering the Splice Clip..........................................................................................................................................................................................52 Choosing a Splice Clip .........................................................................................................................................................................................53 WIRE HARNESS COVERING GUIDELINES ..................................................................................................................................................................54 Wire Coverings ...................................................................................................................................................................................................54 Selecting Convoluted Conduit: ............................................................................................................................................................................56 When Should Circuit Protection Be Used?...........................................................................................................................................................58 Circuit Protection Design Recommendations ......................................................................................................................................................59 ELECTRICAL COMPONENT GUIDELINES ...................................................................................................................................................................60 Ratings................................................................................................................................................................................................................ 60

Best Practices ? Electrical 2018

Revised Date: 09/30/2017

Electrical Best Practices

Page |4

Component Tolerance Levels ..............................................................................................................................................................................61 Component Handling ..........................................................................................................................................................................................61 Component Precautions .........................................................................................................................................................................................62 RADIO FREQUENCY INTERFERENCE (RFI) PREVENTION............................................................................................................................................62 SERVICEABILITY ......................................................................................................................................................................................................63 Design Parameters..............................................................................................................................................................................................63 Diagnosability .....................................................................................................................................................................................................64 Accessibility ........................................................................................................................................................................................................64 Repairability/Replaceability ................................................................................................................................................................................64 Limited-Life Components....................................................................................................................................................................................64 FMVSS/CMVSS REQUIREMENTS..............................................................................................................................................................................64 FMVSS/CMVSS 108: Lamps, Reflective Devices and Associated Equipment .........................................................................................................65 FMVSS/CMVSS 118: Power Operated Window Systems ......................................................................................................................................65 Electrical System ? Installation Guidelines ..................................................................................................................................................................66 WIRE HANDLING GUIDELINES .................................................................................................................................................................................66 WIRE ROUTING GUIDELINES ...................................................................................................................................................................................66 Location .............................................................................................................................................................................................................. 67 Tension ............................................................................................................................................................................................................... 67 Accessibility ........................................................................................................................................................................................................68 Appearance ........................................................................................................................................................................................................68 WIRE FASTENING GUIDELINES ................................................................................................................................................................................68 Additional recommendations are:.......................................................................................................................................................................68 WIRE AND ELECTRICAL COMPONENT PROTECTION GUIDELINES .............................................................................................................................69 Protective Devices ..............................................................................................................................................................................................69 GROUNDING GUIDELINES ...................................................................................................................................................................................70

Best Practices ? Electrical 2018

Revised Date: 09/30/2017

Electrical Best Practices

Page |5

ISOLATION OF "CLEAN" AND "DIRTY" ELECTRICAL GROUNDS..............................................................................................................................70 Clean Grounds ....................................................................................................................................................................................................71 Dirty Grounds .....................................................................................................................................................................................................71 WELD NUTS, WELD STUDS, SCREW/WASHERS AND TERMINALS USED FOR GROUNDING........................................................................................71 Weld Nuts...........................................................................................................................................................................................................71 Weld Studs .........................................................................................................................................................................................................72 Electrical System ? OEM Components ........................................................................................................................................................................73 OEM COMPONENT LOCATION GUIDELINES.............................................................................................................................................................73 Safety Systems: ......................................................................................................................................................................................................73 Electrical Components (non-safety system related) ................................................................................................................................................73 Under-hood/Vehicle: ..........................................................................................................................................................................................73 Under-dash:........................................................................................................................................................................................................ 73 Doors:................................................................................................................................................................................................................. 73 Under Seats: .......................................................................................................................................................................................................74 Rear Stowage Areas:...........................................................................................................................................................................................74 General Recommendation: .................................................................................................................................................................................74 RepairingDamagedWireInsulation...................................................................................................................................................................... 75 Splicing Inline Harness Diodes..............................................................................................................................................................................76 Splicing Twisted or Shielded Cable .......................................................................................................................................................................77 Wire to Wire Repair..............................................................................................................................................................................................79 Splice Sleeve Selection .........................................................................................................................................................................................80 WeatherpackTM Wiring Repair. . . . . . . .........................................................................................................................................................................84 Connector Position Assurance Locks .....................................................................................................................................................................86 Terminal Position Assurance Lock.........................................................................................................................................................................86 CPA Connectors....................................................................................................................................................................................................86

Best Practices ? Electrical 2018

Revised Date: 09/30/2017

 ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download