Installation Manual 12 Automotive Fuse Panel (AFP12) Version 2.2 March 2018 Table of Contents Introduction... 2 What s Included... 3 Installation... 4 Features & Helpful Tips... 9 WAS492 Wire Harnesses... 11 Harness Wiring Diagrams... 12 Wire Gauge Table... 15 Warranty... 17 Nomenclature applied throughout this document MGI Medusa Group Inc. NEC National Electrical Code SAE Society of Automotive Engineers SCP Switch Control Panel RCP Relay Control Panel IKS Ignition Key Switch www.mgispeedware.com A Division of Medusa Group Inc.
Introduction This installation manual contains general information and installation instructions for the MGI Automotive Fuse Panel with 12 fuses (AFP12). The AFP12 is a universal OEM replacement fuse box intended to be connected to an ignition key switch (IKS). In addition to the information in this manual, other helpful resources can be found online at: www.mgispeedware.com/guides-documentation What you should know before starting Connecting a 12vDC battery and its associated circuitry should only be accomplished by a licensed professional. Always follow the load manufacturer s wire and fuse sizing instructions for a particular load over that of MGI s installation manual guidelines. AFPs are supplied with MGI s standard feeder conductors, standard main fuse size, and optional standard load wiring bundle which may or may not be appropriate for your individual loads and total load. Adhering to NEC and SAE standards, consult the Wire Gauge Selection Table found at: https://mgispeedware.com/guides-documentation/wire-size-chart/ as to properly determine the size of main feeder, main fuse, and branch circuit requirements for specific loads. Although this manual makes reference to load types and load names and illustrates the connection of such to a particular screw terminal, it is the user s responsibility to ensure that all loads are suitable for the circuit and appropriate as defined by the NEC and SAE for the user s specific application. It is advised by MGI that all electric motors, halogen, xenon, LED lighting, high amperage electronics, and other high amperage (or high peak current) loads are to be controlled with a switching relay. Always consult the manufacturer of your specific load to determine if a switching relay is to be used. o Need one or more relays? Consider an MGI Relay Control Panel (RCP) or Relay Control Set (RCS). For more MGI relay products, see: https://mgispeedware.com/product-tag/relays/ AFP branch circuit fuses are of the Smart Glow type. A damaged fuse will glow as long as continuity exists in the circuit path. Simply replace the damaged fuse with a new fuse of the same size. All wire used in the AFP12 is either TXL, GXL, or SGX high-temperature wire. AFP screw terminals are labeled for quick and easy wiring. See the installation section. 2 P a g e
What s Included AFP12 fuse panel a) 12 Branch fuses / 21 circuits fed through 70A main fuse from battery b) IKS (Start) feeds 1 fused neutral switch/starter solenoid circuit c) IKS (Accessory) feeds 2 individually fused branch circuit + 1 sub-circuits d) IKS (Ignition) feeds 4 individually fused branch circuits + 4 sub-circuits e) Battery directly feeds 5 circuits and 4 sub-circuits (not switched through IKS) f) Integrated horn relay g) Integrated signals flasher h) Integrated hazards flasher i) #8 AWG SGX (high temperature) feeder conductor j) Numbered screw terminal strips for outgoing circuits k) Dedicated relay control circuit with ignition key ON l) Dedicated relay control circuit with ignition key ACC/OFF/IGN/STR WAS492 wire set m) TXL high temperature AFP exiting load circuits wire bundle color coded with wire marking every 5 n) Ground wiring sets & ring terminals o) Includes an orange wire set marked as [14-014] for the gauge cluster (oil pressure, water temperature, tachometer, and fuel level), plus a package of wire crimp ring terminals for gauge connections p) Complete package of wire crimp fork terminals for connection of all AFP12 output terminals to exiting load wires q) Complete package of wire crimp fully-insulated female/male bullet type in-line connectors for AFP wiring to existing OEM fixture socket wires The AFP12 is supplied with 5 Feet of 8 AWG SGX feeder conductor that is rated 125A at 20 C or 70A at 80 C. Keep in mind that the feeder conductor originates from the engine compartment where higher temperatures exist. See: https://mgispeedware.com/guides-documentation/wire-size-chart/ for an interactive wire chart. 3 P a g e
Installation STEP 1 AFPs are designed to be installed inside the cabin of the vehicle (under the dashboard), and where adequate ventilation exists. Secure the AFP #18 AWG black 12 ground wire with red ring terminal to a proper chassis ground. STEP 2 The AFP12 has a separate group of six (6) incoming conductors: One main AFP feeder conductor (labeled as #33 in Figures 1 & 2) Four ignition key switch conductors (IGN #35, ACC #36, START #37, and BAT #38) One regulator/power (BAT) conductor for use with a 2-wire alternator (#34) o For 1-wire alternators, simply coil up this 5 #14 AWG conductor (#34) and do not use. The end of this conductor has a fully insulated female disconnect attached. Leave the female disconnect on the coiled-up wire for safety. Each AFP also includes a 10 power transfer conductor (#31/32) that connects the fuse panel, alternator, and battery together through fuse MF1 (see Figures 1 & 2). Cut this wire as required (shorter is better). While adhering to NEC and SAE standards, use the following wiring diagram and electrical schematic to connect the AFP12, battery, alternator, and ignition key switch: Figure 1: AFP12 Battery, Alternator, and Ignition Key WIRING DIAGRAM 4 P a g e
Figure 2: AFP12 Battery, Alternator, and Ignition Key ELECTRICAL SCHEMATIC 5 P a g e
STEP 3 The AFP12 has circuits that are key switched per the colors outlined below and on the AFP12 Fuse and Circuit Color Schemes (a) & (b). Use Figures 3 5 to connect your loads to the AFP12. a) RED color IKS Start 1 fuse / 1 circuit b) GREEN color IKS Accessories 2 fuses / 3 circuits c) YELLOW color IKS Ignition 4 fuses / 8 circuits d) BLUE color IKS Battery + Battery power 5 fuses / 9 circuits Figure 3: AFP12 Load Wiring Diagram 6 P a g e
Figure 4: AFP12 Fuse and Circuit Color Scheme (a) 7 P a g e
Figure 5: AFP12 Fuse and Circuit Color Scheme (b) 8 P a g e
Features & Helpful Tips Adding another circuit to the AFP12 The screw terminal design of an MGI fuse panel allows for the addition of extra circuits. Where it is deemed safe to do so (considering the circuit capacity and actual load of the user selected circuit), start by loosening the fuse block screw terminal. Then, slide in another fork crimp terminal with the sub-circuit wire, making sure that both the new and original fork terminals are back-to-back. Finally, tighten the screw and check that both fork terminals are secured. Crimp Terminal Sizes Supplied crimp terminals for GXL or TXL wire may best be used per the following MGI standard: Red crimp terminals: Use with #18, #16, and #14 AWG Blue crimp terminals: Use with #12 AWG Yellow crimp terminals: Use with #10 AWG Relay Wiring MGI advises that all electric motors, spotlights, and high ampacity electronic loads are to be controlled with a switching relay. When connecting a load using a relay, always install the power circuit of the relay (terminals #30, #87) to the AFP BLUE color circuits only, which are battery-direct and not switched through the ignition key. The control circuit terminals of the relay (terminals #85, #86) can be connected to either the AFP BLUE color circuits or to the AFP YELLOW color circuits depending on whether you prefer to have a specific load operating with the ignition key just in the ON position (or operating in all ACC/OFF/ON/STR positions). e.g. Radiator cooling fan operational with the ignition key in ANY position The relay control circuit (relay terminals #85, #86) should be connected in the AFP BLUE color circuit area (AFP terminal #16). e.g. Radiator cooling fan operational with the ignition key ONLY in the ON position The relay control circuit (relay terminals #85, #86) should be connected in the AFP YELLOW color (ignitionswitched) circuit area (AFP terminal #21). 9 P a g e
Fuse Sizing The following table outlines MGI s maximum fuse sizing recommendations for various electrical inputs. Caution! Always follow the manufacturer s fuse size requirement (or any other requirements) for your specific load over that of the general recommendations in this manual. It is the user s responsibility to ensure that the main feeder & branch conductor sizes, main fuse size, and branch fuse sizes selected and installed are appropriate as defined by the NEC and SAE for the user s specific application. 10 P a g e
WAS492 Wire Harnesses The WAS492 Wire Assembly Set is an optional add-on to the AFP12 fuse panel. This complete wire set includes 492 feet of wire specifically cut and labeled for the AFP12 connections. All wire harnesses and/or wires not connected directly to an AFP screw terminal are color coded and supplied in a plastic bag, with that bag marked as for the intended circuit. Table 1: WAS492 wire assembly sets include all wire below. Wires are labeled for easy installation to an AFP12 fuse panel. Markings take the form of AA-BBB where AA indicates the wire gauge and BBB is the screw terminal to connect to. Circuit Wire Marking Wire Gauge Wire Color Wire Length (Ft) AC/Heat 14-004 14 Orange 13 Accessory 14-019 14 White 5 Brakes 16-018 16 White 5 Coil (ignition) 14-008 14 Brown 7 Dome Lighting 18-013 + Color 18 Grey/White 20 Fuel Tank NIL 16 Orange 20 Gauges Power Harness 14-014 + Color 14/16 Orange/Orange 8 Ground Color 14 Black 20 Ground Color 18 Black 20 Ground Harnesses Color/Col/Col 14/16/18 Black 38 Hazards Flasher 16-017 16 Brown 5 Headlight High Beam Harness Color 14 Blue 17 Headlight Low Beam Harness Color 14 Red 21 Headlight Switch - Dash/Gauges Color 18 White 10 Headlight Switch Feed 1 12-022 12 Red 5 Headlight Switch Feed 2 Color 14 Red 1 Horn(s) Control Circuit 18-020 18 Black 5 Horn(s) Power Circuit 14-028 14 Purple 15 Left Turn Front + Dash Indicator Color 16/18 Purple/Black 17 Left Turn Rear Color 16 Green 23 Park Lights Harness (Front) Color 16/18 Orange/White 25 Park Lights Harness (Rear) Color 16/18 Orange/White 38 Power Door Locks 14-029 14 Red 5 Power Windows 14-002 14 Blue 5 Radio 18-003 18 Grey 5 Relay Control Circuit - Key 4 pos. 16-021 16 Yellow 5 Relay Control Circuit - Key IGN only 18-016 18 Grey 5 Reverse Lights 16-015 16 Purple 28 Right Turn Front + Dash Indicator Color 16/18 Blue/White 23 Right Turn Rear Color 16 Yellow 28 Signals Flasher 16-009 16 Purple 5 Spare 14-030 14 Red 5 Start Solenoid 12-010 12 Red 15 Washer Pump 16-001 16 Yellow 10 Wiper Motor 16-011 16 Yellow 15 492 feet of wire The WAS492 includes several different types and sizes of wire crimp terminals. Because you may attach the new AFP12 wiring to your existing fixtures (eg: headlights, tail lights, etc), the WAS492 includes fully insulated male/female wire crimp terminals for that exact application. Harnesses can be modified per the user s wire length requirements. The WAS492 Wire Assembly Set includes additional uninsulated crimp connectors and heat shrink sleeving for multiple wire connection points as shown in the harness drawings below. 11 P a g e
Harness Wiring Diagrams Figure 6: WAS492 Harnesses Section / Headlight Switch 12 P a g e
Figure 7: WAS492 Harnesses Section / Gauges, Dome, and Ground Harnesses 13 P a g e
Figure 8: WAS492 Steering Column + Dashboard Indicators 14 P a g e
Wire Gauge Table All AFP installations should be completed minimally per the current and wire sizing specifications outlined in the Wire Gauge Table outlined below, and per SAE electrical codes for low voltage circuits under 32v. Table 2: NEC Recommended AWG/Ampacity chart for copper GXL or SGX automotive primary wire, applied in a Free Air 12vDC circuit. Found online at www.mgispeedware.com/guides-documentation/wire-size-chart/ Find This Interactive Table Online This printable table is a captured photo of the online interactive chart with calculations set for a) single load branch conductors, b) 20 C ambient air temperature, and c) 3% voltage drop based on a 13.8vDC nominal voltage. Use the interactive version on MGI s website located under Guides and Documentation to properly determine the size of your branch and feeder conductors. Free Air Definition While this table outlines specifics for single copper conductors in Free Air per the NEC, your automotive electrical installation does not necessarily conform to a Free Air definition. MGI can, however, appropriately suggest that you increase the Ambient Air Temperature correction factor to allow for any additional heat restraints present in typical automotive projects. Maximum Voltage Drop NEC standards allow for a maximum 3% voltage drop in feeder conductors, and a maximum 5% voltage drop in branch conductors. 15 P a g e
Branch conductor Branch conductors are sized to carry 100% of load rated amperage per the NEC minimal requirement for noncontinuous use (defined by the NEC as having less than 3 hours of continual use). Feeder conductor Feeder conductors are sized slightly larger than the NEC minimal requirement for non-continuous use. Feeder conductors are sized to carry a minimum of 125% of the largest load s rated amperage + the total amperage of all other individual loads that are connected to the feeder conductor. 16 P a g e
Warranty 1.1 Medusa Group Inc. warrants each of its products to be free from defects in materials or workmanship when operated under normal working conditions and in accordance with manufacturer's installation and operating instructions, for a period of twelve months from the date of purchase. This warranty shall be in lieu of any other warranty expressed or implied, including but not limited to any implied warranty of merchantability or fitness for a particular purpose. 1.2 MGI shall not be responsible for removal, installation, or any other incidental or consequential damages arising from, or caused by the use of any of its products. 1.3 MGI s liability under this warranty shall be solely limited to the replacement or repair of its defective product within the warranty period, and shall not be liable under any circumstances for any damages including but not limited to personal injury or labor costs. Under no circumstances will MGI be responsible for any repairs made by anyone other than the factory or authorized repair depot, unless such repairs have been authorized in writing by MGI. 1.4 Remedy for warranty shall include one of the following: Where the complete product is returned to MGI 1.4.1 MGI will repair or replace, at its sole discretion, any component that has been found to be defective by the manufacturer, and is within the warranty period, provided that the complete product is shipped with factory authorization, freight prepaid, to the nearest MGI factory outlet or authorized service facility. Upon completion of warranty repairs, MGI, or its authorized service center will return the product freight prepaid, using Standard Ground delivery service as selected by MGI. Where the product remains installed in the automobile, and where one or more components are determined to be faulty 1.4.2 Where any component is determined by MGI to be faulty within the warranty period, and where such a component is provided for under the terms of warranty, the replacement component will be shipped freight prepaid, (component pre-billed to the client) using Standard Ground delivery services as selected by MGI. 1.4.3 Any faulty or damaged component that has been replaced under the terms of warranty must be returned to MGI within 15 days, freight prepaid, in order to validate the warranty. MGI will evaluate and will either approve or deny the warranty claim, and will credit the client s payment method according to MGI s ruling. Some exceptions may apply. 1.5 Where any warranty component is requested by the recipient with delivery service other than Standard Ground, the product will be shipped freight collect only. For technical help, contact MGI at support@mgispeedware.com 17 P a g e