Flaming River Ind. 800 Poertner Dr Berea, OH 44017 800-648-8022 FR1057 Watch Dog Automatic Battery Disconnect Switch
Table of Contents Introduction...pg 3 Mounting and Dimensions...pg 4 Mechanical Fixation...pg 5 WatchDog Operations...pg 5 WatchDog Programming...pg 6 Wiring Connections...pg 7 WatchDog Product Specifications...pg 8 Included in Box: Watch Dog main battery disconnect switch ON/OFF External Emergency Switch w/led Push-Button Switch 7-Way Wiring Harness (for main unit) (8.33 ft) 4-Way Wiring Harness (for LED/emergency switch (13.25 ft) WARRANTY DISCLAIMER: Flaming River s Limited Warranty Flaming River warrants its products to be free from defects in material and workmanship for a period of one (1) year after the date of purchase, except that: All steering columns are warranted for a period of three (3) years from the date of purchase. The Big Switch (part number FR1005) is warranted for a period of three (3) years from the date of purchase, provided that it is not mounted with a steel bracket and provided further that it is adequately protected from environmental conditions. All electrical products other than the Big Switch are warranted for a period of ninety (90) days from the date of purchase. Flaming River s warranty liability is limited to the replacement of defective products. Flaming River is not liable for any labor costs associated with any warranty claim, or for any incidental or consequential damages. Improper installation, abuse, racing, and/or modification of the products voids this warranty. No warranty of merchantability or fitness for a particular purpose is made by Flaming River with respect to any of its products. Warnings and Recommendations It is the customer s responsibility to determine the suitability of a given Flaming River product for the customer s uses. Likewise, it is the customer s responsibility to install a Flaming River product. Contact the vehicle manufacturer whenever installing a switch to confirm the appropriateness of using such a switch and the recommended placement of the switch on the vehicle. Use qualified chassis specialists for the installation of all steering related components. Be aware that the installation of certain Flaming River products may adversely impact a manufacturer s warranty with respect to certain vehicles and other manufactured goods. Flaming River will repair or replace any product found to be defective in material or workmanship. Improper installation, abuse, racing and/or modification VOID WARRANTY. Flaming River is not responsible for any labor costs associated with any warranty. Flaming River Industries 1-800-648-8022 2
Watch Dog Main Unit System Activation Button 7-Way Harness (13.25 ft.) Battery Cables 4-Way Harness (8.33 ft.) Battery Manual Emergency Switch Watch Dog Advanced Automatic Battery Disconnect Switch or in demanding ADR (Dangerous Goods Transportation) environments. Multiple installation orientations, and positive Powerful (300 Amps). or negative battery disconnect supported. Time Designed for heavy loads. delay duration can be adjusted on the main Bistable magnetic latch technology. Main switch. switch can maintain either of its two positions Safe. Emergency external battery disconnect without current consumption. Reliable. Excels in tough conditions, operating switch is available. Built-in LED indicates electrical system status: ON, OFF, or counting more than 100,000 cycles. Automatically works down time delay. with your vehicle s ignition system. Durable. Maximum protection from dust and water ingress with an IP76 and IP69K rating. High NOTE: The Watch Dog system is an electromechanical battery disconnect switch. The corrosion resistance (salt spray test, 300h). emergency external switch will only disconnect Requires more than 80G of force to the battery from the electrical system. This mechanically manipulate internal contacts. product is NOT designed to deactivate the Versatile. Available for 12V and 24V alternator or shut down the vehicle completely.* systems. Can be used in simple installations Flaming River Industries 1-800-648-8022 3
Dimensions 1.26 M10 2.20 M10 2.36 6.57 Ø.24.87 3.31 M10 NUT 2.20 M10 LOCKWASHER 4.80 4.06 Set of terminals NUTS INCLUDED ATTENTION The following information must be reviewed before beginning the assembly: The installation instructions are to be thoroughly read. The installation should be carried out by qualified personnel with the relevant technical knowledge. The vehicle manufacturer s current technical notices S2 - External emergency switch and information on retrofitting must be followed. with GREEN LED LIGHT indicator LITTELFUSE is not responsible for improper use of the (Ref. 00227000) product once installed. Flaming River Industries 1-800-648-8022 4
WATCH DOG (MAIN UNIT) Use four M6 bolts and tighten the nuts to 4.43±1.5 ft lb of torque. Install the Watch Dog on the chassis in a protected location as close as possible to the battery. The cable length between the main terminals BATTERY on MAIN the Watch SWITCHDog and the battery pole should be less ng 4 M6 bolts than with 20 a inches closing torque long, on and nuts of at 6±2 least Nm [53,1±17,7 32 inches lbf*in] from the the WatchDog ground to the to chassis avoid in gravel a protected impact. position: s close as possible to the battery (the cable length between the WatchDog the battery The pole Watch should be Dog < 0,5m can [20 ]); be installed in any orientation t 0.8m [31,5 ] EXCEPT (at least) with from the the ground; studs pointing towards the ot exposed ground. to gravel Use impacts; of the included terminal covers is highly recommended to protect the studs and battery cable device connections. can be installed If in the any Watch orientation Dog except main with unit studs is installed nting to inside the ground; the protections battery box for studs terminal are recommended covers are still ether the recommended. WatchDog is installed inside or outside the battery box). nition Key S1 - PUSH BUTTON S2 - EMERGENCY SWITCH Mountingation BATTERY SWITCH FIXING DIAGRAM 84mm [3,31''] Flaming River Industries 1-800-648-8022 5 60mm [2,36''] 4 x 6.4mm [0,26''] BATTERY SWITCH FIXING DIAGRAM Electrical Connections Emergency Shutdown EXTERNAL EMERGENCY SWITCH REF. 00227000 EXTERNAL EMERGENCY SWITCH REF. 00227000 FIXING DIAGRAM EXTERNAL EXTERNAL EMERGENCY EMERGENCY SWITCH SWITCH WITH 2 x Ø 6,5mm [0,26"] WITH GREEN LED LED INDICATOR INDICATOR EXTERNAL EMERGENCY SWITCH REF. 00227000 g 2 M6 bolts Use with two a closing M6 bolts torque and on nuts tighten of 8±2 the Nm [70,8±17,7 nuts to 5.9±1.5 lbf*in] ft lb FIXING DIAGRAM referring of to the torque. fixing diagram, Install fix the emergency switch to the chassis switch in a in protected a protected ition: location on the chassis as close as possible to the 2 x Ø 6,5mm [0,26"] as close as driver s possible door. to the driver The door switch (the should switch shall be be clearly visible and and easily easily accessible); accessible. Install the switch at least 32 inches 60mm [2,4"] at 0.8m [31,5 ] from (at the least) ground from the to ground; avoid gravel impact. not exposed to gravel impacts. Watch Dog Operation ny other switch is used, it shall have minimum contact current 60mm [2,4"] ng of 10mA System (at 12V Activation and 24V) and IP67 / IP69K protection degrees. 1. Switch S2 (External Emergency Switch) must be in the ON position. tallation layout 2. Push - Example Switch S1 (Dash/Cabin Pushbutton). 3. The Watch Dog will enter ON status, and close the main contacts allowing current to flow from the battery to the vehicle. The green LED located on Switch S2 will turn ON. NOTE: The ignition key does not need to be in the ON position to activate the Watch Dog. Time-Delayed Shutdown Ref. 00712500 1. With Switch 4-WAYS S2 in the HARNESS ON position, 4x1mm 2 [AWG turn 18] the ignition key to the OFF position. This will start the preprogrammed time delay and cause the LED on Switch S2 to blink. 2. Once the time delay cycle Ref. is complete, 00712600the LED on Switch S2 will turn WatchDog OFF and the main contacts 7-WAYS HARNESS 2x1,5 [AWG 15] + 5x1mm 2 [AWG 17] (close to the battery) on the Watch Dog unit will open. 3. If at any time the user wishes to abort the time delay sequence, simply turn the key back to the ON position, or push Switch S1. The time delay will stop and the system will remain in operation. 1. Flipping Switch S2 to the OFF position any time during operation will force the Watch Dog into emergency deactivation. This will open the main contacts, turn off the LED on Switch S2 and the electrical aborts connection the time of the delay WatchDog sequence to the if vehicle active. system, er to the wiring diagrams in section 5. S1 (dashboard push button) is a push-button for the device activation. It shall have minimum contact rating of 5mA (at 12V and 24V);
Watch Dog Programming BLUE BROWN GRAY BLACK YELLOW GREEN BLUE BROWN BLACK RED LED Blinks Sequence Time Delay 1 30 seconds 2 1 minute 3 3 minutes 4 6 minutes Remember: Start Switch S2 in OFF position before starting the programming procedure. WatchDog Programming Wiring Diagram Switch S2 Diagram (External Emergency Switch) Programming Instructions NOTE: The default value for the time delay is 6 minutes. To start the programming procedure, connect the WatchDog as illustrated in the wiring diagram (see attached). NOTE: The Switch S2 (External Emergency Switch) should be in the OFF position. The GREEN wire (Pos. Battery) should NOT be connected. Now connect the GREEN wire to the positive battery terminal. The light will blink a specified number of times depending on the current time delay setting (see time delay table above) memorized by the device. The green LED on Switch S2 will then turn on for 2.5 seconds. Within 3 seconds after the green LED turns off, toggle Switch S2 ON and then OFF. Wait for the green LED to blink the required number of times for the chosen time delay (see time delay table above). The light will blink slowly to give you enough time to select your preferred time delay. Once the green LED has blinked the desired number of times, toggle Switch S2 ON and then OFF. NOTE: If the green LED blinks rapidly for a long period of time, disconnect and reconnect the GREEN wire from the positive battery terminal to reset the programming mode. Flaming River Industries 1-800-648-8022 6
Wiring Connections 5.1 OPERATING MODE: BATTERY POSITIVE POLE DISCONNECTION LOAD KEY 0 1 2 OFF 15 50 PUSH BUTTON (in cabin) (ON) 0 S1 1234 Pinout 7-pole DIN connector 3 5 4 2 1 7 R DL1 OFF ON 4 3 2 1 S2 Pinout 4-pole DIN connector + - BATTERY 5.2 OPERATING MODE: BATTERY NEGATIVE POLE DISCONNECTION 86 30 85 87 * RELAY RELAY OFF 15 50 KEY PUSH BUTTON (in cabin) 0 (ON) 0 S1 Pinout 7-pole DIN connector 7 3 5 4 2 1 1234 R DL1 OFF ON LOAD 4 3 2 1 S2 Pinout 4-pole DIN connector + - BATTERY 4-Pin Wire Harness Pin-Out (External Emergency Switch) Slot Number Wire Color Function 1 Black Negative Battery Terminal (-) 2 Blue Emergency Switch Command 3 Brown Ignition Key Command 4 Red Positive Battery Terminal (+) 7-Pin Wire Harness Pin-Out (Main Unit) Slot Number Wire Color Function 1 Gray Push-button Command 2 Black Negative Battery Terminal (-) 3 Yellow Ignition Key Command 4 Blue Emergency Switch Command 5 Brown System Status (Controls External Emergency Light LED) 6 White NOT CONNECTED 7 Green Positive Battery Terminal (+) Flaming River Industries 1-800-648-8022 7
WatchDog Product Specifications Description Part No. Warranty Voltage Max Continuous Current Max Surge Current Environmental Protection Rating Waterproof Corrosion Resistance Terminal Length Terminal Diameter Tightening Torque Operating Temperature Range Internal Contacts Contact Terminals Contact Hardware Automatic Shut-Off Manual Emergency Shut-Off Time Delay Battery Disconnect Mode Terminal Covers Included 300 Amp Watch Dog Battery Disconnect FR1057 1 Year 12V/24V 300 Amps 1,000 Amps (30 seconds) 2,000 Amps (5 seconds) IP67 and IP69K (water pressure cleaning) Yes Salt Spray Test: 300h 0.670 (approx. 43/64 in) M10 14 ft lbs (+/- 1 ft lbs) -40 C to +85 C -40 F to +185 F Silver Plated Copper with Silver Pads Silver Plated Copper with Silver Pads Nickel Plated Brass Yes Yes Yes, programmable for 30sec, 1min, 3,min, or 6min disconnection delay Positive and Negative Yes WARNING: Flaming River Industries, Inc. make no recommendation as to mounting location or product suitability to your vehicle application. For each kit, contact your vehicle s manufacturer to determine proper placement and suitability. When installed, a battery disconnect switch is a functioning and live part of the electrical current system and should be treated like battery terminals. Flaming River Ind. 800 Poertner Dr Berea, OH 44017 800-648-8022 Flaming River Industries 1-800-648-8022 8