EASTERN BEAVER PC-8R Manual
PC-8R Installation Guide Version 1.0 Rev 1.1
PC-8R
Install Manual
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PC-8R Installation Guide Version 1.0 Rev 1.1
TABLE OF CONTENTS:
I. Introducon…………………………………………………………………….……. 3
II. Descripon…………………………………………………………………….……… 4
III.Power Cable Design………………………………………………………….…… 5
IV. Switching Lead……………………………………..………………………….…... 6
V. Installaon…………………………………………………………….……………… 7
VI. Installaon Tips…………………………………………………………..……….. 8
VII.Fuse Selecon……………………………………………………………...…...… 9
VIII.Specificaons………………………………………………………...…………... 20
IX.Cauons……………………………………………………………………...…..…… 12
X. Repair Service & Spares…….………………………………………...……….. 13
XI.Plain English Warranty Summary……………………………….……….... 13
XII.Warranty……………………………………………………………………………… 14
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PC-8R Installation Guide Version 1.0 Rev 1.1
INTRODUCTION:
The PC-8R is the 2nd generaon fuse box from Eastern Beaver Inc. It is heavily based on the
ultra-reliable PC-8 fuse box, which has had over 9,000 installaons. The objecve for the PC-8R
was to make the “overall install package” smaller, and make it easier for customers to do their
own wiring, if desired.
The PC-8R compliments the PC-8. It does not have the configurability in that you cannot
make all outputs switched, and also, it is rated for lower total power at 40A maximum. That said,
it takes up less space when installed ( important on newer bikes with less under seat space), has built in noise
suppression for the relay and also has diode protecon on the switched input.
Like the PC-8 we will offer standard and bike specific installaon kits. We also offer a 2yr
warranty on the PC-8R ( terms apply—see warranty secon ).
For those travelling the globe we offer a spare kit so the unit can be repaired anywhere
access to a soldering iron is available. We also offer fixed price repairs for any issues that
might happen, aer the 2yr warranty expires. Condions apply so see our warranty
secon.
We thank you for purchasing the PC-8R and look forward to supporng all your
electrical accessory needs, with new products in the coming years.
Figure 1: PC-8R
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PC-8R Installation Guide Version 1.0 Rev 1.1
DESCRIPTION:
The PC-8R is a 40A, 8 output fuse box/PDM with 2 baery direct fused connecons and 6
switched connecons. The posive switched outputs are outputs 3 through 8 on connector J2.
The baery direct outputs are 1 through 2 on connector J2. Each output can be up to 15A
( max ), provided the total current does not exceed 40A.
Baery direct outputs can be used for connecng heated gear, chain oilers, or baery chargers,
but be careful of devices that can cause parasic drain. A typical bike ECU will draw less than
1.0mA when the bike is powered off. We found that currents of around 5mA or higher can cause
an average baery to be unable to start a bike, aer just 4 weeks of storage.
The switched outputs on the PC-8R, of course, switch off when the bike is turned off ( provided it
has been installed correctly ). They are typically used for power devices that are needed during
riding such as navigaon systems, USB ports, radar detectors, camera systems, communicaons
systems and accessory lights, horns etc.
While the posive outputs on J2 are specified as direct or switched, the ground connecons are
all common, so you can use any ground connecon without any J2 connecon.
The switched input should be connected to input 2 on J4. Pin 1 on J4 can be used, if the switched
input is to be looped though to another device ( should be low current & less than 0.2A ) .
Figure 2: PC-8R Block Diagram
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DESCRIPTION Connued:
Power is connected to the PC-8R though J3. Pins 1 and 2 are grounds. Pins 3 & 4 are posive.
Double check aer installing wires to make sure there are no loose strands that could cause
a short.
POWER CABLE DESIGN:
We recommend using an inline fuse with any PC-8R power cable, unless the connecon to
the baery is under 12” ( 30cm ), for extra safety. You should note that the stamped value on a
fuse is it’s blow rang, not it’s connuous use rang. We recommend to use a fuse that is at least
25% higher than the connuous current you intend to protect.
For applicaons up to 30A the connecon is prey simple.
For connecons up to 40A there are a few opons:
Figure 3: Power Connecon < 30A
Figure 4: Power Connecon 40A ( Type 1 )
Figure 5: Power Connecon 40A ( Type 2 )
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PC-8R Installation Guide Version 1.0 Rev 1.1
SWITCHING LEAD:
The switching input on the PC-8 requires under 0.070A so there are many sources that can
be used for the switching input. We recommend using one of the following sources;
1. Aux power port ( preferably in the under seat area ).
2. Number plate light using a splice cable or Posi-tap.
3. Tail/driving light using a splice cable or Posi-tap.
Generally it is best to avoid using diagnosc port connectors or any signal, that carries data
or that you are not sure of its funcon. The switched input to the PC-8 is diode protected and the
relay circuit has a flyback circuit to eliminate any switching noise.
The switching input is diode protected and the relay has a damping circuit to cancel any
switching noise, making the PC-8R safe to use on bikes with canbus systems. We have carried out
bench tests using Oscilloscopes & installaon tests on various canbus motorcycles.
Wire diameter from 0.5mm2 ( 20 AWG ) to 1.25mm2 ( 16 AWG ) can be used ( smaller wires
are fine, but harder to work with ).
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PC-8R Installation Guide Version 1.0 Rev 1.1
Installaon:
Installaon of the PC-8R is quite simple. Decide on the locaon you want the PC-8R mount-
ed. Most installaon posions will be under the rider’s or passenger’s seat. In some cases the PC-
8R can be mounted under a side cowl or seat cowl. Points to note concerning the mount posi-
ons are:
· Access for changing fuses
· Access for wiring changes/connecons
· Cooling, the PC-8R does not need forced air but it does keep cool via convecon so we
recommend to avoid stacking items on top that may hinder cooling.
· For reliable operaon we recommend mounng the unit out of the direct weather and away
from wheel spray/splashing etc.
( The PC-8R is designed such that should the unit be submerged in water, or mud, simply removing it and washing the unit in fresh clean water asap will
ensure it’s connued reliable operaon. The unit itself generates a small amount of heat and any moisture or water that remains in the case, will evapo-
rate. Usually a good shake aer cleaning & before reinstalling is all that is needed. )
· It is always best to mount the PC-8R firmly to a panel or tray. Strong Velcro can be used or
self tapping screws or push rivets. Loose mounng or allowing the unit to move around can
lead to premature failure of connected wires.
Connecons to the PC-8R are straight forward. Depending on applicaon ( power requirement ) there
will either be 1 or 2 power and ground connecons. The switching input is normally connected to
a source of switched power ( very low current is drawn, less than 0.1A ).
CAUTION:
When ghtening or
loosening J4 and J3 screw
terminals, we recommend
you support the terminal
block against twisng.
Figure 6: Installaon
Connecons
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Installaon Tips:
1. Install the main fuse last. Make sure all connecons that you need to make, are made, before
installing the main fuse. We also recommend that the PC-8R mini blade fuses be installed
with the main fuse removed. When ready to test, install the main fuse.
2. Check carefully that nothing has been dropped into the fuse box before aaching the cover.
3. The fuse box has a spare fuse posion. This can be used to store a spare fuse or two fuses, if
only one leg of each fuse is used. For offroad riders, we recommend that the only 1 spare be
fully inserted into both fuse clips.
4. When using cable es, avoid tying wires so ght, that it put pressure on connecons. The e
is to keep the cable in place and should just be ght enough such that the e does not move.
5. Avoid storing so cloths on top of the PC-8R. So rags can be put in small plasc containers
and stored.
6. Avoid running cables near seat mechanisms or devices that move, or if there is no choice,
e the cable into posion, so It cannot be damaged by the mechanism.
7. Ensure that all cables entering the PC-8R screw terminals, do not have frayed wires that could
cause a short. If not possible to get the cable in cleanly, any frayed wires can be trimmed off.
8. The bare wire connecon to the PC-8R ( stripped secon ), can be 5mm to 6mm ( 1.4” ).
Avoid stripping too long a secon of wire.
9. If the wire size is large 2mm2 ( 14AWG ) or larger, avoid twisng the strands as this increases
the wire diameter. To get the wire into the screw terminal, squeeze together & straighten the
strands as much as possible, then fit the wire into the terminal at an angle and once the
lower stands are in, apply a ny amount of downward pressure as you insert the wire.
10. Eastern Beaver does all it’s tesng using Japanese made, copper mulstrand wire. Please
note that not all wires are created equal, and some of the stated current carrying capacies
of cheaper wires, are quesonable. CCA ( Copper coated Aluminum ) for example has about
twice the resistance of pure copper wire for a given diameter.
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Fuse Selecon:
The PC-8R uses mini blade fuses. The fuses come with a number stamped on top of the fuse in
white i.e. the fuse value. Do not use cheap reproducon fuses ( usually no white value stamp on the top and not made
from a nylon plasc ). The number stamped on each fuse is it’s connuous current rang at 25˚C,
however, running a 10A fuse at 10A causes a heat to be generated at the fuse element. With a
10A ATM fuse in three different ( brand name ) manufacturer fuse holders, and a current of 10A,
we measured temperatures of up to 90˚C. When operated at 75% of the rated current, this tem-
perature dropped to a much more acceptable 49˚C. Lilefuse ( patent holders ) recommend derang
of the fuse value by 25% to avoid heat/reliability issues. A quote from Lielfuse_fuseology.pdf
“For example, a fuse with a current rang of 10A is not usually recommended for operaon at
more than 7.5A in a 25˚C ambient”.
In short, if you want to fuse 15A circuit, use a fuse that is at least 15A/0.75= 20A
Example 2: Switched output 3 is to protect a navigaon systems that requires 4.8A connuously.
To select the fuse we divide 4.8/0.75= 6.4A. Since there are no 6.4A fuses we use the next higher
value, which is 7.5A ( standard value ).
Example 3: Switched output 6 is to protect a set of LEDs that draw 10A connuous. Dividing
10A/0.75= 13.3A. Since 13.3A is not a standard value we would use a 15A fuse ( the next higher
value ).
Mini Blade fuses are sold in the following values: 2, 3, 4, 5, 7.5, 10, 15, 25, 30
Figure 7: Mini Blade Fuse Standard Values ( LileFuse )
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PC-8R Installation Guide Version 1.0 Rev 1.1
SPECIFICATIONS:
· Maximum Total Current: 40 A
· Maximum Switched Outputs: 30 A
· Maximum Direct Outputs: 20 A
· Maximum Current Per Output: 15 A
· Switched Outputs: Posion 3 Through Posion 8 on J2
· Direct Outputs: Posion 1 Through Posion 2 on J2
· Main Fuse: 40A or 50A
40 Amp BUSSMANN ( 30A or under applicaons ) or
50 Amp LP JCASE ( 40 A applicaons )
· Switched Input Current: 62 mA
· Switched Input Loop Through: 1
· Switch Input Protecon: 2 Types
Inline diode and
Diode + Resistor Flyback Damping
· Power Cable Size: 16 AWG—12 AWG
· Output Cables Size: 22 AWG - 12 AWG
· Operang Temperature: -20c to 70c
· Case Size : 80mm Long ( 3 1/4” )
58mm Wide ( 2 1/4” )
30mm Height ( 1 1/8” )
· Fuse Type PC-8R Outputs: Mini Blade Fuses ATM
( 20 Amp Maximum )
· Main Fuse Type: ATO Blade or LP JCASE
40 Amp ATO Blade for <30A applicaons or
50 Amp LP JCASE for <40A applicaons
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PC-8R Installation Guide Version 1.0 Rev 1.1
CAUTIONS:
I. Avoid twisng the wire strands, if possible as it increases the wire diameter. For smaller diameter
wires this is not such an issue.
II. Check that there are no loose or frayed strands once a wire is screwed into a terminal.
III. Install the main fuse last, aer installing the PC-8R and making all electrical connecons.
IV. Never make PC-8R connecons with the main fuse installed.
V. For J3 and J4 we recommend supporng the screw terminal against twisng when ghtening
the screw to clamp the wire.
VI. 5mm to 6mm ( 1/4 “ ) is a perfect length of copper for clamping in the screw terminals.
VII. 40A applicaons require the use of all power connecons on J3. Use a LP JCASE type fuse rated at
50A.
VIII.30A applicaons ( or under ) can use Bussmann 12AWG ( 3mm ) inline fuse holders.
IX. Ensure the fuses are fully inserted into clips and not bent over hing other fuses.
X. Fuses generate heat when they are incorrectly selected or close to their blow current.
XI. Avoid pung rags or visor cleaning cloths on top of the fuse box. The PC-8R requires convecon
cooling to dissipate heat.
XII. Always ensure the PC-8R is secured to the bike, to avoid unnecessary problems with connecons.
XIII.Do not over ghten the lid. The lid is made in Japan and quite strong, but ham-fistedness could see
it damaged.
XIV.Never e cables in posion too ghtly. Always allow some slack near connectors or entering looms.
Allowing some slack when tying cables in place helps avoid creang stress points and allow a degree
of vibraon damping to be carried out by the cable slack.
XV. The switched input loop though is not to be used for more than 0.2A
XVI.There is no need to overghten screw terminal connecons. Hold the cable being clamped in place,
and lightly ghten the screw. Then give it one small tweak. Never use anywhere near your full
strength. For some screw terminal like J3 and J4 it is beer to support the terminal when ghtening.
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REPAIR SERVICE & SPARES:
Eastern Beaver Inc offers fix price repairs for PC-8R unit that are out of warranty and damaged by accident or failure. We
also offer 50% discount on replacement units, for units that were damaged in a rider accident, provided we are shown proof of
damage to the unit concerned. The repair service and accident damage replacement service are direct though Eastern Beaver
and not though dealers. Shipping fees are not included.
Replacement Parts Price List
Fixed Repair Costs
Fixed prices repairs offers certainty in repair costs, so no big surprises. All work is carried out by qualified
technicians. We offer 1yr warranty on repairs & replacement parts per our Standard Warranty Policy.
Shipping to and from Eastern Beaver Inc is not included and constutes a separate cost.
1. Replacement top cover label…………………………………………………………………………………. $2
2. Replacement top cover…………………………………………………………………………………………. $8
3. Replacement base………………………………………………………………………………………………… $7
4. Replacement Omron relay……………………………………………………………………………………. $8
5. Replacement 2 Posion screw terminal……………………………………………………………….. $2
6. Replacement 4 posion screw terminal……………………………………………………………….. $3
7. Replacement 8 posion screw terminal……………………………………………………………….. $4
8. Replacement diode/resistor set ( 2 diodes & 1 resistor )……………………………………… $2
9. Replacement fuse holder clips ( 2 )……………………………………………………………………… $5
10. Replacement main board with fuse holders, relay, diodes, resistors, terminals…… $60
11. Accident damage replacement……………………………………………………………………………. $45
1. Relay replacement & tesng……………………………………………………………………………………..……….. $28
2. Screw Terminal replacement & Full Unit Tesng ( 8 Way )………………………………....……………… $24
3. Screw Terminal replacement & Full Unit Tesng ( 4 way )………………………………………………….. $23
4. Screw Terminal replacement & Full Unit Tesng ( 2 way )………………………………………………….. $22
5. Diodes & Resistor Replacement & Full Unit Tesng……………………………………………………………. $22
6. Fuse Clips ( set ) replacement & Full Unit Tesng………………………………………………………………. $25
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PLAIN ENGLISH WARRANTY SUMMARY:
The PC-8R is warranted against defects, per the Standard Eastern Beaver Inc Warranty
Policy for a period of 2yrs from the date of purchase.
The following exclusions apply:
1. Failure or damage due to improper installaon, or proper care during installaon.
2. Exceeding specificaons on power.
3. Crash or accident damage ( though we will offer a discount on replacement units for PC-8R’s damaged in riding accidents ).
4. Use in corrosive environments.
5. Misuse or lack of care during use that leads to physical damage to the PC-8R.
6. Where a unit is not cleaned properly aer being exposed to flooding or submerged in water.
Liability is limited to the inial purchase price of the PC-8R, excluding shipping or wiring kit
costs.
Proof of purchase, from an authorized dealer or Eastern Beaver Inc is required, to make a
warranty claim.
Shipping costs are not covered by warranty and the customer is responsible for shipping cost
to Eastern Beaver Inc and the return to the customer. Eastern Beaver Inc, at its sole discreon
may offer to cover some of the shipping costs, depending on the circumstances.
The Standard Eastern Beaver Inc Warranty Policy is the determining policy. This secon is
just a brief summary of that policy.
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WARRANTY:
Standard Eastern Beaver Inc. Warranty Policy
This is a return to base warranty. The customer is responsible for all shipping costs.
I. All implied condions and warranes which may by law be excluded in relaon to the supply of products or provision of
services by Eastern Beaver Inc are hereby excluded, the exclusion, of which would render the agreement incorporang
these Condions between Eastern Beaver Inc and the Customer void or voidable or Eastern Beaver Inc liable to a penalty
or which may not by the terms of relevant State Legislaon be excluded or modified, then such condions or warranes
shall apply.
II. In connecon with the supply by Eastern Beaver Inc to the Customer of any goods or services, where, any legislaon
provides for redress in the event of Eastern Beaver Inc breach of a condion or warranty, whether statutory or otherwise,
then the Customer’s sole remedy for any such breach shall at the opon of Eastern Beaver Inc be limited to;
III. the replacement of Eastern Beaver Inc goods; or
IV. the repair of Eastern Beaver Inc goods; or
V. refund of the purchase price of Easter Beaver Inc goods.
VI. Eastern Beaver Inc shall not be liable for the cost of removal and reinstallaon or loss or me due to failure of a
component or system of its products other than stated in Clause II.
VII. Subject to any provision of relevant State legislaon which may not be excluded or modified, Eastern Beaver Inc will not be
liable for any costs, claims, damages or demands arising from any personal injury, loss or damage to products whatsoever
occurring as a result of either the act or omission of Eastern Beaver Inc, its distributors or agents and in no case will
Eastern Beaver Inc be liable for consequenal loss or damage.
VIII. Subject to the provisions of this document, if systems or parts fail, supplied as new parts, within a period of 24 months of
purchase, due to faults in manufacture, these parts are warranted as per Clause II.
IX. When returning faulty units, the Customer must provide invoice number and date, product serial number ( where applica-
ble ) and a descripon of the product failure.
X. Subject to the provisions of this document, if system parts which have been Upgraded or Modified as part of an OEM
Upgrade, fail, within a period of 365 days, these parts are warranted as per Clause II.
XI. This warranty is void if Eastern Beaver Inc determines, in its sole business judgment, the defect to be the result of abuse,
neglect, alteraon, or aempted repair by unauthorized personnel.
XII. The several clauses which constute or evidence this warranty shall be taken as mutually explanatory and anything
contained in one but not in another shall be equally binding as if contained in all. Any ambiguity, discrepancy or
inconsistency shall be explained by Eastern Beaver Inc upon reference thereof in wring to Eastern Beaver Inc by the
Customer or on discovery thereof by Eastern Beaver Inc, who shall thereupon direct the Customer as to the interpretaon
to be followed. If the Customer finds any such ambiguity, discrepancy or inconsistency he shall immediately refer it in
wring to Eastern Beaver Inc.
XIII. Eastern Beaver Inc shall not be liable for failure to perform its obligaons if the failure arises from circumstances beyond
its control, including but not limited to fire, explosion, strikes, lock - outs or any other industrial disputes, failure or refusal
of its supplier to supply the goods, inclement weather, acts of God, Governmental acon, in no such event shall the
Customer be entled to damages of any kind for late performance or failure to perform.
XIV. Eastern Beaver Inc specifically disclaims any and all implied warranty of merchantability or of fitness for a parcular
purpose. The buyer acknowledges and agrees that in no event shall the company be liable for any special, indirect,
incidental or consequenal damages, or for injury, loss or damage sustained by any person or property, that may result
from this product failing to operate correctly at any me.
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