EASTERN BEAVER PC-8R Manual

PC-8R Installation Guide Version 1.0 Rev 1.1
PC-8R
Install Manual

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2 PC-8R Installation Guide Version 1.0 Rev 1.1
TABLE OF CONTENTS:
I. Introducon…………………………………………………………………….……. 3
II. Descripon…………………………………………………………………….……… 4
III.Power Cable Design………………………………………………………….…… 5
IV. Switching Lead……………………………………..………………………….…... 6
V. Installaon…………………………………………………………….……………… 7
VI. Installaon Tips…………………………………………………………..……….. 8
VII.Fuse Selecon……………………………………………………………...…...… 9
VIII.Specificaons………………………………………………………...…………... 20
IX.Cauons……………………………………………………………………...…..…… 12
X. Repair Service & Spares…….………………………………………...……….. 13
XI.Plain English Warranty Summary……………………………….……….... 13
XII.Warranty……………………………………………………………………………… 14

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INTRODUCTION:
The PC-8R is the 2nd generaon fuse box from Eastern Beaver Inc. It is heavily based on the
ultra-reliable PC-8 fuse box, which has had over 9,000 installaons. The objecve 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 protecon on the switched input.
Like the PC-8 we will offer standard and bike specific installaon kits. We also offer a 2yr
warranty on the PC-8R ( terms apply—see warranty secon ).
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, aer the 2yr warranty expires. Condions apply so see our warranty
secon.
We thank you for purchasing the PC-8R and look forward to supporng all your
electrical accessory needs, with new products in the coming years.
Figure 1: PC-8R

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DESCRIPTION:
The PC-8R is a 40A, 8 output fuse box/PDM with 2 baery direct fused connecons and 6
switched connecons. The posive switched outputs are outputs 3 through 8 on connector J2.
The baery 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.
Baery direct outputs can be used for connecng heated gear, chain oilers, or baery chargers,
but be careful of devices that can cause parasic 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 baery to be unable to start a bike, aer 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 navigaon systems, USB ports, radar detectors, camera systems, communicaons
systems and accessory lights, horns etc.
While the posive outputs on J2 are specified as direct or switched, the ground connecons are
all common, so you can use any ground connecon without any J2 connecon.
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 Connued:
Power is connected to the PC-8R though J3. Pins 1 and 2 are grounds. Pins 3 & 4 are posive.
Double check aer 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 connecon to
the baery is under 12” ( 30cm ), for extra safety. You should note that the stamped value on a
fuse is it’s blow rang, not it’s connuous use rang. We recommend to use a fuse that is at least
25% higher than the connuous current you intend to protect.
For applicaons up to 30A the connecon is prey simple.
For connecons up to 40A there are a few opons:
Figure 3: Power Connecon < 30A
Figure 4: Power Connecon 40A ( Type 1 )
Figure 5: Power Connecon 40A ( Type 2 )

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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 diagnosc port connectors or any signal, that carries data
or that you are not sure of its funcon. 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 & installaon 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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Installaon:
Installaon of the PC-8R is quite simple. Decide on the locaon you want the PC-8R mount-
ed. Most installaon posions 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/connecons
· Cooling, the PC-8R does not need forced air but it does keep cool via convecon so we
recommend to avoid stacking items on top that may hinder cooling.
· For reliable operaon we recommend mounng 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 connued reliable operaon. 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 aer 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 mounng or allowing the unit to move around can
lead to premature failure of connected wires.
Connecons to the PC-8R are straight forward. Depending on applicaon ( power requirement ) there
will either be 1 or 2 power and ground connecons. 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 twisng.
Figure 6: Installaon
Connecons

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Installaon Tips:
1. Install the main fuse last. Make sure all connecons 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 aaching the cover.
3. The fuse box has a spare fuse posion. 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 connecons. 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 plasc containers
and stored.
6. Avoid running cables near seat mechanisms or devices that move, or if there is no choice,
e the cable into posion, 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 connecon to the PC-8R ( stripped secon ), can be 5mm to 6mm ( 1.4” ).
Avoid stripping too long a secon of wire.
9. If the wire size is large 2mm2 ( 14AWG ) or larger, avoid twisng 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 tesng using Japanese made, copper mulstrand wire. Please
note that not all wires are created equal, and some of the stated current carrying capacies
of cheaper wires, are quesonable. CCA ( Copper coated Aluminum ) for example has about
twice the resistance of pure copper wire for a given diameter.

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Fuse Selecon:
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 reproducon fuses ( usually no white value stamp on the top and not made
from a nylon plasc ). The number stamped on each fuse is it’s connuous current rang 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. Lilefuse ( patent holders ) recommend derang
of the fuse value by 25% to avoid heat/reliability issues. A quote from Lielfuse_fuseology.pdf
“For example, a fuse with a current rang of 10A is not usually recommended for operaon 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 navigaon systems that requires 4.8A connuously.
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 connuous. 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 ( LileFuse )

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SPECIFICATIONS:
· Maximum Total Current: 40 A
· Maximum Switched Outputs: 30 A
· Maximum Direct Outputs: 20 A
· Maximum Current Per Output: 15 A
· Switched Outputs: Posion 3 Through Posion 8 on J2
· Direct Outputs: Posion 1 Through Posion 2 on J2
· Main Fuse: 40A or 50A
40 Amp BUSSMANN ( 30A or under applicaons ) or
50 Amp LP JCASE ( 40 A applicaons )
· Switched Input Current: 62 mA
· Switched Input Loop Through: 1
· Switch Input Protecon: 2 Types
Inline diode and
Diode + Resistor Flyback Damping
· Power Cable Size: 16 AWG—12 AWG
· Output Cables Size: 22 AWG - 12 AWG
· Operang 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 applicaons or
50 Amp LP JCASE for <40A applicaons