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Electrical System Schematic Review

 
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jonlaury



Joined: 06 Nov 2006
Posts: 336

PostPosted: Tue Jul 20, 2010 10:12 am    Post subject: Electrical System Schematic Review Reply with quote

I would appreciate anyone's comments on my electrical schematic.
I'm unsure about the placement of the over voltage module for the Ground Power jack. I used a single post continuous duty contactor which I had and it necessitated some changes in Bob's Z-31 drawing.

Thanks
John


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PostPosted: Tue Jul 20, 2010 10:43 am    Post subject: Electrical System Schematic Review Reply with quote

For some reason I can only see page two of the PDF - cutting off some
portion to the left of the main battery bus on your schematic. Page one
is blank.

Dick Tasker

jonlaury wrote:
Quote:


I would appreciate anyone's comments on my electrical schematic.
I'm unsure about the placement of the over voltage module for the Ground Power jack. I used a single post continuous duty contactor which I had and it necessitated some changes in Bob's Z-31 drawing.

Thanks
John


Read this topic online here:

http://forums.matronics.com/viewtopic.php?p=305607#305607


Attachments:

http://forums.matronics.com//files/z13_8q_mine_155.pdf



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jonlaury



Joined: 06 Nov 2006
Posts: 336

PostPosted: Tue Jul 20, 2010 11:02 am    Post subject: Re: Electrical System Schematic Review Reply with quote

I know what happened. I'll put it up again.
J


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user9253



Joined: 28 Mar 2008
Posts: 1920
Location: Riley TWP Michigan

PostPosted: Wed Jul 21, 2010 4:25 am    Post subject: Re: Electrical System Schematic Review Reply with quote

The crowbar over-voltage module needs to be in parallel with contactor coil, not in series as drawn. The way that it is now and in the event of an over-voltage condition, even if the module shorts out, the circuit breaker will not trip because the contactor coil will limit the current. Another way to look at is, if the over-voltage module is replaced with a solid piece of wire, the contactor will still function and the circuit breaker will not trip.
Also, the diode needs to be in series with the contactor coil to prevent reverse polarity damage from the ground power. See Bob's drawing Z-31B.
Joe
http://www.aeroelectric.com/PPS/Adobe_Architecture_Pdfs/Z31K.pdf


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jonlaury



Joined: 06 Nov 2006
Posts: 336

PostPosted: Thu Jul 22, 2010 10:08 am    Post subject: Re: Electrical System Schematic Review Reply with quote

user9253 wrote:
...
Also, the diode needs to be in series with the contactor coil to prevent reverse polarity damage from the ground power. See Bob's drawing Z-31B.
Joe
http://www.aeroelectric.com/PPS/Adobe_Architecture_Pdfs/Z31K.pdf


Joe,

I'm doing a separate post of my schematic revisions, titled ...RevA, B, etc.

Made the correction re the OVM.

Re Diodes

Because I'm using a continuous duty contactor with one 8-32 coil post, as drawn, I asked about placement and orientation. Bob N responded
" The banded end of the diode connects to the
"BAT" terminal of the contactor which in turn
faces incoming power from the ground power
connector."
I thought that my schematic complied with Bob's suggestion???
Is the second diode on the wire to the switch breaker superfluous once the contactor diode is oriented/located properly?

Thanks,
John


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user9253



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Location: Riley TWP Michigan

PostPosted: Thu Jul 22, 2010 11:59 am    Post subject: Re: Electrical System Schematic Review Reply with quote

Quote:
Is the second diode on the wire to the switch breaker superfluous once the contactor diode is oriented/located properly?

John,
Your GROUND POWER / ALT 2 contactor circuit is looking good now. As for the diode, the one below the contactor going to the GND PWR 2 amp breaker, it is wired correctly and will protect against reverse polarity from an exterior battery.
The other diode on the right side of the contactor does not serve any useful purpose that I can see. It does not hurt anything, except that it is an unnecessary failure point. If this diode was intended as a coil arc suppression diode, it is connected to the wrong contactor terminal. It should have been connected where the O.V. module is now. Not to worry about that, just get rid of that unnecessary diode because the O.V. module guards against voltage spikes.
I agree that as long as the battery is not dead and the E-BUS ALT FEED switch is turned on, then the AUX Alternator should work and energize the contactor coil.
Joe


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jonlaury



Joined: 06 Nov 2006
Posts: 336

PostPosted: Fri Jul 23, 2010 8:29 am    Post subject: Re: Electrical System Schematic Review Reply with quote

Joe, thanks.

The correction is on Rev. B that I'll post this morning.

I have one other question and then I think I've got this knocked.

From the Ebus alt feed contactor to the Ebus, there is a fusible link called for. My Ebus is fused at 30a at the battery bus and will run at about 20-24 amps and I'm using an 8AWG wire to keep temps down so the fuse link would be a 12AWG. I think that I will put a 40a at the batt bus for the 8AWG protection and to give some head room for the Ebus. Would it be a better design to use a 30a ANL current limiter in place of the 12AWG Fuselink?

John


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PostPosted: Fri Jul 23, 2010 11:12 am    Post subject: Electrical System Schematic Review Reply with quote

At 11:29 AM 7/23/2010, you wrote:
Quote:


Joe, thanks.

The correction is on Rev. B that I'll post this morning.

I have one other question and then I think I've got this knocked.

>From the Ebus alt feed contactor to the Ebus, there is a fusible
link called for. My Ebus is fused at 30a at the battery bus and
will run at about 20-24 amps and I'm using an 8AWG wire to keep
temps down so the fuse link would be a 12AWG. I think that I will
put a 40a at the batt bus for the 8AWG protection and to give some
head room for the Ebus. Would it be a better design to use a 30a
ANL current limiter in place of the 12AWG Fuselink?


I thing the concept for an E-bus has run off
into the weeds. The original idea for
the e-bus was to craft a plan-b that offered
an option for a system that would take you
comfortably to airport of intended destination . . .
battery only. When vacuum pumps started dropping
like flies, we reasoned that e-bus loads could
take a jump by supplementing a battery with
an 8A engine driven power source. Even then,
sizing of continuous operating loads during
an alternator failure event was still LIMITED.
A modicum of planning was necessary to craft the
optimal plan-b.

Your aux alternator is large enough to run
all normal operating loads of 99% of all OBAM
aircraft flying. Hence, the notion of segmenting
electrical loads into "normal" and "endurance"
camps for the purpose optimizing battery-only
operations is curious.

With a 40A aux alternator one is inclined
to run a battery until it croaks . . .
If you're not running a battery maintenance
program designed to maintain some required reserve
capacity, then the whole idea of an e-bus is moot.

Further, the notion of battery-only operations
for a electrically dependent engine under the best
of conditions is a scenario most system designers
would rather not contemplate.

I'll suggest you stand back and review the
big picture. Consider something like Figure
Z-12 and no e-bus. This is how hundreds of
TC aircraft are configured to integrate robust
alternators into the electrical system.

Before you get deeply distracted with
the details of what fuse or diode goes
where, you need to Work through anticipated
failure modes and see first how ARCHITECTURE
mitigates those failures. Keep in mind that
crafting a preventative maintenance plan
unique to your needs marches hand-in-hand
with architecture and sizing of hardware.

I think you'll find that a Z-12 basis for
your proposed system is simpler, easier to
operate, and better suited to an airplane
with an electrically dependent engine.

Bob . . .


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user9253



Joined: 28 Mar 2008
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Location: Riley TWP Michigan

PostPosted: Fri Jul 23, 2010 1:57 pm    Post subject: Re: Electrical System Schematic Review Reply with quote

Quote:
Would it be a better design to use a 30a ANL current limiter in place of the 12AWG Fuselink?

Short answer is no.
The long answer is that I agree with Bob that the electrical system is much more heavy duty than most airplanes. If you are sure that you need this redundancy for IFR over hostile terrain or whatever, then this is what I would do. Get rid of the fuse at the battery bus and mount the E-Bus relay as close to the battery as possible and use a 14awg wire (fuselink) between the battery bus and the relay. Put a 30amp ANL at the relay in series with 10awg to the E-bus. I am not saying that this is the right way to do it, just the way that I would do it. Your way will work too. Keep in mind that it will difficult to blow a 40amp ANL fuse or even a 30 amp for that matter. Use double insulation where the wire passes though the firewall or bulkheads and take care with the installation and a fuse will never blow, nor will there be smoke. I am heading for OSH.
Joe


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jonlaury



Joined: 06 Nov 2006
Posts: 336

PostPosted: Sat Jul 24, 2010 10:37 am    Post subject: Re: Electrical System Schematic Review Reply with quote

Bob and Joe,

OK, I got kind of buried in the details and my goal became to build an absolutely bullet- proof redundant electrical system rather than one that is practical for my purposes. Also at work was a lack of confidence in my understanding of electrical theory and principle and a visceral notion that electricity is a mysterious, unpredictable serpent , so to compensate for that and to gain a level of comfort, I chose to just overbuild its cage.

After both of your responses and re-reading the purpose of Ebus, I see that somewhere along the development of my system, I came to view the Main bus as something that might “fail” and misconceived the Ebus as a back up. After discussion offline with a Glasair III builder (using Z-12) and Bob’s suggestion to “stand back and review the big picture” I can now reason that the MB has switches and fuses for every circuit and that my apprehension that, despite proper construction, it could crash altogether is simply unsupportable.

With the above in mind, Z-12 now seems elegantly appropriate for my needs and I will eliminate the Ebus altogether, per Bob’s suggestion. The one feature of my drawn architecture that deviates from Z-12 is the SB Alt B lead landing on the battery side of the MB contactor. I perceive that this will allow me to use the Generic Ford Regulator over the B&C SB-1 and eliminate the MB contactor as a single point of failure in the charging circuit. I seem to remember Bob recommending a mechanical lock out of the SB alt, if not using the SB-1??

Z-12 w- SB ALT contactor is attached.


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PostPosted: Sat Jul 24, 2010 12:10 pm    Post subject: Electrical System Schematic Review Reply with quote

At 01:37 PM 7/24/2010, you wrote:
Quote:


Bob and Joe,

OK, I got kind of buried in the details and my
goal became to build an absolutely bullet- proof
redundant electrical system rather than one that is practical for my purposes.

I hope you don't feel that this has been a "wasted" exercise.
The elegant solution is like a fine wine. Not only are the
choices of simple-ideas large and varied, the time that it
takes to hypothesize, assemble and consider the results doesn't
happen like magic. In fact, one must be wary of new designs
offered by anyone in any discipline until that caution is
displaced by understanding.

I'm going into production on the 9024 series devices after
perhaps a year of mulling over the options . . . and I've
been doing this for a long time. The B&C starter was over
6 years in development. I can probably recall many more
examples of how the roots of many products run deep in
man-years of preparation.

Quote:
With the above in mind, Z-12 now seems elegantly
appropriate for my needs and I will eliminate
the Ebus altogether, per Bob’s suggestion. The
one feature of my drawn architecture that
deviates from Z-12 is the SB Alt B lead landing
on the battery side of the MB contactor. I
perceive that this will allow me to use the
Generic Ford Regulator over the B&C SB-1 and
eliminate the MB contactor as a single point of
failure in the charging circuit. I seem to
remember Bob recommending a mechanical lock out
of the SB alt, if not using the SB-1??

Not sure where that might have come from. Note that Z-12
as published is illustrative and demonstrative of a minimalist
approach to adding robust aux alternators to a TC aircraft. Note
that unlike the rest of the z-figures, Z-12 shows breakers on
the bus as opposed to fuse blocks. A Z-12 for new design where
crowbar ov protection is proposed might lean toward fuse blocks
but take both B-leads to fat wires under the cowl through
current limiters. Of course, the field supply leads still need
breakers . . . run a 20 pair of 18AWG feeders protected with
22AWG fusible links to their respective alternator control switches.

This might be a Z11-1/2 where you simply add a second alternator
that needs only one more switch (field supply) on the panel.
Eliminate the e-bus. Run ALL electrically dependent engine
loads from the battery bus.

In further "stirring of simple-ideas" I note that another
feature of the e-bus is a plan-b for dealing with a
battery contactor failure. These are rare and can
probably become still more rare if fitted with
power a management module to reduce operating temperature.
Even so, we could consider tying your aux alternator b-lead
to the battery side of the contactor with a Schottky diode
to isolate the always-hot, fat wire between battery and
alternator. In this case, you'd also need to power the
aux alternator field from the battery bus. This variant
would cover the failed-contactor scenario.

Let me ponder this some more. Take a whack at implementing
this using your current CAD skills. By the way, good work
with the CAD drawings.

I'm pretty certain that we're boiling the options down
toward the essence of an elegant solution. The
40A aux alternator offers a Z-12 like architecture
that accommodates more demanding engine support
loads.

Bob . . .

Quote:
Z-12 w- SB ALT contactor is attached.


Read this topic online here:

http://forums.matronics.com/viewtopic.php?p=306153#306153


Attachments:

http://forums.matronics.com//files/z12_w_sb_alt_contactor_208.pdf

Checked by AVG - www.avg.com
- Release Date: 07/24/10 01:36:00


Bob . . .


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Phil White



Joined: 10 Jan 2006
Posts: 45
Location: Downers Grove, IL

PostPosted: Sun Jul 25, 2010 3:23 am    Post subject: Electrical System Schematic Review Reply with quote

Jon: Your solutions appear similar to my system, and the Schematic is beautiful! I see there are many Notes referred to on the schematic. Are the notes available?
(I'm still under construction, and don't have your documentation skills.)

Phil
RV10 w/Mazda 20B electrically dependent engine installed
________________________________________________________
Bob and Joe,
"snip"
With the above in mind, Z-12 now seems elegantly appropriate for my needs and I
will eliminate the Ebus altogether, per Bobs suggestion. The one feature of my
drawn architecture that deviates from Z-12 is the SB Alt B lead landing on the
battery side of the MB contactor. I perceive that this will allow me to use
the Generic Ford Regulator over the B&C SB-1 and eliminate the MB contactor as
a single point of failure in the charging circuit. I seem to remember Bob recommending
a mechanical lock out of the SB alt, if not using the SB-1??

Z-12 w- SB ALT contactor is attached.


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PostPosted: Sun Jul 25, 2010 4:16 am    Post subject: Electrical System Schematic Review Reply with quote

At 06:23 AM 7/25/2010, you wrote:
Quote:


Jon: Your solutions appear similar to my system, and the
Schematic is beautiful! I see there are many Notes referred to on
the schematic. Are the notes available? (I'm still under
construction, and don't have your documentation skills.)

Phil

Jon was willing and able to exploit the CAD drawings
published at:

http://www.aeroelectric.com/PPS/ACAD_Architecture_Dwgs/

and repeated as ordinary .pdf drawings at:

http://www.aeroelectric.com/PPS/Adobe_Architecture_Pdfs/

I might remind List members who were referred to
the AeroElectric-List from other associations that
there is an AeroElectric website at

http://aeroelectric.com/

with some 500 Megabytes of articles, photos,
and drawings including a complete compilation
of sample system architectures extracted from
the back of the book . . .

http://aeroelectric.com/R12A/AppZ_12A4.pdf
Bob . . .


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jonlaury



Joined: 06 Nov 2006
Posts: 336

PostPosted: Sun Jul 25, 2010 10:30 am    Post subject: Re: Electrical System Schematic Review Reply with quote

[/quote]
I hope you don't feel that this has been a "wasted" exercise.

Not at all. In the course of building my plane, I have spent hours, weeks, years even, in developing ideas that ended up in the trash. But they are just the steps that I had to take to get to where I am.



Quote:

....
A Z-12 for new design where
crowbar ov protection is proposed might lean toward fuse blocks
but take both B-leads to fat wires under the cowl through
current limiters. Of course, the field supply leads still need
breakers . . . run a 20 pair of 18AWG feeders protected with
22AWG fusible links to their respective alternator control switches.

Done in my schematic

This might be a Z11-1/2 where you simply add a second alternator
that needs only one more switch (field supply) on the panel.
Eliminate the e-bus. Run ALL electrically dependent engine
loads from the battery bus.

Knee jerk reaction is the all-eggs-in-one-basket apprehension. Granted the failure modes of the battery/bus seem awfully remote, but what harm is there in having an essential engine complement on the main bus so that it can run from a self-excited alternator with the Main contactor open?

In further "stirring of simple-ideas" I note that another
feature of the e-bus is a plan-b for dealing with a
battery contactor failure. These are rare and can
probably become still more rare if fitted with
power a management module to reduce operating temperature.
Even so, we could consider tying your aux alternator b-lead
to the battery side of the contactor with a Schottky diode
to isolate the always-hot, fat wire between battery and
alternator. In this case, you'd also need to power the
aux alternator field from the battery bus. This variant
would cover the failed-contactor scenario.

In my system this seems like a moot exercise because of the redundant SB Alt/GP contactor. But for a system that isn't installing a GPJ, the Schottky variant on the B lead is a nice solution.

Let me ponder this some more. Take a whack at implementing
this using your current CAD skills. By the way, good work
with the CAD drawings.

Thanks and here's a " Z11.5" Draft

I'm pretty certain that we're boiling the options down
toward the essence of an elegant solution. The
40A aux alternator offers a Z-12 like architecture
that accommodates more demanding engine support
loads.

Bob . . .

Quote:
Z-12 w- SB ALT contactor is attached.


Read this topic online here:

http://forums.matronics.com/viewtopic.php?p=306153#306153


Attachments:

http://forums.matronics.com//files/z12_w_sb_alt_contactor_208.pdf

Checked by AVG - www.avg.com
- Release Date: 07/24/10 01:36:00



Bob . . .


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PostPosted: Sun Jul 25, 2010 12:04 pm    Post subject: Electrical System Schematic Review Reply with quote

At 01:31 PM 7/25/2010, you wrote:
Quote:



I hope you don't feel that this has been a "wasted" exercise.

Not at all. In the course of building my plane, I have spent
hours, weeks, years even, in developing ideas that ended up in the
trash. But they are just the steps that I had to take to get to where I am.
[/quote]
Great.

Take a look at the drawing I posted at:

http://www.aeroelectric.com/Laury/

There's a .pdf version there too for folks that want
to watch/participate in what's going on.

The advent of 9024 production offers a "switched"
alternative to the "crowbar" ov system which makes
it more fuse-friendly. The fusible link fed circuit
breaker goes away.

I've drafted an architecture that might become a
new z-figure. It sort of addresses the problems
I was having with the abortive Z-13/20 drawing
I published a few years ago . . . and later
decided it was too much of a cluge.

The proposed architecture retains the "two layer"
power generation system (Like Z-13) that turns the
battery bus into a very robust as well as capable
power source. All circuit breakers go away.

If a builder can accommodate a relatively
large aux alternator, then the need for an
e-bus goes away too.

Let's stir this stew pot of simple-ideas for awhile
and see if it doesn't come closer to the elegant
solution for your project.
Bob . . .


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jonlaury



Joined: 06 Nov 2006
Posts: 336

PostPosted: Sun Jul 25, 2010 11:15 pm    Post subject: Re: Electrical System Schematic Review Reply with quote

Z-Laury...I like it!
I need to get up to speed on the 9024 OVM and what it is capable of.
I already have an LR-3 that I was planning to use on the 60a alt.

This architecture is so simple that I hate to kluge it up, but I want a GPJ so I will insert my GP /SB alt B lead contactor schematic and eliminate the SB alt B lead diode.
Why is the 9024 more fuse friendly and why does it obviate the need for an alt field CB?
Are you still seeing all engine essential power coming from the battery bus?

Ironic that this evolution started with my wanting to use Z-13/20 and you informed me that you had pulled that Z-figure from the AEC book.

Cheers,
John


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PostPosted: Mon Jul 26, 2010 2:36 pm    Post subject: Electrical System Schematic Review Reply with quote

At 02:15 AM 7/26/2010, you wrote:
Quote:


Z-Laury...I like it!
I need to get up to speed on the 9024 OVM and what it is capable of.

See:

http://www.aeroelectric.com/Catalog/AEC/9024/

Quote:
I already have an LR-3 that I was planning to use on the 60a alt.

Hmmmm . . . okay, the LR3 has crowbar ov protection so you'll
need to configure for the panel breaker . . .

Quote:
This architecture is so simple that I hate to kluge it up, but I
want a GPJ so I will insert my GP /SB alt B lead contactor
schematic and eliminate the SB alt B lead diode.

Would you plan to close two switches to bring
the aux alternator on line? You need one switch
to control the aux alternator field supply. If
You double-up on the ground power contactor
functionality, then selecting the aux alternator
requires an feature that closes that contactor
too. Let me ponder this a bit.

Quote:
Why is the 9024 more fuse friendly and why does it obviate the need
for an alt field CB?

Because it doesn't "crowbar" it "breaks". If you simply
switch off the alternator, then there's no risk to nuisance
tripping a field supply fuse so crew accessible reset
is unnecessary. This is a throwback to ov protection
of yesteryear (the very first product I qualified for
use on a TC aircraft was an OV relay in 1975 or thereabouts).

The crowbar configuration came about as a parts reduction
scheme that was readily adaptable to aircraft that already
used circuit breakers. It got sticky when those slightly
demented OBAM aircraft guys renewed the romance with
fuses.

While the 9024 is designed to drive (ugh!) relays, it's
broad applicability as a contactor power controller, ABMM,
LVWarn and OVProtection, device renewed some interest in
relays . . . this was further enhanced by the availability
of automotive grade relays that are inexpensive while
being also robust.

In a sense, incorporation of microprocessors into
a single, multi-application accessory has re-opened
the books on 'older' technologies that were (and
still are) on the hit list for new designs in some
venues. But my grandpa would remind me that for all
the pneumatic nail and brad drivers I now possess,
sometimes the best way to drive some nails is with
a hammer!

Quote:
Are you still seeing all engine essential power coming from the battery bus?

Yes.

Quote:
Ironic that this evolution started with my wanting to use Z-13/20
and you informed me that you had pulled that Z-figure from the AEC book.

Yeah . . . see what can happen when one breaks
a fixation on a bad idea and starts with a clean
slate?

Bob . . .


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jonlaury



Joined: 06 Nov 2006
Posts: 336

PostPosted: Mon Jul 26, 2010 5:24 pm    Post subject: Re: Electrical System Schematic Review Reply with quote

Quote:
Would you plan to close two switches to bring
the aux alternator on line? You need one switch
to control the aux alternator field supply. If
You double-up on the ground power contactor
functionality, then selecting the aux alternator
requires an feature that closes that contactor
too. Let me ponder this a bit.


In the 9th post of this thread, beginning "Bob and Joe..." I attached Z-12 w/SB Alt contactor. I would wire the two contactors through a DPST as drawn with a 9024 instead of the OVM module

Quote:
Are you still seeing all engine essential power coming from the battery bus?

Yes.


I was tapping power from the Ebus and Batt bus to diode bridges to drive my single EFI ECU, and on another circuit the EFI Injectors. It seems that nothing changes with engine essentials all on the battery bus. The redundancy of power sources is just happening upstream of the batt bus and I still use two DPST switches feeding the diode bridges, w/ ECU and Injector legs on each switch to eliminate a single point of failure, i.e. the switch.

I'm feeling very comfortable with this scheme.

J


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