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Old 06-07-2016, 06:19 PM
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Auxillary relay box

I am taking on a bit of a project for my TJ. I want to add an aux relay box under the hood. Reason is that I want to clean up the engine bay and make things a bit more safer. I am currently running a Derale efan, 3 sets of LED cubes, green underside LEDs (with plans to add a set of white ones as well), CB, winch, and aux power outlets. My plans are to add on board air, rear power outlets, and possibly an amp and sub.

I was able to get 2 nice ones from a couple WJs at the local pull-a-part complete with fuses and relays. Right now when the e-fan comes on I get a major drop in RPMs. Spoke to tech support at Derale and they say it is either my alternator (new remanned 136a) or battery. Also when the fan kicks on I get feedback in my CB. Fan is powered from the OEM relay box for hot only but does have the external relay in line and a resetting 30a circuit breaker. Another issue I have been having is eating fuel pumps, specifically the regulators in them seem to keep crapping out and I am not sure if it could be electrical as well as garbage delphi, airtek, and spectra pumps. This coming weekend I will be pulling the alternator (found 2 broken wiring tabs on it a week after install and have not had time to replace it), the battery and take for testing, and the fuel pump (going to get my money back from AZ and get a bosch from NAPA).

I think by moving all the other accessories from the battery and pcm to a second one I can eliminate a lot of issues and make a more safe electrical system.

My question is when I wire this new box up I want to add a circuit breaker between it and the battery. What would be a good size to use? I am thinking along the lines of a 300 but that may be way overkill for the system. Any electrical gurus out there done this and what did you use for a breaker if any?

I did do a search but found nothing for this sort of question.

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98 TJ
4.0L, 5spd, 4.25 Zone lift, Currie Anti-rock, Trutrac D30 4.56 gears, Locked D35 w/Super 35 kit 4.56 gears, MCE GEN I Flares, 35 Wrangler MTRs, Engo 10K# winch, rear disc brake conversion, Core 4x4 Stage 1 control arms, home fabbed interior rear storage rack.

My idea of help from the man above is a sniper on the roof.
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Old 06-07-2016, 06:51 PM   #2
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Relays serve a purpose but none of those items you mentioned, the Derale fan or LED lights, require one. Certainly the winch should not be connected to a relay, and the CB doesn't even come close to requiring a relay.

I've done a lot of wiring and installed/used a lot of relays over the past 50+ years of being in the electronics/electrical business but when they're not needed, don't use them... they just add unnecessary complexity to a circuit and add another potential point of failure.

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Old 06-07-2016, 09:35 PM
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I know the CB and winch don't need them and I really didn't think I would with the LEDs. The fan did come from Derale with the relay and since it has been installed I have killed 2 and countless inline 30a fuses.

Right now the fan is still on the relay (well a replacement 40/60a like they had sent but with a new holder) and a resetting 30 breaker. I have checked all the wires for it and made sure they were protected and none were frayed, exposed, or damaged, trying to figure out why it would melt down the fuse holders and relay plugs like it did. So that is kind of the other reason I want to do this. Separate the accessories from the main components to avoid a worse meltdown.

I do appreciate your input Jerry. Am at a bit of a loss for answers.
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98 TJ
4.0L, 5spd, 4.25 Zone lift, Currie Anti-rock, Trutrac D30 4.56 gears, Locked D35 w/Super 35 kit 4.56 gears, MCE GEN I Flares, 35 Wrangler MTRs, Engo 10K# winch, rear disc brake conversion, Core 4x4 Stage 1 control arms, home fabbed interior rear storage rack.

My idea of help from the man above is a sniper on the roof.
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Old 06-08-2016, 06:59 PM   #4
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The relay may be miswired, perhaps the fan is drawing its load through the coil instead of the contacts.

I also have a Derale with a fan but there is no relay and the Derale kit that I installed didn't come with one. It's been running fine for years. Wired properly, it doesn't draw enough current to require a relay.
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Old 06-08-2016, 07:49 PM
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Quote:
Originally Posted by Jerry Bransford View Post
The relay may be miswired, perhaps the fan is drawing its load through the coil instead of the contacts.

I also have a Derale with a fan but there is no relay and the Derale kit that I installed didn't come with one. It's been running fine for years. Wired properly, it doesn't draw enough current to require a relay.
HMMMMMMMM.
This is the one I am running.

Direct Fit : Direct Fit Jeep Wrangler Performance Electric Fan Kit - 19-1/2"W x 18"H x 3-3/4"D

Are you running the efan solo or as a pusher with the OEM fan?
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98 TJ
4.0L, 5spd, 4.25 Zone lift, Currie Anti-rock, Trutrac D30 4.56 gears, Locked D35 w/Super 35 kit 4.56 gears, MCE GEN I Flares, 35 Wrangler MTRs, Engo 10K# winch, rear disc brake conversion, Core 4x4 Stage 1 control arms, home fabbed interior rear storage rack.

My idea of help from the man above is a sniper on the roof.
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Old 06-08-2016, 08:22 PM   #6
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Oh ok that's a significantly bigger fan than I'm running, a relay is a good idea for for yours.

Just make sure the fan is only wired to the normally-open contacts, and not passing through the coil windings.



Connect Pin 30 via a fuse and 12-14 gauge wire to the + post on the battery.
Connect Pin 87 to the fan. Ground the other fan lead via the same gauge wire as is connected to Pin 30.
Connect Pin 86 to the same + power pin 30 is going to.
Connect Pin 85 to a switched ground, like through a thermostat switch.

The wiring to pins 85 and 86 can be a lighter gauge like 16 or so, not much power runs through them.
The wiring to pins 30 and 87 is where the heavy fan motor current passes through, use an adequate wire gauge there.
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Old 06-12-2016, 12:39 PM
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Quote:
Originally Posted by Jerry Bransford View Post
Oh ok that's a significantly bigger fan than I'm running, a relay is a good idea for for yours.

Just make sure the fan is only wired to the normally-open contacts, and not passing through the coil windings.



Connect Pin 30 via a fuse and 12-14 gauge wire to the + post on the battery.
Connect Pin 87 to the fan. Ground the other fan lead via the same gauge wire as is connected to Pin 30.
Connect Pin 86 to the same + power pin 30 is going to.
Connect Pin 85 to a switched ground, like through a thermostat switch.

The wiring to pins 85 and 86 can be a lighter gauge like 16 or so, not much power runs through them.
The wiring to pins 30 and 87 is where the heavy fan motor current passes through, use an adequate wire gauge there.
Thank you Jerry.

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98 TJ
4.0L, 5spd, 4.25 Zone lift, Currie Anti-rock, Trutrac D30 4.56 gears, Locked D35 w/Super 35 kit 4.56 gears, MCE GEN I Flares, 35 Wrangler MTRs, Engo 10K# winch, rear disc brake conversion, Core 4x4 Stage 1 control arms, home fabbed interior rear storage rack.

My idea of help from the man above is a sniper on the roof.
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