Owner manual pgs 454-7 Auxiliary Switchs 1-6 have 1.5mm(16AWG) 30AMP (#60 fuse) on 1/6 -yellow wire by firwall butunder rate for electric loads?

Chart:

AWG gauge Conductor Diameter Inches Conductor Diameter mm Conductor cross section in mm2 Ohms per 1000 ft. Ohms per km Maximum amps for chassis wiring Maximum amps for power transmission Maximum frequency for100% skin depth for solid conductor copper Breaking force Soft Annealed Cu 37000 PSI
8 0.1285 3.2639 8.37 0.6282 2.060496 73 24 1650 Hz 480 lbs Battery
9 0.1144 2.90576 6.63 0.7921 2.598088 64 19 2050 Hz 380 lbs
10 0.1019 2.58826 5.26 0.9989 3.276392 55 15 2600 Hz 314 lbs brake
11 0.0907 2.30378 4.17 1.26 4.1328 47 12 3200 Hz 249 lbs
12 0.0808 2.05232 3.31 1.588 5.20864 41 9.3 4150 Hz 197 lbs
13 0.072 1.8288 2.63 2.003 6.56984 35 7.4 5300 Hz 150 lbs
14 0.0641 1.62814 2.08 2.525 8.282 32 5.9 6700 Hz 119 lbs
15 0.0571 1.45034 1.65 3.184 10.44352 28 4.7 8250 Hz 94 lbs
16 0.0508 1.29032 1.31 4.016 13.17248 22 3.7 11 k Hz 75 lbs switches
17 0.0453 1.15062 1.04 5.064 16.60992 19 2.9 13 k Hz 59 lbs
18 0.0403 1.02362 0.823 6.385 20.9428 16 2.3 17 kHz 47 lbs
19 0.0359 0.91186 0.653 8.051 26.40728 14 1.8 21 kHz 37 lbs
20 0.032 0.8128 0.519 10.15 33.292 11 1.5 27 kHz 29 lbs
21 0.0285 0.7239 0.412 12.8 41.984 9 1.2 33 kHz 23 lbs
22 0.0253 0.64516 0.327 16.14 52.9392 7 0.92 42 kHz 18 lbs speakers
23 0.0226 0.57404 0.259 20.36 66.7808 4.7 0.729 53 kHz 14.5 lbs
24 0.0201 0.51054 0.205 25.67 84.1976 3.5 0.577 68 kHz 11.5 lbs speakers

Metric
2.0 0.00787 0.200 0.0314 169.39 555.61 0.51 0.088 440 kHz
33 0.0071 0.18034 0.0255 206.9 678.632 0.43 0.072 540 kHz 1.3 lbs

Metric
1.8 0.00709 0.180 0.0254 207.5 680.55 0.43 0.072 540 kHz
34 0.0063 0.16002 0.0201 260.9 855.752 0.33 0.056 690 kHz 1.1 lbs

Metric
1.6 0.0063 0.16002 0.0201 260.9 855.752 0.33 0.056 690 kHz
35 0.0056 0.14224 0.0159 329 1079.12 0.27 0.044 870 kHz 0.92 lbs

Metric
1.4 .00551 .140 0.0154 339 1114 0.26 0.043 900 kHz
36 0.005 0.127 0.0127 414.8 1360 0.21 0.035 1100 kHz 0.72 lbs

Metric
1.25 .00492 0.125 0.0123 428.2 1404 0.20 0.034 1150 kHz
37 0.0045 0.1143 0.0103 523.1 1715 0.17 0.0289 1350 kHz 0.57 lbs

Metric
1.12 .00441 0.112 0.00985 533.8 1750 0.163 0.0277 1400 kHz
38 0.004 0.1016 0.00811 659.6 2163 0.13 0.0228 1750 kHz 0.45 lbs

Metric
1 .00394 0.1000 0.00785 670.2 2198 0.126 0.0225 1750 kHz
39 0.0035 0.0889 0.00621 831.8 2728 0.11 0.0175 2250 kHz 0.36 lbs
40 0.0031 0.07874 0.00487 1049 3440 0.09 0.0137 2900 kHz 0.29 lbs

AWG Wire Sizes (see chart above)
AWG: In the American Wire Gauge (AWG) system, wire size diameters can be calculated by applying the formula D(AWG)=.005·92((36-AWG)/39) inch. For the 00, 000, 0000 etc. gauges you use -1, -2, -3, which makes more sense mathematically than "double nought." This means that in American wire gage every 6 gauge decrease gives a doubling of the wire diameter, and every 3 gauge decrease doubles the wire cross sectional area. Similar to dB in signal and power levels. An approximate but accurate enough form of this formula contributed by Mario Rodriguez is D = .460 * (57/64)(awg +3) or D = .460 * (0.890625)(awg +3).

Metric Wire Gauges (see table above)

Metric Gauge: In the Metric Gauge scale, the gauge is 10 times the diameter in millimeters, so a 50 gauge metric wire would be 5 mm in diameter. Note that in AWG the diameter goes up as the gauge goes down, but for metric gauges it is the opposite. Probably because of this confusion, most of the time metric sized wire is specified in millimeters rather than metric gauges.

Load Carrying Capacities (see table above)

Definition:

ampacity is the current carrying capability of a wire. In other words, how many amps can it transmit? The following chart is a guideline of ampacity or copper wire current carrying capacity following the Handbook of Electronic Tables and Formulas for American Wire Gauge. As you might guess, the rated ampacities are just a rule of thumb. In careful engineering the voltage drop, insulation temperature limit, thickness, thermal conductivity, and air convection and temperature should all be taken into account. The Maximum Amps for Power Transmission uses the 700 circular mils per amp rule, which is very very conservative. The Maximum Amps for Chassis Wiring is also a conservative rating, but is meant for wiring in air, and not in a bundle. For short lengths of wire, such as is used in battery packs you should trade off the resistance and load with size, weight, and flexibility. NOTE: For installations that need to conform to the National Electrical Code, you must use their guidelines. Contact your local electrician to find out what is legal!

Well class, as one of my granddaughters play school, we see that under any circumstances a 30 amp fuse #60 in the battery power(fuse) box can sent 30 Amps dc (30x12=360 watts heat like 3.6 100w light bulb) I was an assistant controller out of college for a large toy company. We manufactured EZ Bake oven, ( now Mattel) we used a 100 w light bulb to bake a Betty Crocker cake mix, we sold millions thru Sears, etc.

Well now see what 3.6 100 w light bulbs can bake you $1,300 battery distribution box, near that mat glass battery. As a fireman, batteries will explode under high heat! EV car with lithium batteries will really go bang. See warning on your 1.5 v litium, do not burn!

Well now we go to that expensive start stop AMG battery if we overheat the battery distribution box, due to over loading switch one #60 location, 30 amp fuse on 1.5mm foreign auto yellow wire by the firewall and left inside fender well in the engine bay.

What’s Thermal Runaway?
It’s when too much heat is generated in a battery ( or a 1.5 mm2 wire) that can’t be expelled accordingly. If this situation continues, temperatures will increase until the battery cells dry out (wire insulation) and the container softens and melts.

Destruction from a thermal runaway can release toxic chemicals, and cause electrical fires or batteries to explode.Thermal runaway occurs most often in VRLA batteries.

Have you over loaded switch one 30A of your Auxiliary switches. KC light bars ( halogen). LED use 1/10 the amps than a 1.0 amp halogen, that's why Ford non base models are LED. Less electrical requirement, less time the alternator pulley takes power from engine, more mpg. That's FORD engineering, but the electricians did not check the 1.5 mm2 yellow cheap foreign 1.5 mm2 wire. See chart above, Keep a fire extinguisher handy!

Last observation, My Land Rover dealer, got me on the allocation list for a MY23.5 DEFENDER 110 . In a test ride hybrid 110, a salesperson was asked, where the starter battery was located. He open cargo , then lifted a lid and said here, next to the 48 Amp electric hybrid charging. I stated its under passenger seat in UK, then he corrected himself , and said, under my drivers seat. Toxic chemicals, appears no vent tubes like my Cayenne Turbo, PIA. $500 if battery goes dead Parts and labor, seat gets unbolted.

The good, bad and ugly in the 4×4 new truck business.

Cant any 4×4 OEM to get it right.

My RR Sport and wife's Eddie Bauer Explorer runs after many year, just Ford suspension issues due to boat ramps. Dont use your Bronco Outer Banks in or near salt water, the box frame rails are going to rust out. Lower control arms now aluminum , but shock coil over springs are still iron but painted.

Remember FIX Or Repair Daily is FORD's known motto!

Frank -
You need to adjust your meds.

30A at 12V is indeed 360W, but where is that power being dissipated? Is it in the fuse box?
How could that be?
You already stated that 16AWG wire is 4 mΩ/foot. If that’s true, and there is, say, 6” of wire in the fuse box, that means that there is 2mΩ of resistance in the fuse box.
Power in Watts = I^2 R
So, 30A * 30A * 2mΩ = 900 * .002 = 1.8W

1.8W is not 360W.
Please stop trying to pretend that you understand electricity.

frankgoss

Last observation, My Land Rover dealer, got me on the allocation list for a MY23.5 DEFENDER 110 . In a test ride hybrid 110, a salesperson was asked, where the starter battery was located. He open cargo , then lifted a lid and said here, next to the 48 Amp electric hybrid charging. I stated its under passenger seat in UK, then he corrected himself , and said, under my drivers seat. Toxic chemicals, appears no vent tubes like my Cayenne Turbo, PIA. $500 if battery goes dead Parts and labor, seat gets unbolted.

The good, bad and ugly in the 4×4 new truck business.

Cant any 4×4 OEM to get it right.

My RR Sport and wife's Eddie Bauer Explorer runs after many year, just Ford suspension issues due to boat ramps. Dont use your Bronco Outer Banks in or near salt water, the box frame rails are going to rust out. Lower control arms now aluminum , but shock coil over springs are still iron but painted.

Remember FIX Or Repair Daily is FORD's known motto!

I don’t know you, sir, but you seem really unhappy. Perhaps you would be happier owning and picking a GM vehicle apart…. You seem to have pretty well exhausted your efforts on Ford and Land Rover.

I just had a seizure and died

thgdfathr

I just had a seizure and died

Condolences ;)

frankgoss

@ Laura

Here is what a 16 AWG can do if over loaded it with current:

AWG #16 copper wire has a resistance of 4.016 Ω per 1000 feet, or 4.016 mΩ/foot, or 13.18 mΩ/m. If you need to keep the voltage drop along 1 m of wire to 100 mV or less, then you can't push more than 7.59 A thru it. If you need to limit the power dissipation to 1 W/foot, then you can't push more than 15.8 A thru it. 1 W/foot would get noticably warm, but should not be dangerously so for most uses.

If you are using it for house wiring, then it becomes a legal matter and you simply look up the answer. One chart I looked at says the limit is 3.7 A for "power transmission". That was chosen to be very conservative so that some amount of degradation and screwups can happen and your house is unlikely to burn down due to overloaded wiring. Legal limits will vary by jurisdiction and which electrical code is being applied. You will have to consult the electrical code that applies to your area and circumstance to get the answer.

That same chart that shows 3.7 A as the maximum for power transmission also shows 22 A maximum for "chassis wiring". Presumably more temperature rise is acceptable inside a Electrical chassis.( like tv, computer ,not auto, since those chassis have small fans to cool them).

Some say the ampacity of 16AWG IS 13 A. Ford elected to only use 1.5 mm foreign wire on auxiliary switch one , a 30 Amp fuse in fuse #60 location in engine power distribution box. If that relay gets blown the cost of a complete battery distribution ( fuse/relay) which is non- serviceable is say $1300.00

Ford has advertised 30-15-10 amp switches for $195 but for safety sake 16 AWG is good for 3.7A.

Recommendation:

Ford should issue a recall and change all six fuses to 2.5A not 30-15-10A as sold to be safe. The fuse must always be lower than the rating of the wire it is powering. We have the NEC and local electrical inspectors to thank for our home safety and Ford wants to sell 50% electrical vehicles(EV). Tell them they now must meet NEC rules, and stop putting cheap thin foreign wiring in our Bronco!

Below do you see 16 gauge wire in the chart. No. Just got from etrailer 10AWG for brake controller run.

You are completely forgetting about the use of relays in which allows the use of a less heavier gauge wire and the 1.5mm wire is actually 1.5mm squared so more like a 15ga wire. I'm sure FoMoCo knows how to wire a vehicle.

Hi

You are missing the point. Its not the wiring rating its the load that determines when the fuse will trip. A 100 watt light bulb can cook a cake. if 3.5 100 watt light bulbs are in series that 350 watts load. The 15 or 16AWG will get hot.

Ask any college kid how he cooked a frankfutter on 16 gauge lamp cord.. Wires will heat up. Ford made an error. Here us SAE J1292 rrad it. Again its the load!

All this testosterone is making everyone emotional

Hi three dog.

Its the load. So 1.8 watts is at 6" now multiply that by 20 feet run to point E tear wheel well so 1.8 w × 40 ( 2×20 ') thats 76.4 watts at point E or say 7 ampacity maximum, but there is voltage drop at 20 feet , big time on 16 AWG maybe 50% . once the load, lije an 1000 inverter not a mini refrig is drawing current or simular high draw appliance, that wire is over loaded maybe two to three tine the rated wire.

Daisy A relay allows a small rated wire to switch a much larger gauge wire. Yes you can use switch one, but also witch 2-6 to control a replay. But the output of a relay will generally be off a direct wire to the battery with say #10-8-6-4 gauge wire. Here we have a 16 ga yellow wire. Just to small to handel a load greater that some LED lights. A mini ref may draw 60 watts but voltage drop could make only 48 watts maximum. See tabke below. For you purists 1.5 mm2 is between 16-14 ga, but not exactly 15 ga, since ekectrician will alway go to a larger ( small # ga) wire for safety reasons.

Most Bronco owners will just put lights on lower rated switches, and some can use switch 1 as a relay fir a high motor wattage winch, but that relay will handel many times the 30 amp. That yellow 1.5mm2 would have to be wired to the low side of that second high voltage new relay switch.

I am an accountant, but worked directly with electrical engineer. I had to pay for millions of feet of cable used in NYC street and traffic lights, bridges and tunnels. My engineers did the calculation, I only said can we save our stakeholfders some money by using one size smaller wiring. Electrical engineers , won ot for safety reasons.

If that 1.5mm2 yellow wire was as stated in next chart a load rated wire, I would nit have wasted my time.

Sulley

All this testosterone is making everyone emotional

What testosterone?

BTW you don't push amps, you draw them.

frankgoss

Hi

You are missing the point. Its not the wiring rating its the load that determines when the fuse will trip. A 100 watt light bulb can cook a cake. if 3.5 100 watt light bulbs are in series that 350 watts load. The 15 or 16AWG will get hot.

Ask any college kid how he cooked a frankfutter on 16 gauge lamp cord.. Wires will heat up. Ford made an error. Here us SAE J1292 rrad it. Again its the load!

Im not missing the point, I know how a breaker and fuse work. What I was trying to convey is wire length is everything because of the resistance which causes heat. The longer the wire the heavier gauge it has to be, so if you have 15ga or 14ga you can run 30 amps all day long if the wire is only 2 feet in length. Now, if that same wire is 20' long then you should use a 8 ga wire, hence the use of relays. Relays allow shorter wire distances which allow use of less gauge wires to be used. I guarantee you it's perfectly fine to wire an accessory per the fuse rating that Ford provided.

frankgoss

Hi

You are missing the point. Its not the wiring rating its the load that determines when the fuse will trip. A 100 watt light bulb can cook a cake. if 3.5 100 watt light bulbs are in series that 350 watts load. The 15 or 16AWG will get hot.

Ask any college kid how he cooked a frankfutter on 16 gauge lamp cord.. Wires will heat up. Ford made an error. Here us SAE J1292 rrad it. Again its the load!

Oh my.
3.5 -100 watt light bulbs in series still equals 100 watts.
They would have to be in parallel for the total circuit wattage to be 350 watts.
Ever heard of ohm’s law?

You are both right.
series circuit, the current that flows through each of the components is the same, and the voltage across the circuit is the sum of the individual voltage drops across each component.[1] In a parallel circuit, the voltage across each of the components is the same, and the total current is the sum of the currents flowing through each component.[1]
As for length of wire . Voltage drop is the key. But when bundled more caution is needed. NEC recommends 1.25 factor. There are many calculators for dc current. A 16AWG will carry 13Ampacity in open air, the drop to 5 amps at 3 meters say at point E .
Now pump 30 ampacity (30amp switch #1) and see what happens in bunched harness and inside the cargo sidewall.

The proof is the 12v power right near it is on a 20Amp fuse. If anyone think he can pump 30 amps constant, like using an inverter on point E , he will most likely blow the fuse and maybe the $1300 battery junction box which is not serviceble per Ford .

Here is one calculator:
Voltage Drop Calculator
Wire / cable voltage drop calculator and how to calculate.

Wire type:
Copper

Resistivity:
1.72e-8Ω·m
Wire diameter size:
15AWG
Wire/cable length (one way):
20feet
Current type: DC
Voltage in volts: 13V
Current in amps: 13A
Voltage drop in volts: 1.65197V
Percentage of voltage drop: 12.7074%
Wire resistance: 0.127074Ω
* @ 68°F or 20°C
** Results may change with real wires: different resistivity of material and number of strands in wire.
*** For wire length of 2x10ft, wire length should be 10ft.
Here is the chart I am using:

I am gonna wire stuff to every switch and I double dog dare, Ford to cook my Bronco! Come on, fry it all! Burn baby burn!

frankgoss

@ Laura

Here is what a 16 AWG can do if over loaded it with current:

AWG #16 copper wire has a resistance of 4.016 Ω per 1000 feet, or 4.016 mΩ/foot, or 13.18 mΩ/m. If you need to keep the voltage drop along 1 m of wire to 100 mV or less, then you can't push more than 7.59 A thru it. If you need to limit the power dissipation to 1 W/foot, then you can't push more than 15.8 A thru it. 1 W/foot would get noticably warm, but should not be dangerously so for most uses.

If you are using it for house wiring, then it becomes a legal matter and you simply look up the answer. One chart I looked at says the limit is 3.7 A for "power transmission". That was chosen to be very conservative so that some amount of degradation and screwups can happen and your house is unlikely to burn down due to overloaded wiring. Legal limits will vary by jurisdiction and which electrical code is being applied. You will have to consult the electrical code that applies to your area and circumstance to get the answer.

That same chart that shows 3.7 A as the maximum for power transmission also shows 22 A maximum for "chassis wiring". Presumably more temperature rise is acceptable inside a Electrical chassis.( like tv, computer ,not auto, since those chassis have small fans to cool them).

Some say the ampacity of 16AWG IS 13 A. Ford elected to only use 1.5 mm foreign wire on auxiliary switch one , a 30 Amp fuse in fuse #60 location in engine power distribution box. If that relay gets blown the cost of a complete battery distribution ( fuse/relay) which is non- serviceable is say $1300.00

Ford has advertised 30-15-10 amp switches for $195 but for safety sake 16 AWG is good for 3.7A.

Recommendation:

Ford should issue a recall and change all six fuses to 2.5A not 30-15-10A as sold to be safe. The fuse must always be lower than the rating of the wire it is powering. We have the NEC and local electrical inspectors to thank for our home safety and Ford wants to sell 50% electrical vehicles(EV). Tell them they now must meet NEC rules, and stop putting cheap thin foreign wiring in our Bronco!

Below do you see 16 gauge wire in the chart. No. Just got from etrailer 10AWG for brake controller run.

What?