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I too have had the same thoughts about protecting alternator output wiring..
My conclusions a 1) Alternator output wiring should go directly from the alternator to the battery. This wiring should be protected with a fuse or circuit breaker within 7" of the battery by a fuse or circuit breaker sized according to the wiring's current capacity (wire gauge). This provides protection from a short causing the battery to discharge at a very high current. Also there should be a switch to completely disconnect the battery from all connections. This allows the battery to be disconnected in case of fire caused by current less than the fuse or circuit breaker rating. This switch is normally left on, allowing the battery to be charged. The handle for this switch should be readily accessible from the outside of the compartment containing the battery. 2) Even if a short causes the fuse or circuit breaker at the battery end to blow or trip, the alternator can continue to provide current to the short. The alternator output wiring should be sized to safely carry maximum alternator output. Since the alternator output current is limited to the maximum amount the alernator can produce, overcurrent protection (fuse or circuit breaker) at the alternator end of the wiring doesn't work. Instead the wiring to the battery should be physically protected against damage such as running it in conduit. 3) The above all protect alternator output wiring from overheating and causing a fire due to a short or other overcurrent. However disconnecting an alternator from the battery can cause high voltage at the alternator output causing failure of the alternator's diodes. A Zap-Stop or similiar device connected to the alternator's output can shunt the high voltage to ground, protecting the diodes. |
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