Audiovox PRO-0412/C Installation Manual

INSTALLATION GUIDE FOR:

PRO-O412/C

3-12 BAR COPPER ELEMENT DEFOGGER

WITH TIMER AND ON-OFF PANEL SWITCH

ADD PRO-OO20 FOR GRIDS NEEDING MORE BARS

Printed in U.S.A.

FORM NO.128-3881

Fig.2

IMPORTANT NEW INSTRUCTIONS
REVISED DEFOGGER GRID LAYOUTS AND WIRING METHODS

TO INSURE PROPER OPERA TION OF THIS DEFOGGER. THE FOLLOW­ING NEW INSTRUCTIONS MUST BE EXACTLY FOLLOWED.

1. Total grid current must not be less than 6 AMPS (the window will
not heat properly if it is below this).

2. Total grid current must not be more than 19 AMPS (the timer or
grid may fail or operate incorrectly if you exceed 19 AMPS).

3. Usethegrid examples provided in this manual as a guide butjfin
doubt, use the formula provided to calculate the actual grid
current your car will use.

=~4.This kit contains sufficiel1t ~aterials to make a grid upto 12bars
'{:Jc cby 5 feet wide. If your grid will exceed this. youiequiieaPRb-

~-'7!:0020accessory k!l -:'::~-,e;c-"';;"

HOW To SET-UP THE GRID PATTERN :

1- Measure your window to determine how many grid lines

(horizontal heating bars) your vehicle requires by the following
method (see Fig. 1 ).
A. Measure the height of the window at the edge of the window

since this is usually the smallest dimension (H).

B. Measurethe width of the window at the top and at the bottom

(W1 and W2).

C. Add W1 and W2 and divide by (2). This is the average width of

your window. -c c

Fig. 1

3. Determining the grid grouping required to achieve the idea[
current range of 6 AMPS to 19 AMPS.
A In our example we want 13 bars that will each be 38'c wide.
B. The formula to determine the current of this grid is:

a. ,012times the width (38") divided by the number ofbars in

each group (1) times the number of groups (13). This is
then divided into 13.2 volts (the average voltage of most

cars).

./ b. .012 (x) 38 = .456 (divided by) 1 = .456 (x) 13 = 5.9 (13.2

divided by 5.9 =2.2 AMPS)
As you can see this is way below the 6 AMP minimum,

c. Therefore. we cannot use 13 bars. So we now have a

choice, we can either delete one bar and make if a 12 bar
grid or we can close-up the spacing between bars by
overlapping the clear carrier tape and make it a 14 bar

grid.

d. For our example we will cfose-upthespacing and make it

a 14 bar grid. Now we can group the bars into groups of 2
bars each (14 is evenly divisible by 2). This will give us 7
groups of 2 bars each. (It is not divisible by 3 or 4.)

e. Using the formula we get

.012 (x) 38 (divided by) 2 (x) 7 = 1.59. We divide this into

13.2 and get 8.3 AMPS. This is within our 6 to 19 AMP
range.So our grid willfook like Fig. 3.

NOTE:

In our example the window is 18" high and W1 is 36" and
W2 is 40". So we add W1 (36") to W2 (40'1 and divide by (2)

36 + 40 = 76" divided by 2 = 38" "
Our average width is 38".

Our height is 18".

FIG. 3

2. Determine how many horizontal grid lines you require by the
following method (See Fig. 2).

A. The normal spacing between bars is 1%" (1.3751.

B. You must allow 5/a" clearance at the top and bottom of the

grid.

C. Therefore. divide the height of your window by 1 %" (1.375).

NOTE: In our example the height is 18". Divided by 1 %" we
get 13 lines.

D. Actually, we can fit 14 bars in 18" of height, but the top and

bottom bars would almost be touching the edges of the glass
area and this is not acceptable.

E. Now we want 13 bars but is this suitable for resistance

grouping to ~chieve the ideal current range of 6AMPS to 19
AMPS? For grouping, the number of lines must be evenly
divisible by 2, 3 or 4. As you can see, (13) is not evenly
divisible by any of these. Therefore. we can only use 13 bars
as single line groups provided it meets the current range of 6
AMPS to 19 AMPS. How we determine this will be explained

next

NOTE:

We have provided typical groupings for most windows on
the following pages. You will only need to use the formula
if your window doesn't work with one of the pictured

examples.

STEP 11. (CUTTING SIDE CONTACT BARS)

A. In order for the defogger to work properly. you must make

specific cuts in the side bars. Refer to the grid diagram for the
amount of the heating bars you installed to find where these cuts
must be made.

B. Once you are certain where you must cut, remove a Y." thick

piece of the vertical side bars at all indicated points where you
are shown to .'CUT". CAUTION -FAILURE TO CUT IN THE
PROPER PLACES WILL RESULT IN AN INOPERATIVE
DEFOGGER OR MA y POSSIBLY CAUSE SEVERE OVERHEAT ­ING WHICH CAN RESULT IN AN ELECTRICAL FAILURE. NOTE:

Jf you should accidently miscut an area that should not have

been cut, you can solder in a splice patch using left over side bar
copper strips.

STEP 10. (CONNECTING THE GROUND & 12 VOLT FEED WIRES)

A. Locate the 12 inch long BLACK GROUND wire with the screw

terminal on one end and locate the 17 foot BLACK 12 VOL T
FEED wire with the female spade on one end.

B. Refer to the appropriate grid diagram for your defoggerto locate

the connection points for the (+) and the (-) wires. NOTE: These
two points may be reversed if necessary.

C. Determine where you are going to secure the screw end of the

ground wire to (this must be a metal area as near to the window
as possible -DO NOT use an existing trim molding screw). Once
you decide where to ground the wire. cut off any excess length
and remove V2' of insul.ation.

D. Secure the screw end of the ground wire. Clamp the wire as

close as possible to the window frame using the wire clamp
provided.

E. Pre-solder the ground wire's stripped end and pre-solder the

point it is to solder to on the vertical bar.

F. Pre-form the wire so it lays completely flat against the glass and

does not have any stress on it.

G. Solder the wire to the vertical strip where shown. Do not disturb

1he wire until the joint is cooled off.

H. Repeat the same procedure for the 17 foot (+) feed wire (except

route the wire to the dash area where it will later be wired to the
time). If the vehicle is a hatchback, use the wire ties provided to
secure the wire to the hatchback's hinge (allow enough slack to
open hatch completely).

CAUTION THERE MUST BE NO STRESS APPLIED TO EITHER WIRE
WHERE IT IS SOLDERED TO THE DEFOGGER AND THE WIRES
MUST BE CLAMPED TO THE WINDOW FRAME AS CLOSE TO THE
SOLDER POINTS AS POSSIBLE.

~

CLAMP

WINDOW
TRIM

-

PRE-FORM WIRE
(NO STRESS ON WIRE)

PRE- TIN WIRE

NEGATIVE & POS.
WIRES SOLDER IN
SAME MANNER

STEP 12. (WIRING THE SYSTEM)

A. Select mounting location for switch assy. on a smooth non-

textured flat area of dash easily accessable to the driver. Check

behind dash for any obstructions. .

B. Drill a 5/16" diam. hole to route the switch wires through.
C. Clean the dash area where the switch will mount to with alcohol

to remove any grease or wax.

D. Route the five wires (from the switch) through the hole in the

dashboard.

E. Remove paper liner on backotswitch to expose adhesive and

press switch assy. firmly against the dash. Do not disturb torS
minutes.

F. Refer to wiring diagram for connection of all wires to the timer

assy. and defogger.

G. Secure the time assy. behind the dash using the tie wraps

provided. Do not allow the timer to hang free or the wiring may
pull out

STEP 13. (SELECTING THE PROPER FUSE)

A. This package contains two fuses (one 10 AMP and one

AMP). One of these is to be installed in the receptacle of the
FUSED FEED wire.

B. All grids under 10 AMPS require the 10 AMP fuse. All grids over

10 AMPS require the 20 AMP fuse. Once selected, install the
proper fuse.

STEP. 14. (TESTING THE SYSTEM)

A. Turn on the vehicle's ignition switch and start en.gine.

B. Turn on the defogger switch and note the time. Verify the light in

the s.witch is on.

C. Wait at least 30 seconds, then feel the OUTSIDE of the window

for heat. Check from top to bottom to insure all bars are heating.

D. The timer should automatically turn off the defogger in 5 to 10

minutes.

E. Once the timer has completed the cycle and turned off, turn the

defogger on again. Verify the light is on and then turn engine off.
The defogger light must go out Verify the defogger is not h&ating

up.

STEP 15. (COMPLETE THE INSTALLATION)

A. Check all defogger bars for proper adhe!;ion to the glass (if any

signs of separation has occurred, repeat the smoothing process

described earlier).
B. Check that all wires are properly routed and are well concealed.
C. Clean up the rear deck area and remove any solder drops or

waste materials.
D. Use an ammonia dampened, soft cloth to clean the window by

using gentle horizontal wiping motions.

E. Remove all guide lines to the outside of the window and clean

outside of window.

F. Place owner's manual in glove box.