Electrial Draw

Presumably the gloves and vest are just passive and the control is elsewhere?

If the gloves are just passive what exactly is the failure?

We need more info...circuit diagram ideally, especially of the 'failed' part.

It should be relatively easy to isolate the area of the fault.

If the system is controlled by a microcontroller then there could be spikes getting through and damaging it.

What causes the gloves to fail, the heat strips burn open, wear and flexing cause an open circuit ?

Good luck, James

Is the splitter just a simple parallel connection?

Is the controller variable [voltage, current] or simple on off?

Are the heating elements simple resistive?

Any difference [vendors] in the connectors?

Any discoloration of failed connectors?

You should check for the fault on the table with both batteries and vest/gloves removed from the vehicles , see if failiure happens , you can rectify there whether controller , Y-spliter , wires ,check for max ratings of coils in gloves /jacket are failing , if no than look for static charges produced by vest and gloves high enough to cause malfunctions , if every thing okay , check for vehicle ,battery terminals when reving for surges ,spikes , over voltage and all that , try regulation before controller .

I concur with all the other replies. Need some serious troubleshooting here, can't give yourself a "black-eye" with what sounds like a good marketable product....I'd be interested myself.

Motorcycle alternators aren't the strongest "tools in the shed", so it's unlikely that its responsible for "killing" the gloves.

Did you say that when the gloves do NOT work thru the controller and cable, that they WILL work when connected directly? If so, the problem seems to be localized.

Does the controller have separate outputs for a twin circuited splitter cable? Could it be that the controller intermittently or permanently "craps out" on the one output?

Or is it a single output, which would lead you to a physical connector pin problem....

Thanks for the reply guys

Please find the attached connection layout below.

yes, there is variable controller to control the heat in gloves and vest. it do have a inbuilt 16F series micro controller. the controller seems to be working fine w.o any blank outs.

ye, its just a simple parallel connection. well the controller has a display that shows the heat level from 0-9.heating elements are resistive. well yes the gloves and harness are manufactures by two different sources. no discolorations found in the connectors.

i did conduct a on- table test and everything seems to be fine. in fact i tried with all possible connecting methods. as i said earlier have no clue about surges and spikes occurring in bikes. at d worst case if thats d problem, would it be possible to fit in some protection circuit?

well yes the gloves and vest seems to work fine when connected directly to the battery. but the y-splitter is just a simple cable. whats causing it to fail? Please refer the attached image.

Here's what I'm thinking. How about make a "test cable" to be inserted in between the the Y-splitter cable and their individual outputs to the gloves and/or vest. This test cable is made to allow you to measure "in-circuit" voltage and current flow. This way, you could see if the present operating parameters are within acceptable levels of both the controller and the apparel. I suppose you have an idea of the safety margins you'd need for devices doing "hard work" ( resistance heating ). A "swag" margin is 80% max.

If this reveals nothing, you might question the integrity of the apparel. Vendors often exaggerate the tolerances / output / efficiencies of their products.

I'm probably being dense here, but I'm still uncertain what fails:

I'm assuming that it is the gloves themselves - that when you put a new pair of gloves in the system using the same splitter, they are (temporarily) OK.

What are the symptoms as the gloves fail - do they perhaps overheat and then stop heating?

One remote possibility is if this is a pulsed power controller, that the pulse frequency just happens to hit a resonance of the leads and the gloves when the loading is exactly wrong.