Date: Sun, 31 Jan 1999 17:48:18 -1000
Reply-To: Peter Zendzian <peterz@GTE.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Peter Zendzian <peterz@GTE.NET>
Subject: Re: Flash Alert! Dual Battery Relay
Content-Type: text/plain; charset="iso-8859-1"
Just some relay info for everyone. I haven't done it yet, but I will as
that part of my camper conversion is ready. there are heavy duty relays
that are capable of 90+ continuous amps available at West Marine, or just
about any auto, R/V, or marine supply. I mentioned West Marine because they
usually have them on their shelf for about $30.00. This type of relay
should solve any type of battery problems out there.
Pete
peterz@gte.net
83.5 vanagon (quasi camper)
>Hi Phillip,
>You asked:
>What would it take to use a higher amp. relay or manual switch?
>How would these be set-up?
>
>My opinion:
>1) A manual batt. switch can give you more flexibility.
>You can switch between different batteries.
>Drawback, one always has to switch back and
>forth, to use the aux. batt., or to charge the aux batt.
>The vanagon "Adventurewagen" has such a system.
>It can be more expensive and time consuming to install.
>
>2) A battery cut-out relay is very simple and relatively
>inexpensive to install.
>I guess Larry Johnson already answered that question.
>I will try to give you some more details.
>It would be helpful, to take a look at a Bentley diagram,
>for a dual batt. setup in a vanagon. In the diagram you can
>see the aux. batt. and the main batt. It actually is a very simple
>diagram. Once you spent some time looking at it, you are ready
>to go to the vanagon and do the installation.
>Things you might need:
>
>1) A section of # 8 gauge or better # 6 gauge wire, long enough
> to go from one battery to the other.
> VW uses a 6.0mm that is about a # 8 gauge wire.
> The distance between the two batteries is not that much.
> #8 ga. is good for up to 15 feet and 50 Amp charging.
> You also need a short section of # 18 gauge wire.
>2) one 12 volt heavy duty 30 or 40 amp relay.
>3) one 12 volt 30 amp fuse or optional 12 volt 30 amp circuit breaker.
>4) at least 4 ring terminals, for the #8 or #6 wire, to connect
> the wire to the relay and the fuse.
>5) one batt. ground strap. For the aux. batt.
>6) one batt.-terminal-connector to use with the # 8 or #6 wire,
> for securing it to the + terminal on the aux. batt.
> You also need a connector to fasten the other end of the wire
> to the + terminal on the main batt.
>7) Two quick splice connectors for small #18 ga. wire,
> and two female connectors for # 18 ga wire. The female
> connectors have to fit the small terminals on the new
> "Battery-cut-out relay".
> (you need this to connect the new battery-cutout-relay
> to terminals 85 and 86 on the existing refrigerator-12 volt-
> heater-relay)
> If you look carefully, you will see tiny numbers stamped
> next to the contacts on the frig. relay.
> See diagram for camper with 3 way frig in Bentley.
> These wires are used to trigger the new relay, that is, to
> make the battery cutout relay go on and off.
>8) some plastic ties, and electrician's tape and
> a few sheet-metals screws.
> The sheet-metal screws are for fastening the new relay in place.
>9) a couple of rubber grommets, for routing the large wire
> through sheet metal.
> My guess, total cost of all this maybe 50 to 70 .
> Optional:
> A section of flexible conduit to protect the wire when routing under
> the vanagon. I usually use a piece of clear vinyl hose, to protect the
> wire from chaffing, where it contacts the body. If the hose is
> watertight, make sure it will not collect water.
> Buy some plumber's putty, to seal holes you might have to drill, to
> route the wire.
> I wonder what I forgot. Oh... the aux. battery.
> To put all this stuff together is another post.
>
> Note: Disclaimer: You should double-check everything
> with a professional auto electrician. I might have made a mistake.
> In my own westy, I installed a battery isolator, so I have no
> long-term experience with the relay setup.
> But the relay installation is fairly simple and straightforward.
>
> Also I encourage listmembers to contribute to this collection
> of items needed or tricks or tips,
> if you have some experience with dual battery setups.
>
> Have fun.
> Harald
> 90 westy.
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