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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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