Date: Fri, 29 Jan 1999 10:49:32 -0800
Reply-To: harald_nancy <harald_nancy@EARTHLINK.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: harald_nancy <harald_nancy@EARTHLINK.NET>
Subject: Re: Flash Alert! Dual Battery Relay
Content-Type: text/plain; charset=ISO-8859-1
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.
| 
