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  • Wiring in AUX battery and accessories

    I'm in the process of designing my dual battery install. I want a AGM battery in a battery box (which has a cigar and hella socket on in). I want the battery box somewhat portable also when camping so I can take out the fridge and run lights etc whilst not in the car.

    I hope to have a Fusebox which has my UHF, Cigar socket, hella sockets etc wired to a load changeover relay so that when my ignition is on, the load on the fusebox is from the MAIN battery (and allows the battery charger to charge the AUX battery), and when the ignition is off the load or battery drain is from my AUX battery. I have put together a little diagram and dont know any auto sparkys to check this over. If anyone has any comments or can highlight any issue with this setup Id be glad to hear them.

    This little project is on a budget so I will be going for the ABR sidewinder DC->DC charger. http://www.sidewinder.com.au/page168aa.html It uses the ignition sense wire to start the charging process (blue wire on diagram). Ive used this to control my load changeover relay.

    [b]Silver 2008 D4D Auto GXL[/b]
    [url=http://www.pradopoint.com/viewtopic.php?f=38&t=6032]My build up[/url]

  • #2
    Re: Wiring in AUX battery and accessories

    Hi mate, you've got quite a good idea going there.You really dont need 2 fuses on the positive to the charger,if anything throw it on the neutral to the charger too. Main thing is just to choose your cable sizes with some thought..voltage drop,good joints,fuse your installation to protect your cables not your appliance...im sure you know the drill! Just calculate you maximum demand (amps) for all the gear running off the fuse box and select you cable from that info! Quick thought, i dont know if there is any inplications with having the charger running as you crank the vehicle..for example unkown voltage and current spikes off the starting battery that could effect the charger due to it starting when the ignition is turned on? the fuses are there on the cable, mayby check there is protection on the charger..in case of something unexpected! Cheers
    08 GXL Diesel Auto,ARB bar/roofrack, ATS liftkit

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    • #3
      Re: Wiring in AUX battery and accessories

      I've been thinking about this too. I am wondering if a charger/voltage booster could be incorporated with one of the traditional dual battery controllers.
      ( eg Piranha or Traxide ). Some dual bettery controller designs monitor the voltage of the main battery and disconnect it from the aux battery before it gets too low to start the vehicle. Theoretically you could put the charger on the aux battery side of that device. ( ie so the output of the dual battery controller gets boosted before it reaches the aux battery ). If that works you could get the benfits of a proper dual battery controller along with a boosted voltage to your aux. battery. This would avoid having the ignition sense and relay which would cause a short power break to your auxilliary devices every time you stopped the engine. ( as you switched from main battery to auxilliary ). For fridges etc that's not an issue but for some devices it might be.
      Cheers, Wayne

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      • #4
        Re: Wiring in AUX battery and accessories

        Thanks guys for the comments.
        Thinking late last night that since it is going to be a portable AUX battery, I would like to have a single anderson plug connection to the AUX battery, rather then have 3 negative and 2 positive cables.. just less cables that I will need to connect/disconnect when the battery is removed.

        EDIT: I have come up with another suggestion to the cabling to include a terminal block. All main cabling would be 6b&s with the accessories being small gauge wire.

        [b]Silver 2008 D4D Auto GXL[/b]
        [url=http://www.pradopoint.com/viewtopic.php?f=38&t=6032]My build up[/url]

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        • #5
          Re: Wiring in AUX battery and accessories

          2 things you haven't dicussed:

          1. How will it be retained in place, ie will it be bolted down, held down by straps etc.

          2. When you say it will be in a box - what sort of box? Normal car batteries are required to be in a sealed container vented to the outside atmosphere in order to comply with regs when located inside the passenger compartment or boot.

          If you can't do this then you might as well carry one of those booster/jump start/fridge style power packs.

          Or you could stick a second battery under the bonnet and run the fridge from this.

          I recycle ice blocks from the big orange esky and back into the engel for freezing. Engel stays in the car, keeps a cold beer on hand when away from camp. Esky keeps food and beer cold back at camp.
          Dave
          Views expressed are mine alone and are not intended to compromise the integrity of my employer nor offend those who may read such views.
          Bugger Bali, get out and see Australia before we sell it all to China.

          Comment


          • #6
            Re: Wiring in AUX battery and accessories

            He's got there that its going to be an AGM battery mate, so no dramas there! At the end of the day depending on how long he requires the battery external to the vehicle...at some stage it will require being in the vehicle again for charging, so its really a give or take thing!
            08 GXL Diesel Auto,ARB bar/roofrack, ATS liftkit

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            • #7
              Re: Wiring in AUX battery and accessories

              Originally posted by Cruisin 120
              He's got there that its going to be an AGM battery mate, so no dramas there! At the end of the day depending on how long he requires the battery external to the vehicle...at some stage it will require being in the vehicle again for charging, so its really a give or take thing!
              Yep an AGM in the cargo area in a battery box tied down. I will be placing the order soon for all this gear, I think Im ready to rock'n'roll. Pics to come..
              [b]Silver 2008 D4D Auto GXL[/b]
              [url=http://www.pradopoint.com/viewtopic.php?f=38&t=6032]My build up[/url]

              Comment


              • #8
                Re: Wiring in AUX battery and accessories

                You will need around 10G restraint for the battery. An AGM will weigh in around 30kg so what ever battery restraint you install will need to be good for at least 300kG.
                Assuming you're going to be using an off the shelf plastic battery box, I think your going to need some type of strap (most 25mm webbing is rated at 250KG) or clamp over the top of the battery & box that is boted to the OEM tie down points

                Leachy
                EX-Prado Owner

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                • #9
                  Re: Wiring in AUX battery and accessories

                  Originally posted by leachy_9
                  You will need around 10G restraint for the battery. An AGM will weigh in around 30kg so what ever battery restraint you install will need to be good for at least 300kG.
                  Assuming you're going to be using an off the shelf plastic battery box, I think your going to need some type of strap (most 25mm webbing is rated at 250KG) or clamp over the top of the battery & box that is boted to the OEM tie down points

                  Leachy
                  Thanks Leachy, your right about using a plastic battery box. Supercheap have a sale on right now, and I looked at the lower end of the boxes and they included a fairly heavy duty strap. The more upmarket box with accessory sockets wasnt in stock but I should be able to get a good look at it on Friday.

                  I am thinking about using these jaycar connectors, although I need to get down there to see if they are suitable.
                  [b]Silver 2008 D4D Auto GXL[/b]
                  [url=http://www.pradopoint.com/viewtopic.php?f=38&t=6032]My build up[/url]

                  Comment


                  • #10
                    Re: Wiring in AUX battery and accessories

                    I have been thinking about a set-up somewhat similar and considered using an Ark Power Pack http://www.arkcorporation.com/images.../powerpack.pdf(RRP$179.95) which is a battery box with an inbuilt charger and conditioner. The folks at Ark Corporation say that the Powerpack can charge from the cigarette lighter in your car, but they also say that both the cigarette socket in your car and on the Powerpack are 10amp fuse protected and if your battery in the Powerpack is very low, it will want to pull more than 10amps from your car so this might blow some fuses. Does the ARB charger and your set-up limit current in some way? I actually like the Ark concept and wonder if the current can be limited so fuses don't blow?
                    [color=#000080][b]Stephen[/b][/color]
                    [color=#BF0000]Aug 2008 GXL D4D Auto, White, Toyota Sovereign Alloy BB, Toyota Tow Bar, VIP Protector II Elect Rust Protection, Toyota Rubber Floor Mats, Toyota Cross Bars, Uniden UHF UH400SX-RM, AusGuard Cargo Barrier, TJM Snorkel, Diff/Trans/Auto Breathers, Platinum Seatcovers, Dual Batteries (Piranha Battery Tray, Redarc Isolator, Exide ED5), Maxtrax [/color]

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                    • #11
                      Re: Wiring in AUX battery and accessories

                      Originally posted by leachy_9
                      I am thinking about using these jaycar connectors, although I need to get down there to see if they are suitable.
                      I have used one of these for my fridge circuit (6B&S) off the auxiliary and it works fine. Just make sure you buy a spare fuse because if you accidentally kill one in the bush it is unlikely you will get another easily. I keep my spare in the centre console in some hollowed out styrofoam.
                      My 150 build - http://www.pradopoint.com/showthread.php?27423-A-Random-approach-to-a-Bluestorm-150-GXL-D4D-automatic

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                      • #12
                        Re: Wiring in AUX battery and accessories

                        I have been thinking about a set-up somewhat similar and considered using an Ark Power Pack http://www.arkcorporation.com/images/pd ... RRP$179.95) which is a battery box with an inbuilt charger and conditioner. The folks at Ark Corporation say that the Powerpack can charge from the cigarette lighter in your car, but they also say that both the cigarette socket in your car and on the Powerpack are 10amp fuse protected and if your battery in the Powerpack is very low, it will want to pull more than 10amps from your car so this might blow some fuses. Does the ARB charger and your set-up limit current in some way? I actually like the Ark concept and wonder if the current can be limited so fuses don't blow?
                        Charging auxiliary batteries from the standard cigarette outlets in a Prado is not a good idea. The outlets are fused at 10A but at this load the standard gauge wring will cause significant voltage drop, giving a large delta across your boost charger and reducing the current available to the battery. A boost charger running off the rear outlet in the Prado is unlikely to deliver more than 7A max. current to the battery before blowing the fuse. So even if you were able to limit the current it is going to take a lot of driving to charge the battery.

                        The Sidewinder unit does not appear have current wind down capability and the voltage selection is restricted to dip switch settings. If you want full flexibility to set the output current and voltage of a DC-DC charger you will need a Ranox.

                        This little project is on a budget so I will be going for the ABR sidewinder DC->DC charger. http://www.sidewinder.com.au/page168aa.html It uses the ignition sense wire to start the charging process (blue wire on diagram). Ive used this to control my load changeover relay.
                        This is a 3OA charger - check the max. charge rate from your battery manufacturer. A rule of thumb is the max charge rate is approx. 20% of the A/H capacity of the battery. It may become an expensive proposition to use a battery large enough to match the output of the charger and chances are it would not fit in a standard battery box.

                        Leachy
                        EX-Prado Owner

                        Comment


                        • #13
                          Re: Wiring in AUX battery and accessories

                          It's all a bit of a Ben Hur scenario when you start looking at ways to keep all things electrical running and charging.

                          I'd like a solar charger set-up but would need to spend over a grand to get a decent capacity.
                          Dave
                          Views expressed are mine alone and are not intended to compromise the integrity of my employer nor offend those who may read such views.
                          Bugger Bali, get out and see Australia before we sell it all to China.

                          Comment


                          • #14
                            ABR Sidewinder DC charger

                            Just an update, most things are installed and happily charging. Taken from my BuildUp thread

                            09/09/2009 Update
                            Well, I have a few more additions to make. Been busy coming up with a charging system for a AGM in the rear. Have since purchased a couple of new toys, Waeco CF50 dual zone, Ritar 120s battery, battery box and a whole stack of cables, conduits etc etc etc.
                            Here are some Pics:

                            ABR's version of a 3 stage DC charger. Very similar to the Ranox charger, without the bells and whistles. It comes in much cheaper then the Ranox, although a little larger, and no adjustable current output. This model I have has a nice 30A output. Quiet and fits under the passenger seat without any issues.



                            Wasn't too happy with the terminals left open for fear of shorting them out. Just dabbed a little silicone in the meantime. Will possibly look at insulating them in a different way.



                            I placed a fairly large order at ABR, including the battery box. Much better quality and bigger then the equivalent ones at SuperCrap. Added an additional 20A marine socket. Sitting inside is a Ritar120s AGM battery. Going out tomorrow to find a suitable strap to tie the battery down to the rear seat floor mounts



                            Not planning on utilising the 6 and 7th seat, I removed the passenger side seat mounting lock mechanism to make way for an area to mount my Anderson plugs used for connecting in and charging the AGM . In its place, I cut up some stud offcuts, and covered with a small bit of vinyl given to me by a chap at an auto trimmer (for free )

                            BEFORE being covered:



                            AFTER vinyl and with the Anderson plug mounted:





                            Now with the seat mount cover in its place, the Anderson plugs/cables are protected.



                            Now my setup includes a load changeover relay so that when driving, all my items such as fridge, UHF, outlets are running from the starter battery. When the ignition is off, and the AGM connected, the load is coming from the AGM. Tested and all seems to be working well. Still need to wire in the UHF and fridge,sockets etc into my Baintech distribution box. I didnt really want to cut into the trim, but with all the wiring, I didnt have much choice
                            [b]Silver 2008 D4D Auto GXL[/b]
                            [url=http://www.pradopoint.com/viewtopic.php?f=38&t=6032]My build up[/url]

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