Dual battery set up advice

I'm going to run a dual battery on my 2002 toyota hilux soon. I have all the wiring, battery, isolator and so on. I have a turbo diesel hilux so the battery is on the same side as the turbo and was wanting to put the battery in my tray. Was just wondering if anyone has any ideas on the best way to get to the positive wire from the engine bay to the tray. Be really appreciated!
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Reply By: Bazooka - Sunday, May 03, 2020 at 16:46

Sunday, May 03, 2020 at 16:46
Not exactly what you were asking but THIS
or
THIS might help ?

Google will turn up plenty more.
AnswerID: 631345

Reply By: Bushranger1 - Sunday, May 03, 2020 at 17:03

Sunday, May 03, 2020 at 17:03
G'day.
I had a Hilux & installed 2 deep cycle batteries in the tray.
Ran Pos & neg on top of the chassis rail then thru grommet into the tray. Covered the wires with split cable protector as well.
Make sure you use thick wire to avoid voltage drop & ensure good solid connectors. I had circuit breakers under bonnet & in tray.
Also run the ground (neg) back to earth point under the bonnet.
Rubber mounts on tray make a bad ground return hence running back to under bonnet ground.
Just did the same in my new Dmax but used Dc/Dc charger this time.
Cheers
Stu.
AnswerID: 631346

Reply By: swampy - Sunday, May 03, 2020 at 17:06

Sunday, May 03, 2020 at 17:06
HI
Running an AGM battery is best done in the tray body because most donot like heat and the size would be decent 100--120Ah compared to running a typical 80ah or smaller in the engine bay .
Use 13mmsq or 6 b&s cable prefer twin core sheathed in split tube conduit . Wrap the flex conduit in tape . Zip tie accordingly .
AnswerID: 631347

Reply By: HKB Electronics - Sunday, May 03, 2020 at 18:07

Sunday, May 03, 2020 at 18:07
As above, 13mm2 min, VSR, fit a booster diode if required to up the charge voltage.
AnswerID: 631348

Reply By: RMD - Sunday, May 03, 2020 at 19:03

Sunday, May 03, 2020 at 19:03
Patt96
I see bushranger mentioned using circuit breakers. While they are a good item to have in one line of the battery circuit, for safety of normal use of loads they only need a rating a percentage above any combined load. However, if a switched solenoid or VSR is used in the charge line, if the Aux battery is quite discharged the inrush current may trip the circuit breaker and NO charge actually happens. Two ends of the spectrum to be considered there.
AnswerID: 631350

Follow Up By: Bushranger1 - Sunday, May 03, 2020 at 19:15

Sunday, May 03, 2020 at 19:15
Good point there re circuit breakers.
Never had them trip but I have a in line battery monitor so can see straight away the voltage going to & from the batteries.
Forgot to mention that additional monitor & mate has one that goes thru bluetooth to the phone.
Cheers
Stu
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FollowupID: 907342

Follow Up By: Bushranger1 - Sunday, May 03, 2020 at 19:25

Sunday, May 03, 2020 at 19:25
One more thing. The circuit breakers I used were around 50 or 60 amp to deal with a dead short in main wiring.
All other circuits are individually fused with the automotive 10 & 15 amp fuses as required.
Cheers
Stu
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FollowupID: 907343

Follow Up By: RMD - Sunday, May 03, 2020 at 20:07

Sunday, May 03, 2020 at 20:07
Bushranger, you mean the monitor is reading the amps , I think. The voltage simply takes care of itself.
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FollowupID: 907344

Follow Up By: Bushranger1 - Sunday, May 03, 2020 at 20:32

Sunday, May 03, 2020 at 20:32
Can read volts & amps.
The volts give me an idea of the state of discharge when stationary for a while.
Also lets me know at what point to setup the solar panel & watch voltage rise confirming solar or charging circuit is functioning correctly.
Cheers
Stu
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FollowupID: 907346

Follow Up By: qldcamper - Monday, May 04, 2020 at 07:38

Monday, May 04, 2020 at 07:38
Thats why I miss the fuseable link wire yazaki used to make. I blame internet forums for its demise.
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FollowupID: 907353

Follow Up By: RMD - Monday, May 04, 2020 at 11:18

Monday, May 04, 2020 at 11:18
QLD
You can reset a breaker or replace a fuse as needed, but no one carries or easily obtains a specific FUSIBLE link and so the vehicle or system is rendered inoperative. They were a really stupid idea and when they fractured on early Toyota’ they left the alt charging the system but not attached to the battery, so devices got a nice surge of 80 v or so and subsequent current forced through them to destroy them. What a nice thing to happen. I have had experience with fusible links causing the above.
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FollowupID: 907357

Follow Up By: qldcamper - Monday, May 04, 2020 at 11:44

Monday, May 04, 2020 at 11:44
Yep when used in applications that they were not suited for they would fail as would anything else. They were used as a main fuse built in to the harness of Holdens from 1964 till the VB commodore and had so little trouble very few people even realised they were there.
The alternator on these vehicles were not running through it, in fact they were not fuse protected at all.
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FollowupID: 907359

Follow Up By: HKB Electronics - Monday, May 04, 2020 at 12:41

Monday, May 04, 2020 at 12:41
Agree withqldcamper, fusible links for under bonnet, the wire type, they have been used for a long time in cars and cause few issues. The new plastic plug in types not so good. If you have made up fusible links for your project then spares aren't an issue as you would make your own spares.

I would recommended either fusible links (wire type) or bolt down fuse fuses simialr to the below, never had any issues with them:

bolt down fuse


Terminal fuse
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FollowupID: 907361

Follow Up By: qldcamper - Wednesday, May 06, 2020 at 08:17

Wednesday, May 06, 2020 at 08:17
Another little advantage I use a lot is the fact that fuseable link wire runs warm to hot by nature ( and yes I understand that means voltage drop but it is neglagable ) so by a touch you can get a feel for how hard the system is working without the need for any instruments.
I run a manual reset cct bkr at the crank battery end and the output from the BCDC and a 4 inch black fuseable link at the ACC battery.
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FollowupID: 907396

Follow Up By: Bushranger1 - Wednesday, May 06, 2020 at 12:16

Wednesday, May 06, 2020 at 12:16
Yea fuses or breakers work if you spec them right.
Think I like being a bit more scientific than how warm the fuse is running to judge the system performance.
Volts & Amps meter hard wired in tell you at a glance what is happening. If your really up with technology then as I said earlier you can read via bluetooth to your smartphone.
Cheers
Stu
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FollowupID: 907397

Reply By: Patt96 - Thursday, May 07, 2020 at 19:30

Thursday, May 07, 2020 at 19:30
Just had another question about the isolator. Am i able to place it in the back of the near the second battery
AnswerID: 631397

Follow Up By: Member - shane r1 - Friday, May 08, 2020 at 08:52

Friday, May 08, 2020 at 08:52
Yes,
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FollowupID: 907439

Follow Up By: Allan B (Sunshine Coast) - Friday, May 08, 2020 at 09:44

Friday, May 08, 2020 at 09:44
.
That should be a conditional "yes".

If your isolator is a solenoid of the voltage-sensing type (as distinct from ignition-controlled) then there may be a problem with locating it remote from the alternator. Typically, the voltage-sensing isolator will energise at 13.2v and de-energise at 12.7v. When the isolator senses 13.2v coming from the alternator and connects the aux battery, current begins to flow and a voltage-drop will occur in the cabling from the alternator. If this voltage-drop is sufficient to reduce the voltage applied to the isolator below 12.7 volts then the isolator will drop out and the process will be repeated ad infinitum and the aux battery will not be charged. It all depends on the state of the aux battery and the capacity of the cabling.

It is better therefore, that the isolator is positioned close to the alternator in order to sense the applied voltage.
Cheers
Allan

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FollowupID: 907445

Follow Up By: Zippo - Friday, May 08, 2020 at 11:26

Friday, May 08, 2020 at 11:26
What Allan said, with one possible exception. IF the sensing terminal of a VSR is (or can be) separated from the "power in" terminal AND a separate line run to it from the cranking battery, then you would be able to locate it near the auxiliary battery.

Whether running that extra cable is something you WANT TO do is up to you.
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FollowupID: 907453

Follow Up By: Frank P (NSW) - Friday, May 08, 2020 at 11:37

Friday, May 08, 2020 at 11:37
Another option for a smart isolator remote from the crank battery is to use a dumb solenoid and then a small, adjustable VSR such as this one to control it. You can then tailor the cut-in voltage to suit your setup which might be affected by a so-called "smart" charging system and/or voltage drop in the cabling.
FrankP

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FollowupID: 907456

Follow Up By: HKB Electronics - Friday, May 08, 2020 at 12:04

Friday, May 08, 2020 at 12:04
May as well just buy a smart programable VSR.
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FollowupID: 907459

Follow Up By: Allan B (Sunshine Coast) - Friday, May 08, 2020 at 12:17

Friday, May 08, 2020 at 12:17
.
Considering the hassles of the options above, I would ask why on earth one would consider placing the isolator anywhere but near the alternator?
Cheers
Allan

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