Bushpower 140AH Dual Battery Kit

Bushpower Dual Battery Kit - 140 Amp Smart Isolator with BONUS Battery Tester

This kit is everything you will need to wire up your dual battery system to your vehicle. The elements in the kit are of the highest of quality with 100% australian made oxygen free solid copper cable, marine grade terminals and stainless steel bolts and nuts.

Featuring the new 140A voltage sensitive relay, the Bushpower designed smart isolator detects when your main battery is fully charged and automatically begins charging the auxiliary battery.

The kit is extremely easy to install and comes with a complete installation manual, read our installation guide below.

Dual Battery isolator is hermetically sealed so it is perfect for your 4x4, caravan or camper trailer.

The entire kit is 100% Australian Made and backed with a 2 year warranty!

Cut In	13.3V
Cut Out	12.8V

Contents of Box

• 140A Bushpower Voltage Sensitive Relay
• 6m of 16mm² Double Insulated Weldfex Cable
• 1x B&S 600mm Earth Cable
• 2x Positive Heavy Duty Brass Battery Terminals
• 1x Negative Heavy Duty Brass Battery Terminals
• Copper Lugs and Heat Shrink to finish
• Cable Ties
• Instruction Manual

Fitting the Bushpower Dual Battery Kit is relatively simple and requires tools
readily available in most home workshops.

Tools required:

a) Cutting pliers, side cutters or Stanley knife to cut and strip the cable
b) Crimping tool or electricians pliers for terminal crimping
c) Spanner set, socket set or shifting spanner
d) Philips screwdriver
e) Hairdryer or lighter for heat shrink
f) Drill and 3.5mm (9/64) drill bit
g) Multimeter or voltmeter (optional)

These instructions assume you have purchased and mounted your auxiliary battery (preferably a deep cycle) in your vehicle.

1. Lay out the contents of your Dual Battery Kit and check that all the components are in the kit.
You should have the following:

1 x 140 Amp Bush Power Voltage Sensitive Relay
6 x Metres x 16mm2 Double Insulated Weldflex Cable
1 x B&S 600mm Earth Cable
2 x Positive Heavy Duty Brass Battery Terminals
1 x Negative Heavy Duty Brass Battery Terminals
Copper Lugs and Heat Shrink to finish
Cable Ties
Easy to read and understand instructions

    2.     Disconnect the start battery by removing the negative terminal. 
   
3.     Select a location for the Voltage Sensitive Relay that is easily accessible and will not have the cables running near exhausts or turbochargers and is preferably close to the start battery.

    4.     Remove the lower mounting plate from the VSR to use as a template and mark the position of the four (4) holes
to be drilled. Drill the holes using a 3.5mm (9/64) drill bit.

    5.     Secure the top right and lower left holes of the base with the short 4mm screws.

    6.     Take the 6 metre length of red cable, which has been lugged at both ends, and starting from the centre of the mounting plate run the cable to the positive terminal of the start battery being careful to keep the wiring away
from any moving parts and preferably running the cable along the inner guard and firewall. Cut the cable to length.

    7.     Repeat the above process but this time go to the positive terminal of the auxiliary battery.

    8.     Strip the un-lugged ends of both cables back 15mm, fit the lugs and crimp in place with crimping tool or pliers, making sure the connection is secure. If you prefer you can also solder the cable to the lug.

    9.     Slide the heat shrink over the lug and heat with a flame or hairdryer until secure.

    10       . A ttach the insulated ring terminal to the black wire on the VSR. This is an earth wire and it is important that it has a secure and clean (Bare Metal) contact. If possible select a nearby bolt or screw that is earthed to the body.

11. Attach both red cables to the VSR. The cable from the start battery goes to thestud on the VSR with the painted RED DOT and marked “Positive + Sense Batt”. The cable from the auxiliary battery goes to the unpainted stud and marked “Positive + Second Batt”.
Note – You may have to widen or cut out the slots in the housing to ensure the cable fits through.

12. Mount the VSR to the bottom plate and fix with the two (2) longer 4mm screws.

13. Secure the black earth lead on the VSR to the selected earth point.

14. Fit the Positive (Red) battery terminal and the Negative (Black) battery terminal to the auxiliary battery and tighten securely
(not over tight).
 
15.  Select a nearby body bolt or drill an 8mm hole and secure one end of the 24” (61cm) black earth cable for the auxiliary battery, make sure to have a secure and clean (bare metal) connection.

 16.  Secure the other end of the black earth lead to the negative (black) terminal of the auxiliary battery.

 17.  Connect the red lead from the VSR to the positive terminal of the auxiliary battery and then secure the cable using the cable ties.

 18 . Be fore fitting the supplied battery terminal to the positive of the start battery, check the type of the existing battery terminal and if it has a stud and nut on the terminal to secure the existing wiring connect to the existing terminal.

19. Connect the red cable from the VSR to the positive terminal of the start battery and secure the cable
using the cable ties.

20. Re connect the start battery earth cable. The hard work has been done and it’s now time to do some tests.

21. Test for a proper earth on the auxiliary battery by placing a voltmeter across the positive and negative terminals and take a reading. Remove the negative probe and place on an earth point on the body or engine (not the point the earth cable is mounted), both readings should be the same. If the readings are not the same check the earth cable has clean and secure mountings.

22. Start the vehicles engine.

23. When the starting battery’s voltage is above 13.3V the relay will close automatically and allow the auxiliary battery to be charged. This is indicated by the red light on the left hand side of the VSR front panel being illuminated.

24. Ensure that the auxiliary battery is charging by checking that the voltage is above 12.8V.

25. Turn off the engine.

26. Check that the VSR disengages when the start battery’s voltage falls below 12.8V. This can take some time so to speed up the process turn on the headlights or leave the door open and interior lights on.

If the VSR works as per the above tests you have successfully installed the Dual Battery Kit.