Bushpower BP98511 User manual

BP98511
Installation Guide
Fitting the Bushpower Dual Battery Kit is relatively simple and requires tools
readily available in most home workshops. Tools required are:
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)
1. Lay out the contents of your Dual Battery Kit and check that all the
components are in the kit. You should have:
1 x Voltage sensitive relay with mounting screws
2 x 7 meter length of 8mm² twin core cable cable with Anderson plug at one end.
2 x Positive Marine type battery terminals
2 x Negative Marine type battery terminal
8 x Copper crimp lugs (2 spare)
6 x Red heat shrink (2 spare)
4 x Black heat shrink (2 spare)
1 x Insulated ring terminal
10 x 200mm cable ties
2 x Anderson Covers
1 x Antizap
1 x Battery Monitor

2. Disconnect the start battery by removing the negative terminal. Ensure ALL
accessories, lights and any other powered equipment is off and
“temporary” power is fed into the vehicle via a “memory minder” or
alternate battery.
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. Layout cable from main battery via the VSR position to the location of the
main battery.
5. Where the cable meets the position of the VSR carefully cut through the
outer sheath of the cable exposing the positive (red) and negative (black)
cable inside.
6. Cut through the outer sheath exposing approximately 15cm of cable
(remove outer sheath).
7. Cut through positive (red) cable at the centre of the splice.
8. Remove from each end of the cable approximately 1cm of outer coating.
9. Using a set of pliers crimp onto each end supplied cable lugs.
10.Connect the red positive cable from the battery to the VSR (red marking on
post).
11.Connect the other lugged cable to the other post on the VSR, twist cable so
both positive and negative wires pass through the housing of the VSR.
12.Using supplied screws attach VSR to vehicle.
13.Connect the earth” wire (small black wire) to a suitable earth on the
vehicle.
14.Run remaining cable to the rear of the vehicle avoiding moving parts and
extreme heat areas.

15.At or near to your towing hitch mount the Anderson plug and cable from
the VSR.
16.Reconnect negative terminal to battery and disconnect memory minder or
alternate battery.
17.Locate the auxiliary battery in the trailer/caravan.
18.Locate and attach the Anderson plug and 8mm Twin Core cable to the draw
of the trailer/caravan. Leave enough cable to connect to the vehicle. Run
the cable from the draw through to the auxiliary battery attaching with
cable ties as needed.
19.Cut the cable to desired length to reach the battery comfortably. Attach
supplied lugs and connect to battery terminals.
20. The hard work has been done and it’s now time to do some tests.
21.Start the vehicles engine.
22.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.
23.Ensure that the auxiliary battery is charging by checking that the voltage is
above 12.8V.
24.Turn off the engine.
25.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
Caravan and Trailer Dual Battery Kit.