Cartek GT User manual

USER GUIDE AND INSTRUCTIONS JULY 2016

CONTENTS
INTRODUCTION PAGE 1
SPECIFICATION PAGE 2
SAFETY NOTES PAGE 3
INSTALLATION
FITTING PAGE 4
SWITCH CONNECTIONS PAGE 5
ENGINE KILL CONNECTION PAGE 6
FINAL CONNECTION PAGE 7
ADDITIONAL WIRING CONSIDERATIONS PAGE 8
MULTILINGUAL WIRING DIAGRAMS PAGE 9
FAULT DIAGNOSIS PAGE 10
CONTACT INFORMATION
Unit 25, Mitchell Point
Ensign Way, Hamble
Southampton
SO31 4RF
UNITED KINGDOM
[phone]
[e-mail]
www.CARTEKMOTORSPORT.com

INTRODUCTION
1
The Battery Isolator GT is a fully electronic ‘master/kill switch’ system designed specifically for
race car applications. This system contains no moving parts and the solid construction provides very high
resistance to shock, vibration, water and dirt. Using the latest MOSFET technology this isolator provides safe,
spark-free isolation of the vehicle’s battery and engine electrics in accordance with FiA safety regulations.
PRINCIPLE OF OPERATION
The unit contains two isolating/switching circuits. The first breaks the connection between the negative side
of the vehicle’s battery from chassis/earth, thereby disconnecting the battery from all of the car's electrical
systems, while the second cuts electrical power to the engine ECU or ignition system forcing the engine to
stop and electrical power generation by the alternator/generator to cease.
Alternator run-down protection is incorporated.
The electronic isolation circuits are controlled by a microprocessor and incorporate various safety systems
including over-temperature and over-current monitoring. The microprocessor also monitors the kill
switches/buttons for instant activation while eliminating false triggering. The unit will instantly trigger into
isolation mode when any of the kill buttons are struck or on detection of any break in switch wiring circuits.
The Isolator also incorporates an LED which displays status as well as fault codes.

SPECIFICATION
Typical installation
2
Size: L = 92mm, W = 50mm.
Weight: 140g.
Battery negative terminal: M8 stud.
Positive power terminals: M6 stud.
Operational Voltage: 7v - 18v.
Current consumption: 50mA ON, 7mA OFF
Battery negative switching current: 600A cranking, 2000A surge
Positive power switching current: 30A.
Operating temperature: -10°C - +85°C.
Storage temperature: -40°C - +125°C
Technical Details
+
+
CHASSIS MOUNTED
CLOSE TO BATTERY
B
A
T
T
E
R
Y
P
O
S
I
T
I
V
E
+
+
F
U
E
L
o
r
I
G
N
3
0
A
m
a
x
B A T T E R Y
I S O L A T O R
B
A
T
T
E
R
Y
N
E
G
A
T
I
V
E
-
-
M O T O R S P O R T . c o m M A D E I N U . K .
FUEL / ECU / IGNITION
POWER FEED
FOR ENGINE KILL
INTERNAL ON/OFF
BUTTON WITH
INTEGRAL LED
EXTERNAL KILL
BUTTON
CAR BATTERY
VEHICLE
ELECTRICAL
SYSTEMS
+
-
ALTERNATOR STARTER MOTOR
BATTERY ISOLATION
VIA NEGATIVE TERMINAL
30A max

SAFETY NOTES
●Please read through the Instructions thoroughly before installing on your race car. If not installed correctly
then damage may occur to the Battery Isolator.
●The Battery Isolator MUST be fully connected before starting the engine. If the terminal marked 'FUEL or
IGN' is not properly connected when the engine is running then damage to the Battery Isolator may occur.
(Cars without alternators do not apply).
●Do not use the Internal Button for any other application, it is designed specifically for use with
CARTEK Battery Isolators ONLY.
●It should be noted that this device does consume a very small amount of power even when switched
OFF. If the car is fitted with a small capacity battery then it is recommended that the battery be
disconnected if the vehicle is not to be used for a long period of time.
●The Isolator must be removed if any electric welding is being carried out on the car.
●When using a Battery Charger or an external starter/booster battery then it is important to connect both
terminals directly to the car battery. DO NOT CONNECT THE NEGATIVE LEAD OF THE CHARGER OR
EXTERNAL BATTERY TO THE CHASSIS. THIS MAY CAUSE DAMAGE TO THE BATTERY ISOLATOR.
3
MOTORSPORT IS DANGEROUS.
THIS PRODUCT IS DESIGNED FOR MOTORSPORT USE ONLY AND SHOULD NOT
BE USED ON ROAD/STREET VEHICLES OR ON PUBLIC HIGHWAYS.
NO WARRANTY IS MADE OR IMPLIED REGARDING ANY CARTEK PRODUCTS TO
PROTECT USERS FROM INJURY OR DEATH.
USER ASSUMES ALL RISKS.
+
-
+
-
EXTERNAL
BATTERY
+
-
DIRECT TO CAR BATTERY
+
-
+
-
EXTERNAL
BATTERY
+
-
TO CHASSIS

B
A
T
T
E
R
Y
P
O
S
I
T
I
V
E
+
+
F
U
E
L
o
r
I
G
N
3
0
A
m
a
x
B A T T E R Y
I S O L A T O R
B
A
T
T
E
R
Y
N
E
G
A
T
I
V
E
-
-
M O T O R S P O R T . c o m M A D E I N U . K .
INSTALLATION
Step 1. FITTING
The Isolator should be mounted directly to the vehicle’s metal chassis close to the vehicle’s battery but
away from any high temperature sources.
The Isolator should be mounted securely with unpainted screws/bolts to provide good electrical contact
with the chassis.
If mounting directly to a metal chassis is not possible then an 'earth' cable can be used to connect the
metal casing of the Battery Isolator to a suitable point on the chassis or engine block.
4

+
+
B
A
T
T
E
R
Y
P
O
S
I
T
I
V
E
+
+
F
U
E
L
o
r
I
G
N
3
0
A
m
a
x
BATTERY
I S O L A T O R
B
A
T
T
E
R
Y
N
E
G
A
T
I
V
E
-
-
M O T O R S P O R T . c o m M A D E I N U . K .
INSTALLATION
Step 2. SWITCH CONNECTIONS
The Isolator can be controlled by any number of on-off/kill switches although the usual configuration is one
internal on-off button and one external kill button.
The internal switch needs to be of a latching type, either toggle or pushbutton, such that the ON position
makes the circuit while the OFF position breaks the circuit. When using the internal pushbutton
switch with integrated LED, it is important to observe the polarity, i.e. Red to Red, Black to Black.
The external kill switch should be of the non-latching, momentary action, normally-closed (NC) type and
connected across the two Blue wires of the external switch circuit. If required, multiple kill switches/devices
can be incorporated by connecting in series. If only a single internal on-off switch is to be used with no
external switch then the external circuit needs to be complete by joining the two Blue wires together. If any
wire connection becomes broken due to fatigue or accident then the Battery Isolator will automatically
switch OFF killing the engine and disconnecting the battery.
WARNING: Do not test the Internal Button by passing power through it, this will damage it. It will only
work correctly when connected to the Battery Isolator.
+
+
INTERNAL ON/OFF
BUTTON WITH
INTEGRAL LED
EXTERNAL KILL
BUTTON
ADDITIONAL KILL
BUTTON
5
Battery Isolators allow for
an external 'kill' button to be mounted on
both sides of a race car for instant access and
maximum safety.

+
+
B
A
T
T
E
R
Y
P
O
S
I
T
I
V
E
+
+
F
U
E
L
o
r
I
G
N
3
0
A
m
a
x
BATTERY
I S O L A T O R
B
A
T
T
E
R
Y
N
E
G
A
T
I
V
E
-
-
M O T O R S P O R T . c o m M A D E I N U . K .
INSTALLATION
Step 3. ENGINE KILL CONNECTION
For cars equipped with an alternator the Battery Isolator needs to kill the engine by cutting power to the
engine ECU, Fuel system or Ignition system. One way to find a suitable point within the car's electrical system
to kill the engine is to:
START ENGINE.
LOCATE FUSE FOR ECU OR IGNITION SYSTEM.
REMOVE FUSE TO CONFIRM SUITABILITY FOR KILLING ENGINE.
Once a suitable fuse is located then remove it permanently. The power input to this fuse can now be
connected to the Battery Isolator terminal marked BATTERY POSITIVE and the output of the fuse connected
to the terminal marked 'FUEL or IGN'.
Note : The Battery Isolator can only handle 30-40 Amps through the terminal marked 'FUEL or IGN', any
higher then the Battery Isolator will automatically shut down to protect itself from over-current damage.
WARNING: The Battery Isolator MUST be fully connected before starting the engine. If the terminal
marked 'FUEL or IGN' is not properly connected when the engine is running then damage to the Battery
Isolator may occur. (Cars without alternators do not apply).
POWER IN
12V
TO ECU/FUEL/
IGN
LOCATE SUITABLE FUSE
POWER IN
12V
TO ECU/FUEL/
IGN
REMOVE FUSE
POWER IN
12V TO ECU/FUEL/
IGN
Use cable of 30-40 Amp
capacity.
6
POWER CABLE
CONNECTION
INSULATING CAP
CABLE CONNECTIONS
DO NOT OVER
TIGHTEN NUTS
1 2
3
CONNECT TO
BATTERY ISOLATOR

INSTALLATION
Step 4. FINAL CONNECTION
Once Steps 1,2 & 3 are completed a final connection should be made from the negative terminal of the
vehicle battery to the Battery Isolator terminal marked BATTERY NEGATIVE. This connection should be made
with cable of 100-200Amp capacity and by keeping as short as possible will offer maximum weight saving of
the complete installation.
When making this final battery connection the LED on the Battery Isolator will be seen to flash 3 times
quickly and then extinguish. This is part of the power-up sequence of the Battery Isolator.
Once this final step is complete please check all connections before switching on.
When fitting or removing the Isolator always connect the battery last and disconnect first.
Here is an example of a completed installation:
Battery Negative
Cable
12V Power In Power out to ECU/IGN/FUEL
Connections to
Internal & External Buttons
Mounted
to Chassis
7

+
+
+
+
B
A
T
T
E
R
Y
P
O
S
I
T
I
V
E
+
+
F
U
E
L
o
r
I
G
N
3
0
A
m
a
x
BATTERY
I S O L A T O R
B
A
T
T
E
R
Y
N
E
G
A
T
I
V
E
-
-
M O T O R S P O R T . c o m M A D E I N U . K .
+
+
B
A
T
T
E
R
Y
P
O
S
I
T
I
V
E
+
+
F
U
E
L
o
r
I
G
N
3
0
A
m
a
x
B A T T E R Y
I S O L A T O R
B
A
T
T
E
R
Y
N
E
G
A
T
I
V
E
-
-
M O T O R S P O R T . c o m M A D E I N U . K .
INSTALLATION
For cars not fitted with alternators it is not necessary to connect anything to the terminal marked FUEL or
IGN as the battery disconnection will cause the engine to stop.
INTERNAL ON/OFF
BUTTON WITH
INTEGRAL LED
EXTERNAL KILL
BUTTON
CAR BATTERY
VEHICLE
ELECTRICAL
SYSTEMS
+
-
STARTER MOTOR
BATTERY ISOLATION
VIA NEGATIVE TERMINAL
TERMINAL
NOT USED
+
-
+
STARTER MOTOR
ALTERNATOR
CAR BATTERY
30Amps max
+
FUSE
PANEL
+
-
EXTERNAL
BATTERY
+
-
IGNITION
SWITCH
CHARGING WARNING LAMP DIODE
CUT
INTERNAL ON/OFF
BLACK
RED
EXTERNAL KILL
BLUE
BLUE
ADDITIONAL WIRING CONSIDERATIONS
If the alternator has an old style warning bulb (not LED) which is connected to the ignition switch then a
diode must be placed in series as shown. e.g. 1N5819.
8