INSTALLATION
Fitting is very simple; the following is an abstract of the instructions in every kit. Click here to download the full Instructions as a PDF file
Tools
For surface mounting, the only tools needed are:
A hand or rechargeable drill, 1.6 mm (1/16") twist drill for the wire-entry hole, twist drill(s) to suit any additional fasteners to be used to mount the case, small (3 mm) electrical screwdriver, 'Pozidrive' No 1 point screwdriver for the case screws.
For flush (panel) mounting, in addition to the above you will need:
3.2 mm (1/8”) twist drill for the case screw holes, jig or pad saw plus a suitable drill to start it, a file or rasp to clean up the edges of the cut-out.
Mounting - When deciding where to put your VoltWatch, you will want to put it somewhere relatively conspicuous so that it is a constant reminder. As a bonus, VoltWatch can also act as a useful ‘night-light’ - the green glow from the LEDs is enough for most people to see to move around down below without spoiling their night vision.
Flush Mounting - VoltWatch can be flush mounted in an instrument panel up to 3.5 mm thick by sandwiching the panel between the case front and back. Longer screws are available for panels 3.5 - 9 mm thick; please specify when ordering. Don't discard the case back as it protects the electronics. Open the case by undoing the four stainless screws on the front. A rectangular cut-out 37 x 68 mm is required. First mark out the opening (“measure twice - cut once” as my Dad used to say, and don’t forget to check for clearance behind) cut the opening slightly undersize and clean-up to the marks. Offer up the VoltWatch unit (right way up!), carefully mark and drill (3.2 mm, 1/8”) the screw holes. Click here to see a sequence of photos.
Surface Mounting - The case back can be drilled in the base or sides for surface mounting with screws or other fasteners as required.
General - It is good practice to arrange the wire entry so that any drips can’t run down the wires onto the bared ends. The edges of holes, nuts and screw heads must be at least 8 mm from the joint face of the case to avoid fouling the electronics unit. Lightly chamfer wire entry holes to remove sharp edges and burrs. Don't over-tighten the case screws, the plastic (ABS) can't seize to the stainless screws but does have limited strength. Replacement case backs are inexpensive if you do have a disaster.
Connections - The wire supplied (a length each of red and black) has a low current rating so each positive connection should be protected by a 100mA fuse (not circuit breaker) as close as possible to the battery switch. Suitable water-resistant fuse-holders with fuses, as in the Twin Battery Kits are available separately. Connection is to the screw terminals on the back of the electronics unit; connect red to positive (marked + on the circuit board), black to negative (-). Strip 10 mm of insulation from one end of the wire, twist together the bared strands, fold in half and, if possible, tin with solder. Leave enough spare wire at each end to allow for reconnection in the future.
Twin Battery Kit - On the premise that one battery is dedicated to engine starting, and the service/domestic battery (bank) is to be continuously monitored by VoltWatch, the engine start battery leads an easy life and only needs an occasionally check. You may find the recommendations under Choice of Batteries in Useful Info are informative. Please also refer to the circuit diagrams - the switch, pair of fuse-holders, fuses (plus a spare), and extra connection wire are all included in the kit. Fit fuse-holders as close as possible to battery switches and support them. First make the negative connection from VoltWatch to the common negative between the batteries.
Separate Battery Master switches: Fit fuses last to remove the risk of blowing the fuses by an accidental short. Connect terminal 1 on push switch to VoltWatch, terminal 2 to the starter battery switch and terminal 3 to the service battery switch.
1-2-Both switch: On the positive side, first connect VoltWatch to terminal 1 on the push switch. Then make up the connections (complete with fuse-holders and fuses) from terminals 2 and 3 of the push switch to the battery switch, but DON’T connect either of them to the battery switch yet. To identify the battery switch terminals, turn it to ‘1’ (presuming that 1 is the engine start battery) and start the engine. Touch the bare of the end of the wire from terminal 3 to each of the battery switch terminals in turn. The two terminals showing a ‘charging’ voltage on VoltWatch are the ones to connect to - note which they are. To identify which is which, stop the engine and turn the battery switch to ‘Off’. Test those two terminals again - connect the the wire from terminal 3 to the one that gives no reading, and the other wire (from terminal 2) to the second of these two terminals. Turn the battery switch to ‘2’, the normal position when not charging, and check the operation of VoltWatch.
Charging and operating regime - you may find this section in Useful Info is informative.
