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4x4 Gear
Dualmate Battery Management
By Simon Ward-Hastelow
Published: 6th Jun 2007
Original article: http://www.difflock.com/magazine/4x4_Gear/Dualmate_Battery_Management.shtml
 Dualmate
 info@oecinternational.com
 http://www.acecom.com.au/dualmate.htm
 Price: £235

Most of us fit additional electrical equipment at some point but unless you are careful you could find that you'll flatten the battery and be left stranded or your main battery and standard alternator will just not be able to keep up with the drain you are demanding.

The solution is to fit a 2nd or auxillary battery to take care of the additional equipment and leave the main battery purely to start the engine. The benefit of this is that you can choose a battery more suited to providing relatively low amounts of current for longer periods.

The standard and simplest way to charge the auxilary battery is via a solenoid that separates the batteries when stationary, to preserve the charge in the starter battery, but joins them together when on the move to charge both at the same time. Effectively it is just a big dumb switch that is thrown when the key is turned to connect the two batteries together.

The Interface and manual override switch (left) and standard split-charge relay (right) as fitted in the battery box of a Land Rover Defender


So far, so simple.

The problem comes when the batteries are of different types, or capacities and at different levels of charge. If the starter battery is low on juice for some reason connecting the relay will allow the starter motor to try and draw power from the auxillary battery, even if it wasn't designed to provide the massive current draw that this would trigger. If the auxillary battery is fused it will blow, if it isn't fused it'll just heat and melt the wiring unless you've fitted it with starter cable (not everyone does)

Conversely if the starter battery is fully charged but the leisure battery is flat connecting them together will allow the flat batterry to draw power from the starter. In most cases it won't draw much in the split second it takes you to turn the key but if, for some reason, you have turn the ignition on without starting (like waiting for your glow plugs to warm up) the flat battery could conceivably draw enough juice from the full starter to make it struggle when trying to start the engine.

The answer is to fit a 'smart' system that knows all this and that monitors your individual batteries and distributes the charge and power drain accordingly.

The Control Unit gives an accurate reading of the condition or voltage of the batteries down to one hundredth of a volt. Here is shows the main battery being charged at 14.14v just after the engine has started. The auxillary battery (12.75v) is not connected until 60 seconds after starting
  The Dulamate is just such an Intelligent Battery System. It will monitor the voltages and warn you (with visible and audible warnings) when something is not right and isolate the batteries when the engine is off. This unit does not 'connect' the auxillary battery for a full 60 seconds after the engine has started. This allows ample time for the alternator to replenish what has just been consumed to start the vehicle and prevents the 'dualling-battery' problem discussed earlier.

The Dualmate gives a very handy, and precise, reading of each battery's voltage. Much better than a line of green LEDs, the voltage can be measured down to one hundredth of a volt. When the drop of a whole volt can be crucial to the performance of a battery a basic green LED light is simply not a good enough indicator of what is going on.

While driving it also monitors the state of both batteries and optimises the charge to suit. So if you have a high electrical draw, like running your air con, windscreen wipers, lights and radio it will disconnect the auxillary battery and concentrate solely on keeping the starter battery fully charged.

The Dualmate also has the ability, when necessary, to deliberately override the battery isolation so that both batteries can be used to start the engine.

For our expedition vehicle we considered this unit to be just about as perfect as it could be to ensure our battery performance can be monitored and optimised whilst on the road. I know a lot of people don't like to rely on electrickery and microprocessors in vehicles that are used out in the wilds but Dualmate have thought of that. A manual override switch is also provided allowing you to disconnect the Dualmate altogether in the rare event of failure or other problem. In that case the standard split-charge relay will have to suffice but hopefully you will now have a good idea of its limitations and can take precautions accordingly.

Fitting the Dualmate

Fitting the Dualmate couldn't be simpler. First you must have a standard split-charge relay in place. (many vehicles like Land Cruisers already have these as standard but if you have a Land Rover you will need to fit one.) Then it is just a matter of fitting the relevant wires to the existing connections. (full and clear instructions are supplied)

The control interface (a box with a manual switch on it) needs to be mounted somewhere easy to reach but out of the way. In the engine bay or battery box is ideal.

The Control unit can then be mounted somewhere visible if you want to be able to see, at a glance, what your batteries are up to.

25 minutes should be sufficient to see the job done.

We give this unit a double thumbs-up!




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