Complete 12/240V Solution Fitting Instructions

Thank you for your purchase, and I hope you’ll be satisfied with your product.

If you have any queries on the fitting process please don’t hesitate to drop me an email
at James@RayneAutomotive.co.uk or visit us at www.RayneAutomotive.co.uk

Fitting

This walkthrough is based on fitting the product to a Volkswagen T4/5. However the electrical
principles and processes are the same for any 12V vehicle, the locations of components and routing
of wires may be different. If in doubt, please contact us for help.

This walkthrough also gives an idea of a standard kit, so may not apply to your exact model, for
example if you have a voltage sensing relay the split charge fitting may be slightly different. (Details
below.)

Routing

The split charge system runs from your main/engine battery through the passenger’s footwell under the step
then up across to your leisure battery mounting location when the earth, fuse board and inverter are wired
from. The 240V kit originates at the inlet/hook up socket. Then the cable runs through the consumer unit
before the wiring goes to each of your 3 pin 240V sockets. The battery charger should be plugged into the
single socket and then the eye terminals should be connected to the battery terminals (RED for Positive &
BROWN for negative).

The detail

Here’s a diagram to give an idea of how the various parts link together.
Step 1 – Route the main, long split charge lead from your engine battery through the bulkhead,
down the N/S foot well then across behind the driver’s/passenger’s seat and on to the O/S rear
wheel arch (depending on where you are mounting your leisure battery. (Leave connecting the live
lead to your main battery until last))

Step 2 – (this step only applied if you have an ignition triggered relay, if you have the voltage sensing
relay (VSR) move onto step 3.) - Run the long red relay trigger wire to your fuse board and connect it
to an ignition live, on a T4 this can be found on pin KL 15A. (pictured below) On a T5 this can be
found in the Black/Yellow wire on the back of the light switch, for all vehicles it may be possible to
connect this to your alternator warning light feed wire as this should only be live when the engine is
running.

Step 3 – Mount the split charge relay safely near the battery and run the thin BROWN (if you have a
VSR, this will be thin BLACK) relay earth wire onto the negative terminal (but at this stage do not
connect either Battery terminal to your leisure battery for safety reasons).

Step 4 – Find a good, clean, suitable earth to connect your

main leisure battery earth lead to, often the seat mount
bolts or the battery retaining clamp. If you are mounting
your leisure battery in the rear of the vehicle then the rear
seat belt mounts are good earthing points. (Note: Clean up
the face of the earth point with some abrasive paper and
then apply some electrical grease for best results.)
Step 5 - Mount your auxiliary 12V fuse board,
inverter and smart charger firmly in your
desired locations, allowing at least 7cm of
space on all sides for cooling, and then run
the wires back to the leisure battery and
connect them to the terminals. (be sure to
apply a suitable electrical contact grease to
the connections)

The 12V live connections are red, the earths

are brown. (please note the split charge
system is black, this is a positive live system.)
Step 6 – Mounting the control panel – Cut a hole in the desired position measuring 18cm x 6.5cm
this is for the control panel to mount into. Put the wiring looms through the hole then affix the
control panel. The best way to mount this is preparing the surfaces well (clean and with a good key)
and use a strong adhesive.(TIP: a small amount of hot glue works nicely here.) This gives a good neat
finish.

Step 7 – Route the

wiring looms to the
labelled
components. Mount
the earth block onto
a suitable location.
We recommend just
to the side of the
control panel as
pictured left. Then
cable clip the wiring
looms in neatly.
Step 8 – Led lights will need to be joined, they only work when wired the correct way round. If the
lights were supplied by us then the BROWN (EARTH) wire joins to the White/Black wire and the
YELLOW (LIVE) wire joins to the plain White. (although don’t worry, we’ve already wired them up for
you, simply plug and play.)

Step 8 – Wiring the fridge/sink. The Fridge requires a straight connection of the two wires when
running on 12V. The WHITE wire is the live and the BROWN wire is the earth. The water pump and
tap switch are again simple connections from our switched loom onto the components.

TIP: With all of the 12V wiring looms we recommend that you connect them with the component via
removable connectors, this is not only easier than working in confined spaces, but it may help you in
the future;
(Note: Step 9 is only applicable if we haven’t wired your consumer unit for you. However it’s
extremely important to note; that with 240V electrics, the LIVE is BROWN, the NEUTRAL is BLUE and
the EARTH is GREEN/YELLOW. ) (If you are in anyway unsure at this stage, please have a qualified
electrician complete the 240V install.)

Step 9 – Choose the mounting locations of your sockets, cut your 3 core flex to the correct lengths. It
is easier to wire the consumer unit first (as per the instructions supplied with the unit, If unsure
about this consult an electrician) bearing in mind that with 240V electrics, the LIVE is BROWN, the
NEUTRAL is BLUE and the EARTH is GREEN/YELLOW Once you have wired the unit then mount it
securely using all 4 screw holes before running the cable through to your socket locations.

Note – The RCD requires the neutral (Blue) to

be wired in the unit marked N. The MCBs
require Lives (BROWN).

Note – The consumer unit and all cables going

in or out of it must be earthed using the earth
terminals and the green/yellow earth lead
Out
supplied to take it to a known good earth.
In

NOTE: If we have wired in your consumer unit then the lengths of cable have labelling on them to
show which socket they are intended for.

Step 10 – Wire in the back of the outlet sockets, and the surface mount inlet socket (pictured below)
Once wired all of the sockets should be securely mounted in the desired locations. The surface
mount socket must be accessible to plug in your hook up lead. We normally locate them in the
engine bay or the rear fog light so you can stay hooked up and lock your van.
Step 11 – Once you have wired all of the sockets and installed the split charge kit you can fix the
thick black live cable onto the engine battery.

Step 12 – Have the entire electrical install checked over by a qualified electrician before connecting
any 240V input. Once the electrician has completed the assessment you are free to connect the
Leisure battery earth strap to the battery.

Step 13 – once the electrician is satisfied with the install, you are free to enjoy your new camping
experience and the freedom it brings. Put the kettle on, you’ve earned it.

Note/warnings

Loom should be checked regularly for abrasion and rubbing against the car and itself. Any abrasion should be treated and prevented. All
sockets/relays/units must be secured and firmly onto a suitable base using all mounting points.

Inverters and chargers must be mounted with the recommended amount of space around them to allow sufficient cooling.

In the event of any product failure cease usage of all wiring and remove the leisure battery earth strap.

The inverter, although marked 1000W continuous, for best results use components of up to only 600W. Please use only the kettle
provided and nothing of a higher power, always check power usage before using the inverter, always switch it off after use.
Each fuse in the auxiliary fuse box is rated to 10A only, for components with a higher drain, the power should be taken directly from the
leisure battery ensuring the correct fuse is utilised.

Once fitted, please ensure you have a qualified auto electrician check the fitting before use, also repeated inspections to ensure maximum
safety are recommended. We accept no liability for the misuse or poor fitting/maintenance of this product or any effects caused from ill
practice.