Mazda Bongo Conversion Kit Fitting Instructions

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1 Mazda Bongo Conversion Kit Fitting Instructions Thank you for your purchase, and we hope you ll be satisfied with your product. If you have any queries on the fitting process, please don t hesitate to drop us an at info@rayneautomotive.co.uk or visit us at Fitting This walkthrough is based on fitting this product to a standard conversion with the leisure battery mounted in the spare battery tray on the nearside of the engine bay. The components are then designed to be mounted in a rear conversion. If in doubt, please contact us for help. Routing The split charge system runs from your main engine battery across the front panel to the nearside. This is where the voltage sensing relay will mount and the leisure battery will be located. From here the component changeover loom will run into the vehicle where the first 12v fuse box will be located, near the vehicles original fuse box. The thick red lead will run the length of the vehicle to connect to the inverter in the rear of the vehicle. All of the components will then be located in the rear, including the second fuse box. The detail Here s a diagram to give an idea of how the various 12v parts link together.

2 Step 1 Route the main, long thick black split charge lead from your engine battery through the front panel, across to the nearside of the engine bay where the leisure battery will mount (Leave connecting the live lead to your main battery until last). Step 3 Mount the split charge relay safely near the battery and run the 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 (around 45cm long with a negative battery terminal on one end) to a known good earth point, often the battery retaining clamp. (Note: Clean up the face of the earth point with some abrasive paper until you see bare metal and then apply some electrical grease (copper slip is good for this) for best results.) For more tips on preparing a good earth, please visit our blog;

3 Step 5 - Mount your auxiliary 12V fuse board (the one with the shorter lead), inverter and smart charger firmly in your desired locations, allowing at least 7cm of space on all sides for cooling, and then run the thick red wire back to the leisure battery and connect it to the terminal. (be sure to apply a suitable electrical contact grease to the connections) From the inverter the thick black lead will need to run from the negative post to a good chassis earth, this should be prepared in the same way as the earth connection for the leisure battery above. The 12V live connections are red, the earths are brown. (please note the split charge system is black with red banding, this is a positive live system.) From here, the battery charger will need to plug into your fuse board and the fuse board should be screwed onto the red terminal on the back of the inverter along with the thick red lead.

4 Step 6 Installing your component changeover loom Run the leisure fuse box from the positive battery terminal on your leisure battery into the vehicle and mount it near the main vehicle fuse box. The changeover loom then runs from the leisure fuse box (supplied) to the main fuse box under the steering wheel. Here remove the fuses for the radio, interior lights, 12v sockets, electric blinds (if applicable) etc. Plug the changeover loom into the now empty fuse spot. Ensure you put it on the out side of the fuse (that doesn t have power, usually the left). There are 5 wires in the loom, the two RED wires are for the blinds. WHITE for interior lights or cabin, YELLOW for the cigarette lighter and finally BLACK for the Radio.

5 Here's a diagram to show how the various 240V parts link together. To fuse box (Note: Step 7 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 7 Choose the mounting locations of your sockets, cut your 3 core flex to the correct lengths, allowing a little extra for a safe routing. 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.

6 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 block (pictured below left) and the green/yellow earth lead supplied to take it to a known good earth. Note The two neutral wires from each socket cable should go into the neutral block, marked with the N (pictured below left) Step 8 strip the blank end of the thick 6.0mm green/yellow main earth lead and screw it into the earth block, then take the eye terminal end down to a clean good earth and apply some electrical grease before fixing it in.

7 A fully wired consumer unit, with 2 output wires (pictured left) Note; pictured above is a completely wired consumer unit. The cables on the left are the outlets, the blue cable on the right is the inlet and the green/yellow cable is the earth wire. Note; the MCBs (miniature circuit breakers) are in their on position then the small square above the switch is RED, in the picture above, the middle switch is on, the outside two are off.

8 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 9 Wire in the back of the outlet sockets. First select the back box mounting location. Decide which way the cable will come into the back box. Select the closest breakout section of the back box and neatly make the hole in here. We would recommend that you file it smooth to avoid any scoring or damage to the cable. Once you have done this thread the back box onto the cable and strip the outer insulation back about 7cm to allow you to work on the back of the socket. Cut each of the inners to the appropriate length to reach it s screw terminal on the back of the 240v outlet socket. Then strip the insulation back to reveal bare copper. Give this a twist with your thumb and forefinger so make sure there are no stray strands that may cause injury or electrical danger.

9 From here; screw the back box onto your wall/unit and then carefully put the socket onto the front of it and fix using the screws supplied. If you have multiple sockets to be linked radially, below is a schematic of how to do this. TIP: Particularly if you have coloured sockets, it can look a lot better to cut a larger hole in your unit and then to place the back box behind the unit with the socket face on the outside or in front of the unit then fix using extra-long screws.

10 Step 10 Wiring in the Hook up/inlet socket. Similar to the outlet sockets it s important to have the cable routed and neatly pinned/cable tied in place except for the last 30cm or so, this can be done once the plug is wired in. Remove the plug from its white housing. Again remove the breakout sections in the white housing and thread the grommet onto your blue wire. Once this is done strip the outer insulation back about 7cm and strip the inner back about 2cm on each core. Twist the strands to make sure that there are no stray strands and to ensure that the screw terminal can get a good grip of the wire. Screw the wires into their respective terminals as pictured below. (please note picture is for illustrative purposes only and you must check that this applies to the socket you have)

11 Step 11 Wiring up your auto intelligent battery charger As previously we have positioned the charger so that it is well ventilated and accessible for regular inspections. The 3 pin plug should be affixed to your single 240V socket that is to be left on. The negative eye terminal is to be fastened to the chassis earth and the positive wire is to be plugged into the 12v fuse board. Remembering as these wires are 12V the RED wire is POSITIVE + and the BROWN wire is NEGATIVE -. DO NOT REVERSE THE POLARITY OF THE CHARGER AS THIS WILL CAUSE THE UNIT TO FAIL.

12 Step 12 Once you have wired all of the sockets and installed the 12v split charge kit you can fix the thick black live cable onto the engine battery. Step 13 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 14 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 travel equipment with ratings of 600W or under, 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.