SINGLE DISCONNECT BATTERY CONTROL CENTER
Contents
1. SERVICE MANUAL ONNECT BATTERY INGLE oN Qo 55 65 Q N gt LO S 55 N S N N 044 S 13q0WN 199 AdsSLLVE ATONIS 34015 403 JSN HOLIMS 310 34015 403 S ASN 403 la ALON 2 COACH f INE m C Ae VE SEM 5 LOANNOO YSINI HOLIMS HOVOD ALIA HOVOD WALSAS OL LOANNOOSIG AYVITIXNY Pg Intellitec P N 53 01087 000 Rev A 071813 10 www intellitec com ONTROL CENTER ONNECT BATTERY INGLE SERVICE MANUAL ainbig ues 1012105 NIYIN 5 E E Hes O JOOUUODSIG 05 1000 pieog uo pjeog 4 OL peor sisseud 0 Bee Figure 3 SP ON 55 2 6 N LO a S 55 N S N N Pg Int2. INGLE DISCONNECT BATTERY CONTROL CENTER SERVICE MANUAL Part No s 00 01087 000 Product Description The Battery Control Center is a centralized power switching fusing and distribution center Power from the main and the auxiliary batteries is fed into the Battery Control Center The full power of both batteries is available at the box The system consists of a Battery Disconnect Relay a bi directional battery charging circuit an auxiliary start function to provide a jump start from the auxiliary battery and ignition power switching CAUTION All servicing of the Battery Control Center should be done only by a qualified Service Technician Inadvertent shorts in and around the Battery Control Center could result in severe damage and or injury TOOLS REQUIRED Low current Test Light Accurate Voltmeter digital read out preferred 1485 Jacobs Road 1 DeLand Florida 32724 Y Intellitec 386 738 7307 1 800 251 2408 www P N 53 01087 000 071813 INGLE DISCONNECT BATTERY CONTROL CENTER SERVICE MANUAL How The Battery Control Center Works Battery Disconnect The Battery Disconnect relay is used to disconnect the auxiliary battery during periods of storage or during service The disconnect relay operates by momentarily applying 12 volts to the solenoid coil in either of two directions 12 volts the S terminal and ground on the I terminal for opening and 12 volts
3. ad going to the coach mounted switch and the other protects the lead powering the indicator on the switch panel Circuit Breakers There two 30 Amp type III manual reset circuit breakers They are connected to the Auxiliary battery through the Disconnect relay These breakers are intended to connect to the converter and fuse panel within the Auxiliary These circuit breakers are located near the box To reset the breakers press the buttons on the ends Contact our sales department if the breakers are not present 1485 Jacobs Road le 117 DeLand Florida 32724 Ej intellitec on 386 738 7307 1 800 251 2408 www intellitec com 8 P N 53 01087 000 Rev 071813 INGLE DISCONNECT BATTERY CONTROL CENTER SERVICE MANUAL Plugs Pins amp Functions J1 Auilary Battery Input J2 6 pin Mate N Lok Mating Housing Amp 640585 1 Pin Function Fuse 1 Aux Start Switch 2 Ignition Input 3 Ignition Switched Power F4 4 Ignition Switched Power F3 5 Ignition Switched Power F2 6 Inverted Ignition Switched Power OR Main Battery F1 J3 Main Battery Input J4 5 pin Mate N Lok Mating Housing Amp 1 480763 0 Pin Function Fuse 1 Power Step F10 2 Auxilairy Battery Power F9 3 Auxilairy Battery Power F8 4 Auxilairy Battery Power F7 5 Auxilairy Battery Power F6 J6 Ground 1485 Jacobs Road Tan DeLand Florida 32724 Ej intellitec 386 738 7307 1 800 251 2408 www intellitec com 9 P N 53 01087 000 Rev 071813 ONTROL CENTER
4. ch 12 volts is not available check wiring if OK replace the switch Ignition Relay A The auxilairy powered functions do not operate 1 Check for 12 volt ignition power coming into printed circuit board on plug J4 pin 11 2 Check respective fuse 3 Check for faulty wiring from the ignition switch 1485 Jacobs Road DeLand Florida 32724 Intelitec 386 738 7307 1 800 251 2408 www intellitec com T P N 53 01087 000 Rev A 071813 INGLE DISCONNECT BATTERY CONTROL CENTER SERVICE MANUAL Fuses The fuses used on the Battery Control Center are a standard plastic ATO blade automotive type There are 10 positions for fuses on the board These are fed from five main sources the Disconnect Switched Main Battery Ignition Switched Main Battery Disconnect Switched Auxiliary Battery and the Auxiliary Battery The 10 fuses and their size are as follows Fuses Fuse No Function Fuse Size Source Connection F1 Reverse Ign 15 Amp Main Bat 42 6 F2 Ign Sw 7 5 Amp Main Bat J2 5 F3 Ign Sw 15 Amp Main Bat J2 4 F4 Ign Sw 10 Amp Main Bat J2 3 F5 Aux Start Sw 5 Amp BIRD J2 2 F6 Spare 10 Amp Disconnected Aux Bat J4 1 F7 Spare 15 Amp Disconnected Aux Bat J4 4 F8 Spare 15 Amp Disconnected Aux Bat J4 3 F9 Spare 15 Amp Disconnected Aux Bat J4 2 F10 Step Power 25 Amp Disconnected Aux Bat J4 1 Battery Disconnect Fuses There are two 5Amp fuses located on the battery disconnect relay One of these protects the power le
5. e 7 Remove the board Printed Circuit Board Replacement Replace the board in the reverse order from the removal 1485 Jacobs Road DeLand Florida 32724 Eg intellitec 386 738 7307 1 800 251 2408 www intellitec com 4 P N 53 01087 000 Rev 071813 INGLE DISCONNECT BATTERY CONTROL CENTER SERVICE MANUAL JS J1 q 1 2 l EH J4 AUX BAT 25 E SS F AUX BAT 0 fe D J4 7 T 15 AM 9 4 a Mm 01 4 7 axa O Ej AUX BAT JO 036 5 4 lt same AUX BAT YSZ On 10 gt C T D J6 GROUND 2 ee I gt 5 AUX START SW IGNITION INPUT 7 5 O lt Z gt 7 5 AMP O YSZ IGNITION 10 8 15 15 7 REVERSE Ra nr 15 15 YGZ 282 CAUTION prevent burning of ground foil trace Assembly Remove spade terminal that is connected to Ground befo
6. ellitec P N 53 01087 000 Rev A 071813 11 www intellitec com INGLE Pin1 Pin 1 A ONNECT BATTERY CONTROL CENTER SERVICE MANUAL To To Converter Converter F10 25 Ta F6 15A Bi Directional Isolator Delay Circuitry Removable Jumper 1000000 oO Figure 4 Battery Auxiliary Battery 1485 Jacobs Road DeLand Florida 32724 386 738 7307 1 800 251 2408 Pg Intellitec www intellitec com 12 P N 53 01087 000 Rev A 071813
7. located on the printed circuit board and are easily visible for testing and replacement The fuses for the battery disconnect are located on the relay The fuses can be checked either visually or with a test light To check the fuses visually Remove the suspected fuse and examine it for damage to the fusing element To check using a test light Ground the test light to a convenient ground Check for power on both sides of the fuse If applicable make sure Battery Disconnect Relay is on when checking fuses Checking the Battery Disconnect The Battery Disconnect relay coil terminals are available on the front of the relay To engage a relay momentarily apply 12 volts to the I terminal and the S terminal is grounded The relay should click and latch in To open the relay momentarily apply 12 volts to the S terminal and the I terminal is grounded The relay should click and then open Isolator Relay An isolator relay is provided on the unit to connect the main and auxiliary batteries together for charging It also is used to connect the two batteries together for auxiliary start This allows the auxiliary battery to be used to jump start the main battery if it doesn t have enough charge to start he engine Circuit Breakers Contact our sales department ifthe breakers are not present The converter circuit breakers which are in parallel carry the current between the Auxiliary battery and the converter If the coach is not being sup
8. main and the auxiliary batteries together through the isolator relay This function is accomplished by pressing the dash mounted switch which applies 12 volts to the isolator relay coil See Charging Circuit Aux Start schematic Figure 3 Ignition Switched Power The ignition circuits are switched by an on board relay to supply power to the ignition switched circuits The power for this relay coil comes from the ignition switch through J2 pin 2 See Charging Circuit Aux Start schematic Figure 3 Circuit Breakers There are two 30 Amp circuit breakers located near the box that are used to protect the wiring between the Auxiliary battery and the converter These breakers have manual reset buttons that pop out when they are tripped Contact our sales department if the breakers are not present See Figure 4 1485 Jacobs Road DeLand Florida 32724 y Intellitec eLand 386 738 7307 1 800 251 2408 www intellitec com 2 P N 53 01087 000 Rev A 071813 INGLE DISCONNECT BATTERY CONTROL CENTER SERVICE MANUAL Trouble Shooting The Battery Control Center is built in two layers the printed circuit board and the relays The unit has been designed so that nearly ALL trouble shooting can be done without the removal of the printed circuit board Read and understand the trouble shooting procedure first before EVER removing the printed circuit board Checking Fuses The fuses protecting the main and auxiliary battery power are
9. plied 120 volts AC the current is flowing from the battery to the converter If the coach is being supplied 120 volts AC the converter is usually charging the batteries and the current will flow from the converter to the batteries If there is a fault or overload between the converter and the batteries the circuit breakers will open as indicated by the reset buttons being popped out To reset the breakers turn off the 12 loads and push the buttons in until they latch 1485 Jacobs Road DeLand Florida 32724 is Intelitec 386 738 7307 1 800 251 2408 www intellitec com 3 P N 53 01087 000 Rev A 071813 INGLE DISCONNECT BATTERY CONTROL CENTER SERVICE MANUAL Printed Circuit Board Removal In the event that the printed circuit board needs to be removed the following procedure should be followed 1 Remove the negative wires from both batteries to prevent injury to individuals and the equipment Be sure that these wires stay clear of the battery posts Remove power to the converter 2 Remove the cover and pull chassis harness plugs from connectors J4 and J2 3 Disconnect the battery cables from the coach battery chassis battery and battery disconnect studs being careful to be sure the studs do not rotate 4 Disconnectthe ground wire from J6 5 Disconnect the wires from the board at J5 and J3 6 Remove the PCB mounting screws and the coach battery nut J1 attached to the printed circuit board The unit should be fre
10. re disconnection or installing battery cables Top of board as seen with cover removed Figure 1 1485 Jacobs Road 1 DeLand Florida 32724 intellitec 386 738 7307 1 800 251 2408 www 5 P N 53 01087 000 Rev A 071813 INGLE DISCONNECT BATTERY CONTROL CENTER SERVICE MANUAL Troubleshooting Battery Disconnect A The relay fails to operate 1 Batteries may be dead Check for voltage at the battery terminal of the relay The voltage should be at least 11 volts If the voltage is less charge either battery If the voltage is more than 11 volts continue 2 The fuse on the relay be blown Check the fuse Replace fuse if the necessary 3 Wiring or switch may be faulty To check the operation have an assistant operate the Battery Disconnect switch inside the coach Check for voltage on the I terminal and ground on the S terminals at the test points on the printed circuit board 4 Disconnect Relay may be faulty If at least 11 volts is available on the I or S terminal and the relay fails to operate replace the relay B Coach functions operate when coach is plugged in but not from the battery 1 Circuit breakers feeding converter may be open Reset circuit breakers at box Charging Circuit A Auxiliary battery does not charge 1 The isolator relay may not be closing Operate the engine at a high idle for at least twenty 20 seconds and check the chassis batter
11. the I terminal and ground on the S terminal for engaging The actuation voltage is supplied from the auxiliary battery through the fuse on the disconnect relay The voltage is supplied to the momentary switch mounted in the coach and then fed back to the relay on the box See Battery Disconnect schematic Figure 2 Charging Circuit The charging circuit which utilizes an isolator solenoid to connect the two batteries together for charging will charge both batteries if either battery is being charged It operates by sensing the voltage on the Main and Auxiliary batteries If either voltage goes above 13 3 volts the minimum necessary to fully charge a battery for more than 14 seconds the isolator solenoid will pull in charging both batteries If while the ignition is on the voltage falls below 12 volts for more than 4 seconds the isolator relay will open keeping all of the alternator s output available for the chassis functions If the ignition is off and the auxiliary battery voltage should drop below 12 8 volts voltage of a fully charged battery for 4 seconds the isolator relay will open preventing the coach loads from discharging the main battery See Charging Circuit Aux Start schematic Figure 3 Auxiliary Start The Auxiliary Start function is used to provide a jump start from the auxiliary battery in the event that the main battery does not have sufficient charge to start the engine It operates by momentarily connecting the
12. y voltage The voltage must be at least 13 3 volts before the isolator activates Check the alternator if the voltage is less than 13 3 volts Check for voltage on the coil terminal of the isolator relay If there is no voltage on the coil check fuse F5 and replace if necessary If 25 is good replace the printed circuit board If there is voltage on the coil check for voltage between the main and auxiliary batteries If the voltage is more than 0 1volts replace the relay B Main battery continues to drain 1 Isolator relay be bad Check for voltage on the solenoid coil lead which is available on J1 5 when the engine is off If there is no voltage replace the relay 1485 Jacobs Road DeLand Florida 32724 is Intelitec 386 738 7307 1 800 251 2408 www intellitec com 6 P N 53 01087 000 Rev A 071813 INGLE DISCONNECT BATTERY CONTROL CENTER SERVICE MANUAL Troubleshooting C Main battery doesn t charge from converter 1 The converter is not putting out at least 13 3 volts Check converter turn off excess 12 volt loads if necessary 2 Converter circuit breakers in Battery Control Center open Reset the breakers located near the box Auxiliary Start A Auxiliary Start fails to operate 1 Fuse 17 may be blown Check F17 2 The Auxiliary battery may be dead Charge battery Isolator relay be defective 4 Switch or wires may be faulty Check for 12 volts at J4 pin 2 while pushing swit
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