AIRSTREAM - BATTERY CONTROL CENTER - Diesel
Contents
1. All Fuses 20A Radio Aisle Gen Comp Lights F1 Refer Light Lounge Area Lights Fan F2 Ceiling Patio Step Lights Luggage Comp Lights F3 Pwr Cord Reel Furnace Bath Area Lights F4 Spare Bedroom Lights Fan F5 Water Pump Monitor Panel Galley Locker Light Coach Battery Spare 20 Amp Bat Disconnect Pwr 5 Amp Chassis Battery Spare F10 20 Amp Spare F11 20 Amp Spare F17 20 Amp Ignition Switched Chassis Battery Spare F7 20 Amp Ignition Signal F8 5 Amp Spare F18 20 Amp These values may be different than the ones listed Check the label on the cover for the correct value 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 11 P N 53 00755 000 Rev C 023105 AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL CIRCUIT BREAKERS There is one 135 Amp and 30 Amp type lll manual reset circuit breaker mounted in the box The 135 Amp breaker is connected to the Coach battery This breaker is connected to the Secondary BCC fuse panel within the coach The 30 Amp unit is connected to the disconnect switched Coach battery This breaker feeds 12 volt power to the slide out room Plugs Pins amp Functions CNA 8 pin in line Mate N Lock Mating Housing AMP 640586 1 U 5 Function Refer Light Water Pump Monitor Panel Galley Locker Lights Ignition Signal Ceiling Patio Step Lights Spare Pwr Cord Reel Spare Spare2. NOU G N CNB 6 pin in line Mate N Lock Mating Housing AMP 640585 1 Function Spare Lounge Area Lights and Fan Spare Spare Spare Luggage Comp Lights CNC 4 pin Mate N Lok Mating Housing AMP 1 480702 0 Function Spare Bedroom Lights and Fan Furnace Bath Area Lights Radio Aisle Gen Comp Lights CND 5 pin Mate N Lok Mating Housing AMP 1 480763 0 Function Start Switch Spare Spare Spare Spare 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 12 P N 53 00755 000 Rev 023105 AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL J5 4 pin Mate N Lok Mating Housing AMP 1 480702 0 To Solar Charger Pi Function Aux Battery Not Used Ground Main Battery CNF 9 pin Mate N Lok Mating Housing AMP 1 480706 0 Function Fuse Chassis BD lI terminal Chassis BD S terminal Coach BD S terminal NC NC Coach BD I terminal Coach BD Power Chassis BD Power ign switched BD Relay Ground U 5 O GQ N J7 3 pin Molex KK156 in Function 1 Isolator relay coil 2 Coach BD Power 3 Chassis BD Power Intellitec www intellitec com 13 Wire Color Violet Grey Brown White Red Orange Black Violet Red Orange 131 Eisenhower Lane North Lombard IL 60148 630 268 0010 1 800 251 2408 P N 53 00755 000 Rev C 023105 AIRSTREAM BATTERY CONTROL CENTER D
3. Check for 12 volt power feeding switch plugged in but not from battery atconnector G pin 2 No 12 volt powerto switch Ifthere is no 12 volts check fuse F9 Circuit breakers feeding converter opened Reset circuit breakers in box 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 2 P N 53 00755 000 Rev C 023105 84015 403 IVNIWH3I S ASN IVNIINS3L I 3 LON 84015 NMOG JSN SAHOLIMS JAON g AM3LIVS Na xnv LOANNOOSIA 131 Eisenhower Lane North Lombard IL 60148 630 268 0010 1 800 251 2408 P N 53 00755 000 Rev C 023105 MOV 927 AONVHO 027 Tr x Lu 9 m Y LOANNOOSIC TAN OT O OM OO ON 5 NOILINSI I I I O HOLIMS ddllv8 NOLLINSI S Q Qc m x lt N x lt HA1NAO IOULNOD 1ANVd HOLIMS HOVOO Intellitec www intellitec com AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL CHARGING CIRCUIT The charging circuit 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 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 fo
4. check solar panel for damage Check wiring from panel Relay K4 on board should be closed If not replace board Check for excessive drain on batteries Turn off Battery Disconnect relays to see if charging occurs 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 8 P N 53 00755 000 Rev C 023105 AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL To Coach Bat To Chassis Bat J2 N gt O O O aa U C O oO O Solar Panel Charging LED Charged LED FIGURE 3 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 9 P N 53 00755 000 Rev 023105 AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL FROM SOLAR PANEL HARNESS SOLAR CHARGER MODULE 131 Ei h L North Intellitec abend 00148 630 268 0010 1 800 251 2408 www intellitec com 10 P N 53 00755 000 Rev C 023105 AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL FUSES The fuses used on this board are standard plastic ATO blade automotive type There are 18 positions for fuses on the board See Figure 4 These are fed from four main sources Disconnect Switched Coach Battery Coach Battery Chassis Battery and Ignition Switched Chassis Battery The 18 fuses and their size are as listed Disconnect Switched Coach Battery
5. panel can put out up to 22 volts and as much as 75 amps of current The 53 watt panel can put out up to 22 volts and as much as 3 3 amps of current When the batteries are below 13 volts and there is output from the panels the controller will operate in the full charge mode applying the full output of the panel s to the batteries through a relay mounted on the printed circuit board When the voltage on the batteries reaches 14 4 volts the controller switches into a current limited constant voltage mode In this mode the battery voltage is maintained at 13 6 volts ata maximum of 1 Amp In either of the first two modes the CHARGING LED on the monitor panel will be lit When the current falls below 0 25 Amps the CHARGING LED goes out and the CHARGED LED will come on Ifthe voltage falls below 13 volts the controller will switch back into the full charge mode The voltage thresholds are temperature compensated to assure proper charge on the batteries See Solar Charging Schematic Figure 3 Possible Problem Cause Solution CHARGING LED does not come on Solar panel not putting out sufficient power Check for sun light on panel Check for voltage coming from anel CNE1 If low check panel wiring CHARGED LED does not come on More than 0 25 Amp drain on batteries Turn off Battery Disconnect Relays Batteries not charging Check voltage from solar panel when in sunlight Should be more than 15 volts If less
6. AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL BATTERY CONTROL CENTER FUSES AND RELAYS INSIDE CAUTION DISCONNECT BATTERY CABLES BEFORE REMOVING COVER P N 00 00755 000 CAUTION The Battery Control Center is a centralized power switching fusing and distribution center Power from both the chassis and coach batteries is fed into the box The full power of these batteries is available within this box Inadvertent shorts inside this box could result in severe damage and or injury All servicing within this box should be done only by a qualified Service Technician Tools Required Low current Test Light Accurate Voltmeter digital read out preferred Access to circuit protection To gain access to the fuses and circuit breakers turn each of the two latches a quarter turn to the left and pull the cover away from the box 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www 1 P N 53 00755 000 Rev 023105 AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL BATTERY DISCONNECT The Battery Disconnect relays are used to disconnect the batteries during periods of storage or during service The disconnect relays operate by momentarily applying 12 volts to the solenoid coil in either of two directions 12 volts on the S terminal and ground on the I terminal for opening and 12 volts on the I terminal and ground on the S terminal fo
7. ec com AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL TO O 4 HI i O GEN SET SEN DISCONNECT r9 COACH SPARE Fe CHASSIS SPARE F10 204 CHASSIS SPARE r11 COACH BATTERY BEDROOM LTS FAN r5 20 AREA LTS r4 2204 RADIO AISLE amp GEN zi COMP LIGHTS 204 LOUNGE AREA LTSIFAN r2 UVOOUF 4 4400000 LUGGAGE COMP LTS F3 CHASSIS SPARE F17 UOOOOU TO SLIDEOUT REFER LIGHT F12 WTR PUMP MNTR PNL r16 IGNITION CEILING PATIO STEP LTS F13 CHASSIS BATTERY CHASSIS SPARE F7 POWER CORD REEL F14 CHASSIS SPARE F18 AUOOOOOOU COACH SPARE F15 y 131 ok Lane North Intellitec mbard IL 60148 630 268 00107 1 800 251 2408 www intellitec com 7 P N 53 00755 000 Rev C 023105 AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL SOLAR CHARGER MONITOR PANEL OPTIONAL The Solar Charger is used to control the output of roof top mounted solar panels Depending on options your coach is equipped with a single 10 watt panel ora combination of a 53 watt and a 10 watt panel The 10 watt
8. hat the chassis battery does not have sufficient amount of charge to start the engine It operates by momentarily connecting the chassis and coach batteries together through the isolator relay This is accomplished by pressing the dash mounted switch which applies 12 volts to the isolator relay coil See Charging Circuit Aux Start schematic Figure 2 Possible Problem Cause Solution Auxiliary Start fails to operate Bad switch Check dash mounted switch and wiring Coach battery dead Charge battery Isolator relay defective Replace relay 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 5 P N 53 00755 000 Rev C 023105 u 2 Q Qc m x lt N x lt x Lu 9 m Y uejs s HEIS 11 ysep uo 5 O VS L3 oeuuoosiq apeg JoJelsuss O Speo Mo dim UND Aelag JoJelosl Ieuofoella ig Adidllvd NIYIN YOUMS Uonub Pass A eyeg 0 BB ule E p eog UO sesn SISSEUD OL 08 pJeog uo sAejoy uous Lombard IL 60148 131 Eisenhower Lane North 630 268 0010 1 800 251 2408 tec lli Inte 000 Rev C 023105 00755 P N 53 www intellit
9. iesel SERVICE MANUAL Printed Circuit Board BAT DISCONNECT 5 AMP COACH SPARE 20AMP CHASSIS SPARE 20 AMP CHASSIS SPARE 20 AMP BEDROOM LTS FAN 20 AMP FURNACE BATH LTS 20 AMP RADIO AISLE GEN COMP LTS 20 AMP LOUNGE LTS FAN 20 AMP LUGGAGE COMP LTS 20 AMP CHASSIS SPARE 20 AMP qjUOOOOUR REFER LIGHT 20 AMP WTR PMP MNTR PNL 20 AMP IGNITION SIGNAL 5 AMP CEILING PATIO STEP LTS 20 CHASSIS SPARE 20 AMP POWER CORD REEL 20 AMP UOOOOOOUR CHASSIS SPARE 20 AMP COACH SPARE 20 AMP Fuse values may be different See label on cover for proper values FIGURE 4 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 14 P N 53 00755 000 Rev C 023105 AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 15 P N 53 00755 000 Rev C 023105 AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www 16 P N 53 00755 000 Rev C 023105
10. r engaging the relay The actuation voltage is supplied from the coach battery through F9 It is supplied to the momentary switches mounted in the coach and then fed back to the relays in the control center See Battery Disconnect schematic Figure 1 Possible Problem Cause Solution Both disconnect relays fail to operate Coach battery may be dead Check for voltage at the top end of F9 the feed from the coach battery F9 is located at the top center ofthe printed circuit board This voltage should be at least 11volts If itis less charge the coach battery If itis more than 11 volts go on F9 may be blown Using a test light check for voltage at both ends of F9 This voltage should be at both ends of F9 If not replace fuse F9 Ground lead to switches may be open Check for ground and 12 volts on 4 and S terminals of the Disconnect Relay while pressing the switch in the coach One disconnect relay fails to operate Wiring or switch faulty To check the operation have an assistant operate the switch inside the coach while checking for voltage on the I terminal ofthe relay and ground on the S terminal Disconnect Relay faulty If at least 11 volts is available on I or S terminals and relay fails to operate replace relay Chassis relay fails to operate Ignition may be on Check to be sure that the switched ignition voltage is 0 volts Coach functions operate when coach is Interlock relay K3 faulty
11. r 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 for 4 seconds the isolator relay will open preventing the coach loads from discharging the main battery To prevent overcharging when connected to shore power for long periods of time the system monitors the battery voltage and when it exceeds 13 8 volts for one hour the chassis battery will be disconnected When the voltage on that battery drops below 12 6 volts the isolator will reconnect to recharge the battery See Charging Circuit Aux Start schematic Figure 2 Possible Problem Cause Solution Coach battery does not charge from alternator The isolator relay is not closing Check for voltage on coil terminals of isolator relay should be approximately 4 volts Operate the engine at a high idle for at least 20 seconds and check the chassis battery voltage at the J1 MAIN BAT faston and at connector J9 pin 3 Both locations check alternator If no voltage on coil replace printed circuit board If there is voltage on coil should be approximately 4 volts check for voltage on both main terminals of relay If different replace relay Chassis battery does not charge from convertor The isolator relay is not closing Check for voltage on coil terminals of isolator relay should be approximately 4 volts With the converto
12. r operating check the coach battery voltage at the J11 AUX BD bolt plate It must be atleast 13 3 volts Ifitis less check convertor If no voltage on coil replace printed circuit board If there is voltage on coil should be approximately 4 volts check for voltage on both main terminals of relay If different replace relay Chassis battery continues to drain Isolator relay not opening Replace relay 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 4 P N 53 00755 000 Rev C 023105 AIRSTREAM BATTERY CONTROL CENTER Diesel SERVICE MANUAL IGNITION RELAY The ignition relay K1 turns power on with the ignition switch to feed the ignition signal and igniton powered accessories Failure of this relay will prevent the operation of these functions The power for the coil of this relay comes from the ignition switch through Connector D pin 3 See Charging Circuit Aux Start schematic Figure 2 Possible Problem Cause Solution Ignition powered accessories do not function Ignition relay fails to operate Check for 12 volt power at terminals of ignition relay at relay Check for 12 volt power coming into printed board on Connector D pin 3 If no power here check for faulty wiring from ignition switch Replace printed circuit board AUXILIARY START The Auxiliary Start function is used to provide a jump start from the coach battery in the event t
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