Cartek Battery Isolator XR User manual

USER GUIDE AND INSTRUCTIONS JAN 2017

CONTENTS
INTRODUCTION PAGE 1
SPECIFICATION PAGE 2
SAFETY NOTES PAGE 3
INSTALLATION
FITTING PAGE 4
SWITCH CONNECTIONS PAGE 5
ENGINE KILL CONNECTION PAGE 6
FINAL CONNECTION PAGE 7
MULTILINGUAL WIRING DIAGRAMS PAGE 8
FAULT DIAGNOSIS PAGE 9
Unit 25, Mitchell Point
Ensign Way, Hamble
Southampton
SO31 4RF
UNITED KINGDOM
CONTACT INFORMATION
[phone]
[email protected]
www.CARTEKMOTORSPORT.com

INTRODUCTION
1
INTRODUCTION
The Battery Isolator XR is a fully electronic ‘master/kill switch’ system designed specifically for race
car applications. This device contains no moving parts and the solid construction provides very high resistance
to shock, vibration, water and dirt. Using the latest MOSFET technology this Battery Isolator provides safe,
spark-free isolation of the vehicle’s battery and engine electrics.
Meets FiA safety regulations.
PRINCIPLE OF OPERATION
All race and rally master switches must perform two functions, (1) disconnect the battery from all electrical
circuits and (2) kill the engine. The Battery Isolator XR performs the battery disconnection function by breaking
the connection between the NEGATIVE battery terminal and CHASSIS/EARTH. The Battery Isolator XR performs
the engine kill function by outputting a signal which can be used to enable/disable ECUs or PDMs or used to
control an engine relay.
Alternator run-down protection is incorporated.
The electronic isolation circuits are controlled by a microprocessor and incorporate various safety systems
including over-temperature and over-current monitoring. The microprocessor also monitors the kill
switches/buttons for instant activation while eliminating false triggering. The unit will therefore instantly
trigger into isolation mode when any of the kill buttons are struck or on detection of any break in switch wiring
circuits such as during an accident.
The Isolator also incorporates an LED which displays status as well as fault codes.
Battery Isolators are designed for SAFETY and RELIABILITY.

SPECIFICATION
2
Technical Details
Typical installation
Size: L = 60mm, W = 45mm.
Weight: 70g.
Battery negative terminal: M8 stud.
Electrical Connector: Binder 09 0415 90 05
Connection cable (supplied): Binder 79 1456 272 05 (2 meter long)
Operational Voltage: 7v - 18v
Current consumption: 25mA ON, 0mA OFF
Battery negative switching current: 600A cranking, 2000A surge
Engine signal kill current: 12v 0.5A when ON, switched to
chassis/earth when OFF
Operating temperature: -10°C - +85°C.
Storage temperature: -40°C - +125°C
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EXTERNAL KILL BUTTON
(Now with chassis connection)
+
-
+
-
ENGINE KILL SIGNAL TO ECU, PDM
or ENGINE RELAY.
ALTERNATOR. STARTER MOTOR.
START BATTERY (Optional)
CHASSIS MOUNTED CLOSE TO BATTERY.
CAR BATTERY
BODY ELECTRICAL SYSTEMS.
INTERNAL ON/OFF BUTTON
(2 wires)

3
SAFETY NOTES
●Please read through the Instructions thoroughly before installing on your race car. If not installed correctly
then damage may occur to the Battery Isolator.
●The Battery Isolator must be fully connected before starting the engine. If the engine kill output signal is
not connected when the engine is running then damage to the Battery Isolator may occur. (Cars without
alternators do not apply).
●Do not use the Internal Button for any other application, it is designed specifically for use with
Battery Isolators only.
●The Battery Isolator must be removed if any electric welding is being carried out on the car.
●When using a Battery Charger or an external starter/booster battery then it is important to connect both
terminals directly to the car battery. DO NOT CONNECT THE NEGATIVE LEAD OF THE CHARGER OR
EXTERNAL BATTERY TO THE CHASSIS. THIS MAY CAUSE DAMAGE TO THE BATTERY ISOLATOR.
MOTORSPORT IS DANGEROUS.
THIS PRODUCT IS DESIGNED FOR MOTORSPORT USE ONLY AND SHOULD NOT
BE USED ON ROAD/STREET VEHICLES OR ON PUBLIC HIGHWAYS.
NO WARRANTY IS MADE OR IMPLIED REGARDING ANY CARTEK PRODUCTS TO
PROTECT USERS FROM INJURY OR DEATH.
USER ASSUMES ALL RISKS.
+
-
+
-
EXTERNAL
BATTERY
DIRECT TO CAR BATTERY
+
-
+
-
EXTERNAL
BATTERY
+
-
CHASSIS
EARTH
+
-

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INSTALLATION
Step 2. FITTING
The Battery Isolator should be mounted directly to the vehicle’s metal chassis close to the vehicle’s battery
but away from any high temperature sources.
The Battery Isolator should be mounted securely with unpainted screws/bolts to provide good electrical
contact with the chassis.
If mounting directly to a metal chassis is not possible then an 'earth' cable can be used to connect the
metal casing of the Battery Isolator to a suitable point on the chassis or engine block.
4
ADDITIONAL
EARTH CABLES
ADDITIONAL
EARTH CABLES

INSTALLATION
Step 2. SWITCH CONNECTIONS
The Isolator can be controlled by any number of on-off/kill switches although the usual configuration is one
internal on-off button and one external kill button.
The internal switch needs to be of a latching type, either toggle or pushbutton, such that the ON position
makes the circuit while the OFF position breaks the circuit.
The external kill switch should be of the non-latching, momentary action, normally-closed (NC) type and
connected between the Blue and Grey wires of the external switch circuit. If required, multiple kill
switches/devices can be incorporated by connecting in series. If only a single internal on-off switch is to be
used with no external switch then the external circuit needs to be complete by joining the Grey and Blue
wires together. If any wire connection becomes broken due to fatigue or accident then the Battery Isolator
will automatically switch OFF killing the engine and disconnecting the battery.
WARNING: Do not test the Internal Button by passing power through it, this will damage it. It will only
work correctly when connected to the Battery Isolator.
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+
-
+
+
+
-
INTERNAL
ON/OFF
SWITCH
with LED
GREY (Battery 12V+)
EXTERNAL KILL SWITCH
BROWN (Internal Switch)
WHITE (Engine kill signal)
BLUE (Ext kill)
RED
TO BATTERY POSITIVE 12V+
CHASSIS
ADDITIONAL KILL
BUTTON
Battery Isolators allow for
an external 'kill' button to be mounted on
both sides of a race car for instant access and
maximum safety.
5
BLACK
BLACK (Internal Switch)
CHASSIS
BLUE

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INSTALLATION
Step 3. ENGINE KILL CONNECTION
For cars equipped with an alternator, the Battery Isolator needs to kill the engine by sending a signal to the
engine ECU or electronic Power Distribution Module (PDM) or by shutting down the main engine relay.
The engine kill output signal has two states:
Battery Isolator ON - 12V (0.5A max).
Battery Isolator OFF - 0V(Earth).
Make sure the ECU or PDM is able to accept this type of Engine Kill Signal. Most OEM ECUs will not be able
to accept this type of signal while most programmable Motorsport ECUs and PDMs will.
6
BROWN
BLUE
WHITE (Engine kill signal)
BLACK
GREY
TO ECU/PDM
It is also possible to use the Engine Kill Signal to control an Engine Relay/DME. Please check the
manufacturers specification before installing.
BROWN
BLUE
WHITE (Engine kill signal)
BLACK
GREY
+
ENGINE
RELAY
Maximum
current 0.5A
TO FUEL PUMPS
IGNITION
ECU
ETC
+
-
+
-
WARNING: The Battery Isolator must be fully connected before starting the engine. If the engine kill
output signal is not connected when the engine is running then damage to the Battery Isolator may
occur. (Cars without alternators do not apply).

INSTALLATION
Step 4. FINAL CONNECTION
Once Steps 1,2 & 3 are completed a final connection should be made from the negative terminal of the
vehicle battery to the Battery Isolator terminal marked BATTERY NEGATIVE. This connection should be made
with cable of 100-200Amp capacity and by keeping as short as possible will offer maximum weight saving of
the complete installation.
Once this final step is complete please check all connections before switching on.
When fitting or removing the Isolator always connect the battery last and disconnect first.
Here is an example of a completed installation:
BATTERY NEGATIVE
CONNECTION
Wired up to: Internal Button
External Button
ECU/PDM/Engine Relay
7
ADDITIONAL EARTH CABLES
WHEN NOT MOUNTED DIRECTLY
TO CHASSIS

INSTALLATION - MULTILINGUAL
8
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(GB) EXTERNAL KILL BUTTON.
(IT) PULSANTE DI ARRESTO ESTERNO.
(ES) BOTÓN DE DESCONEXIÓN EXTERNO.
+
-
+
-
(GB) ENGINE KILL SIGNAL TO ECU, PDM
or ENGINE RELAY.
(IT) SEGNALE ARRESTO MOTORE E ECU PDM
o RELÈ DEL MOTORE.
(ES) SEÑAL DE DESCONEXIÓN DEL MOTOR
A LA ECU, AM MÓDULO DE DISTRIBUCIÓN
DE ENERGÍA O AL RELÉ DEL MOTOR.
(GB) ALTERNATOR.
(IT) ALTERNATORE.
(ES) ALTERNADOR.
(GB) STARTER MOTOR.
(IT) MOTORINO D'AVVIAMENTO.
(ES) MOTOR DE ARRANQUE.
(GB) START BATTERY (Optional)
(IT) BATTERIA AUTO.
(ES) ARRANCADOR BATERIAS.
(GB) CHASSIS MOUNTED CLOSE TO BATTERY.
(IT) CHASSIS MONTATO VICINO AL DI BATTERIA.
(ES) BASTIDOR MONTADO CERCA DE LA BATERÍA.
(GB) CAR BATTERY
(IT) BATTERIA AUTO
(ES) BATERÍA DEL
VEHÍCULO
(GB) BODY ELECTRICAL SYSTEMS.
(IT) SISTEMI PER VEICOLI ELETTRICI.
(ES) SISTEMAS ELÉCTRICOS DEL VEHÍCULO.
(GB) INTERNAL ON/OFF BUTTON.
(IT) INTERNA PULSANTE.
(ES) BOTÓN INTERNO DE ACTIVACIÓN
/ DESACTIVACIÓN.
MADE IN UK
(GB) Installation diagram (IT) Collegamenti per installazione (ES) Conexiones de instalación
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MADE IN UK
(GB) EXTERNAL KILL BUTTON.
(FR) BOUTON EXTERNE D'ARRÊT MOTEUR
(DE) EXTERNER KILL-TASTER.
(GB) INTERNAL ON/OFF BUTTON
(FR) BOUTON MARCHE/ARRÊT INTERNE.
(DE) INTERNER AN/AUS-SCHALTER.
+
-
+
-
(GB) START BATTERY (Optional)
(FR) BATTERIE DE VOITURE.
(DE) AUTOBATTERIE.
(GB) CHASSIS MOUNTED CLOSE TO BATTERY.
(FR) MONTÉ SUR LE CHÂSSIS PRÈS DE LA BATTERIE.
(DE) FAHRGESTELLMONTAGE IN BATTERIENÄHE
(GB) ENGINE KILL SIGNAL TO ECU, PDM
or ENGINE RELAY.
(FR) SIGNAL DE L'ARRÊT MOTEUR, ECU,
PDM OU RELAIS DU MOTEUR.
(DE) MOTORABSCHALTSIGNAL AN
MOTORSTEUERUNG, PDM
oder MOTORRELAIS.
(GB) ALTERNATOR.
(FR) ALTERNATEUR.
(DE) LICHTMASCHINE.
(GB) STARTER MOTOR.
(FR) DÉMARREUR.
(DE) ANLASSER.
(GB) BODY ELECTRICAL SYSTEMS.
(FR) SYSTÈMES ÉLECTRIQUES DU VÉHICULE.
(DE) ELEKTROSYSTEM DES FAHRZEUGS.
(GB) CAR BATTERY
(FR) BATTERIE DE VOITURE
(DE) AUTOBATTERIE
(GB) Installation diagram (FR) Installation des connexions (DE) Installationsanschlüsse

FAULT DIAGNOSIS
9
FAULT DIAGNOSIS
Once fully installed, the Isolator is switched ON by activating the internal ON-OFF switch/button. On
activation the Isolator performs a system check before electrical power is switched on. If any fault is
detected then the Isolator will remain in the OFF state and display the fault status via the LED in a sequence
of flashes:
1 flash - External Kill Button pressed or External Kill Button circuit broken.
If the External Kill Button has not been activated then check the wiring between the
Battery Isolator and the External Kill button. One way to confirm this fault is to
temporarily connect the blue wire to chassis therefore bypassing the External Kill Button
and wiring.
2 flashes - Maximum temperature exceeded.
The Battery Isolator will automatically switch OFF if maximum temperature is exceeded.
This may occur after very prolonged engine cranking or if the Battery Isolator is mounted
close to a source of heat e.g. engine, coolant pipes, exhaust, radiator fan, etc.
8 flashes - Maximum current in NEGATIVE circuit exceeded.
Check for a short circuit from battery positive to chassis such as faulty Alternator or
Starter Motor.
Once the fault is remedied the Isolator can be reset by switching OFF the internal switch/button then switching
ON again. The unit will also be fully reset by disconnecting from the vehicle battery and reconnecting.
POSSIBLE ERRORS
1. Make sure there is only one cable attached to the negative terminal of the battery and that this
cable connects to the Battery Isolator and nowhere else. There must be no cable between the
negative terminal of the battery and chassis.
2. If the Battery Isolator does not switch ON when the internal button is pressed to the ON position
then observe any flashing LED error code and identify the fault from the list above. If the Battery
Isolator does not switch ON and does not display any error code then check the connections
between battery and Battery Isolator, make sure the battery is fully charged. Also check
connections to the Internal ON-OFF switch.