Intellitec 00-00696-240 Supplement

131 Eisenhower Lane North
Lombard IL 60148
630 268 0010 / 1 800 251 2408
www.intellitec.com
Intellitec
P/N 53-00696-241 Rev. B 032105
REVERSE BATTERY PROTECTED BATTERY GUARD
INSTALLATION & SERVICE MANUAL
CAUTION
Tools Required:
Some of the components of Reverse Battery Protected Battery Guard are connected directly to the vehicle's
batteries. The full power of these batteries is available at the terminals of the disconnect relays. Inadvertent
shorts of these cables could result in severe damage and/or injury.
Accurate Voltmeter ( ).
All servicing of this system should be done only by a qualified Service Technician.
digital read-out preferred
Part No. 00-00696-240

131 Eisenhower Lane North
Lombard IL 60148
630 268 0010 / 1 800 251 2408
www.intellitec.com
Intellitec
P/N 53-00696-241 Rev. B 032105
REVERSE BATTERY PROTECTED BATTERY GUARD
INSTALLATION & SERVICE MANUAL
2
HOW IT WORKS
The Reverse Battery Protected Battery Guard is used as a main battery disconnect for both the 24 volt and the 12
volt batteries in a dual battery system or the 24 volt battery in a single battery system. It also provides battery run-
down protection and protection from reverse battery installation. The system consists of a control module, one or
two latching relays, and a dash-mounted switch. The system provides a number of features, including Master
Disconnect, battery run-down protection and reverse battery protection.
The Master Disconnect feature allows the driver to disconnect both the 24 volt and 12 volt batteries at the same
time, from the dash-mount switch. This can be done with the ignition on or off. To switch off the batteries, the driver
presses and momentarily holds the Master Disconnect switch in OFF position. If the ignition is on, the system will
interrupt the power to the ignition system prior to disconnecting the batteries. When the batteries are connected,
the indicator on the dash-mount switch will be illuminated. If the batteries are disconnected, the indicator will be
flashing. To reconnect the batteries, the driver presses and momentarily holds the switch in the ON position.
If the ignition is off, the system constantly monitors the batteries for drain by measuring the voltage of the batteries.
If the voltage falls below 24.0 volts for more than 4 minutes, the system will disconnect the batteries to prevent
further discharge. The indicator light, will begin to blink two minutes prior to disconnecting, to alert
the driver of the impending shut-down.
If the battery cables are removed, the unit senses the sudden drop in voltage and opens the disconnect relays.
When the batteries are re-connected, the relays are open and the batteries must be connected in the correct
polarity before the system will close the relays, thereby preventing the application of reverse polarity to the vehicle's
electrical system.
There is an input to the module that allows the indicator light to be extinguished for dark running operation. When
this input is high, the indicator will be off.
The module is potted and contains no user serviceable components. The electronics in the module control the
latching solenoids to perform the functions described above.
The Latching Relays (Intellitec Part # 00-00507-024) operate by the momentary application of voltage to the coil
terminals. When the voltage is in one polarity, the relay is pulled in and latched. When the voltage is applied in the
opposite direction, the relay is un-latched. The control electronics in the module perform the application of the
power to the relays.
Master Disconnect
Battery Run-Down Protection
Reverse Battery Protection
Indicator Light Extinguishing
The Module
Latching Relay
Master Switch

131 Eisenhower Lane North
Lombard IL 60148
630 268 0010 / 1 800 251 2408
www.intellitec.com
Intellitec
P/N 53-00696-241 Rev. B 032105
REVERSE BATTERY PROTECTED BATTERY GUARD
INSTALLATION & SERVICE MANUAL
CAUTION
To prevent damage, continuous power should never be applied to the relay coil.
There are no dealer serviceable parts in this box.
Replacement of a defective box is the only way to correct a failed unit.
To remove the module, unplug the ten pin plug by pulling the latch outward, while gently rocking and pulling the
plug. The module is held in place with two screws through the flanges on the ends of the module. The module can
now be removed and replaced by reversing the removal procedure.
The relay(s) can be removed by first disconnecting the ground cable from the battery(s). Be sure the cable is
positioned a distance from the battery post to prevent accidental reconnect while working on the system. There are
four connections to the relay, two battery cables and two coil wires.
The relay will have to be reconnected with the identical connections for proper operation.
Once the wires are removed, the four mounting screw are removed to free the relay. The new relay can be installed
using the reverse order of the removal. Tighten the battery cable connections to a torque of 150 in/lbs.
All servicing of this system should be done only by a qualified Service Technician.
SERVICING
REMOVALAND REPLACEMENT
Module
Relay
Observe the color code of the wires as they are
removed form the relay.
3

131 Eisenhower Lane North
Lombard IL 60148
630 268 0010 / 1 800 251 2408
www.intellitec.com
Intellitec
P/N 53-00696-241 Rev. B 032105
REVERSE BATTERY PROTECTED BATTERY GUARD
INSTALLATION & SERVICE MANUAL
Battery Terminals
Coil Terminals
Mounting Holes
Disconnect Relay
The Disconnect Relay used in the system is Intellitec's standard 200 Amp Latching Relay (Intellitec Part No. 00-
00507-024). This relay is a mechanical latching unit that requires NO power to keep it open or closed. To close the
relay, +24 volts is momentarily applied to the "I" terminal of the relay and "S" terminal is grounded. To open the
relay, +24 volts is momentarily applied to the "S" terminal and the "I" terminal is grounded.
Application of continuous power to the coil will permanently damage the unit.
CAUTION:
4

131 Eisenhower Lane North
Lombard IL 60148
630 268 0010 / 1 800 251 2408
www.intellitec.com
Intellitec
P/N 53-00696-241 Rev. B 032105
REVERSE BATTERY PROTECTED BATTERY GUARD
INSTALLATION & SERVICE MANUAL
ORG - TO IGN SW
TO LED DEFEAT
S
TO VEHICLE
24V ELECTRICAL
SYSTEM
This terminal of the Battery Guard Relay should be the only accessory connected directly to the battery. Main power to the vehicle electrical system and any accessories should be connected to the opposite terminal on the relay.
YELLOW
VIOLET
BLUE
BLACK
WHITE - TO "I"
ON RELAY
BROWN - TO "S"
ON RELAY
TO IGNITION
FED CIRCUITS
RED
10A IN-LINE
FUSE
RESET
SWITCH
IGNITION
DISCONNECT
RELAYS
+12 Volt VEHICLE BATTERY
+12 Volt VEHICLE BATTERY
JUMPER
A
E
F
K
SINGLE VOLTAGE
REVERSE BATTERY PROTECTED
BATTERY GUARD
5

131 Eisenhower Lane North
Lombard IL 60148
630 268 0010 / 1 800 251 2408
www.intellitec.com
Intellitec
P/N 53-00696-241 Rev. B 032105
REVERSE BATTERY PROTECTED BATTERY GUARD
INSTALLATION & SERVICE MANUAL
ORG - TO IGN SW
TO LED DEFEAT
S
S
TO VEHICLE
24V ELECTRICAL
SYSTEM
This terminal of the Battery Guard Relay should be the only accessory connected directly to the battery. Main power to the vehicle electrical system and any accessories should be connected to the opposite terminal on the relay.
YELLOW
VIOLET
BLUE
BLACK
WHITE - TO "I"
ON RELAY
BROWN - TO "S"
ON RELAY
TO IGNITION
FED CIRCUITS
RED
10A IN-LINE
FUSE
RESET
SWITCH
IGNITION
DISCONNECT
RELAYS
+12 Volt VEHICLE BATTERY
+12 Volt VEHICLE BATTERY
TO VEHICLE
12V ELECTRICAL
SYSTEM
JUMPER
A
E
F
K
DUAL VOLTAGE
REVERSE BATTERY PROTECTED
BATTERY GUARD
6

131 Eisenhower Lane North
Lombard IL 60148
630 268 0010 / 1 800 251 2408
www.intellitec.com
Intellitec
P/N 53-00696-241 Rev. B 032105
REVERSE BATTERY PROTECTED BATTERY GUARD
INSTALLATION & SERVICE MANUAL
TROUBLE SHOOTING
NOTE:
Many installation problems can be created by improper connections. Before proceeding with module or relay
replacement, be sure that all the wiring connections are correct and the battery/batteries are charged and
connected in the correct polarity.
Symptom/Problem
Won't connect the battery/batteries.
Won't disconnect the battery/batteries.
Keeps disconnecting the battery/batteries with the
ignition off.
No power through the relay.
Possible Cause/Cure
Be sure battery/batteries are connected in the correct
polarity and charged to at least 24.2 volts.
Check the 10 amp fuse feeding the module power.
Replace if necessary.
Check the 10 amp fuse feeding the module.
This is a normal function for the system to prevent
excessive draining of the batteries. Check for draining
loads. Turn off unnecessary loads.
Check the condition of the batteries. They may be
failing.
Check to be sure the relay has been closed by actuating
the dash-mounted switch. Connect a voltmeter between
the relay coil terminals to see if power and ground are
applied when the switch is pressed. (Both coil terminals
are normally grounded through the module. External
application of power to either of the coil terminals will
damage the module. The relay may be operated without
the module by first removing the connections to the
module and then MOMENTARILY applying +24 volts and
ground with test or jumper leads.)
If power has been applied in the correct polarity and
the relay is still open, replace the relay.
7

131 Eisenhower Lane North
Lombard IL 60148
630 268 0010 / 1 800 251 2408
www.intellitec.com
Intellitec
P/N 53-00696-241 Rev. B 032105
REVERSE BATTERY PROTECTED BATTERY GUARD
INSTALLATION & SERVICE MANUAL
8