Intellitec Big Boy 00-00507-512 User manual

1
131 EISENHOWER LANE NORTH
LOMBARD, ILLINOIS 60148
630-268-0010 / 1-800-251-2408
Intellitec
P/N 53-22117B100 Rev 021700
200 AMP BATTERY DISCONNECT
SERVICE MANUAL
Battery DisconnectBattery Disconnect
Battery DisconnectBattery Disconnect
Battery Disconnect provides a simple and safe means of remotely disconnecting batteries
of an RV or boat. With a touch of a remote switch, the batteries will be completely
disconnected, preventing unwanted drain when the RV, or boat are put into storage.
The heart of the system is a unique latching relay developed specifically for this purpose.
While this relay is capable of carrying heavy currents, it requires NONO
NONO
NO power to stay open
or closed. It only draws power during activation. The relay is sealed against the
environment and is designed to withstand the shock and vibration experienced in the
most severe RV, or boat applications.
WARNING
The Battery Disconnect system connects directly to the vehicle’s positive battery terminal.
Inadvertent shorts across the battery or to ground, may cause severe damage and injury.
Use extreme caution when working with these wires. Always wear safety glasses when
working with the battery connections.

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131 EISENHOWER LANE NORTH
LOMBARD, ILLINOIS 60148
630-268-0010 / 1-800-251-2408
Intellitec
P/N 53-22117B100 Rev 021700
200 AMP BATTERY DISCONNECT
THE RELAYTHE RELAY
THE RELAYTHE RELAY
THE RELAY - How It Works
The Battery Disconnect Relay is a mechanically latching switch. It operates by the
momentaryapplicationofbatteryvoltagetothecoilterminalsinonedirectionforlatching
(closed), or the other direction for unlatching (open).
To close the relay, +12 volts is applied to the “I” terminal and ground to the “S” terminal
of the relay. When this is done, the plunger is magnetically pulled into the solenoid coil
andthecontactwasherconnectstothecontactstuds,makingelectricalconnection. While
thishappens,therodmagnet,suspendedbelowtheplungerinaplasticholder,isattracted
(opposite poles attract) to the plunger, by the magnetic field. It swings into position at
the end of the plunger ( See FIGURE 1 ). When the voltage is removed from the coil, the
plunger gets pushed back by the return spring, but is blocked by the magnet holder. The
contacts remain CLOSED.
Toopen the relay, +12 voltsis applied to the “S”terminal and ground on the“I” terminal.
When this is done, the plunger is again pulled into the coil. However, since the magnetic
polarity of the coil is reversed, the rod magnet is repelled (like poles oppose), and swings
out of the way ( See FIGURE 2 ). When the voltage is removed from the coil, the plunger
gets pushed out by the return spring, breaking the connection between the two large
terminals.
COACH BATT
SWITCH
COACH PANEL
SINGLE BATTERY DISCONNECT
MODELS BD0 & BD1
+12V
GND
LED 2.2K
NOTE: MOVE SWITCH
DOWN FOR USE
UP FOR STORE
FUSE
7.5 AMP
INTER-CONNECT CABLE
FUSE
7.5 AMP TO SYSTEM
NOTE: I TERMINAL + FOR USE
S TERMINAL + FOR STORE
COACH
DISCONNECT
COACH
BATT
BLANK
BROWN
RED
WHITE
GREEN
BLACK
1
2
3
4
5
6

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131 EISENHOWER LANE NORTH
LOMBARD, ILLINOIS 60148
630-268-0010 / 1-800-251-2408
Intellitec
P/N 53-22117B100 Rev 021700
200 AMP BATTERY DISCONNECT
NS
DISCONNECT CLOSED & LATCHED
Figure 1
NS
CONTACTS
OPEN
DISCONNECT OPEN
Figure 2

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131 EISENHOWER LANE NORTH
LOMBARD, ILLINOIS 60148
630-268-0010 / 1-800-251-2408
Intellitec
P/N 53-22117B100 Rev 021700
200 AMP BATTERY DISCONNECT
Trouble Shooting
Problem
Relay won't engage
Relay won't disengage
Light on panel remains on although relay is off.
Light is off although relay is on
BD1 No voltmeter reading
Possible
Cause/Solution
Check fuses on relay
Check battery voltage, must be greater than 10.5
volts.
While switch is engaged, check for voltage across
the coil terminals (+ on the ""I" terminal and ground
on the "S" terminal). If 0 volts, replace panel, if +
voltage, replace relay.
Check wiring
Check fuses on relay
Check battery voltage, must be greater than 10.5
volts
While switch is engaged, check voltage across the
coil terminals (+ on the "S" terminal and ground on
the "I" terminal). If 0 volts, replace panel, if +
voltage, replace relay.
Check wiring
Is coach plugged in? Unplug coach
Is engine running? Turn engine off
Check wiring
Check fuses on relay
Check wiring
Replace panel assembly
Check fuses on relay
Check wiring
Check voltage on green wire. If + voltage, replace
panel