Intel Solenoid Instructions.cdr

Intel Solenoid Instructions.cdr
Instruction Booklet
TIMER ACTIVE > 13.1 Volt
Battery Information
Batteries used in modern motor vehicles are typically lead-acid
batteries. These batteries have been chosen for their high
current supplying capabilities and their capacity.
In order for a lead-acid battery to be able to maintain full
capacity, it needs to be charged correctly.
In a single battery system, the vehicle’s alternator supplies an
appropriate voltage to the battery, allowing it to charge.
This voltage ranges from 13.5 volts to 14.5 volts.
If an auxiliary battery is installed, the load on the alternator will
be increased.
For a typical lead-acid battery to charge correctly, a minimum
voltage of 13.7 volts is recommended. A higher voltage such
as 14.2 volts allows the battery to charge at a higher rate and
to full capacity.
Some batteries (such as deep-cycle batteries) require this
higher voltage in order to charge correctly.
It is important to check whether your alternator can supply
sufficient voltage under this high-load condition.
Dual Battery Isolator
Split-charge systems
Split-charge systems are designed to control charge to more than
one battery, usually installed in a motor vehicle, boat or truck.
Split-charge systems vary in design and technique, but they all have
a common task of ensuring an auxiliary battery receives charge.
Preferred split-charging systems allow an auxiliary battery to
receive charge when a vehicles’ engine is running. When the
engine is stopped, the two batteries are automatically isolated.
(This prevents the vehicle starting battery from being flattened).
Intelligent Solenoid
The National Luna Intelligent Solenoid monitors voltage on the
main battery. If the engine is started, the Intelligent Solenoid
allows the main vehicle battery to recover charge first.
Unique Features
1. The Intelligent solenoid is designed with a 5-minute time
delay (before connecting the auxiliary battery) in order to
ensure that the main battery has a sufficient recovery/charge
period after starting.
2. The intelligent solenoid timer will automatically activate after
the vehicle has started and the alternator is charging above
Safety features : The intelligent solenoid has been designed
to detect and protect against fault conditions.
1. The solenoid will not engage in the case of the auxiliary
battery being absent (not connected) or completely flat.
2. Should the auxiliary battery be incorrectly connected
(i.e. reverse polarity), the solenoid will not engage.
3. If under a charging condition, the alternator (main battery)
voltage collapses below 12.7V, the system will disconnect
the auxiliary battery.
Because battery voltage varies with temperature, battery testing
is carried out at 25°C. (This is an international test standard)
Before Installation
Before installing your split-charge system, it is recommended to
check the vehicle charging system.
Installing a second battery may affect the vehicle’s charging
Checking the system : Perform the following test to determine
whether the charging system is capable of delivering charge to
a second battery : (You will need a digital voltmeter)
1. Start the vehicles’ engine and measure the voltage on the
terminals of the main battery. (The standard voltage of most
vehicle alternators should be between 13.7V and 14.5V)
Once a 5-minute time-period has elapsed, the auxiliary battery
is connected in parallel to the main battery. ( At this point,
charge will flow from the vehicle’s alternator to both batteries. )
2. Testing the alternator under load: With the engine running,
turn on the headlights, air-conditioning, and any other loads
(such as spot-lights). This will test the alternator under its
standard load. Under this condition, the voltage at the main
battery should not vary significantly from its original no-load
When the engine is stopped, both batteries remain connected
until their floating charge has dropped to 12.7V. Once this level
is reached, the auxiliary battery is automatically disconnected.
If the voltage drops significantly with the standard vehicle load,
it is recommended that the alternator and the vehicle charging
system be inspected for proper operation.
The National Luna Intelligent Solenoid uses voltage sensing and
timing to automatically control multi/dual battery systems.
NOTE - Because battery voltage varies with temperature, the
set-points listed may change.
The Intelligent solenoid is designed with the
following specifications at 25°C.
Supply voltage
Operating current
Standby current
Continuous current rating
Minimum ignition voltage
Automatic cut-out voltage
Timed connection >13.2V
10.0Vdc to 15.0Vdc
690mA @ 12.8Vdc
19mA @12.8Vdc
85 Amps DC
13.1 Vdc
12.7 Vdc
5 minutes to connect
TIMER ACTIVE > 13.1 Volt
Note that fuses marked FUSE 1,FUSE 2 and
FUSE 3 are not supplied but are recommended
for safety reasons in the event of accidental
electrical short-circuits.
(Cables and fuses are not supplied)
WINCHING (Dual Battery Controller required)
Should a winch be fitted to the vehicle, power
draws in excess of 300Amps can be expected.
In this case fuses 1 and 2 cannot be fitted.
3 16mm
Basic Installation
Disconnect the main battery before installation.
Securely mount the Intelligent Solenoid in a convenient position.
Make sure that it is installed upright.
Connecting the negative electrical path
Using a minimum cable thickness of 16mm2, connect the negative
1 of the main battery to the negative of the auxiliary battery.
Connecting the positive electrical path
Using a minimum cable thickness of 16mm2, make a connection
between the positive terminal of the auxiliary battery 2 to the
terminal marked “AUXILIARY BATTERY” on the Intelligent Solenoid.
Similarly, connect the positive of the main battery 3 to the
terminal marked “MAIN BATTERY” on the Intelligent Solenoid.
Finally, connect the thin BLACK wire 4 from the Intelligent
Solenoid unit directly to the negative terminal of the main battery.
Check all connections and secure all cables.
NB - Keep the unit and cables away from sources of heat
(such as the exhaust manifold) and sources of mechanical
movement (such as fan, fan belt or suspension components)
B ux
The National Luna Dual Battery Controller / Monitor
is compatible with the Intelligent Solenoid.
This monitor allows the user to observe the state
of both main and auxiliary batteries while warning
the user of overcharge and low-voltage conditions.
The monitor also allows the user to “over-ride” the
timer and force a connection at any time.
This is useful for “jump-starting” the main battery
or providing extra power from the auxiliary battery
during winching applications.
The Intelligent Solenoid is designed to automatically
disconnect the auxiliary battery if the main battery
voltage drops below 12.7V. (Typical during winching)
Optional Accessories
By fitting the Dual Controller, the user can over-ride the
12.7V cut-out feature and force the two batteries to connect.
(The timer/winch over-ride will remain active for 5 minutes).
The Dual Battery Controller is available with 3.5m or 6m cable.
Accessory / Auxiliary outputs
Safety considerations
The Intelligent Solenoid is a “FULL-POWER” device
designed to optimise auxiliary battery charging.
It is highly recommended to install fuses (labeled “FUSE 1” &
“FUSE 2”) in the main current path. These fuses should be rated
at the maximum expected current during normal operation
(between 50A and 100A).
If an unexpected overload occurs, these fuses will isolate both
batteries from the source of the fault.
The appropriate fuse (FUSE 3) rating, depending on the load
from the auxiliary battery, should be selected.
NOTE - Fuses are always fitted on the positive cable.
Cable considerations
Generally, thicker cable reduces voltage losses. This enables
a auxiliary battery to receive optimum charge.
A minimum cable thickness of 16mm is recommended for a
typical installation of up to 7m. For installations where the total
cable length exceeds 7m, 25mm2 or 35mm2 cable should be
Double-check all connections and crimping!
Poor connections will affect the performance of the system!
National Luna can also supply an extensive range of cables,
fuses, lugs, connectors and a range of battery monitors.
How it works !
The Intelligent Solenoid works by sensing voltages on both the
main and auxiliary batteries.
When the vehicle engine is started, the voltage applied to the
main battery rises as a result of alternator charging.
If the applied voltage rises above 13.1V, the Intelligent Solenoid
activates a 5-minute timer. During the timer phase, the GREEN
light (TIMER ACTIVE>13.1V) will flash.
Once the timer has expired, the Intelligent solenoid will
connect the auxiliary battery. The GREEN light will stop
flashing and the YELLOW light (SOLENOID ENGAGED)
comes on.
The Intelligent Solenoid will not allow a connection if the
auxiliary battery has reverse polarity, is short-circuited or
does not exist.
The Intelligent Solenoid will stay connected until the main battery
voltage drops below 12.7V. This happens when the engine is
stopped and the battery float voltage drops. Both GREEN and
YELLOW lights will go off once the solenoid has disengaged.
Note - The Intelligent Solenoid may stay connected for a short
period after the engine is stopped. The duration of this period
depends on the state of the batteries, temperature and load.
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