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12 Volt Electrical Distribution and Charging System Required parameters are missing or incorrect. Digital Volt Meter - + Digital Amp Meter 12V Power Switches and Solenoids function and placement 12V Power from Metered Voltage Signal Input 1. All switches except the B switch are mounted on the right side of the main dash. 2. The B switch is located on the left auxiliary dash. 3. HI Sol and B Sol are mounted in a can behind the driver’s side rear tires. 4. The Isolator is mounted on the outside of the above can. 5. H Sol is mounted on the electronics panel in the upper section of the battery box. DVM SPDT SPDT Isolator Solenoid or Switch 6. HI = House Center off 7. B = Boost Solenoid or Switch 8. H = House solenoid or Switch 9. All Shunts are within 0.050 Volts of ground potential. 10. The DVM SPDT On/On - selects House or Chassis voltage HCB-DPDT to be displayed. BA-DPDT 11. The HCB-DPDT On/On - selects between the House or Chassis Battery shunts for the Red Lion display. ON/ON ON/ON SPST 12. The AM BA-DPDT On/On selects between the Battery or Alternator shunts for the Red Lion display. ON/OFF 13. The AM SPST On/Off - provides 12 volt power for the Red Lion display. 14. The AM switch is located on the right of and at the back of the Red Lion enclosure. 15. 12 TheVolt B SPST Buss rocker switch is the top right switch on the left auxiliary dash. Solenoids From House Tyco Electronics EV200AAANA batteries 500state Amps The HI solenoid is normally kept in the open state and is activated using HI switch. The open of Continuous the solenoid will 2000 Amps Momentary insure no current from the alternator will reach the House batteries until the user determines the alternator can supply House Batteries the Lifeline current necessary GPL-4C to prevent over working the alternator. H, HI and B Solenoids Examples would be: AGM You– wish 61.Each 6 voltto wait until the Chassis Batteries are fully charged before sending current to the house batteries. 2. You wish to separate the two charging systems because you are running the generator to charge the House HB Shunt 660 AMP Hours batteries via the converter. 3. You are charging the House batteries as you drive using solar. HI Solenoid H Inverter/Converter Solenoid 3000 TheMagnum H solenoid is normally kept in the closed state. Opening this solenoid will remove the House batteries from supplying power to the 12 volt house buss. HI Sol This solenoid will be opened when the user wishes to run the house while driving using the alternator to supply the power to the house and inverter if used. Running the House and Chassis using the alternator should only be attempted afterShunts the Chassis batteries are fully charged. This will insure a lighter load for the alternator. While operating in this condition havetothe shunt selected so alternator current can be monitored. Try to keep the alternator current 500 Amps 50alternator MV Isolator below 50 % of alternator rated output. I operate a 24 inch LCD monitor requiring 110 volts from my inverter for GPS software as well as the 12 volt requirements for House and Chassis. Once the Chassis batteries are fully charged my alternator output is a little over 30 amps while driving with the House batteries off line. Running with the lights on will A Shunt CB Shunt up this current by 25 to 30 amps. B Solenoid The B or Boost solenoid switch via the Boost solenoid provides charging current for the Chassis batteries and Starting Alternator Output Chassis current Batteries (Boost)Alternator current for the engine. The B solenoid has a continuous rating of 500 amps and a momentary of 2000 Trojan Mileage Master amps. Lease Neville GEL 160 Amps 2 - 12 volt – 1000 CCA 12 Volt Electrical Distribution and Charging System Switch Layout 1. The H, HI, DVM, BA, and HCB switches are located on the right side of the main dash under the 12 volt auxiliary power outlet. 2. The B switch is located on the side switch console under the Retarder Joy Stick. This is the Boost switch. 3. The AM switch is located on the right side of the Red Lion enclosure in the back near the top. 12 Volt Auxiliary Power Outlet. Switch Number 1 H switch that controls the H solenoid HI switch that controls the HI solenoid DVM - switch that controls the readout of the Volt Meter. Up is for House and down is Engine. 2 HCB – switch that selects the House or Coach Battery current to be seen on the Amp Meter. Up is for House and down is for Coach. 3 4 5 BA – switch that shows ether one Battery pack or the Alternator current to be seen on the Amp Meter. The HCB switch selects the battery pack. 12 Volt Electrical Distribution and Charging System How this system can and should be used. 1. Monitor Starting Current a. Before Engine Start setup (I numbered the switches to simplify this part) i. Switch 1 on or up position. House batteries are providing power to the House. ii. Switch 2 off or down position. This will prevent Alternator from charging House batteries after engine start. iii. Switch 3 N/A or set to see the voltage you wish. iv. Switch 4 on in up position to monitor battery current. v. Switch 5 on in down position to monitor Engine Start batteries. vi. Switch B (Boost) off so House batteries are not boosting engine start. vii. Record engine coolant temperature. Use this information to determine if the maximum starting current is normal. As the engine coolant temperature at engine start drops the expected maximum starting current will increase. Record what is normal for your engine at given temperatures. b. During Engine Start i. The Red Lion will monitor and change the display reading every second and the display will keep that reading for a full second. This provides a stable output that can be monitored and understood when the current on the selected Shunt is changing rapidly. Because of this noncontinuous display of current you can use this feature to monitor and understand what is happening. ii. The Engine should take between 3 to 5 seconds to start. If your Engine takes 5 second to start then you will see 5 changes in current during that starting period. What this system will tell you in that 5 seconds is as follows: 1. The maximum current used to start the engine. 2. When in seconds that maximum current was reached. 3. How many seconds it took to start the engine. iii. Record the information in step “ii” for future use to determine if the time taken and current required in starting the engine is normal. If the information starts to become abnormal then steps can be taken before a failure occurs. c. After Engine Start i. Monitor charging current of the engine start batteries. ii. Record charging current for future use to determine if the current is normal. iii. Higher charging currents after engine start may be caused by: 1. Longer than normal engine start interval 2. Temperature 3. Aging engine start batteries 2. Monitor and control Battery Charging a. After the engine is running the Alternator will provide current at 14.1 volts to the engine start batteries. This current and voltage will need to be monitored and controlled to prevent excessive current draw from the Alternator. The Alternator will try to supply as much current as the batteries will ask to be supplied plus the current required to run the engine. Try to keep the output amperage from the Alternator below 80% of the rated capacity. To keep the output current from the Alternator below 80% the following steps should be taken: i. Do not close the HI solenoid (House Inverter) to charge the House batteries until the engine start batteries are fully charged. Fully charged engine batteries will be taking less than 10 amps of charging current. ii. Do not have the Head Lights, Dash Air or Dash A/C on when closing the HI solenoid. iii. Monitor House batteries charging current to determine when the Head Lights, Dash Air or Dash A/C can be turned on without excessive output current from the Alternator. iv. Monitor Alternator current whenever making changes in output demand to insure the 80% maximum is maintained. 12 Volt Electrical Distribution and Charging System 3. Monitor Battery Voltage a. Select the battery pack you wish to monitor for voltage. 4. Monitor Alternator Amperage a. Monitor Alternator current whenever making changes in output demand to insure the 80% maximum is maintained. b. Monitor Alternator current when House batteries have been Isolated (disconnected) from electrical system. c. Monitor Alternator and system currents “before engine shutdown” to insure the following: i. The House batteries are back on line providing power for the House. The H switch is on and the H solenoid is closed. You will see that this is true because of the increase in Alternator current and the current is positive going into the House batteries. When the House batteries were isolated the current into or out of the House batteries was 00.0. ii. At this point open the HI solenoid by turning off the HI switch. Caution: Make sure you have completed step “i” above before this step because if the HI solenoid is opened before the H solenoid is closed the House batteries will not be able to power the House and all House functions requiring power will discontinue operation. iii. If the above two steps were completed correctly the following will be true: 1. The current into or out of the House batteries is negative. This indicates the House batteries are supplying power to the house. 2. The Alternator is not supplying current to the House. 3. It is now safe to shutdown the engine. If this is not completed correctly you will not damage anything but you will not have power to the house. You most likely will do this incorrectly two or three times before you finally check this procedure before engine shutdown. 5. Isolate House Batteries from high Alternator voltage when traveling. a. The reason for using this feature is to save battery life in the AGM or GEL batteries by removing the high 14.1 voltage from the House batteries after they have been charged. This should occur approximately one to two hours of charging after the House batteries were placed on line with the Alternator. b. To understand this charging method three stage charging must be understood. Your converter when operating properly will place 14.1 to 14.3 volts to the AGM or GEL batteries during charging and then drop the voltage to 13.1 to 13.3 volts to Float the batteries. The Alternator doesn’t have a Float feature so removal of the Alternator voltage and current from the House batteries is the only option. c. The removal of the House batteries from the electrical system is completed by opening the H solenoid with the H switch. To accomplish this correctly the following must be completed in the order listed below: i. The engine must be operating properly. ii. The Alternator is operating properly. iii. The HI solenoid is closed providing charging current to the House batteries. (The House batteries show a positive current.) iv. The Alternator has charged the House batteries to the Float point or you have determined that you don’t wish to fully charge the House batteries before Isolation. Fully charged House batteries in most cases will be receiving less than 25 amps of current from the Alternator when the batteries are at the point of needing a Float voltage. v. Only after you have completed the above 4 steps should you open the H solenoid with the H switch that will isolate (Remove) the House batteries from the electrical system. d. Caution: When Isolating the House batteries make sure you put the House batteries back on line following the correct engine shutdown procedures listed in step 4 to prevent engine shutdown without electrical power to the House. 12 Volt Electrical Distribution and Charging System Here are some of the switches that control the solenoids: 1. The two switches on each side of he Road Relay 4 (BA-DPDT and HCB-DPDT) determine the shunt providing the input to the display below the Road Relay. 2. The square red pushbutton to the right of the Road Relay is the pushbutton for the HI solenoid. 3. The black handled toggle switch above the SmartTire monitor is the switch controlling the H solenoid. 4. The LEDs to the left of the AUX POWER text shows the state of the H Sol and HI Sol Solenoids. 5. The LEDs to show the state of the generator were relocated above the word GENERATOR to make room to mount the Sirius radio. The LEDs are barely seen in the top of the photo. 6. The top of the backup monitor was tilted backwards 1 inch with PC board spacers to permit a better viewing angle and show the color depth and contrast properly. 12 Volt Electrical Distribution and Charging System 12 Volt Electrical Distribution and Charging System 1. The red handled toggle switch (DVM SPDT Center Off) in the middle provides input to the digital volt meter. Up is House while down is Chassis batteries. The switch is currently centered and is providing no input to the volt meter. 2. The black handled toggle switch provides high or low panel decorative lighting. When I purchased this coach the potentiometer and voltage controller for this lighting was fried. I called the manufacture and found that this feature was installed with a built in failure. The controller requires a minimum voltage or it will burn up and take the potentiometer out as well. When operating the marker or headlights with the potentiometer at a minimum does not provide the minimum voltage to the controller and it will burn up. I added this toggle switch with a resistor on the low position to provide that minimum voltage and give the user a high and low setting for the decorative lighting. 3. Momentary rocker switch to control the B Sol and ES Sol Solenoids. 4. Group of small SPST switches that control the 12 volt power for the Red Lion (AM SPST), and visual feedback for LEDs as to the state of other solenoids and the headlights. 5. Feedback LED (4) (3) (1) (2) (5) 12 Volt Electrical Distribution and Charging System Amp meter showing selected shunt current 12 Volt Electrical Distribution and Charging System This shows visual and tactile feedback that the headlights are on and the BA DPDT switch. Digital Volt meter and visual feedback LED showing the state of the marker and headlights. Great aide for the audio challenged. 12 Volt Electrical Distribution and Charging System