Intellitec Battery Disconnect Relay

[Lt46]

I'm troubleshooting this relay on my motorhome and I'm just not getting anywhere. While in storage I use this device all the time. On my monthly startups and genset exercise, I engage the relay from my dash switch and hear the typical "click" associated with energizing the relay. 12 volt power is present and I start the engine and genset. All is well until it comes time to shut things down. The process I follow is engine off, genset off and relay off. However, the disengagement of the relay is requiring more and more button pushing. To engage takes one push of the button, but to disengage requires many, many pushes and if lucky it will disengage. Is this a signal of a failing relay? Any discussion is welcomed. Thanks

[enblethen]

Thanks for the update!

[Lt46]

The fix was replacing the Intellitec relay. I opened the old unit and found the copper washer well scored around its edges and areas where it would stick rather than move up and down via return spring pressure. Thanks for all your help.

[dougrainer]

Matt_Colie wrote:
Peter,

The part you are trying to diagnose may be stranger than you expect. It is a tall solenoid affair, then it is one of these and in lots of years, I have only seen one actually fail.

The trick is that it is not a Normally Open or Normally Closed type of contactor (electrician for BIG relay). It has two permanent magnets that will hold it either open or closed. The switch feeds it a pulse with the polarity one way for Open and a reversed polarity pulse for Close. So the switch is the same as the type for reversing a simple DC motor.

I will lay odds that the switch is failing. I have recovered these a few times (usually in power boat trim tab motor controls). If the switch can be removed without too much effort and you feel adventurous then get the switch loose and get someplace where you can take it apart. Be very careful at this stage because there are little springs and brass fingers that can attain escape velocity and then you have to buy a new switch. It will probably have lots of old hardened grease that is keeping one set of contacts from making good.

If you need to buy one, what you want is a DC reversing switch that is momentary both ways. It may say DPDT Mom On-Off-Mom On. I don't have
the catalog I want here so I can't give you a part number.

Matt

Matt, you are way off on your diag. Intellitec Relays are called Latching Relays. So named because they require NO POWER for either Open or Closed, hence no current draw when used or not used. I have 40 plus years as a Service tech and I have replaced upwards of hundreds of defective Intellitec solenoid relays. The SWITCH IF it causes the relay to "click" is NEVER at fault. RARELY have I ever had a defective wall relay switch. You reference Boat applications. I assume that is your main expertise. Well, I don't work on boats but have worked on RV's for 42 plus years. I stand by the fact it is the relay(Intellitec is the ONLY brand replacement you can use) for this application. Click the link to view the relay the Poster has. Notice the 2- 5 amp fuses. THOSE protect the wall switch panel. Doug

https://www.amazon.com/INTELLITEC-0100055000-Battery-Disconnect-Relay/dp/B072N8NYN2/ref=asc_df_B072N...

[wa8yxm]

Ok try this.. The only guarantee is the ultimate money back guarantee (If it does not work, or even if it does, your FREE is herby refunded)

Disconnect all batteries. You want no power source.. -OR- (alternatively)
Disconnect the switch OR pull the fuse (5 amp) feeding it.

Operate the switch like 100 times.

Restore power and try again.

If it works continue reading if not Stop here

So what happned:

For this post switches come in two types.
One type the contacta are either one above the other or beside each other and they come straight together. Most relays are like this.

The other is the "Self Cleaning" switch
In this type the contacts "Wipe" across each other. and thus polish (Burnish) themselves.. But if they get dirty enough. that don't get it done due to arching as they wipe.. So removing power (Removing the arc) and operating. cleans 'em up.

Finally.
If it works.. Consider this question
When you hot, you hot so go out and buy lotto tickets.
Or
I done used up all my luck for this time period (don't by lotto tickets)

[Lt46]

Thanks guys! Great answers and I'll check everything over closely. Should I need to replace, it is good to see the cost is relatively cheap.

[Bobbo]

Matt_Colie wrote:
It has two permanent magnets that will hold it either open or closed.

Not according to Intellitec.

Intellitec wrote:
The Battery Disconnect Relay is a mechanically latching switch that operates by the momentary application of battery voltage to the coil terminals in one direction for latching (closed) or the other direction for unlatching (open).

See page 3 of this online manual: Online Intellitec Battery Disconnect Manual

[pianotuna]

If it is the relay, replace with a non latching unit. Get one rated for twice the amperage that may be in use.

Test the switch by deliberately shorting it, and see if the issue is gone.

[enblethen]

There is two different styles of the latching relays. Mine uses the
INTELLITEC 0100055000 Battery Disconnect Relay.
Intellitec latching relays

[Matt_Colie]

Peter,

The part you are trying to diagnose may be stranger than you expect. It is a tall solenoid affair, then it is one of these and in lots of years, I have only seen one actually fail.

The trick is that it is not a Normally Open or Normally Closed type of contactor (electrician for BIG relay). It has two permanent magnets that will hold it either open or closed. The switch feeds it a pulse with the polarity one way for Open and a reversed polarity pulse for Close. So the switch is the same as the type for reversing a simple DC motor.

I will lay odds that the switch is failing. I have recovered these a few times (usually in power boat trim tab motor controls). If the switch can be removed without too much effort and you feel adventurous then get the switch loose and get someplace where you can take it apart. Be very careful at this stage because there are little springs and brass fingers that can attain escape velocity and then you have to buy a new switch. It will probably have lots of old hardened grease that is keeping one set of contacts from making good.

If you need to buy one, what you want is a DC reversing switch that is momentary both ways. It may say DPDT Mom On-Off-Mom On. I don't have
the catalog I want here so I can't give you a part number.

Matt

[dougrainer]

It is a failing relay. Just replace it. There is a metal disc that moves up and down in the relay. After lots of moving over the years, it gets burned edges and "sticks". That is why repeated pushing of the switch will then move it. Doug

[enblethen]

Could be low battery condition.
Failing switch.