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Battery Boost relay

Yahoo Message Number: 67527
I just replaced my battery boost solenoid. It was not making connection when I hit the boost switch or when oil pressure switch closed. After I replaced the solenoid and checked that it worked, I dissected the old one.
First thing I found was one of the internal riveted coil connections was very heat corroded and actually broke when I pulled on it. It looked as if the rivet had not had a good elect connection.
Second item was the main contacts. There was very little contact area pitting. Less than 1/8th inch in diameter. (This is a 200 amp rated contact!) The contacts looked new except for the small area of pitting. What I found was at full travel the contact just barely made. No spring tension was applied to the contacts at all. Not very reassuring as I replaced with same manufacturer and model. Past performance is no indication of future results, but, if this fails again I will have to look for a suitable replacement from another manufacturer. Not very good for a $50 solenoid.

Dave

aka Billy Byte (trusty hound)
2000 Allure #30443

Re: Battery Boost relay

Reply #1 –
Yahoo Message Number: 67528
Dave,

What was the orientation of the solenoid when mounted in your coach? Does the plunger move up and down, against and with gravity, or sideways , perpendicular to gravity? Not related to corrosion, obviously, but perhaps to contact pressure.

Dave

2000 Allure
#30444

Re: Battery Boost relay

Reply #2 –
Yahoo Message Number: 67541

Dave The contact is mounted on its side with the mounting facing to the rear of the coach. It Does have a release spring which had good tension. Your point is good, under ideal conditions it would be mounted vertically with the terms facing up. As far as contact pressure goes, it is unable to actually apply pressure in any position as the travel was not enough to compress the contact tension spring. It is either a bad design or incorrect assembly. Having rather rudely disassembled the solenoid with no thought of rebuilding I will not try to repair as a spare. However, should the new one present problems I will try to rebuild that one and improve the function should the failure be the same.

Dave

aka Billy Byte (trusty hound)
2000 Allure #30443

Re: Battery Boost relay

Reply #3 –
Yahoo Message Number: 67544
Dave,

What made you aware the solenoid was not working - inability to use the battery boost to bring up the coach battery sufficient to start or non- charging of the house battery bank by the alternator going down the road?

Jim M

'02 Intrigue #11410 ISL 400

Re: Battery Boost relay

Reply #4 –
Yahoo Message Number: 67550
Dave,

Yes that is how mine was mounted, also. Not surprising, since we have consecutive coach numbers.
When mine failed a few years ago, I obtained a replacement which I promptly dropped and fractured the case, breaking off one of the riveted flanges. So, head hung low, I returned the old one to service, re-orientating it to vertical as the mfg'r suggests. It's been working fine ever since, and I did nothing to it other rotate 90 degrees.
Riveted wires certainly do not give one a warm feeling as to a reliable electrical connection, especially in a non-hermetic environment. I would have expected spot-welds or solder.
I'll have to pull off the shelf the broken unit and have another look at it's plunger travel sometime and see how it compares.

Good Luck,

The other Dave
2000 Allure
#30444

Re: Battery Boost relay

Reply #5 –
Yahoo Message Number: 67552

Dave

By the way, in my battery compartment there is a panel with enclosed fuses on the wall to the rear of the coach. It is marked 30444. I wonder if your is 30443.............

Dave

aka Billy Byte (trusty hound)
2000 Allure #30443

Re: Battery Boost relay

Reply #6 –
Yahoo Message Number: 67553

Jim

It was not charging the coach batteries while running down the road. When I tried the boost it did not work either. I have a digital volt meter I can see from the drivers seat to keep me apprised of my battery conditions.

Dave

aka Billy Byte (trusty hound)
2000 Allure #30443

Re: Battery Boost relay

Reply #7 –
Yahoo Message Number: 67559
By "coach batteries" do you mean all of the batteries, the chassis/start battery or the domestic/house battery bank? I think you meant the domestic/house bank which wouldn't charge if the solenoid was defective.

Jim M

'02 Intrigue #11410 ISL 400

Re: Battery Boost relay

Reply #8 –
Yahoo Message Number: 67563
I googled Battery Boost Relay, A thread shows a photo of several and some good reading. Working for Cat Our endusers used Isolater's which were just two large diodes mounted on heat sinks, Im, not a fan of this as there is a voltage drop across these Diodes. The thread is food for thought! Like CC Ilike relays rated for proper amps. If the House Battery is low it puts a atrain on the Battery Charging Alternator! The relay coil must be rated Continoius Duty. Ken 99 Allure 30356 http://www.neon-john.net/RV/Electrical/rv_battery_isolation_relays.

Re: Battery Boost relay

Reply #9 –
Yahoo Message Number: 67961
Dave

I'm looking for one of those relays as I have the same problem. Can you put up the information for the relay like maker and part number?

Thanks

Jack 1997 Allure 30076

Re: Battery Boost relay

Reply #11 –
Yahoo Message Number: 67978
Jack,

I bought two of these 12VDC 200 amp arm and hammer relays model number 6041H105 off of Ebay as NOS. Very popular on small aircraft such as Piper Cherokee 6's (I owned one for awhile) They were used for running the master switch so they had to be approved for aircraft and be good. Same as used on our coaches.
I am at the end with one of my relays right now so I have two brand new backups. I got both of them for $39.99 just two weeks ago in the orignal boxes. Just type in the model number above on google and if there are some on ebay or elsewhere it will take you to them.

Dallas 2004 intrigue ovation 42 11688

Re: Battery Boost relay

Reply #13 –
Yahoo Message Number: 67982

Bob

That will work as a charging unit, however it will not give you 200 amp boost capability for starting.

Dave

aka Billy Byte (trusty hound)
2000 Allure #30443

Re: Battery Boost relay

Reply #14 –
Yahoo Message Number: 67985
Thanks Dave,

WW Williams found one today. I am going to buy one of these as a spare.

Thanks again

Jack Allure 40 1997 # 30076
 

Re: Battery Boost relay

Reply #15 –
Yahoo Message Number: 68006
Off subject a little but I think I've seen several mentions on this forum about the battery boost relay being rated for 200A to withstand the current surge when starting. If I recall the directions for use, it's stated that properly the boost should be activated for 30 or 90 seconds and then disengaged before attempting to start to avoid damaging the solenoid by the start current. The 200 A rating is so it can handle being continuously "on" while the engine is running. Maybe not quite the same thing but it's apparently not meant to handle starting current.

JiM M

'02 Intrigue #11410 ISL 400