Intellitec Mini-Bus Application Installation And Troubleshooting Manual Download Page 5

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Intellitec

131 Eisenhower Lane North
Lombard, IL 60148
630 268 0010 / 1 800 251 2408

P/N 53-00778-100 Rev. 062003

www.Intellitecsve.com

Intellitec

Application Installation and Trouble Shooting Guide

Mini-Bus Multiplex System

BASIC

SYSTEM

WRING

DIAGRAM

SPARE

FUSES

MiniBus Multiplex

Master Module

P/N 00-00778-000

MADE IN THE USA

by Intellitec

Switch

Adapter

Aux

Heater

Door

Aux

Output

Modules

Lighting

Output

Lighting

Output

Aux

Output

Aux

Output

+Ign., Neg Bat -

J1-1

J2-1

J3-1

J4-1

J5-1

J6-1

J7-1

Switch

Adapter

Master

Module

Light

Aux

Ignition

Source

Battery

Page 5

Summary of Contents for Mini-Bus

Page 1: ...the bus Multiplexing reduces the number of wires for the switches from as many as 48 to 3 MULTIPLEX COMMUNICATIONS See channel allocation table on Page 2 THE MASTER MODULE The power from the battery is connected to the Master Module and switched there eliminating the need for heavy wires at the switches The Master Module provides automatic features to help manage the battery power on the bus The M...

Page 2: ...y This module can also be used to operate a hot water booster pump The Door Control Module provides a number of features to control the door and operate the step well light and the interior lighting To operate the door the switch adapter mounted switch is flipped to the OPEN position The door will travel to the end of travel and the controller will sense the motor over current and shut off the pow...

Page 3: ... allow for easy replacement of the fuses for service and also allow easy connections to both the battery input and the loads The location should also provide some amount of ventilation to provide cooling for the module Mount the module with four 8 screws through the holes in the cover Connect the battery cable to the 1 4 bolt on the top of the module using wire capable of safely carrying all the p...

Page 4: ...480700 0 J4 1 12 V out F5 J4 2 IPX Signal J4 3 Signal Ground Mating Connector AMP 1 480700 0 J5 1 12 V out F6 J5 2 IPX Signal J5 3 Signal Ground Mating Connector AMP 1 480700 0 J6 1 12 V out F7 J6 2 IPX Signal J6 3 Signal Ground Mating Connector AMP 1 480700 0 J7 1 12 V out F8 J7 2 IPX Signal J7 3 Signal Ground J3 J4 J5 J6 J7 Aux Output Door 1 Door 2 Aux Heater Switch Adapter Page 4 AMP CONTACTS 1...

Page 5: ...G DIAGRAM 20 20 10 10 10 SPARE FUSES 3 15 10 MiniBus Multiplex Master Module P N 00 00778 000 MADE IN THE USA by Intellitec Switch Adapter A B Aux Heater Door 2 Door 1 Aux Output Modules Lighting Output 1 Lighting Output 2 Aux Output 1 Aux Output 2 Ign Neg Bat J1 1 J2 1 J3 1 J4 1 J5 1 J6 1 J7 1 F8 F7 F6 F5 F4 F3 F2 F1 Switch Adapter Master Module Light 1 Light 2 Aux 1 Aux 2 Ignition Source To Batt...

Page 6: ...n rotary switch will have to be connected to the 4 pin Mate N Lok on the Switch Adapter This will allow the selection of three speeds If the Switch Adapter sends a signal out on Channel 16 Output A will supply power If the Switch Adapter sends a signal out on Channel 15 Output B will supply power If the SwitchAdapter sends signals out on Channels 15 16 simultaneously Output C will supply power Mul...

Page 7: ... Aux Heater Module The wire connecting pin 1 will carry the fan current and must be sized to safely carry the current of the fan If the control is to be used to operate a circulating pump outputs from J2 2 J2 3 and J2 4 should be connected together to feed power to the pump Page 7 J1 J1 1 12 Volts Input Power J1 2 Multiplex Signal J1 3 Multiplex Signal Ground Inputs Mating Connector AMP 1 480700 0...

Page 8: ...llitec Switch Adapter A B Aux Heater Door 2 Door 1 Aux Output Modules Lighting Output 1 Lighting Output 2 Aux Output 1 Aux Output 2 Ign Neg Bat J1 1 J2 1 J3 1 J4 1 J5 1 J6 1 J7 1 F8 F7 F6 F5 F4 F3 F2 F1 Switch Adapter SYSTEM WIRING DIAGRAM with FAN CONTROL MODULE Master Module Light 1 Light 2 Aux 1 Aux 2 Ignition Source To Battery Optional Remote Four Position Fan Speed Switch Optional Additional ...

Page 9: ...ing the door should it encounter an obstruction such as a curb or sign If while the door is closing the module senses stall current a door obstruction and the door closed switch has not been activated the door will open This feature simulates a sensitive edge on the door When the obstruction has been cleared the Operator must operate the switch again to close the door The door closed switch adjust...

Page 10: ...he door system must be fully installed and operational Start with the control adjusted to minimum current setting fully counter clockwise Operate the door to close it The door will probably not fully close before the controller will turn it off If this is the case turn the control 1 8 of a turn and repeat the open and close cycle to check the operation Once the door operates fully in both directio...

Page 11: ... with the lead connected to J2 1 which should be 12 V to close the door and the lead connected to J2 2 which should be 12 V to open the door Continue the wiring by connecting a power ground to J3 8 A door closed switch is connected to J3 4 5 The position of this switch is not critical but the contacts need to close just prior to the door reaching a fully closed position This switch will only carry...

Page 12: ...ed SW Door Closed SW Sen Edge SW Sen Edge SW Step Well Light Door 1 Door 2 Jumper Setting 20 20 10 10 10 SPARE FUSES 3 15 10 MiniBus Multiplex Master Module P N 00 00778 000 MADE IN THE USA by Intellitec Switch Adapter A B Aux Heater Door 2 Door 1 Aux Output Modules Lighting Output 1 Lighting Output 2 Aux Output 1 Aux Output 2 Ign Neg Bat J1 1 J2 1 J3 1 J4 1 J5 1 J6 1 J7 1 F8 F7 F6 F5 F4 F3 F2 F1 ...

Page 13: ...s Light J2 2 Motor 12 V for Open J3 2 Sensitive Edge Switch Gnd J3 3 Sensitive Edge Switch J3 4 Door Closed Switch Gnd J3 5 Door Closed Switch J3 6 Stand Alone Key Switch Gnd J3 7 Stand Alone Key Switch J1 3 J1 2 J1 1 J3 8 J3 7 J3 6 J3 5 J3 4 J3 3 J3 2 J3 1 J2 2 J2 1 MiniBus Multiplex Door Controller Made in the USA By Intellitec P N 00 00787 000 Com Ground Multiplex Signal 12 Volts CLOSE OPEN Sta...

Page 14: ...ch allowing the adapter to be configured in different ways The dip switch is located on the rear board of the Adapter Dip switch position one is set to determine which door module and which outputs will respond to the switches To make the door switch operate Door moduleA set dip switch one to the OFF position B set dip switch one to the ON position Dip switch one also Dip switch 2 is used to deter...

Page 15: ...DIP SWITCH SETTINGS Position Function Aux 2 Aux 1 OFF Aux 1 output will turn off with ignition ON Aux 1 output off 20 min after ign Off DIP SW1 DIP SW 2 DIP SW 3 Door channel select OFF Door A L1 L2 Aux 1 Aux2 Heater fan ON Door B Aux 3 4 5 6 7 8 OFF Door switch works only with ignition ON ON Door switch is always active OFF Aux 2 output will turn off with ignition ON Aux 2 output Off 20 min after...

Page 16: ...r but allows more flexibility in the location installation of switches and accepting of other input signals For example you may wish to use anAuxiliary output to operate marker lights when the head lights switch on 00 00813 000 00 00813 100 The A module will turn on the lighting circuits and auxiliary 1 and 2 on the Master Module operate the Fan Speed Module and the Door A Control Module The B mod...

Page 17: ...ce J2 3 Indicator Power Source J2 4 Indicator Lamp J3 1 Input J3 2 12V source J3 3 Indicator Power Source J3 4 Indicator Lamp J4 1 Common J4 2 Low Spd Input 15 J4 3 Med Spd Input 16 J4 4 High Spd Inputs 15 16 J4 5 Indicator Power Source J4 6 Indicator Lamp J5 1 Input J5 2 12V source J5 3 Indicator Power Source J5 4 Indicator Lamp J6 1 Input J6 2 12V source J6 3 Indicator Power Source J6 4 Indicato...

Page 18: ... J1 2 12V source J1 3 Indicator Power Source J1 4 Indicator Lamp J2 1 Input J2 2 12V source J2 3 Indicator Power Source J2 4 Indicator Lamp J3 1 Input J3 2 12V source J3 3 Indicator Power Source J3 4 Indicator Lamp J4 1 Common J4 2 Input Aux 7 Low Spd J4 3 Input Aux 8 Med Spd J4 4 Aux 7 8 Hi Spd J4 5 Indicator Power Source J4 6 Indicator Lamp J5 1 Input J5 2 12V source J5 3 Indicator Power Source ...

Page 19: ... 10 SPARE FUSES 3 15 10 MiniBus Multiplex Master Module P N 00 00778 000 MADE IN THE USA by Intellitec Switch Adapter A B Aux Heater Door 2 Door 1 Aux Output Modules Lighting Output 1 Lighting Output 2 Aux Output 1 Aux Output 2 Ign Neg Bat J1 1 J2 1 J3 1 J4 1 J5 1 J6 1 J7 1 F8 F7 F6 F5 F4 F3 F2 F1 Master Module Light 1 Light 2 Aux 1 Aux 2 Ignition Source To Battery To Head Lights To Brake Lights M...

Page 20: ...spond to the same switch offering distributed switching or the outputs of two modules can be paralleled to provide more current for a single load 20 30Amps such as left side right side bank switching SPECIFICATIONS INSTALLATION Be sure the wire feeding the module will safely carry the total current to be drawn from the module MAXIMUM CURRENT Circuit Name Fuse Function Channel Conn Fuse Output 1 10...

Page 21: ...Com Com Not Used by Intellitec 1 2 3 JP1 JP2 JP3 J1 J2 1 1 Power Input from battery J1 J2 Input Outputs Mating Connector AMP 1 480700 0 J1 1 No connection J1 2 IPX Signal J1 3 Signal Ground Mating Connector AMP 1 480702 0 J2 1 Power ground J2 2 Output 1 Aux 6 or 3 J2 3 Output 2 Aux 5 or 7 J2 4 Output 3 Aux 4 or 8 AMP Contacts 14 18 AWG 10 12 AWG 350919 3 640310 3 Page 21 AUXILIARY OUTPUT MODULE JU...

Page 22: ...s low the step well light output on the door module will turn off whether the ignition is on or off If the vehicle is fitted with a door module the step well light can be used as an indicator of a low voltage condition The most common solution to this problem is to recharge the battery or to start the engine A wiring problem could also be at fault Check the connection from the battery stud on the ...

Page 23: ...e purposes when the vehicle does not have a second door If the fuse for door 1 F5 is open no power will be supplied to the door module and therefor the door and stepwell light will not operate If the fuse for Lighting output 1 F4 is open no power will be supplied to the lighting one circuit and therefor the light will not operate from either the switch panel or when the door is open If the fuse fo...

Page 24: ... See the switch adapter settings on page 15 Only an adapter set for A will operate outputs at the master An adapter set for B will operate auxiliary outputs located on the auxiliary output modules At the switch adapter remove the 3 pin plug This harness should go back to J7 on the master Measure the voltages on the harness Pin 1 3 should measure battery voltage and pins 2 3 should measure the comm...

Page 25: ...d go back to J4 or J5 at the master Check multiplex communications on the harness by measuring the voltage between pins 2 and 3 You should measure 6 5 9 volts Check between pins 1 and 3 You should measure battery voltage If these check out the harness is ok If there is an exterior key switch check to make sure that it is not in the close position When the door is closed via the exterior switch the...

Page 26: ...k out the harness is ok Although the wheel chair lift interlock is a stand alone product it is often used with the MiniBus Multiplex System We are therefore including some trouble shooting tips with this manual For data sheets and wiring information please see our web site at www intellitecsve com The wheel chair lift interlock prevents operation of the lift unless the ignition is on the transmiss...

Page 27: ...dule senses that both pins J2 and J3 are at ground Ford Trans Park signal comes from circuits 145 and 146 connector pins 13 and 14 on diesel Park Brake Lift Door Shift Sol Lift Power Dome Light Warning Lights When using message module Do Not make this connection Buzzer or Intellitec message Module inputs 1 7 Ford Brake Switch 12V 12V 12V When output is on this pin switches to ground Internal relay...

Page 28: ...8 0010 1 800 251 2408 P N 53 00778 100 Rev 062003 www Intellitecsve com Intellitec Application Installation and Trouble Shooting Guide Mini Bus Multiplex System For additional information see www intellitecsve com or Contact General Dynamics Intellitec Products ...

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