EGIS XD Series Triple Bi Stable Flex Relay Installation Guide

EGIS XD Series Triple Bi Stable Flex Relay

Product Information

The XD Series Triple Bi-Stable Flex Relay/ACR/LVD is a versatile and reliable device that offers ultra-low power draw and flexible application options. It features a simple and robust installation process with sealed plugs/harnesses included, making it easy to install in any vehicle. The device can be installed as a Time Delay Relay, Battery Management Relay, Low Voltage Disconnect, or Simple Relay. The On/Off trigger is via external Ignition signal and/or alternator voltage sense, and adjustable low voltage protection levels increase flexibility.

The device also features an optional adjustable OFF Time Delay of 0 seconds to 4 hours. Diagnose feedback is available via optional external LEDs control lines and on-board LEDs for each relay. The unit is constructed with high- temperature materials and is sealed to allow mounting anywhere on the vehicle. It also has an integrated thermal overload protection feature.

The XD Series Triple Bi-Stable Flex Relay/ACR/LVD meets stringent OEM standards for electrical transient self-protection and comes with a 4-year industry-leading warranty.

Dip Switch Setting Options & Features

• DS1-DS2 sets delay between Off Trigger and Relay OFF.
• DS3-DS5 defines LVD disconnect voltage (15 sec delay), overrides me delay if both are enabled).
• DS6 determines if input stud Voltage Sense will trigger Relay ON/OFF events.

Specifications

• Input Voltage Range (Vdc): 8.0 – 36.0 Auto-Ranging
• Nominal Voltage (Vdc): 12, 24
• Over Voltage Protection (Vdc) (5 sec): 17.0, 34.0
• State Change Current (20 msec): 5.0 A
• Standby Current (mA): 1.3
• Live Current Switching: 50,000 cycles
• Mechanical Switching Life: 1,000,000 cycles
• Hardware Material: Stainless Steel Self-Locking
• Terminal Stud Torque: 120 in-lbs
• LED/Aux Output Max Drive Current: 400 milli-Amps
• Min Source Current for Inputs: 10 micro-Amps

Product Dimensions

• A: 50 mm (1.96 in)
• B: 163 mm (6.41 in)
• M4: (#8) Mounting Holes
• M10: / 3/8 Size Terminals

Part Numbers

Related Products

Product Usage Instructions

Step 1: Disconnect the battery from the power distribution system before installing the product to prevent electrical shock or product damage.

Step 2: Mount the device anywhere on the vehicle using the M4 (#8) mounting holes and M10 / 3/8 size terminals.

Step 3: Connect the input stud voltage to trigger the Relay ON/OFF events if DS6 is enabled. If DS1-DS5 are OFF while DS6 is ON, the device will act as an automatic charging relay.

Step 4: Set the dip switches DS1-DS5 and DS6 to configure the device to your desired functionality.

Step 5: Connect optional external LEDs and  control lines to access diagnostic feedback.

Step 6: Connect an optional output bus bar to connect RT or CT fuse blocks.

Step 7: Test the installation and functionality of the device.

Note: For custom product configurations, contact support@egismobile.com for low minimum quantities and short lead times for samples or production.

• 500 Amp Continuous Capability Per Relay /Extremely Compact Footprint

• Available With or Without Intuitive Front Facing Manual Override Knob with Ability to Lock Relays ON or OFF for Servicing Flexible Functionality via Dip Switches, utilize each as a Relay/Batiery Disconnect, Automatic Charging Relay, or Low Voltage Disconnect

• Supports Single/Multiple Engine Installations with Dual Start/Engine Isolation Inputs
  Remote ON/OFF/Auto Inputs Allows Forced Close or Open or Allowing Automatic Operation Based on Voltage Sensing

• Local and Remote LED Indicators for Each Relay

• Ultra-Low Power Draw: Lowest off-state current draw in industry (1.3 mA) combined.

• Simple & Robust Installation: Sealed plugs/harnesses included. Combined timer & high-amp relay reduces install time/costs. Optional output bus bar connects RT or CT fuse blocks.

• Flexible Application Options: Install as a Time Delay Relay, Battery Management Relay, Low Voltage Disconnect, or Simple Relay. On/Off trigger via external Ignition signal and/or alternator voltage sense and adjustable low voltage protection levels increase flexibility

• Optional Adjustable OFF Time Delay: 0 seconds to 4 hours.

• Diagnostic Feedback: via optional external LEDs control lines and on-board LEDs for each relay

• Bullet-proof Construction: Sealed unit, high temperature materials allow mounting anywhere on vehicle. Integrated thermal overload protection

• Optional Kill Switch: eliminates the need for using thermal circuit breakers as service maintenance switches, reducing voltage drop to electrical loads.

• Meets Stringent OEM Standards: for electrical transient self-protection

• 4 Year Industry Leading Warranty

Dip Switch Seting Options & Features
DISCONNECT BATTERY FROM POWER DISTRIBUTION SYSTEM BEFORE INSTALLING PRODUCT TO PREVENT ELECTRICAL SHOCK OR PRODUCT DAMAGE

DS1-DS2 sets delay between Off Trigger and Relay OFF. OFF is for install testing or pure relay functionality without time delay
DS3-DS5 defines LVD disconnect voltage (15 sec delay), overrides time delay if both are enabled)
DS6 determines if input stud Voltage Sense will trigger Relay ON/OFF events. IF DS1-DS5 are OFF while DS6 is ON, device will act as an automatic charging relay (see next page for various modes of operation based on dip switches.

Dimensions

Custom product configurations available including control harness wires, time delays, voltage setings, dip switch functionality, and control input functionality. Low minimum quantities and short lead time for samples or production. Contact support@egismobile.com

System Diagram

Specifications

Part Numbers Knob Connection Resell Pack Bulk Pack

Related Products Knob Resell Pack Bulk Pack

Methods Of Operation

Remotely Operated Relay Mode- Specific Functions

Flex Relay Opens (Turns OFF) within 0-3 seconds if:

• Rem Ctrl (Red) wire loses +Vdc and shiti to Gnd or Floating Line

Flex Relay Closes (Turns ON) within 0-3 sec if:

• Rem Ctrl (Red) wire is connected to +Vdc

Automatic Charging Relay (ACR) Mode – Specific Funcons
Flex Relay Automatically Opens (Turns OFF) atier 10 sec if:

1. Voltage on Either Input to Relay < V_Open and
2. Rem Ctrl (Red) wire is not connected to +Vdc

ACR Relay Automatically Closes (Turns ON) atier 3 sec if

1. Voltage on Either Input to Relay > V_Close
2. Rem Ctrl (Red) wire is not connected to Gnd
3. Start Isolation Input Wires SI#1 (Brown) and SI#2 (Green) Not Connected to +Vdc

Low Voltage Disconnect (LVD) Mode – Specific Functions
Flex Relay Closes (Turns ON) if:

1. Voltage on Either Input to Relay > V_Close if V_Sense = ON and
   Start Isolation Input Wires SI#1 (Brown) and SI#2 (Green) Not
   Connected to +Vdc and Rem Ctrl (Red) wire not connected to +Vdc

2. Rem Ctrl (Red) wire is connected to +Vdc

Flex Relay Automatically Opens (Turns OFF) atier 15 sec if

1. Voltage on Either Input to Relay < V_LVD per DS3-DS4 and Rem Ctrl (Red) wire is not connected to +Vdc or Gnd

Time Delay Off Mode – Specific Functionality
Flex Relay Begins Time Delay Countdown if DS1 or DS2 = ON and the following conditions occur and remain for T_Delay per DS1 & DS2:

1. Voltage on Either Input to Relay < V_Open DS6 (V_sense) = ON and Rem Ctrl (Red) wire is not connected to +Vdc or Gnd, or:
2. V_Sense =OFF and Rem Ctrl (Red) wire changes from +Vdc to Float or Gnd

Flex Relay General Functionality Flex Relay Opens (Turns OFF) immediately if:

1. Voltage on Either Input to Relay > 9 Vdc (minimum operating Voltage) and either any of the following three conditions exist:
2. Rem Ctrl (Red) wire is connected to Gnd
3. Start Isolation Input Wire SI#1 (Brown) is Connected to +Vdc and Ctrl (Red) wire is not connected to Gnd

Start Isolation Input Wire SI#2 (Green) is Connected to +Vdc and Ctrl (Red) wire is not connected to Gnd Start Isolation Triggering Prevents Voltage-Based Automatic Closing:

1. For as long as one or more of the two Start Isolation Lines SI#1 and/or SI#2 have +Vdc applied on the wires
2. For 3 minutes atier +Vdc is no longer applied to both Start Isolation Lines SI#1 and/or SI#2 have +Vdc applied on the wires

Manual Override Mode Prevents Voltage-Based Open or Closing:

1. For as long as the manual knob (if equipped) is not positioned in the “Auto/Rem” orientation

Upon Startup or Returning the Relay from Manual to Auto/Rem Mode:

1. The remote LED will remain OFF regardless of the physical status of the Relay until the Relay is remotely forced ON/OFF or automatically attempt to turn itself ON/OFF.
2. The local LED will rapid flash if the device has an input voltage that would dictate a pending ON or OFF is necessary.

Response time to Relay ON trigger may vary due to device hibernation timing. Response to successive ON/OFF triggers may be delayed due to internal relay timing protections

Local / Remote LED Indicators

Priority of Input Response: Flex Relay will utilize the following priority in general when deciding which inputs to follow when a conflict between inputs is present Responses

1. Remote Ctrl (Red) Wire
2. Manual Knob control (if equipped)
3. Low Voltage Protection / Over-Voltage Protection
4. Start Isolation Lines SI#1 & SI#2
5. Automatic Operation via Voltage Sensing of Input Studs (if enabled)

Flex Relay Configuration Options

• Time Delay LVD
• Protect Voltage Sense

Function

Additional Products From XD Family

8720 – Dual XD Relay

XD Relay Family Cluster Examples

Triple Battery Relay / ACR Cluster

Additional System Diagram Examples

Quad Battery Bank Relay / ACR Cluster

Bellingham, WA U.S.A
360.768.1211
www.egismobile.com

References

• Home | Egis Mobile Electric

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