POWERLINE HEAVY DUTY ISOLATORS

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1 POWERLINE HEAVY DUTY ISOLATORS MODELS: 22-15, 22-18, 22-21, 22-63, 33-94, CONGRATULATIONS! for choosing this high quality POWERLINE PRODUCT. The latest state of the art engineering plus years of experience have gone into each POWERLINE product. The attached instructions are provided to assist you with step by step installation. Test procedures are also provided to be kept with your equipment should future reference be desired. Every effort has been made to use the finest materials and workmanship. In the event that service is ever needed or you have questions regarding the product, installation or performance please give us a call. Your Friends at the factory AN ISO 9001 COMPANY R A DIVISION OF INTERNATIONAL INC Fairlane Avenue, Ft. Worth, TX fax: Canada: sales@hehrpowersystems.com FORM MBJ 06/99

2 TEST INSTRUCTIONS POWERLINE C.S. TYPE ISOLATOR USING OHM METER I. Remove all wires from the isolator 2. Using a needle movement ohmmeter on RX-1 scale or digital ohmmeter on diode scale. 3. Hold red probe on terminal A, with black probe touch terminals Bl and B2. A good isolator will show current flow. With red probe on A touch E terminal with black probe. A good isolator will not show any current flow. 4. Place black probe on a terminal and touch terminal Bl and B2 terminal with the red probe. A good isolator will not show any current flow. With black probe on terminal A touch E with red probe. A good isolator will show current flow. Note: on some import ohm meters the red and black leads are reversed for above tests. ELECTRICAL TEST 1. Engine not running, terminal B2 should read system battery voltage. Terminal B2 should read auxiliary battery voltage. 2. The A terminal may read 0 to 10 volts if using a digital ohmmeter. This may be due to the capacitor in the alternator. Ground out terminal A momentarily and retest, voltage reading should be The E terminal should have 0 volt reading. 4. Key on engine not running, terminal E should read system battery voltage, terminal A should read system battery voltage or may be as much as.6 volts less battery but no more. Battery post of alternator should read battery system voltage or as much as.6 volts less than battery but no more. 5. For 12 volt systems the A terminal should read approximately 15 volts. The B1 and B2 terminal should read 13.8 to 14.2 volts. 6. If the A terminal reads 13.8 to 14.2 volts the regulator is sensing the alternator output rather than the main battery. This situation needs to be corrected. for proper charging.

3 Isolator Installation Instructions Delco CS series alternators The POWERLINE solid State Multi-Battery Isolator is a product of extensive heat-chamber engineering and testing. POWERLINE isolators are designed to handle the total current rating through either leg. All POWERLINE isolators designed to be used with Delco CS type alternators are negative ground, multi-battery systems with an excitation terminal. The isolator comes with a #22-50 alternator control plug and harness. (A # adaptor is required for Delco CS -D type alternators) CAUTION: Isolator rating must be equal or greater than alternator amperage rating. Prior to starting isolator installation, start engine and run at fast idle. Measure voltage at the battery terminal, it should be about 14 volts. After installation, re-check above to confirm the same voltage. 1. Disconnect Negative cable from battery. 2. Mount isolator in a location away from maximum engine heat, in a location that will allow the isolator to receive maximum air flow. 3. Remove all original wires connected to the alternator output post (battery connection). A. Attach all original wires removed from output post of alternator together and tape up. 4. Install a new wire from the alternator output post to the A terminal of the isolator. 5. Install a new wire from B1 terminal of isolator to main engine battery. 6. Install a new wire from the B2 terminal of isolator to auxiliary battery. 7. On a 3-battery system connect a new wire from B3 to second auxiliary battery. 8. Connect good grounds from auxiliary batteries to engine. NOTE: See cable chart for correct cable size. 9. E terminal connection: (yellow wire) Connect one end to E terminal on isolator. Connect to 10 amp Self Reset Breaker, and from breaker connect to a 20 amp on / off ignition source. See drawing C88-5 for use with relay to remove overload on late model vehicles. The clear connector fits all Chevrolet and GMC trucks from 1985 thru The blue 1/8 connector is used on all 1995 and up Chevrolet and GMC trucks. 10. Remove the control plug from the alternator (plug can be removed by using a small screwdriver, prying up under locking tab). 11. Install new control plug #22-50 (provided with isolator). NOTE: The control plug is used with the standard Delco CS type alternator. If you have a Delco CS type D alternator, it will also require a # adaptor harness to allow the #22-50 to connect to the alternator. 12. Cut the original control plug wire (wires) approximately 6 from plug. Strip the wires approximately 3/16 to ¼ from the end on the harness side. Using the supplied butt connectors, splice new plug to harness wire s matching colors.

4 13. Connect the red sense lead in the #22-50 control plug to the B1 terminal of the isolator using 5/16 terminal (supplied). NOTE: any wires in the #22-50 control plug that do not have a matching wire in the original harness must be taped up. 14. Re-connect the NEGATIVE battery cable to the battery NEGATIVE POST. 15. Start engine test charging system. 16. See page C88-1 thru C88-6 for your wiring requirements. Page C88-7 is for alternator identification and plug requirements.

5 WIRING DIAGRAM DELCO CS TYPE ALTERNATOR/ISOLATOR INSTALLATION ORIGINAL CHARGE CABLE (TAPE & DO NOT USE) FACTORY HARNESS E B2 MAIN BATTERY B1 A FUSE PANEL CONNECT TO 20 AMP ON/OFF KEY CIRCUIT 10 AMP BREAKER AUX BATTERY C

6 WIRING DIAGRAM DELCO CS TYPE ALTERNATOR/ISOLATOR INSTALLATION ORIGINAL CHARGE CABLE (TAPE & DO NOT USE) FACTORY HARNESS E B2 MAIN BATTERY B1 A FUSE PANEL CONNECT TO 20 AMP ON/OFF KEY CIRCUIT 10 AMP BREAKER AUX BATTERY C

7 WIRING DIAGRAM DELCO CS TYPE ALTERNATOR/ISOLATOR INSTALLATION ORIGINAL CHARGE CABLE (TAPE & DO NOT USE) FACTORY HARNESS E B2 MAIN BATTERY B1 A FUSE PANEL CONNECT TO 20 AMP ON/OFF KEY CIRCUIT 10 AMP BREAKER AUX BATTERY C

8 WIRING DIAGRAM DELCO CS TYPE ALTERNATOR/ISOLATOR INSTALLATION ORIGINAL CHARGE CABLE (TAPE & DO NOT USE) FACTORY HARNESS E B2 MAIN BATTERY B1 A FUSE PANEL CONNECT TO 20 AMP ON/OFF KEY CIRCUIT 10 AMP BREAKER AUX BATTERY C

9 WIRING DIAGRAM DELCO CS TYPE ALTERNATOR/ISOLATOR INSTALLATION ORIGINAL CHARGE CABLE (TAPE & DO NOT USE) FACTORY HARNESS MAIN BATTERY B1 E A B2 10 AMP BREAKER FUSE PANEL CONNECT TO 20 AMP ON/OFF KEY CIRCUIT OPTIONAL IGNITION CONNECTION FOR "E" TERMINAL 86 87A A 30 BOSH RELAY AUX BATTERY C

10 WIRING DIAGRAM ISOLATOR CONVERSION KIT FOR STANDARD ISOLATOR - TO USE WITH CS TYPE DELCO ALTERNATOR ORIGINAL CHARGE CABLE (TAPE & DO NOT USE) FACTORY HARNESS FIELD SUPPLIED WIRE PLUG ADAPTOR KIT #22-50 ALSO REQUIRES # ADAPTOR FOR CS-D TPPE ALTERNATOR B2 B1 A MAIN BATTERY # ALTERNATOR EXCITING KIT SPOT BLOCKING DIODE BLACK SPOT FUSE PANEL CONNECT TO 20 AMP ON/OFF KEY CIRCUIT 10 AMP BREAKER NOTE: ADAPTOR AUX BATTERY CONNECT ONLY MATCHING COLO WIRES IN FACTORY HARNESS. ALL OTHERS EXCEPT, TAPE UP AND DO NOT USE. C

11 PINK / BLACK DELCO CS 130 ALTERNATOR CONNECTOR PINK / BLACK DELCO CS 130D ALTERNATOR CONNECTOR CS 130 CONVERSION HARNESS #22-50 INCLUDED WITH CS ISOLATOR CS 130 TO CS 130D CONVERSION HARNESS # SPECIAL NOTE: POWERLINE PART # THIS MUST BE ORDE SEPERATELY WHEN CONNECTING A CS130D TO A POWERLINE ISOLATOR. C /99

12 RECOMMENDED BATTERY CABLE SIZE (AS A FUNCTION OF CURRENT AND LENGTH) MINIMUM SIZE CABLE TO USE (AWG) SYSTEM VOLTAGE RATED OUTPUT (AMPS) UP TO 5 FT FT FT FT FT FT AWG 4 AWG 2 AWG 2 AWG 1 AWG 0 AWG AWG 4 AWG 1 AWG 0 AWG 0 AWG 00 AWG S AWG 2 AWG 0 AWG 00 AWG 00 AWG 000 AWG AWG 1 AWG 00 AWG 000 AWG AWG AWG AWG 0 AWG 00 AWG AWG AWG AWG AWG 00 AWG 000 AWG AWG AWG AWG 24 VOLTS AWG 14 AWG 10 AWG 8 AWG 8 AWG 6 AWG AWG 10 AWG 8 AWG 6 AWG 6 AWG 4 AWG AWG 8 AWG 6 AWG 4 AWG 4 AWG 2 AWG AWG 6 AWG 4 AWG 4 AWG 2 AWG 1 AWG AWG 4 AWG 4 AWG 2 AWG 2 AWG 1 AWG AWG 2 AWG 1 AWG 1 AWG 0 AWG 0 AWG Length of cable shown is for either POS. lead or GND. lead, not total length. Maximum acceptable voltage drop = 0.5 volts in a 12 volt system, 1.0 volts in a 24 volt system. LIMITED WARRANTY warrants each new product against factory defects in material and workmanship for a period of time as outlined in the Warranty Period schedule (Form W 1OOOA-4/95). Exclusions from this warranty for damage or failure due to accident, misuse, negligence or improper installation. Material required for repair or replacement of defective part is to be supplied at no charge on delivery of the defective part to, 4616 Fairlane Avenue, Fort Worth, Texas, or an authorized service center. The customer is responsible for all freight on returned parts. There are no warranties, expressed or implied (including any implied warranties merchantability or fitness), which extend beyond this warranty period. The loss of use of the product, loss of time, inconvenience, commercial loss or consequential damages are not covered. reserves the right to change the design or any product without assuming any obligation to modify any product previously manufactured. This warranty gives you specific legal rights. You may also have other rights that vary from state to state. Some states do not allow limitations on how long an implied warranty lasts. Some states do not allow the exclusion or limitations of incidental or consequential damages. Therefore, the above limitation(s) or exclusion(s) may not apply to you.

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