BIRD replacement?

[YC1]

I would replace the solenoid. Those things go bad all the time. Do a search using the term bird and you will get thousands of posts.

I have seen many "lazy" relays in my time. Often it took only a small tap and the relay would engage. Intermittent relays could drive you crazy.

[RKins]

The BIRD controls the combining of the charging circuit to the chassis bank IF it sees 13.3V on the house battery bank for more than a minute. If it doesn't see that voltage it won't trigger the solenoid. It does not control charging to the house battery bank, the charger does that.
On the BIRD I have it will trigger the solenoid with 12V and then drops it down to 3.56V.
If you can't figure it out call Mark at Intellitec - he's been there 30 years.

[Qwert66]

Easy to rebuild the solenoid and refresh the contacts if required. As others have suggested it seems your bird is functioning and you should look next at the solenoid and or batteries. With the solenoid engaged please check the resistance across the contacts which should be very low (0-3ohms). If not then the contacts are pitted or boogered. Yes you said the relay is not engaging until after 7volts but should hold at 4-7 after engaged so it may likely be the wrong/incompatable solenoid as others have mentioned.

[RKins]

Qwert - do you hit the contacts lightly with a file? Are they replaceable and where would you find them?

The solenoid at the top left is the "combiner" solenoid controlled by the BIRD - you can see the part # on it if anyone needs it. I checked with Mark at Intellitec and they still sell the same one (White-Rodgers). Best I can tell this is still the original one in my coach.

[Qwert66]

RKins- Our 1999 came original with a different (same mfgr.) solenoid and is the same one of the 2 used for the Cummins intake grid heaters located on top of the frame rail in the back engine area passenger side visible from under the bed.

I clean the contacts with 400 grit wet sandpaper but most anything will work including a pink pencil eraser of the spouses nail file. They have a slight crown vs being flat.

If your closed contact resistance is very low then no conditioning is needed. I have not worked on your style of big boy solenoid so not much help there.

Good luck and the ohm measurement is real easy if you are inclined.

[RKins]

Man you have a lot of room in your electrical bay
When you add a cord reel it eats up a lot of room. Had to get creative to mount the EMS.