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Electrical relations

Recently I posted a couple of threads, one dealing with my charger/inverter and the second on my salesmen sw. After camping this weekend at Lazy Days I cant help but think maybe they are related. Let me explain, first the salesman sw.  Works fine when plugged into shore power or when the engine is running. When unplugged and engine not running does not work. When engine is running I can start the generator and when its plugged in but when unplugged and engine not running it will not start. Also when engine is running I can start the generator but when I shut the engine off the generator shuts off. Now the charger/ inverter. When the engine is running it puts out 14 volts. When plugged in I'm getting 17 volts. And finally all these problems came at once which makes me think they are related. Now I need opinions which I greatly appreciate. 
1995 U320 40', 2013 chevy sonic toad, my real love are corvettes have owned 30

Re: Electrical relations

Reply #1
A bad cell in the house battery can do all that.

Fully charge them then load test them or if wet cell, check each sell with a hydrometer.
Brett Wolfe
EX: 1993 U240
Moderator, ForeForum 2001-
Moderator Diesel RV Club 2002-
Moderator, FMCA Forum 2009-2020
Chairman FMCA Technical Advisory Committee 2011-2020

Re: Electrical relations

Reply #2
This COULD explain it all...

Salesman switch does not MAKE electricity, it just connects house battery bank to coach for lights, gen start, water pump, etc.  When switch is off nothing will be powered.  When switch is on, IF battery is completely dead / empty, nothing will work.

IF house batteries are dead / empty and damaged it is the same as if they are not in the coach.

When switch is on and engine is running, alternator generates electricity that flows though the isolator to power all coach things.  When engine is turned off, nothing will work.

When plugged into shore power the inverter/charger will generate electricity that powers all coach things.  When shore power is disconnected, nothing will work

As to the voltage from charging sources:

Alternator has about correct voltage which means it is working ok and likely will not damage any electronics or working batteries.

Battery charger at 17 volts is incorrect and way too high and left alone for a long time, would likely damage house batteries, and start battery bank if connected to house bank. 

17 volts could come from charger being at an equalize setting, but likely is from a failed charger.  While we don't know why charger is putting out 17 volts, you do have a possible answer to your symptoms so well described.

If you have multiple house batteries, try to run with just one battery at a time.

Try to use a stand alone battery charger connected to house batteries.

Try to temporarily use just a different battery in place of house batteries, but be aware 17 volts if still coming out of charger, will damage a new battery.  So maybe better to install a different battery (any size, from car or start bank) and a stand alone charger.

Good luck.





Re: Electrical relations

Reply #3
Joe, if you can get a meter to the output of the charger you might have your answer.

Re: Electrical relations

Reply #4
Sounds as if there is NO connection to the house batteries. The alternator or the inverter/charger is supplying all the 12Vdc.
The charger with no load connected could read high voltage especially if reading with a very high impedance meter.
Agree with the above statement....... sounds like a problem with the house batteries or connection between them and the salesman switch.
Just a thought...........
Justin & Cathy Byrd
1995 U280 "Old Faithful"
36' Build #4673
C8.3 Cummins
Allison MD3060R 6 speed - retarder
Powertech 10KW  4cyl Kubota

Re: Electrical relations

Reply #5
This COULD explain it all...

Salesman switch does not MAKE electricity, it just connects house battery bank to coach for lights, gen start, water pump, etc.  When switch is off nothing will be powered.  When switch is on, IF battery is completely dead / empty, nothing will work.

IF house batteries are dead / empty and damaged it is the same as if they are not in the coach.

When switch is on and engine is running, alternator generates electricity that flows though the isolator to power all coach things.  When engine is turned off, nothing will work.

When plugged into shore power the inverter/charger will generate electricity that powers all coach things.  When shore power is disconnected, nothing will work

As to the voltage from charging sources:

Alternator has about correct voltage which means it is working ok and likely will not damage any electronics or working batteries.

Battery charger at 17 volts is incorrect and way too high and left alone for a long time, would likely damage house batteries, and start battery bank if connected to house bank. 

17 volts could come from charger being at an equalize setting, but likely is from a failed charger.  While we don't know why charger is putting out 17 volts, you do have a possible answer to your symptoms so well described.

If you have multiple house batteries, try to run with just one battery at a time.

Try to use a stand alone battery charger connected to house batteries.

Try to temporarily use just a different battery in place of house batteries, but be aware 17 volts if still coming out of charger, will damage a new battery.  So maybe better to install a different battery (any size, from car or start bank) and a stand alone charger.

Good luck.
B/C, agree with you, basically what we told Joe last week, he needs to get decent charger and check batteries before he does anything else. Are you sure about gen start going through salesman switch? Your mod? Have not seen it on my coaches, gen start is always dedicated line to coach batteries.
Jim C.
coachfree, previous 1997, 1999, 2000, and 2003 Foretravels.

Re: Electrical relations

Reply #6
Jim, I was generalizing about the salesman switch, and you are correct that it does not power the genset.

Actually years ago, we removed our salesman switch which was mounted on rear-side of step.  We learned that the two large salesman switch cables are both sourced on the top of the 12-volt bay-wall breaker panel behind the big large white cover.  We disconnected both cables at the breaker panel and put a short jumper across the connections.

We wanted to cut a large hole on step wall for access to the air fitting on the air bag located on the other side of the step wall and found the heavy duty cables and switch were in the way, and with the disconnected switch, we had a clear shot at the air bag.  We were changing all 8 air bags and the two front bags were easier to change with our access holes.

Over the last 20 years, we never used our salesman switch and figured we would later put it back in action on the bay wall connection.  Also figured there must be some voltage drop on the pair of very long cables, so removing approx. 40 feet of cable, replacing it with 4 inches could benefit us.

A month ago, we put the salesman switch on the main ground house battery to fully disconnect the battery bank when storing our motorhome.

Re: Electrical relations

Reply #7
Jim, I was generalizing about the salesman switch, and you are correct that it does not power the genset.

Actually years ago, we removed our salesman switch which was mounted on rear-side of step.  We learned that the two large salesman switch cables are both sourced on the top of the 12-volt bay-wall breaker panel behind the big large white cover.  We disconnected both cables at the breaker panel and put a short jumper across the connections.

We wanted to cut a large hole on step wall for access to the air fitting on the air bag located on the other side of the step wall and found the heavy duty cables and switch were in the way, and with the disconnected switch, we had a clear shot at the air bag.  We were changing all 8 air bags and the two front bags were easier to change with our access holes.

Over the last 20 years, we never used our salesman switch and figured we would later put it back in action on the bay wall connection.  Also figured there must be some voltage drop on the pair of very long cables, so removing approx. 40 feet of cable, replacing it with 4 inches could benefit us.

A month ago, we put the salesman switch on the main ground house battery to fully disconnect the battery bank when storing our motorhome.
Good Idea, have never use mine, but thinking about voltage drop and resistance, best to to put it next to batteries. Thanks for the tip.
Jim C.
coachfree, previous 1997, 1999, 2000, and 2003 Foretravels.

Re: Electrical relations

Reply #8
Before taking out the 12V cutoff at the steps, you might see what actually runs thru that 90 amp breaker.  For instance my solar, as most are, is wired directly to the house battery, not thru the 12V panel in the bay.  I like being able to leave for a few hours, easily cutting off most of the 12V draw, and not having to run around the rv making sure all the 12V is off, ceiling fans, water pump, closet light, bathroom light, etc.  I also have a ground cutoff off on both chassis and house batteries for when I'm away longer and wish to cut everything on that bank off.
97 U295 40, Build #5040, 6C8.3 325 HP
Oregon Continuous Traveler
Samsung Residential #RF20HFENBSR,
Xantrex SW2012, (3)AGM8D Hse, (2)AGM Grp24 Eng, Victron BMV-712, 1800w Solar 4 LG & 2 Sunpower
Extreme Full Body Pt w/hdlmps, new furn/floor, 4 down Lexus 2004 GX470 AWD curb weight 4,740 lbs
Prev: 1990 Barth, 10L 300 2 yrs; 91&92 Monaco Signature, 10 yrs, 10L C 300 &  6C8.3 300; 1997 ForeT 6C8.3 325 since May 2017.  Employed by Guaranty RV 14+ yrs.  Former VW New Car Dlr/Service Dlr, Sales Mgr, Rv Sales, and Service Adviser from 1968-2017
"Don't criticize what you can't understand" Bob Dylan

Re: Electrical relations

Reply #9
Before taking out the 12V cutoff at the steps, you might see what actually runs thru that 90 amp breaker.  For instance my solar, as most are, is wired directly to the house battery, not thru the 12V panel in the bay.  I like being able to leave for a few hours, easily cutting off most of the 12V draw, and not having to run around the rv making sure all the 12V is off, ceiling fans, water pump, closet light, bathroom light, etc.  I also have a ground cutoff off on both chassis and house batteries for when I'm away longer and wish to cut everything on that bank off.
Thanks Jack, but I have the PMC Intellitec system with a several control buttons around coach that basically turn off all 12 volt loads [except water pump]. I would keep the breaker, just remove the switch and its wiring.
Jim C.
coachfree, previous 1997, 1999, 2000, and 2003 Foretravels.

Re: Electrical relations

Reply #10
Thanks Jack, but I have the PMC Intellitec system with a several control buttons around coach that basically turn off all 12 volt loads [except water pump]. I would keep the breaker, just remove the switch and its wiring.
Jim,
It's curious that your 2003 does not have the water pump on your Intellitec switch panels. 
Several of my switch panels (and I've seen other 2002 U320's.....but they may have been customized) have the water pump and water fill valve circuits on the appropriate (kitchen, bath, utility bay, front door) Intellitec stations. 

Of course, having an Intellitec station by the entry door makes things even more convenient. For those that don't have an Intelletec System, when leaving the coach for short periods of time, just one (three second) "Master Lights Off" button press and ALL (30) of the Intellitec circuits, power down. The 12 Vdc is removed from all circuits until you once again "press the button for an instant"  for an individual circuit, as needed.

We also have the salesman switch, but when in public spaces such as restaurants, we can leave a few manual lights on, making the coach appear occupied, but power down the Intellitec, which minimizes battery drain and risk of water where it isn't wanted.

Our coach has ten of these Intellitec stations, varying with the circuits pertaining to each particular area, or able to switch lots of lights on and off from the underside of the cabinets over the bed.  DW detests the scheme because she has to read the switches.  I love it because I just push from memory, but also fear it because the stations communicate over twisted wire pairs with computers that are no longer made.  One day, a single failure will be very expensive.
HTH,
Neal
The selected media item is not currently available.
Neal (& Brenda) Pillsbury
'02 U320 SPEC, 4200, DGFE, Build #5984
'04 Gold Wing
'07 Featherlite 24'
'14 Jeep Grand Cherokee Summit
MC #14494
Exeter, NH & LaBelle FL
Quality makes the Heart Soar long after Price is Forgotten

Re: Electrical relations

Reply #11
Neal, I do have the water pump button in 5 places, {wet bay, bathroom, toilet, kitchen and by entry door} but the master 12 volt switches [also labeled master lights off], in the bedroom and by the front door, only turns off 12 volt lighting circuits. May be modified, have not seen another coach of my era with intellitec. I do have intellitec buttons for two 1500 watt aqua-hot heating elements, which I really like because I can run both on 30 amps, [no starting surge like a ac would require]. Will keep coach warm down into the 30's without diesel. Am also dreading the day it starts to cause problems, but have read posts on other forums about an upgrade to current PLC modules, and reprograming available for about 3 grand.
Jim C.
coachfree, previous 1997, 1999, 2000, and 2003 Foretravels.

Re: Electrical relations

Reply #12
Here is a brief update. Disconnected the charge/inverter and charged batteries and load tested. While showing 12 volts they failed the load test. Have ordered to new 8d gell batteries and will install. I plan to reconnect charger/inverter and measure voltage from charger. If still high i will replace with a new one. Maybe the charger was sending high voltage because batteries were dead.
1995 U320 40', 2013 chevy sonic toad, my real love are corvettes have owned 30

Re: Electrical relations

Reply #13
Here is a brief update. Disconnected the charge/inverter and charged batteries and load tested. While showing 12 volts they failed the load test. Have ordered to new 8d gell batteries and will install. I plan to reconnect charger/inverter and measure voltage from charger. If still high i will replace with a new one. Maybe the charger was sending high voltage because batteries were dead.
Just remember, anything over about 14.2 volts [max bulk charge voltage for most gel cells] will damage your new batteries.
Jim C.
coachfree, previous 1997, 1999, 2000, and 2003 Foretravels.

Re: Electrical relations

Reply #14
Just remember, anything over about 14.2 volts [max bulk charge voltage for most gel cells] will damage your new batteries.

Yup, we've got fresh batteries, here's after dry camping for a few days, then charging. It sits at around 13.4 the rest of the time when hooked up. Our "True Charge 40" indicates full charge @ 13.2/ 13.4
1993 U-240 "La Villa Grande"..CAT 3116 w/ Pacbrake PRXB...Allison 3060 6-speed..
Previous: 1983 Airstream 310 turbo diesel, 1979 Airstream 280 turbo diesel
                                      Build # 4297
                                      PNW natives
                      Home base:  'Cactus Hug' (Ajo, Arizona)
                        DW Judy & Chet the wonder dog
                        Full-Timers 'Sailing the asphalt sea'

Re: Electrical relations

Reply #15
Joe
Check the startup mode of your inverter/charger.
When I purchased my 96 U320, the inverter/charger startup mode had been set to "Equalize" which sent 100 amps to the batteries while tripping the 20 amp breaker in the 120 VAC power panel when the inverter/charger received 120 VAC.
This was set using dip switches in the back of the remote control on the OEM inverter/charger in my 1996 U320.

Equalizing new Gel batteries will quickly damage them.
Wyatt
96 U320 40 WTFE, build 4943
84 Toyota Supra towd
2015 Jeep Wrangler towd
Victoria, BC, Canada

Re: Electrical relations

Reply #16
Wyatt i believe i will have to remove the panel by the 4 screws and pull it out to see the dip switches. Im not changing anything or using different batteries they will be 8d gell batteries which has always been in there.
1995 U320 40', 2013 chevy sonic toad, my real love are corvettes have owned 30

Re: Electrical relations

Reply #17
Well here is current status. Brett, The batteries were dead. Replaced them with AGM 8d from oriellys. Great price $849 including tax and they installed. With that the salesmen switch works and I can start Generator. The voltage at the batteries when engine running 13.3v. Now the bad news. When plugged in I get 17volts. I pulled remote and checked dip switches and equalize was off and it was set for gell batteries. I would like to replace with something easy to install and not expensive. My current model is a Heart 25 charger/inverter. Can it be repaired?  Thanks everyone for your help I learn something new every day.
1995 U320 40', 2013 chevy sonic toad, my real love are corvettes have owned 30

Re: Electrical relations

Reply #18
Reset the dip switches for wet cell and check voltage
The selected media item is not currently available.Bill&Doris 97 U270 36'
University of Parris Island Class of 66
Semper Fi  Build# 5174 MC#17094

Re: Electrical relations

Reply #19
And don't scrimp on inverter charger Victron and Magnum good brands to look at, search past posts, a lot of threads on the topic
Tim Fiedler    2025 LTV Unity MBL on Order
2000 Chevy Tracker 2 Door Convertible 4WD Now lifted 4.5"
1985 Citroen 2CV6 Charleston
Murphy Rebel on wheels with 175HP Titan
Cessna P337
1980 48' Westport MY (!/4 Share)

Re: Electrical relations

Reply #20
Eric at bio benefit inverter repair in Costa Mesa, can rebuild heart freedom 25's completely and coats the boards and retightens the many connections internally and replaces the contactors as they pit and reduce the oiutout power to the batteries. $800 flat rate charge. 

Newer magnums use stainless bolts to lessen the corrosion in the older units and have a needed BTMS and are sine wave output and have coated boards to help prevent shorts.

The reduced output may match your dual battery setup.  Mine was maxed at 70 Amos into three 8g8d's.  New magnum is 110 amps in bulk

Call Eric and ask him about the 17 volts after resetting the dip,switch if it continues
"Riding and rejoicing"
Bob
1997 U320 40' Mid entry, build 5132,  wtbi ce27, 4th owner
2007 Solara convertible
2 prodeco tech outlaw ss electric bikes

1095 watts solar
08 Ls 460 and a sc430
2000 Ford F-250 superduty 4x4

Re: Electrical relations

Reply #21
With new batteries and a very old modified sine wave inverter, you are trying too hard to keep your charger alive.  Replace it now and just enjoy not thinking about these things anymore.  Your Heart 25 that we many of had at one time, has probably already cost you $849.  Dozens have replaced the Heart 25 and their write ups are on the Forum and BeamAlarm.com

Re: Electrical relations

Reply #22
Eric at bio benefit inverter repair in Costa Mesa, can rebuild heart freedom 25's completely and coats the boards and retightens the many connections internally and replaces the contactors as they pit and reduce the oiutout power to the batteries. $800 flat rate charge. 

Newer magnums use stainless bolts to lessen the corrosion in the older units and have a needed BTMS and are sine wave output and have coated boards to help prevent shorts.

The reduced output may match your dual battery setup.  Mine was maxed at 70 Amos into three 8g8d's.  New magnum is 110 amps in bulk

Call Eric and ask him about the 17 volts after resetting the dip,switch if it continues

Bob
Good info. There is a place in Seattle that fix them. Had a few done. Was very satisfied with their work.

S3 Maritime LLC
2360 W. Commdore Way, Suite 200
Seattle, WA 98199
Ph. 206-420-4932

I might add, figure $150.00 for the ride at least round trip. Them puppies are heavy

Here is a link to authorized repair stations:

http://www.xantrex.com/contacts/authorized-service-centers.aspx
Chris and Tammy White  CDA Idaho
Previous owners 1997 U295 36' 3126 Cat 300 HP Build # 4998
Former Foretravel tech & RVIA certified tech
Former owner Custom Satellite home/RV satellites 
Former owner Vans LTD  van conversions
Unemployed, panhandler, drag racer NHRA #6348

Re: Electrical relations

Reply #23
As some of you have suggested, I am taking mine in to be repaired. A xantrex repair shop in Bradenton claims he knows whats wrong and can fix with same day service. Cost $275.00. Says these old units are well built and when repaired will give me years of good service. I have remove the unit and labeled all the wires reinstall should go pretty easy. 
1995 U320 40', 2013 chevy sonic toad, my real love are corvettes have owned 30

Re: Electrical relations

Reply #24
As some of you have suggested, I am taking mine in to be repaired. A xantrex repair shop in Bradenton claims he knows whats wrong and can fix with same day service. Cost $275.00. Says these old units are well built and when repaired will give me years of good service. I have remove the unit and labeled all the wires reinstall should go pretty easy.

Do whatever you feel is right for you but I have to say that Barry has given very good advice.  This should be seen as an opportunity to upgrade from the Heart inverter, not put more money into keeping it alive.  While it might be well built, it's still a very outdated system.  A modern unit with better battery management features can easily pay for itself in battery longevity.  Lower idle current draw and pure sign wave power are additional bonuses.  Installation is just as simple as reinstalling the Heart.