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leisure battery - voltage but no current

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leisure battery - voltage but no current

Postby Haddie » Thu Apr 09, 2015 5:37 pm

Hi to all,

We have a MK3 minibus thats been converted to a campervan. We got it last year, and now i'm having a bit of fun with the leisure electrics. Not great with electrics so will try to keep my description as straightforward as I can. :(

The van has 3 batteries - 2 in the engine bay (one cranking battery and one leisure battery - lets call that one "A") and a leisure battery under the rear seats/bed - "B".
Both A and B have +ve feeds to a Zig CP400 unit. Battery B works fine, as it you would expect (but only charges when on EHU via a power pack/battery charger...thats a job for another day lol)

Battery A is charged via the alternator, and rather than being fitted with a relay, there is an old style battery isolator switch to prevent the cranking battery from being drianed when A is being used.

As its the circuit on battery A thats giving me grief...

The -ve terminal of the battery is earthed via the engine. The +ve feed goes first to the isolator switch, then to a 25amp fuse. The wire then works through the engine bulkhead...through the cab to the top connector of a switch on the Zig unit. The feed from Battery B goes to the bottom of the switch.

There is 12.5v at every point on the live from A. At the battery...at the isolator, at either side of the fuse....even at the spade connector that plugs into the Zig Switch.....but no current. Reversing the feeds so B is on the top of switch and A is at bottom shows that the switch is ok because when set up that way, the circuit on B performs as well as it does on the other side of the switch.

I know that the set-up worked when we first got the van otherwise I would swear that it never had :D

So....as I'm running out of ideas on what/how to check...What can cause voltage to be at the connector but no current?

Any ideas/suggestions or explanations gratefully received.

Cheers
Haddie
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Re: leisure battery - voltage but no current

Postby Kedishen » Thu Apr 09, 2015 9:19 pm

Sounds like u got a knackered battery to me. How old is battery? You've checked for burnt looking fuses?

Seems a quick test to perform to rule out circuit problems is to put battery B in battery A's position.

If you get current, Battery A is knackered.

When you try to draw power from battery A, what voltage is at battery?
Plug in something that draws a few amps like a laptop or the blown air heating or summit.

If you want to try to revive battery A, make sure the plates are just covered with deionised water and charge battery for a few days with a 3 stage pulsed battery charger - might get some more time out of it.
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Re: leisure battery - voltage but no current

Postby Haddie » Sat Apr 11, 2015 12:09 pm

Cheers for that. Coz I'd got 12.5v that's holding I never thought of swapping battery...but its that quick a swap seems sensible.Will keep you posted
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Re: leisure battery - voltage but no current

Postby Haddie » Sun Apr 12, 2015 2:09 pm

Okey dokey....quick update....switched batteries, but no difference. However, what I have just discovered this morning is that there is 12.5v at the battery....there is 12.5v at the connector so no loss of voltage but....if I run the voltmeter between the connector and the switch, then turn the switch on, there is a huge drop in voltage...it goes down to 6.5v.

The other leisure circuit still work as it should no matter which side of the switch I run it from...so I find it hard to see it as a problem with the switch (but deffo no expert).

Any ideas what the voltage drop on the one circuit is telling me?

Cheers

Dave
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Re: leisure battery - voltage but no current

Postby Altransit » Sun Apr 12, 2015 2:21 pm

Only 2 reasons to get that 6v voltage drop:-

1/ You have a massive current drain, (which would normally blow a fuse or smoke the wiring) :?

2/ The battery is knackered and has high internal resistance, so won't supply any real power :(
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Re: leisure battery - voltage but no current

Postby Kedishen » Sun Apr 12, 2015 2:24 pm

Sounds like you got a damaged live wire that is touching the chassis somewhere creating a short.. Surprising it hasn't blown any fuses (or knackaered the battery)... You should have an inline fuse with rating lower than the length of cable run within 15cm of the battery live connection...

Inspect full length of live cable for damage and replace... abit of work and a £10 cable is considerably less hassle than a fire.

and don't forget your fuse.
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Re: leisure battery - voltage but no current

Postby Haddie » Sun Apr 12, 2015 3:18 pm

So what's the relationship between the fuse rating and the length of the cable run. I've got an inline fuse 25amp. Found a wiring diagram for the Zig unit which had a fuse that size. Reckon there 3 or 4m of cable.
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Re: leisure battery - voltage but no current

Postby Kedishen » Sun Apr 12, 2015 4:56 pm

25amp is massively oversized, its not surprising fuse hasn't blown.... I can run two laptops, all my lights, water heater + blown air heater and cycle the water pump and still not pull more than 15 amps.

The cable from alternator to batteries in rear is 2x 6mm2 over 5 meters, capable of carrying maybe 50amp prolly more... I fuse them both at 20amp each...

U will prolly never pull more than 10amp from your leisure battery at any one time..... Put a 7.5 - 10amp fuse in after replacing the cable and use at least 3mm2 cable.

Heres a cable size calculator

http://www.energymatters.com.au/climate ... cable_size
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Re: leisure battery - voltage but no current

Postby Haddie » Sun Apr 12, 2015 6:28 pm

Cheers for that....there's so much conflicting info out there. I got the fuse size from a link on zig units that is referenced on loads of leisure battery threads.

http://www.freewebs.com/12voltsdc/Zig%2 ... %20PDF.pdf

Only had that fuse in it for afew days..and not been out in the van since. T'inernet..pfffft :-)
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Re: leisure battery - voltage but no current

Postby Haddie » Sun Apr 12, 2015 6:30 pm

..previous fuse was a 5amp 'domestic type'.
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Re: leisure battery - voltage but no current

Postby Kedishen » Sun Apr 12, 2015 8:19 pm

wat was wrong with old fuse? Had it blown?
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Re: leisure battery - voltage but no current

Postby Haddie » Sun Apr 12, 2015 8:59 pm

No....still got it. Just changed it to a blade-type fuse after seeing quite a bit of advice that suggested uprating. Going to stay with this type but will out a lower rated fuse in tomorrow after work.
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Re: leisure battery - voltage but no current

Postby Kedishen » Sun Apr 12, 2015 10:31 pm

problem existed before changing fuse?
Livin' in me van in Portugal.

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Re: leisure battery - voltage but no current

Postby Haddie » Mon Apr 13, 2015 6:17 am

Yeah, I only looked at changing the fuse as part of the process if trying to work out why this circuit isn't working. One of the first things I checked was the fuse and also double-checked by substituting it for a fuse I knew worked.
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Re: leisure battery - voltage but no current

Postby Kedishen » Mon Apr 13, 2015 1:40 pm

As before, remove old wire and put in a new one. Wrap extra electrical tape around areas that are likely to shafe.
Livin' in me van in Portugal.

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