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Old 07-08-2018, 11:12 AM   #505
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2001 30' Excella
Somerset , New Jersey
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I do perfectly good pizza on my charcoal Volcano grill. Surely somewhere out there is a suitable cooker running on propane I should think.
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Old 07-08-2018, 01:06 PM   #506
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Quote:
Originally Posted by rmkrum View Post
Giggle!!
Seen even less sensible things than thatójust sayiní
Iím scratching my head trying to figure out whether that was intended as a pun or not. #nerdhumor
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Old 07-08-2018, 01:33 PM   #507
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No pun. Observation from too many years of being involved with the military as both active duty and as a defense contractor.

600 dollar hammers, anyone?
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Old 07-08-2018, 06:07 PM   #508
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Military Defense Contractor?
I like that question.
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Old 07-26-2018, 08:41 AM   #509
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I got a question about how I configured the battery and how I wired the sense lines on the Electrodacus battery management system. Pictures are worth a thousand words so here’s a pic:

It may be a bit confusing but the positive and negative terminals of the battery are on the right side. The bottom right is the positive (red) terminal. The top 3 cells on the right have a band across them putting them in parallel. When 3 100 AH cells are configured in parallel, they are functionally serving a one larger 300AH cell. The battery is configured from 12 100AH cells with 4 cells in series and each of these cells consists of 3 individual cells in parallel, yielding a 12v 300AH battery.

Banding the individual cells into larger groups ensures that these individual cells are always at the exact same voltage so they only need 2 voltage sense wires instead of 6. One sense wire is measuring the negative terminal of the top right cell which is also the negative terminal of the entire battery. This is the reference voltage for all the other cells and it should be at 0 volts. The other sense wire on the red cell terminals of the top right group is measuring the voltage contributed from the 3 individual cells grouped together (~3.6v).

Since the positive cells on the top right are connected to the negative terminals on the top left group of 3 individual cells, they are at the same voltage (~3.6v) and can share the same sense wire. In all, only 5 wires should be needed to measure the voltages on a 4 cell battery.

But if you look closely, we’re using 6. This is because the electrodacus BMS is designed to also support 24 volt batteries with up to 8 cells (9 sense wires) and when only sensing a 12 volt battery(actually 14.4 volts), it uses cells 1, 2, 7, 8 so the wire shared between cells 2 and 3 (~7.2v)is not the same wire used between cells 6 and 7. Thus the redundant pair of sense wires on the left side of the battery measuring the exact same voltage.

There is a better pic in the BMS manual. I’ll try to post that shortly.
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Old 07-26-2018, 09:28 AM   #510
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Carlisle , Pennsylvania
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Hi

I'd suggest grabbing a tube of RTV and sticking the sense wires down to the top of the batteries. It doesn't take much, you don't need to glue the entire length. A glob by the end and one or two along the length of the wire is plenty.

Bob
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Old 07-26-2018, 09:40 AM   #511
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Hi

I'd suggest grabbing a tube of RTV and sticking the sense wires down to the top of the batteries. It doesn't take much, you don't need to glue the entire length. A glob by the end and one or two along the length of the wire is plenty.

Bob
Thats a good idea. The tops of each cell has a little groove that holds the wires but where I had to cross over the connecting bands I added electrical tape for a bit more friction protection.
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Old 07-26-2018, 07:56 PM   #512
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Graphic from the manual:
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Old 01-24-2019, 07:33 AM   #513
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League City , Texas
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After a long hiatus, I finished the third of my four-part electrical system summary description. Link and reference photo below.

LITHIUM BATTERY UPGRADE, PART 3: CHARGING / INVERTER SYSTEM



EDIT: My tardy completion of this description was inspired by a Sprinter Forum thread titled Can a lithium pack be charged by alternator alone?

Given our recently-failed alternator and the PSA I published in response to it, of course I had comments to make about that topic. There were enough good ideas emerging on that thread that I decided to advance my own summary descriptions for general consideration.
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Old 01-24-2019, 02:31 PM   #514
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I do perfectly good pizza on my charcoal Volcano grill. Surely somewhere out there is a suitable cooker running on propane I should think.
Roccbox. Worth every cent.
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Old 01-27-2019, 10:59 PM   #515
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Given our recently-failed alternator and the PSA I published in response to it, of course I had comments to make about that topic. There were enough good ideas emerging on that thread that I decided to advance my own summary descriptions for general consideration.
Sorry to hear about your troubles with your alternator IB.

I don't think this is an issue with stock Interstates today. Every stock Interstate comes with charging system that pulls in excess of 100 amps to charge the AGM batteries. The Bosch alternator is rated at 220 amps and actually delivers almost 240 amps. If the clutch were to fail at these currents, we would hear about a ton of such problems from sprinter owners yet we don't.

As with all things mechanical, there are different products with different reliability metrics and ability to handle load. I suspect the 200 amp alternator you used is not as robust as what ships with Sprinter NC3s now.

Personally I have had my alternator charge the Lithium cells multiple times with no sign of any trouble. The load from the Sterling battery to battery charger is just a hair above what I used to measure with AGMs so I think durability is the same.
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Old 01-28-2019, 06:15 PM   #516
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I wish there were a way I could determine it conclusively, Amir. Of course we simply could have gotten a $500 lemon alternator. Unfortunately, the way to test out that hypothesis to its logical extent might lead to loss of property and/or life, so I can't do it.

In other words, if I were to replicate the original operating conditions and I DIDN'T get a failure of the new Bosch, then that outcome would support the "lemon alternator" null hypothesis.

If that exercise instead led to another clutch pulley failure, I could also get the van destroyed and/or myself killed in the process of proving the alternate hypothesis.

There are enough anecdotal reports of clutch failures in a wide variety of high-demand operating scenarios that I can't accept "lemon" on its face, though. Failures seem to be endemic to the newer alternator designs, at least outside of a certain poorly-defined operating envelope. And so there we are.

You can bet your booty, though, that I will be posting back here if I discover more lithium users reporting this same failure mode in the future.
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Old 02-04-2019, 07:07 AM   #517
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Some clever bugger on Sprinter Forum was largely the inspiration behind the design of this, a circuit that my husband stayed up way too late last night to work on. It never ceases to amaze me how much influence people we've never met and don't even know the names of have on our lives. Much of the time, I don't even know what countries they are located in. It's a true hive mind scenario.

Anyway, I already have a mechanism that can effectively manage alternator charging and which is protective of the clutch pulley. The corresponding circuit is embedded in my prefrontal cortex and the mechanism is attached to my shoulder and there are 5 digits at the distal end of it - WITH an opposable thumb to boot. This existing mechanism of mine affixes organically when needed to a switch on the panel which toggles between "on" and "off".

But that's not good enough for my husband, who decided to kick off his entire week with a too-late night. Once he gets this designed, he can have it commissioned as a build. It better not be the kind of circuit board that can develop tin whiskers, though.

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Old Yesterday, 07:36 AM   #518
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Post-script on the solar facet of our electrical system --

A T1N Interstate owner contacted me off-forum (via my blog) and emailed me some pics of his rig. We (meaning LB_3) spent a veritable boat-load of money on the 80/20 frame that straps our panels to the existing T1N Interstate roof rack. A boat-load of money!! Ours is not the only viable design, however. If someone doesn't wish to spend a boat-load of money on a custom-fit frame, and alternatively, doesn't have the tools to do metal cutting and welding, there are other design options, such as this one.

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