Category Archives: Maintenance

Catch Me If You Can… Part 2

28 Thursday Jun 2018

Posted by in Accessories, Amarok, General, Help Guides, Maintenance, Modifications, Technical, Uncategorized, VW Amarok

≈ 6 Comments

Tags

, , , , , ,

You might want to read Catch Me If You Can… (pt 1) first

After a quick four-day break at the Caravan & Motorhome Club’s site at Wirral Country Park (excellent by the way… already trying to work out when we can go back!!) and a bit of work getting in the way it was time to get going again not he catch can… really it should be called the “Air Oil Separator” Install.

Last time, I’d decided if IKB would have been shaking his head… then it wasn’t right. I decided to make a new bracket out of 1.8mm aluminium sheet and go into full on origami mode. (ps.. after the last post someone emailed me asking what IKB was…. Mr Brunel  was not pleased).

I wanted to make a bracket that passed under the air con pipe and bonnet cable release fitting so that it cleared everything and gave good access at the same time. As a test I did a trial bend if some 1mm thick steel I had just to get the shape…

IMG_1441

Once I’d got the angles and size sorted it was time to move on to the aluminium sheet. My press brake… well I call it a press brake, in reality its a cheap basic hand folding machine but it works very well as long as you know its limits and don’t get daft trying to fold big stuff. It was all about the angles…

IMG_1451

The first two were easy and I could form the lip with two folds, the second was less than 90 degrees so I just about got away with enough clearance. However folding the return that would lip over the front cross brace which was also less than 90 degrees also meant that I’d have a problem fitting it in the folder.

IMG_1453However, a little lateral thinking and taking the blade off the folding machine, inserting my workpiece and re-installing the blade meant I could fold in the opposite direction (downward)… result!

IMG_1454A quick trim and rounding off the edges gave me a rough folded bracket. A quick file of the edges and work-over with some fine emery removed all the tool marks… quickly followed up with a coat of etch prime to protect it.

IMG_1455

I now had to work out how to mount the plastic housing the bonnet release cables were located in. On the rear of the fitting were two plastic tabs that locked into two square holes punched into the vehicles cross member.

IMG_1458

So a few minutes spent with a dremmel and a couple of suitable sized swiss files later…

IMG_1457… and the piece was ready for a final rub over with scotch bright a second coat of etch primer and two coats of black.

The Installation…

IMG_1462

All went a bit easy actually… which is flipping’ unusual for me. I released the bonnet (or ‘hood’ for my American friends) cable fitting and simply clipped it back in to the two new holes I’d made.

IMG_1463

The Provent was installed next…

IMG_1464

IMG_1465

… again without any issues. Next was to sort out the plumbing.

I’d done a bit of research and asking around and the guys at ASH… AutoSiliconHose.com had come highly recommended. So a road trip over the Pennines to Mirfield (just east of Brighouse in West Yorkshire) was scheduled.

I had a basic list of what I thought I’d need and the chap behind the counter hooked me up with everything… including the alloy couplers he cut to size while I waited. Great service from ASH and I can definitely recommend them.

Back home with my shopping, it was time to start on the plumbing.

IMG_1469

For securing pipes, I personally prefer spring clips… the type you install with special pillars, however the silicon hose OD was slightly too large for may normal stock of clamps so I had to opt for using the wire type. I’ll order some of the correct size and replace the wire clamps as soon as they arrive.

IMG_1471

IMG_1472

IMG_1473

IMG_1474

It was really simple now to just assemble the bits, cutting the silicon pipe to length as required. I used a pair of plastic conduit cutters to easily slice through the pipe.

Before I made the final connections to the crank case breather port or the turbo inlet port I blew the pipes clear using a high pressure air line.

All that was left to do was install the drain hose, one way valve and drain tap. I used normal 20mm oil line for the drain, inserting the one way valve about three inches below the outlet of the Provent catch can. The remainder of the hose was dropped down to chassis level and the drain tap added and secured with a couple of zip ties.

IMG_1475

The Finale…

IMG_1479

IMG_1477

I secured the pipes in a couple of places with zip ties, now I know the route I can make a small stand-off bracket with two rubber lines “P” clips to mount on the engine to hold the pipes, although they are self-supporting because of the short length.

In the photographs above it looks like the piping is tight across the engine, I did do a pull and push test and there is plenty of movement at the 90 degree bends to allow the torque twist of the engine without pulling or pushing on the pipes at the catch can end.

The current mileage is 11,750 or there abouts, so I’ll check the drain and filter in 100 miles and each 100 miles after that so I can get an idea of how the setup is going. I’m not sure how long the filter is designed to last, but Ill put it on the schedule to replace ever main service. The other thing that is an unknown is how much oil I’ll get. I have been watching some YouTube videos made by Berrima Diesel in Australia (if you watch any of the Australian 4 x 4 or off-road channels you will recognise the name). I only found out about their catch can experience when one of the guys from one of the 4 x 4 adventure channels got in touch… even if you don’t think you need a catch can but drive a big diesel their videos are well worth watching.

Ok… I was saying I don’t know how much oil to expect… but it did surprise me that Berrima Diesels posted a video showing a new 4 x 4 with about 6000Km on the clock had produced about 300ml’s of oil using the same Provent catch can. It’s also worth taking look at what the have to say about the current oil specified in diesel engines.

The other thing I noticed was when I left the engine ticking over for about ten minutes. Bearing in mind I had just come back from West Yorkshire via the M62 and M60 and started the pipe install as soon as I got back so the engine was still hot, the difference in temperature between the short length of pipe exiting the crankcase vent and the inlet pipe of the turbo. The pipe exiting the crankcase vent port was almost at the temperature I could not keep my fingers on it, while the inlet pipe I’d connected too was still cool. I’ll have to get my thermomiterbob laser do-hicky out and get some readings… but anything that helps cool gasses going into the turbo has to be of benefit right?

That’s it for now, I know it’s not caravanning related that much… unless you want to get the best out of your diesel while towing. I promise the next one will be caravan related, honest!

As in part one I’d also like to give a shout out to Charles at HumbleMechanic.com for all the information and videos he produces about VW vehicles. Charles has been an absolute gold mine of information for all things VW and if you drive any of VW’s vehicles please be sure to drop in on his YouTube channel and take a look. 

Catch Me If You Can…

17 Sunday Jun 2018

Posted by in Accessories, Amarok, Maintenance, Modifications, Technical, Towing, Uncategorized

≈ 7 Comments

Tags

, , , , ,

I’m installing a “Catch Can” can on our VW Amarok and this little posting is all about it, but first a bit of history on why I’m installing one.

If you look at modern high performance diesel engines one of the things that they do to reduce emissions is have a number of systems to reduce the harmful emissions. EGR or Exhaust Gas Re-circulation wich is feeding part of the engines exhaust back into the intake but probably the most widely known is the DPF… or Diesel Particulate Filter which captures fine soot particles from exiting the exhaust. The DPF needs to be cleaned regularly, through a process called regeneration. Either active, passive or forced, the accumulated soot is burnt off at high temperature (around 600°c) to leave only a residue of ash, effectively renewing or regenerating the filter, ready to take on more pollution from the engine. To regenerate, the vehicle electronics adjust the timing of the engine to increase the exhaust gas temperatures or commonly it can be achieved by passive regeneration usually on the motorway when exhaust gasses are generally hotter.

In city driving or short trips the regeneration my not take place fully, leading to blocking of the filter. This can lead to higher fuel consumption and a visit to the mechanic for cleaning or replacement.

Forced Regeneration

If the DPF become blocked you will get an engine warning light and/or a DPF warning light to let you know that a regeneration or cleaning is required. If the vehicle continues to be driven and the engine load is not enough for the automatic process to be initiated you will get a second stage DPF warning. When your vehicle displays second stage DPF warning lights it will usually go in to ‘limp mode’ and should be taken to the dealer to ascertain the extent of the problem.

A forced regeneration involves the garage using a computer program to run the car, initiating a regeneration of the DPF.  This will also usually require changing the engine oil & oil filter.

Why does my Diesel Particulate Filter (DPF) block

Problems arise around town with stop start driving where the regeneration process might not complete or the engine never get hot enough for a long period. A warning light will illuminate or a message indicating the DPF is full displays on the dash. If you continue to drive in the same manner, the soot build up will increase until other warning lights illuminate and the vehicle will go into ‘limp’ mode, where driving speed is restricted.

Crankcase Ventilation

In all piston engines a certain amount of ‘blow by’ happens, this is some of the hot gasses treated in the cylinder combustion leaking past the piston rings.. or ‘blowing by’ and entering the crank case in the sump area. This pressure needs to be released and twenty years ago the engine oil filler cap used to have e vent in it. However in modern emission controlled vehicles this is not acceptable and the excess pressure is vented into the air intake of the engine where it passes through the engine cycle and exits through the exhaust. These hot gasses passing through the sump on their way out pickup fine mist of oil from the sump which is carried through to the intake of the engine and this creates three problems. The first is a sticky residue build up on the intake valves that hardens with temperature  – especially on direct injected engines. Secondly the intake pathway gets coated in oil from the engine. If you have a turbo charged engine with an intercooler, this can become an issue as it reduces the heat exchanging effects of the intercooler. Thirdly, when the oil is burnt in the engine it creates a heavy soot that increases the build up in the DPF.

When towing, you generally use more power for accelerating and maintaining speed which is great in one respect for the DPF. The downside though is the piston blow by is more and therefore the crank case pressure is increased.. picking up more of that fine oil mist from the sump.

Now the diesel engine tuning guys and the 4 x 4 guys in Australia have known about this for a number of years and they have a solution to the problem.

Cleaning up the crank cases gasses – “Catch Can’ or Air Oil Separator?

There is a difference. a ‘Catch Can’ is usually just that. A can that the gasses are fed into with an outlet that is fed back into the turbo inlet. Some do have some form of baffle but a lot don’t. More expensive ones may have a gauze wad inside for the oil droplets to form on. A lot don’t have a drain, you have to remove the bottom of the can to empty it. If you look on auction sites you can find nice looking anodised aluminium ones for £20 or £30 but for that sort of money all you are really paying for is the nice looking anodised aluminium. Not for an efficient effective unit.

s-l640

 On the other hand, a true Air Oil separator will have multiple traps in the form of differing size materials making up membranes for droplets to form on. A number of them are designed to swirl the gasses around first before exiting through the centre after passing through the filter membranes.

I wanted to get as much oil out of the gasses before they enter the engine inlet. So I opted for an Air Oil separator with replaceable membrane filter rather than a cheap ‘catch can’.   Seems like a simple device really, but there are a few more things to take into consideration…

I’ve opted to use the Mann-Hummel ProVent 200 on our VW Amarok. It’s been used all over the world with hundreds of installations on Toyota’s,  VW’s,  Mitsubishi’s, Land Rover’s and not just on 4 x 4’s.

My hope is that I’ll reduce the emissions through the engine while prolonging the life of the DPF,  keeping the inlet clean and oil free and importantly preventing that soot and carbon buildup in the inlet ports and valves while maintaining the efficiency of the intercooler.

Getting Started

I did look at the kits available for the VW Amarok and all were sourced in Australia. However I could buy all the individual components in the UK a lot cheaper than importing a kit. Bit’s ordered, the first decision was where to locate the unit…

IMG_1421

In the Amarok’s engine bay there is only two real places viable for the location of the ProVent. The first is on the back wall next to the engine ECU which seems to be the place of choice for most of the kits I’d found, and the second is in the front right hand corner in front of the battery.

Installing it on the rear firewall next to the ECU would mean partially covering up the Air Con gassing ports and I just knew that would be asking for trouble in the future…

IMG_1422

So the location that in my mind seemed the most logical would be to mount it in front of the battery, manufacturing a suitable bracket to hang it off the front top cross-piece where there seemed plenty of room and easy access.

This would also allow the two pipes… one from the crank case pressure release port (left below) and the return to one of the turbo inlet ports (right below) could take a short route from the ProVent across the front of the engine and would give me a couple of suitable points to mount supports for the pipes.

I needed to manufacture a bracket that mounted to the top cross rail and went over the air-con hose and bonnet release cable just below it. As luck would have it in my scrap metal bin I had the chassis from on old bit of electrical kit that was made out of aluminium and looked like it would do the job.

Cutting a section off, filing down the edges and drilling mounting holes didn’t take too long and that was followed up by a coat of etch primer and a couple of coats of high temperature gloss black (I only used that as I had a spare can from a previous job!)

Fitting was fairly easy…. and no, they will not be the final bolts!

IMG_1429

Marking and drilling three holes, followed by a couple of coats of metal protector to stop the edges of the holes rusting soon had the bracket in place. If you are wondering why the shape… well it came like that when I cut it off the scrap chassis, but quite by chance it allowed access to the hole which is access to the headlight adjuster screw.

Mounting the ProVent was now simple enough…

It was at this point I stopped. I didn’t like the way it covered the air-con pipe. There was little chance of it rubbing, the pipe already had a big rubber ring on it to stop chafing against the front cross beam or the bonnet release cable. I also now could not get to the bonnet release cable. The mount covered the point where there was a lubrication and connection block for it. It just wasn’t good engineering design.  IKB would be shaking his head and wafting his cigar around in dissatisfaction..

Back to the bat cave. Time for a rethink and to hone my skills in sheet metal origami.

I would like to thank Charles at HumbleMechanic.com for all the information and videos he produces about VW vehicles. Charles has been an absolute gold mine of information for all things VW and if you drive any of VW’s vehicles please be sure to drop in on his YouTube channel and take a look. 

That’s it for the moment… off to Wirral Country Park Caravan & Motorhome Club site for 4 days R & R.

Be right back after the break…..

E-Trailer….Smart or what!

28 Monday May 2018

Posted by in Accessories, Electrical, Gadgets, General, Maintenance, Modifications, Uncategorized

≈ 5 Comments

Tags

, , , , ,

A few weeks ago Andy Harris (yes that Andy… him off the TV) and of Road Pro fame called me to tell me about a new gadget that Dutch caravanners were getting all excited about. Now not one to turn down the chance to test a gadget or two, when Andy asked if I’d like one of the units to test I of course said in true reserved fashion said “Well I suppose I can take a look at it”. Who wouldn’t pass the chance to check out the latest piece of tech gadgetry being made by those clever Dutch people at e-Trailer. A few days later a large brown box arrived.

On a recent trip to the C & M Club’s site at Blackshaw Moore I took the opportunity to not only put my feet up for a couple of days with Sue but install and play around… er… seriously test… one of the units..

Blackshaw Moor C & M Club

Opening up the box I found five smaller boxes, containing the main unit and four of the modules.

IMG_1400

Ok, so what is e-Trailer? The simple explanation is there is a black box that sends all kinds of information about your caravan to an app on your phone. It works with both Android and iPhones and there are various ‘modules’ you can add-on to get additional info.

IMG_1403The actual unit is about 120mm long by 80mm wide and 40mm high with a good quality power connector at one end.

In the box is the main unit, 1.5 metre long power lead, instruction manual and a card with a QR Code on it.

You get a QR code with each of the modules, and set of instructions, don’t lose the cars with the QR codes on them! (more about these later)

IMG_1401

Installing the unit is serious easy. You just hook up the power lead to a 12 volt supply. I opted to connected to a switched supply sort came on whenever the caravan master switch was on. This would mean it would be active when towing.

IMG_0855

Once you have powered up the main unit, go to the website e-trailer.nl/app and follow the link for your phone. In the case of my iPhone it took me to the App Store were I could download the app. Once downloaded launch the app and follow the on-screen instructions to register. I was a bit surprised it asked for my postcode and house number, but I guess this is how they register the unit to you for warranty etc.

Once you have created your account in the app and logged in… well remember that card with the QR code on it, simply scan the code and it pairs the app with the unit you have just installed.IMG_0861

You are done! It’s that easy. Now to add the modules. The first one I added was the temperature module. You get a small puck shaped device and following the on-screen prompt, scanned the QR code.

IMG_1408

Done… a quick scan and now I have the temperature reading. For each module you can set lower and upper limits and the type of alarm… visual notification, vibrate, sound. From reading the instructions you could put this sensor in the fridge so when you are driving along you can keep an eye on the fridge temperature to make sure your wine or beer is perfectly chilled when you arrive. From what I understand you can add additional temperature sensors so you can check what the temperature is in the caravan at the same time.

IMG_0859

Next was the voltage sensor so you can keep an eye on the battery voltage. Again it was a quick scan of the QR code and I could see instantly what the battery voltage is and its relative state of charge. (I have yet to check how accurate this is).

IMG_0858

Again, it is easy to set the limits, just tap the two cogs in the bottom left corner….

IMG_0857

… And you can adjust the upper and lower alarm voltages. This is really useful as you can correctly set it for flooded call, AGM or lithium batteries.

Want to know if you have left your roof light open or TV aerial up… or even if your fridge door is open? There’s a module for that… The E Switch.

IMG_1409

In the E-switch module you get two magnetic contact switches that come with 3M pads so you can stick them almost anywhere. Again adding them is a simple scan of the QR code and follow the instructions on-screen. I edited the text for the first switch so I know it is the TV Aerial.

IMG_0860

If one of the switches is open, on the home screen you see that the padlock is orange, close the switch and the padlock closes and the icon turns green.

So what else can it do? Well I also have the tyre pressure monitor module. You get two pressure sensors to attach to the tyre valve stems. The sensors are the type that you can change the battery, which I much prefer, as opposed to the sealed type. I’ve not installed the TPMS module yet as I’m still testing out other TPMS systems on the Amarok and caravan but no doubt it will be an easy install… by just scanning the QR code!

IMG_1411

The last little trick that is has is it is an extreme accurate caravan levelling aid. Again a quick scan of the QR code gets this up and running and follow the on-screen instructions to determine your level point and it becomes easy to level next time you pitch.

OK so what did I think about it?

Well it was super easy to install. It was also super easy to add each module. I like the fact that when you hit up to set off you can check the battery voltage and see if it is charging. You can make sure what ever you have attached the magnetic contacts to you can see if they are in the correct position (i.e. closed, lowered etc.) and you can check the fridge or caravan temperature and tyre pressure.

While driving you can keep an eye on things like your caravan’s tyres, battery charge and fridge temperature. when you arrive on site, reversing into your pitch you can easily see if the caravan needs levelling side to side using ramps or blocks and when you un-hitch you can adjust the jockey wheel to get perfect levelling front to back.

“We have a problem Huston…..”

Now I do have a problem with it. Come what may I cannot get it to vibrate, notify me or play a sound when  anything goes out of the parameters (switch open, battery voltage low etc. I made sure I had the latest version of the app, I have double checked all the settings within my iPhone but I cannot get a single ‘vurrrrrr’ or ‘ding’ out of it. Admittedly my iPhone is now 2 versions behind the times but if the app installed I’d have expected it to work ok. I’ll continue to work on this one.

Finally…

I think the idea and technology is great behind the product and I really do like it and can see lots of additional applications could be added on in the future.

Why though is it an after market accessory? When you can be paying the best part of £30k for a top end caravan should not this sort of information system be standard? When I hitch up and set off, I’d love to be able to check the battery voltage (and charging current) check the fridge was working, tyre pressures, doors and hatches closed… and it is not beyond the engineering skills of man to be able to have a bulb out detection system for the road lights even…. all fed directly to your phone.

If a manufacturer decided to install such a unit the price point would drop dramatically.. and that’s one of my other niggles. The technology and ease of installation is great, however there is a bit of an ‘ouch’ in the wallet as currently the comfort pack is priced around £380. That’s a lot of nights on site. You can build up the unit by just buying the individual modules though.

Do I want one… “Yes”…. would I buy one…. I’ll just go and have a word with Sue.

The e-Trailer is currently available from Road Pro here.. www.roadpro.co.uk/catalogue/01m-smart-trailer

Getting All Charged Up – Update 2…

29 Monday Jan 2018

Posted by in Accessories, Blog updates, Electrical, Gadgets, Maintenance, Modifications, Product Review

≈ 10 Comments

Tags

, , , ,

I guess this really is the update to an update (Getting All Charged Up – Update…). We have been living with the Sterling Wildside unit now for about 6 months and a LOT of people have been emailing me asking how we are getting on with it and is it worth it?

IMG_1194Well I have done quite a bit of testing with my leisure battery in various states of discharge. With it at about 50% I have recorded a charging current of 15.9 Amps which is far greater than I could manage before and due to the fact that the Wildside unit uses the correct charging profile for my battery I’m not concerned that I will be reducing or damaging my leisure batteries life expectancy.

Earlier this month I had an email from David Dent who had successfully installed a Wildside unit in his Bailey Unicorn 3 Cadiz and he seemed pleased with the results so far. Although installing it in a Bailey was a bit more of a challenge. I’m looking forward to checking back with David to see how he is getting on with his unit.

A couple of other people have also emailed me reporting that after installing a Wildside unit that it had solved their problem of having enough stored energy to operate their motor movers. I still wonder if people who have been experiencing problems with their motor movers caused by supposedly bad batteries and have had to replace them is possibly down to the fact their battery was never really receiving a correct or full charge before causing its early demise.

New Tool…

One of the things I want to get to add to my ‘tool box’ in the near future is one of the computerised digital battery testers. At the moment I’m basing a lot of my work on the voltage of the battery and chemistry type. I’d like to be able to improve on this.

Watch This Space…

The other thing I’d also like to be able to do is get a voltage and charge current reading for the leisure battery while we are actually driving. I have been looking at a few – mainly American options for bluetooth remote voltage and current sensors that you can connect up to with your phone. There are a couple of devices that offer a separate display to fit in your vehicle.

However, there is a rather exciting unit that will shortly be coming on the market in this area that might be a bit of a game changer. If you want to know what it is well go and see Andy Harris or one of the guys on the Road Pro stand at the NEC in a couple of weeks time as they, along with the manufacturer will be launching and demonstrating a new product that might just be bringing caravan technology bang up-to-date. I hope to be bringing you a bit more about this soon and maybe an install too!

Final Thoughts….

Is the Wildside unit worth it?  Before I answer this let me just say I am not being paid by anyone for any endorsements of this unit. I was supplied one of the first (pre production?) units as a test and to provide feedback to Sterling Power on how easy it was to install and it’s performance in the real world, which I did. As a result a couple of things were ‘tweaked’ hence mine had to be returned, reprogrammed and reinstalled.

Well I’d say if you have a Euro 6 or even a 5 engine and you want to make sure your battery is looked after then yes. If you want to upgrade to a more advanced battery chemistry, again yes.  If I had to return mine would I go out and buy one? Yes I would.

Is there anything I’d like to see changed? Well if they ever did a Wildside 2.0 I’d like to be able to move the caravan’s own charging system so it was routed through the Wildside unit when on mains hook up to take advantage of the Wildside’s smart charging facility and to allow you to move to more advanced battery chemistry. I guess also adding a solar panel input with built-in MPPT would be a big hit too.

In The Future…

I’m starting to wonder if the way we charge and power caravans needs to take a leap forward. I have had an idea that you could basically split an inverter. One half in the vehicle and the other in the caravan. Imagine a small unit that takes the 12 volt DC from the vehicle and inverts it to 48 volts AC. You then have a lead that connects this across to the caravan and there it is converted back into 12 volts DC.

So whats the difference… all you are doing is what’s already happening? Well using a 2.5 mm cable rated for 25 amps at 48 volts gives you 1200 watts of power. To transfer that much power at 12 volts you would need 100 Amps. Keeping it at 48 volts will mean the system is still in the ELV range for safety. (Use 4mm cable and this could be 1680 watts of power which would be equivalent to 140 Amps at 12 volts)

Being able to transfer that sort of energy would allow you to forget LPG cylinders and put 1000 Ah of lithium cells in the caravan with a 240 volt inverter and power everything. Just a thought that I’m throwing out there.

Is A Euro 6 Engine Killing Your Leisure Battery?…

21 Friday Jul 2017

Posted by in Accessories, Amarok, Caravan Electrical Fault Finding, Caravan Electrics, Electrical, Maintenance, Modifications, Off Grid, Technical, Tow Vehicle, VW Amarok

≈ 83 Comments

Tags

, , , ,

OK… so that title was a bit dramatic! However here’s the thing… I don’t think everything is peachy with Euro 6 engines and charging leisure batteries.

If you are a regular reader, you know I have recently installed one of Sterling Power’s Wildside units (and so far I’m super happy with it!) but I did get an email from someone who had read all my postings about it and asked me if it might cure his problem. Here’s the gist of his email….

Note: I have edited this down a bit…. and withheld the name of the person and vehicle.

“I have recently changed my car to a new 2017 xxxxxxxxxxxx and after several trips with it, on arriving home there is never enough charge in the motor mover to manoeuvre our caravan up our drive (which is on an incline) and park the caravan round the back of the garage. I have to plug the caravan in overnight before I can use the mover.

This only seems to have started happening since we changed to the xxxxxxxxxx. I had the caravan’s battery tested at two garages and they said it is OK and it is only 2 years old. The local caravan service man said he could not find anything wrong with the motor mover.

As we are on mains at the caravan sites we visit for a few days the caravan battery should be fully charged.

Can you help?”

This did have me stumped for a bit. Battery tested OK, no issues with the mover, so what was going on?

While doing some of the prep work for writing about my installation of the Wildside unit, I had spent a few days prodding about our VW Amarok with a multimeter and making a few notes about voltages etc. One thing that I did cotton on to was the cyclic way the vehicles ECU seemed to turn off the alternator…. well I should really say put the alternator into “idle” mode. Now with the caravan attached (pre Wildside unit install) I did notice that  at the start it seemed to take longer for the vehicle’s alternator to go into idle mode but also it seemed to stay in idle for a lot longer and I was in the process of trying to work out why as initially I’d have thought it would have been less as it was running the fridge and charging the leisure battery.

A picture is worth… you know the rest. Here’s one of my excellent drawings!

Euro 6 Problem 01

Right, here we go… The drawing shows a caravan plugged into a tow vehicle that has the engine-turned off. Pin 9 is live as it should be, and the habitation relay in the caravan is effectively off allowing the caravan’s leisure battery to connect and power the caravan’s internal 12 volt systems. As the vehicle engine is off, there is no power on Pin 10 the fridge circuit, as this is controlled by the vehicle’s ECU.

Really this could be any vehicle with any engine. Now let’s have a look at what happens with the engine running…

Euro 6 Problem 02

Pin 10 is live, turned on by the vehicles ECU and this powers the caravans fridge. It also operates the caravan’s habitation relay which now disconnects the leisure battery from the caravan’s 12 volt systems and connects it to Pin 9 so that the vehicle can start to charge it.

Again, this could be any vehicle with any engine. This is how our Land Rover Freelander works with our caravan. All straight forward.

Now lets look at what happens when the Euro 6 engine puts the alternator into “idle” (or Eco mode etc.)

Euro 6 Problem 03

This is where it starts to get interesting. I have taken a few liberties here and made a few assumptions. I have shown the vehicle’s alternator disconnected. In practice the ECU doesn’t disconnect the alternator, it will reduce the field voltage and hence the output, not really disconnecting it but reducing the output to a negligible amount.

The ECU will also monitor the vehicle’s battery voltage and continue to allow the vehicles general electrical system to drain the battery to somewhere around 75% charge (this may be a bit of an arbitrary figure) The ECU will then turn on (or up) the alternators output to recharge the vehicle’s battery to about 80%. Why 80% well it needs the remaining 20% ‘free capacity’ so that when you brake, the excess energy of engine braking (regen) can be dissipated into the vehicle battery. Remember that on a Euro 6 engine the alternator is capable of generating round about 2Kw.

Now at this point it dawned on me that something could be happening here, but the idea was a bit ridiculous…. guys with far more agile grey cells than mine must have worked this out and I dismissed the idea. I must have missed a trick somewhere.

I did a bit more checking. I was using two 17Ah sealed lead acid batteries as my “leisure” battery simply because it was quicker to charge or discharge them than a 120Ah battery. For a fridge load I was using 3 x 50 watt light bulbs and it was all jury rigged to a 13 pin plug so I could just plug it in to either the Freelander or the Amarok to make comparisons. I was using a trusty old AVO 8 meter, a couple of digital multimeters and a clamp meter to measure current so really the whole set up was super sketchy for anything that I could write about. I thought that I must have been missing something somewhere and I actually kind of put it to the back of my mind. I just got on with installing the Wildside unit and writing it up.

“DING” You have mail……

I received an email from Charles Sterling with some very interesting information. During testing he had come across exactly the same issue I was pondering over but had put off further testing. I guess by now you have worked it out. Quite simply you can get current flow in the opposite direction… from caravan leisure battery to vehicle battery. In testing Charles had measured a current of around 6 Amps.

It dawned on me that maybe during my initial testing with my jury rigged set up I hadn’t missed something and the readings I had seen were correct. Both Charles and I quite separately had (in my case ‘stumbled’) on a potential issue with Euro 6 engines and caravans.

Back to the original email earlier. It now made sense. The sender of the email was setting off from their campsite to travel home with a fully charged battery (being on EHU while they were on site) and during the course of the drive home, the vehicles ECU was actually reducing the fully charged leisure battery down to 80% charge as it actually thought that the ‘vehicle’ battery was at 100% charge. Hence when he arrived home, the caravan’s leisure battery didn’t have enough charge to run the motor mover long enough to put the caravan away.

So what does this mean in practice?

Well effectively (give or take a bit of loss due to cabling) the caravan’s leisure battery will only get charged to about 80%. You can now think of the vehicle battery and caravan leisure battery as being one battery bank because that is how the vehicle sees it. If the leisure battery is fully charged its voltage will be higher than the vehicle battery so the vehicle will turn off (or down) the alternator so that the vehicles electrical system can drain it to about 75% ready for accepting the excess energy from regen braking. The caravan’s fridge helps the vehicle by draining the battery bank that bit quicker.

This also answers another question. While I was testing, sometimes I’d plug-in my jury rigged setup and if my two little 17Ah batteries were fully charged I’d get a low current drain indicated on my clamp meter. I’d dismissed this to a certain extent, but now I realise that as my two 17Ah batteries were fully charged and the vehicle battery would be at about 80% charge, there would be enough of a voltage difference for a short while, that the two 17Ah batteries would try to equalise with the vehicle battery by recharging it slightly..

Whats the answer?

Well thankfully I solved my problem when I installed the Wildside unit a few weeks ago.

Finally…

If you have had any electrical issues with a Euro 6 engine and towing please drop a comment below. I’ll try to help.

As an aside, I am trying to arrange attending a tow bar installers electrical course with a couple of the OEM electrical equipment manufacturers and one of the approved bodies so I can hopefully increase my knowledge base and widen the number of vehicles I can cover. It’s a bit up-in-the-air at the moment as it would appear its going to cost a small fortune! (Sponsorship deals gratefully received!)

Getting All Charged Up – Part 2…

26 Wednesday Apr 2017

Posted by in Caravan Electrics, Caravan Servicing, Electrical, General, Maintenance, Modifications, Projects, Technical, Uncategorized

≈ 10 Comments

Tags

, , , , , ,

Planning the Install

Remember the Six P’s… “Proper Planning Prevents Piddling Poor Performance”… or something along those lines! Before we start hacking away at the multitude of cables (and my email inbox fills up with help requests) we need to pull out the relevant electrical schematics from the handbook. Our caravan is a ‘dealer special’ based on a 2011 Swift Europa 550 fitted with a Sargent PSU.

We can see from the schematic below that the 13 pin plug enters into the caravan and terminates with two connectors – FB6 and FB7 on fuse unit C44 which in our caravan is located just next to the front draws near the water pump. FB6 is all the road lights and we can ignore this.

Socket Connections

The cables we are interested in are from pins 9,10,11 & 13 which are coloured Orange, Slate Grey, White/Black and White/Red respectively and terminate in connector FB7. We need to now look for these leaving the Fuse Unit and heading off to the PSU.

The most likely candidate will be connector FB2 with four cables going to connector P1 on the PSU. If they are all 2.5mm²  it’s a good clue these are the ones we want. We will need to check these with a multimeter though to be sure. The colours have changed too so we will need to confirm what the new colour is for each circuit.

Socket Connections 2

So that’s the input side of the Wildside potentially sorted out, now we have to find the fridge connections. Looking at the schematic for the Power Circuits we can see that the fridge is connected via four cables. One directly to Neutral and the other three to P7. We can also see from this schematic that the leisure battery is connected to P2 via a 20 Amp fuse. This tells us two things – the wiring is rated for 20 amps and we will have to upgrade the cable size from the Wildside unit to the leisure battery.

Fridge Circuit

For the fridge… We are interested in the two cables that power the heating element and on the drawing they are coloured W/B and R/Y (White/Black and Red/Yellow) and originate from connector P7 on the PSU.

Fridge Circuit 2

We have now identified on the schematics the cables we need to look for and where they run from and to. Next step is to create a new schematic using the information from these two drawings to show how we are going to connect in the Wildside unit.

To The Bat Cave…. err Drawing Board!

If you are handy at using a drawing package such as Sketch-Up or similar (I use “AUTODESK® Graphic” on my MAC) you can have a go at drawing it out, or simply just use a sheet of paper. The important thing here is you DO draw it out.. this is not an option, its a mandatory task!

TIP: If you are drawing this out by hand on a sheet of paper, it might help to photocopy your caravan schematics and cut out the relevant sections… like the fridge and stick them to your drawing to make it easier.

So here’s my efforts….

Wildside Wiring 01

If you remember in part 1 I said we will need to make five connections…. not including the neutral. Well we have the five connections. After looking at the layout I decided not to cut the current leisure battery connections to upgrade, but to install a new Positive and Neutral cable alongside the original cables. This will mean however I will need to drill a new hole in the battery box and install a sealed cable gland.

The three cables that we cut on P1 that are now unconnected should, in theory not be part of any circuit. However to be sure I’m going to terminate both the neutral cables (originally connected to Pin 11 and Pin 13 to the neutral point on the Wildside unit.

The cable that was originally connected to Pin 9 I’ll just crimp on a blind connector and secure out of harms way. I am not sure if this might need to be connected to a +ve supply. There are a couple of things that I’ll need to check, for example, the toilet flush always works when the caravan is connected to the tow vehicle – with or without the engine running ( handy if a quick P(it) stop is required!).

Now… To The Bat Cave!

Well it might be a couple of days as I have just ordered a few bits and pieces I don’t have in stock in the workshop… and I’m still procrastinating whether to do the install as a video to accompany my written ramblings.

Coming up in part 3. I attempt not to destroy our caravan, do a lot of crimping, consume a lot of coffee and I may be swearing a lot on camera!

Getting All Charged Up – Part 1…

25 Tuesday Apr 2017

Posted by in Boondocking, Caravan Electrics, Caravan Servicing, Electrical, Gadgets, General, Maintenance, Modifications, Off Grid, Product Review, Reviews, Technical, Tow Vehicle, Uncategorized, VW Amarok

≈ 6 Comments

Tags

, , , , ,

If you are a regular reader you may remember a couple of posts I wrote about leisure battery charging in caravans and motorhomes (Smart Alternators: how they affect Caravans and Motorhomes…. and NEC Show Roundup – it’s all technical…) and I linked to a few videos that Charles Sterling from Sterling Power has produced covering charging topics and Euro6 engines. At the recent NEC show Sterling Power were featuring a new product that would soon be available that would solve all the issues for caravan owners that were experiancing towing with vehicles that had “smart alternators” which were are standard on Euro5 and Euro6 engines and the issues around regenerative braking on Euro6 engines. Charles promised to send me one of the first pre-production “Wildside” Battery to Battery chargers specifically designed for caravans.

IMG_1127A couple of days ago I was excited to receive   a package from Sterling Power containing one of the pre-production new “Wildside” units. The unit itself is robustly constructed and weighs in at about the same as a bag of sugar – 1Kg.

It comes with a comprehensive 11 page instruction/installation manual that goes through all the steps that you need to install the units and what all the various lights and connections are on the unit itself. For anyone that is familiar with my electrical drawings, Sterling have based their installation drawings on my format so are easy to understand (in my opinion!).

I’ll state now for the record, Sterling Power have sent me this free of charge to install and evaluate and that is what I’m going to do, but I will be honest and tell you if I think there are any issues with the installation or the unit in the way that it operates.

IMG_1131

Looking at the connections for the unit it all looks straight forward. The circuit board is labelled  exactly as the drawings in the installation manual which is reassuring and the manual goes into the various functions of each connection and the programming of the unit.

Why this unit?

Since we had changed from using our 2006 Land Rover Freelander HSE as our primary tow vehicle to our 2016 VW Amarok Atacama I had noticed that our leisure battery was not getting close to a full charge even after towing for a couple of hours. We don’t have a solar charging system installed and relied on the tow vehicle and EHU when on site to keep our leisure battery topped up. I knew about the limitations of smart alternators and have written about them before and answered lots of emails about problems readers were now experiancing. Up to this point I really didn’t have an answer to most of the problems and I was considering going down the same route as our Australian cousins and installing some hefty cables between the tow vehicle and caravan, connected together with Anderson connectors. Works fine down under and would do here, especially coupled with one of Sterling Power’s B2B units which I had been looking at.

Now this would be ideal for us, but anyone who tows using a company car, a lease vehicle or a vehicle on a LP scheme can’t just go ahead and install stuff willy nilly. Unless it is done right, it has the potential to be a bit of a ticking bomb as well and  if I was going to recommend it as a solution there are very few people with experience to do an installation of this type. I have seen some right botch jobs on heavy-duty cabling by so-called “professionals” when installing simple winches and dual battery systems on 4 x 4 off road vehicles. Using a lump hammer, cold chisel and block of metal is NOT the professional way to crimp battery cables!

I was looking round to see if there were other options and talking to the chaps on the Sterling Power stand at the show told me they had a product in development that might just be the solution…. and here we are!

How does it work?

I’m not going to give you chapter and verse on the internals (some of that would be guessing on my part and some is propriety information anyway) so I’ll simplify it as much as I can.

In current tow vehicles you have two connections that supply power to the caravan – one for the fridge which is only live when the engine runs and one for charging the leisure battery which is usually live all the time.  Now the problem is that as it’s quite a distance from the front of the vehicle where the battery and alternator are to where  the leisure battery and fridge are located in the caravan. The size of the cables providing the connections are key to how efficient it all works.

Nearly all good quality tow bar wiring uses 2.5 mm square (2.5mm²) cable for these circuits and they connect between the tow vehicle and caravan through a 13 pin plug and socket (or 12N & 12S in older vehicles). The problem with all this is down to good electrical ‘laws’. In essence the more current you draw through a length of cable the greater the voltage drop ( I go into a bit of techie detail about it here… Understanding Cable and Cable Sizes ) Some people go to the lengths of re-wiring the circuits in 4mm² or even 6mm² cable, which was OK up to a point… usually the point which is the connection between the vehicle and caravan. With the traditional installation what you end up with is two circuits that the voltage is usually too low to provide a good charging capability for the leisure battery and the fridge circuit that might or might not, depending on voltage drop, have some spare capacity but you can’t use it to charge the leisure battery.

Back to the Wildside unit…

What the Wildside unit does and this is really clever, is it takes over the two power circuits, aggregates them and manages the output. It draws the maximum current available through each of the two circuits and provides an output for the fridge always at the correct voltage to maximise the efficiency of your fridge and protect it from the voltage fluctuations inherent with Euro6 and Regen engines and any spare capacity on this circuit it added to the leisure battery charging circuit, steps up the voltage and provides a separate output via a four stage intelligent battery charger to maximise the charging capability to your leisure battery.

This is a very very simple one paragraph explanation, it does have a few other tricks up its sleeve though.

One feature is the “Remote Mode Select” switch option. This allows you to install a switch that will allow you to turn the unit to “Wildside”, “Boondocking” or “Off Grid” mode and run the fridge as though it was being powered from the vehicle. It is actually being powered from the leisure battery.

Take note though… Most caravans and motorhomes are fitted with absorption fridges which use a heated element that is constantly on to make the fridge work. However some motorhomes ( I don’t know of any caravans) are fitted with the more expensive and vastly more efficient compressor fridges which work exactly like your fridge at home but can’t run on gas. If you are camping off grid for a few days with an absorption fridge, then run it on gas. However if you are worried about your fridge not maintaining temperature on an hours ferry crossing or on a euro tunnel crossing then you can use the switch to keep the fridge running. The period you can power it will depend on the capacity of your battery(s)… I would not advise using it with and absorption fridge on a battery bank with anything less than 110Ah capacity.

If you do use this feature on the Wildside unit, it will protect your battery bank from discharging past the safe point by turning off the fridge when the voltage reduces and reaches a critical point that would damage your battries.

You also have the ability to specifically select the type of leisure battries you have installed – GEL I, GEL II, AGM I, AGM II, Sealed, Open, Calcium, LiFePO4 to get the correct tailored charging and maintenance program for your battery bank.

If you are fortunate to have lithium leisure batteries there are a couple of other connections you will need to check out too.

Installation Considerations…

We know what it does so how do we connect it. Well this is where it could get messy unless we have a plan.

IMG_1132

In essence, what do we need to do? Well we have to cut and divert the incoming pin 9 and pin 10 into the Wildside unit and connect one output to the leisure battery. We also need to disconnect the fridge from the caravan’s original control box and reconnect it to the Wildside unit. As the habitation relay is usually buried inside the original control box we need to be able to control this from the Wildside unit. There is a terminal for this (“CVan Dis Output”) but what do we connect to this to make the habitation relay operate correctly?

The original Pin 10 lead that we cut and diverted into the Wildside unit, the other end of this still goes into the installed control box and this will operate the habitation relay. Remember we disconnected the fridge power lead from the installed control box and reconnected it directly to the FRG+ output on the Wildside unit so all it does now is operate the habitation relay.

So summing up, we have to cut 3 cables and re-terminate 5 ends into the Wildside unit. This of course does not include the neutral connections which will be easy and straight forward.

Other Considerations…

The installation of the Wildside unit must be easily reversible so it can be moved to another caravan at some point in the future.

We must also use the correct size cables to connect to the leisure battery as we will now be charging at higher currents than was possible before, the original cable that was installed in the caravan to connect to the leisure battery may not be of a sufficient rating.

We must document the changes properly so that at some point in the future someone can follow what we have done incase they have to fault find.

We must make sure all the connections and general installation are done to a high standard to ensure the installation is safe.

Finally we must be able to do the install without invalidating any warranty on the original installed control unit (i.e. not opening it up) and retain functionality of all the elements of the caravans electrical system. It’s no use installing the Wildside unit if half the electrical features of you caravan don’t work afterwards!

IMG_1130In Part 2…

In the next part I’ll go through the manufacturers electrical schematics of the caravan and show how to find and trace  which cables we are going to look for when we do the install and how we produce a simple drawing showing the changes.

I’ll also come up with a quick check list for all the additional bits (cable, terminals etc) that we will need for the install.

Fit2Go Tyre Pressure Checker…

05 Wednesday Apr 2017

Posted by in Accessories, Gadgets, General, Maintenance, Product Review, Reviews, Technical, TPMS

≈ 6 Comments

Tags

, , , , , , ,

Back in December last year I did a write up and little video with Andy Harris from RoadPro about the Fit2Go tyre pressure monitoring system. In the video he promised to send me one of the new Fit2Go Tyre Pressure Checker units as soon as they were released. Well Andy kept his word and yesterday I received a little package from Road Pro.

IMG_1112

I had seen a sneak preview of one of the first early production units available at the NEC show in February and managed to have a quick run through of it very simple operation.

IMG_1113

The unit comes neatly packaged and isn’t contained on one of those damn near impossible to open blister packs thankfully. It arrive complete with a set of AAA size batteries, a holder which has a pad of 3M VHB tape to allow it to be attached and stowed securely inside the vehicle. VHB if you don’t know stands for Very High Bond, so choose your storage location wisely… it might be a bit of a do-dah to move!

IMG_1114  Operation is really simple. Press and hold the on button for five seconds and the unit will power up and display the status of the units own batteries.

IMG_1116

To obtain a pressure reading, simply place the unit’s logo over the tyre pressure sensor and you will feel a slight pull as the internal magnet pulls it towards the sensor, it’s this magnet that ‘wakes up’ the sensor.

IMG_1118

29 PSI is correct for the Amarok running light, and this sensor is showing 3 battery bars.

After a few seconds the Pressure Checker will beep and you can read the pressure for that wheel… and cleverly, you can also check on the battery level in the sensor. The display is in good old PSI, however if you don’t work in PSI and much prefer BAR, while the Pressure Checker is turned on, simply press the on/off button five times in quick succession and it will beep and the reading will now be in BAR. To change it back, simply do the same again to revert to PSI. To turn the Pressure Checker off, simply hold down the power button for 3 seconds and it will beep and turn off.

That is about as complicated as it gets.. really. The only real challenge is to find a spot to stick the holder!

IMG_1115I have tried a few different TPMS ‘solutions’ over the past couple of years and all have plus points and minus points. As I am one of these people who likes to do walk rounds before setting off (throw back to my flying days I guess) I really didn’t want Formula 1 type information thrown at me all the time. I wanted a simple warning system and a simple way to check the pressure without having to remove any sensors. Fit2Go ticks these boxes.

If I did have a negative point about the Fit2Go system it would be the fact that the batteries in the sensors are not user replaceable. At least I do have a way to check the status of them now. The sensors are not too expensive when they need replacing, but  will be more expensive that replacing just a battery. Part of my brain is shouting “recycling” at me… and I do wonder why the manufacturer hasn’t come up with a recycling scheme… exchange your old sensors for new for a few pounds less than buying new and we will recycle them. Or maybe a discount voucher scheme when you recycle?

The Fit2Go Tyre Pressure Checker is available from RoadPro for just under £40 (exc shipping) or you can always find it on Amazon.

NEC Show Roundup – it’s all technical…

28 Tuesday Feb 2017

Posted by in Caravan Electrics, Electrical, General, Maintenance, Modifications, Technical, Tow Vehicle, VW Amarok

≈ 9 Comments

Tags

, , , , , , , ,

This is really a follow-up to my previous post – Smart Alternators: how they affect Caravans and Motorhomes….

While at the NEC show one of my big tasks was to get a number of technical questions answered by the industry players. One of my first stops was to Westfalia and to meet up with Rick Sykes and his colleague on the Westfalia stand. Rick is the national training manager for Westfalia and I was able to get answers to a number of questions that you have asked me and I’d not been able to answer fully. Continue reading →