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Mastervolt alternator overcharging


Aldo Roldan
 

Yeah! Your batteries have probably suffered. I had to replace mine

On Jul 9, 2019, at 3:17 AM, Joerg Esdorn via Groups.Io <jhe1313@...> wrote:

As I said above, that’s exactly the problem I found and fixed:  loose connection in the voltage sensing cable for the alternator.   But the latest is that the alarm came back on last night after 8 hours on shore power with the 60 A  Charger.  So now I’m retesting the batteries (maybe they got damaged since the last test) and looking for a loose connection in the 60A charger circuit.  The fun never stops with these complicated boats .....


Joerg Esdorn
 

As I said above, that’s exactly the problem I found and fixed:  loose connection in the voltage sensing cable for the alternator.   But the latest is that the alarm came back on last night after 8 hours on shore power with the 60 A  Charger.  So now I’m retesting the batteries (maybe they got damaged since the last test) and looking for a loose connection in the 60A charger circuit.  The fun never stops with these complicated boats .....


Aldo Roldan
 

Regarding my previous post. My problem was much like the one described below by Bill. If wire connections are loose, when they flick the Mastercolt restart itself initializing it with a higher initial voltage charge. Hence, the additional charge

On Jul 3, 2019, at 2:13 PM, CW Bill Rouse <brouse@...> wrote:

Joerg,

That's what I thought when you first started having overheat alarms in your 55 battery area. The Mastervolt alternator is continuing to charge, already charged batteries, causing heat in the battery area. Pochon's suggestion to change the regulator is logical, but I am surprised that they did not check the voltage at the bank and at the regulator to ensure that they were the same.

I am not an electrician: My guess is that either the regulator settings are wrong, the regulator is defective, or there is resistance in the wire and connections between the actual battery bank and the regulator, which is lowering the voltage "seen" by the regulator and "fooling" the regulator to continue charging. 

My non-electrician suggestion: It will be a tedious process checking between both. I believe that you will find the most likely connections near and on the excite relay for the alternator. loosen each connection and use CorrosionX before retightening. Make sure that any crimp connectors are done correctly and have crimped the entire wire, replace any suspects. Check voltage often during the process so that you'll know when you have found and corrected the resistance problem.

As an alternative and temporary patch, maybe you could lower the charged voltage setting at the regulator by 2.5 volts.

Best,

CW Bill Rouse
720 Winnie St
Galveston Island, TX 77550
+1(832) 380-4970 (If I do not have your number in My Contacts, you will go to VoiceMail. Text me in advance with your number and I'll white list it.)



On Wed, Jul 3, 2019 at 12:25 PM Joerg Esdorn via Groups.Io <jhe1313=yahoo.com@groups.io> wrote:
On my 55, I have a 110A/24v Mastervolt alternator for the house bank and the alpha pro regulator.  I’ve had the battery temp alarm come on several times now because the regulator does not switch from Bulk to absorption.  On my voltmeter on the panel, voltage is 30-31V and charge rate goes up and down quickly from 10-40A, all with the batteries full after days on shore charger.   I checked out the regulator with the Masteradjust software and the sense and battery voltage was just below the 28.5V for the switch to absorption.   So the regulator is seeing 2-2.5V less than what the batteries have - I checked the voltmeter with my multitester.   At the suggestion of Pochon, I just replaced the regulator but that wasn’t the problem. 
Any idea what could be wrong would be much app!   

Joerg Esdorn
A55 Kincsem
just left Barcelona for Valencia


Aldo Roldan
 

Had a related problem once. It was blamed on the Mastervolt regulator. Replaced it. Problem continued. It was later determined that wire connections had become loose after 1200 miles passage.

On Jul 3, 2019, at 1:25 PM, Joerg Esdorn via Groups.Io <jhe1313@...> wrote:

On my 55, I have a 110A/24v Mastervolt alternator for the house bank and the alpha pro regulator.  I’ve had the battery temp alarm come on several times now because the regulator does not switch from Bulk to absorption.  On my voltmeter on the panel, voltage is 30-31V and charge rate goes up and down quickly from 10-40A, all with the batteries full after days on shore charger.   I checked out the regulator with the Masteradjust software and the sense and battery voltage was just below the 28.5V for the switch to absorption.   So the regulator is seeing 2-2.5V less than what the batteries have - I checked the voltmeter with my multitester.   At the suggestion of Pochon, I just replaced the regulator but that wasn’t the problem. 
Any idea what could be wrong would be much app!   

Joerg Esdorn
A55 Kincsem
just left Barcelona for Valencia


 

Good news. CorrosionX will help. 

Best,

CW Bill Rouse
Yacht School - Supporting Amel Owners
www.YachtSchool.us
720 Winnie St
Galveston Island, TX 77550
+1(832) 380-4970

On Thu, Jul 4, 2019, 1:35 AM Joerg Esdorn via Groups.Io <jhe1313=yahoo.com@groups.io> wrote:
Success this morning.  Voltage sensing cable to regulator had a loose connection at the alternator.   That connection was very difficult to get at ...  So now voltage at regulator is about .3V HIGHER than at the voltmeter on the switchboard.   That’s understandable since the switchboard measures the voltage after loads.   I need to motor for a bit to get to the switchover from bulk to absorption- batteries are at 88% now.  But I’m confident that I’ve solved the problem.  Thanks much everyone for your help!   

Joerg Esdorn 





Joerg Esdorn
 

Success this morning.  Voltage sensing cable to regulator had a loose connection at the alternator.   That connection was very difficult to get at ...  So now voltage at regulator is about .3V HIGHER than at the voltmeter on the switchboard.   That’s understandable since the switchboard measures the voltage after loads.   I need to motor for a bit to get to the switchover from bulk to absorption- batteries are at 88% now.  But I’m confident that I’ve solved the problem.  Thanks much everyone for your help!   

Joerg Esdorn 





Paul Brown
 

+31 20 342 21 32 this gets you to reception the lady if you ask kindly should transfer you if he has time, his name is Michelle I believe,

Some times he has to call you back

I had issues last week when my MV alternator whodunnit not connect to the MasterBus and traced it to a corroded connection, can happen had the start of the season it appears 

All the best


On 3 Jul 2019, at 7:39 pm, Joerg Esdorn via Groups.Io <jhe1313@...> wrote:

Thanks Paul.  Do you have a phone number?  


Joerg Esdorn
 

Thanks Paul.  Do you have a phone number?  


Joerg Esdorn
 

Thanks Bill.  Great minds think alike.  My next to do was to reprogram the regulator!  Temporary fix only but I agree that there must be a loose connection somewhere.  I will also call Mastervolt.  


Paul Brown
 

Hi Joerg, I have call mastervolt head office and spoke with Michele a technician who is generally very helpful for information, he is on leave until the 8th of July I believe, this is one option 

Regards Paul 


On 3 Jul 2019, at 6:25 pm, Joerg Esdorn via Groups.Io <jhe1313@...> wrote:

On my 55, I have a 110A/24v Mastervolt alternator for the house bank and the alpha pro regulator.  I’ve had the battery temp alarm come on several times now because the regulator does not switch from Bulk to absorption.  On my voltmeter on the panel, voltage is 30-31V and charge rate goes up and down quickly from 10-40A, all with the batteries full after days on shore charger.   I checked out the regulator with the Masteradjust software and the sense and battery voltage was just below the 28.5V for the switch to absorption.   So the regulator is seeing 2-2.5V less than what the batteries have - I checked the voltmeter with my multitester.   At the suggestion of Pochon, I just replaced the regulator but that wasn’t the problem. 
Any idea what could be wrong would be much app!   

Joerg Esdorn
A55 Kincsem
just left Barcelona for Valencia


 

Joerg,

That's what I thought when you first started having overheat alarms in your 55 battery area. The Mastervolt alternator is continuing to charge, already charged batteries, causing heat in the battery area. Pochon's suggestion to change the regulator is logical, but I am surprised that they did not check the voltage at the bank and at the regulator to ensure that they were the same.

I am not an electrician: My guess is that either the regulator settings are wrong, the regulator is defective, or there is resistance in the wire and connections between the actual battery bank and the regulator, which is lowering the voltage "seen" by the regulator and "fooling" the regulator to continue charging. 

My non-electrician suggestion: It will be a tedious process checking between both. I believe that you will find the most likely connections near and on the excite relay for the alternator. loosen each connection and use CorrosionX before retightening. Make sure that any crimp connectors are done correctly and have crimped the entire wire, replace any suspects. Check voltage often during the process so that you'll know when you have found and corrected the resistance problem.

As an alternative and temporary patch, maybe you could lower the charged voltage setting at the regulator by 2.5 volts.

Best,

CW Bill Rouse
720 Winnie St
Galveston Island, TX 77550
+1(832) 380-4970 (If I do not have your number in My Contacts, you will go to VoiceMail. Text me in advance with your number and I'll white list it.)



On Wed, Jul 3, 2019 at 12:25 PM Joerg Esdorn via Groups.Io <jhe1313=yahoo.com@groups.io> wrote:
On my 55, I have a 110A/24v Mastervolt alternator for the house bank and the alpha pro regulator.  I’ve had the battery temp alarm come on several times now because the regulator does not switch from Bulk to absorption.  On my voltmeter on the panel, voltage is 30-31V and charge rate goes up and down quickly from 10-40A, all with the batteries full after days on shore charger.   I checked out the regulator with the Masteradjust software and the sense and battery voltage was just below the 28.5V for the switch to absorption.   So the regulator is seeing 2-2.5V less than what the batteries have - I checked the voltmeter with my multitester.   At the suggestion of Pochon, I just replaced the regulator but that wasn’t the problem. 
Any idea what could be wrong would be much app!   

Joerg Esdorn
A55 Kincsem
just left Barcelona for Valencia


Joerg Esdorn
 

On my 55, I have a 110A/24v Mastervolt alternator for the house bank and the alpha pro regulator.  I’ve had the battery temp alarm come on several times now because the regulator does not switch from Bulk to absorption.  On my voltmeter on the panel, voltage is 30-31V and charge rate goes up and down quickly from 10-40A, all with the batteries full after days on shore charger.   I checked out the regulator with the Masteradjust software and the sense and battery voltage was just below the 28.5V for the switch to absorption.   So the regulator is seeing 2-2.5V less than what the batteries have - I checked the voltmeter with my multitester.   At the suggestion of Pochon, I just replaced the regulator but that wasn’t the problem. 
Any idea what could be wrong would be much app!   

Joerg Esdorn
A55 Kincsem
just left Barcelona for Valencia