RonRM
Senior Member
You all are going to love this...sad as it is.
4 week trip to FLA, all going well. Campgrounds, boone docking...all good.
Final drive day to get to West Palm - Balmar display dead, all 12v systems dead on arrival. Didn't pay attention while driving, so complete surprise on arrival. Luckily, everything works without batteries if plugged in.
After 2 days of troubleshooting, 4 battery chargers (thank you Amazon for 30day returns) and a lot of unnatural yoga poses under the coach - both Relion's are dead and will not wake up. Completely disconnecting and isolating each, they actually read 0 volts at the terminals. 2 chargers would not recognize them (at zero volts can't tell if 6/12v batteries), one charger had a 'refresh' setting (full charge no matter voltage) and finally a lab power supply...none of these would wake-up the batteries.
Addition: I called Mastervolt too...after testing, determined it survived, pretty much disables itself at around 9V.
Tried the emergency switch trick via Thor's video, nope...nothing wakes the batteries up.
Called Relion, turns out Thor engineering geniuses they are, decided that Relion batteries can take the full 175amps (UHG output in practice probably around 150amps) from the UHG for any amount of time, hoping the BMS will kick-out due to over current. Well, guess what, Relion batteries kick out all right, by blowing up the BMS as they can't actually take a high current inrush. Apparently, the BMS might kick-out on slowly rising overcurrent, but more than likely blow up if the current spikes. As the person at Relion said, just the A/C coming on and increasing the RPM's could take a Relion out in the current design. Relion and Thor are working on solution.
Called Thor, they wanted me to take it to a dealer. I asked if I could remove the batteries and just take them to the dealer for warrantee handling. They said that was up to the dealer. I just didn't pursue it with them from there.
So, if you have 2 good batteries, no much of an issue. Current splits between them and they stay way under charge amps that will damage them.
But, let's say one goes to sleep before the other one, that means the other Relion gets the full charge - kiss it good-bye. Then the sleeping battery gets woken-up, guess what, since the first one is now dead, the second one gets the full charge amps...and now it's gone too. You probably should have a Balmar APM-12 installed, since when a battery abruptly disconnects the alternator field dumps - that dump can be way over 12vdc and could take out 12v devices in the coach.
More fun...after reviewing this YT (same exact issue I had) https://youtu.be/9WdCP0wZcIU?si=8x3CwRoASMdWHL9a
I decided to pull the batteries...more Thor genius at work.
Yes, you need to jack the frame up, to clear the rear axle to get 4 nuts off the battery cage - zero fun was had. Once, past that step, it's easy to get the batteries tipped and out - I used a floor jack to support them as in the video.
Once I got them tipped and started disconnecting...no surprises - true to Thor crap engineering. Thor wired the regulator power directly to one of the batteries vs. to the buss bars (that will be changed in the redesign). Not the end of the world, just poor choice.
This was my favorite find, the MRBF fuses on the + post...I would expect them to be 150amp as on the Thor schematics. Well they must have been completely out of stock, so what the heck...'let's just put in 300amp fuses they gotta be twice as good', what are the chances the 2/0 cable (rated under 195amps) will ever see that much current. Yep, both batteries had 300amp MRBF's on the posts. Complete and utter negligence.
Called Balmar, asked if they either had a regulator that could control current or how could I set the 618 to minimize the possibility of 150amp+ charging. Belt Load Management is the key.
I'm going to have to play with it, when I get batteries installed again, I'm thinking of lowering it somewhere between 85% - 75%. I was warned not to go below 65% as there needs to be some room for the regulator to lower the field as the alternator temp increases.
I'm good taking a bit longer to charge, vs. not having to replace another set of batteries.
I have 2 new replacement Relion's on the way, under warrantee...at least Relion stands behind their products very grateful for that. I should say most of the time Thor did their part in all my warrantee claims, but they should really re-consider their engineering choices.
Changes I'll make to the design:
Add 120amp breakers (bussman or blue sea - no knockoffs) vs. MRBF fuses- way easier to reset vs. drop the battery to get at them.
Move regulator power to buss bars vs. single battery
Change Belt Field Management between 85-75% to limit charge current.
Add a DPST switch on both the ignition sense and regulator power - so it can be completely disco'd from power. If disco'ed alternator just free spins. Can also be accomplished by pulling the black connector and the brown ignition sense wire.
Add warning light/audible alarm off regulator Dash Lamp pin
Find a way to run aux 12vdc to fridge from appropriate power bank in the case of battery failure.
Add switch to MV...MV guy was doing a SMH when he learned it wasn't installed by Thor. Saves a bit of power draw when not plugged in.
Adding 3 DC breakers to Solar Controller - 1 on incoming, 2nd on output to coach batteries, 3rd second output to chassis battery (I have a GoPower dual battery bank controller - solar charges both coach and chassis). All these circuits are appropriately fused, just adding breakers more as switches to disconnect loads that are currently hard wired.
Ron
4 week trip to FLA, all going well. Campgrounds, boone docking...all good.
Final drive day to get to West Palm - Balmar display dead, all 12v systems dead on arrival. Didn't pay attention while driving, so complete surprise on arrival. Luckily, everything works without batteries if plugged in.
After 2 days of troubleshooting, 4 battery chargers (thank you Amazon for 30day returns) and a lot of unnatural yoga poses under the coach - both Relion's are dead and will not wake up. Completely disconnecting and isolating each, they actually read 0 volts at the terminals. 2 chargers would not recognize them (at zero volts can't tell if 6/12v batteries), one charger had a 'refresh' setting (full charge no matter voltage) and finally a lab power supply...none of these would wake-up the batteries.
Addition: I called Mastervolt too...after testing, determined it survived, pretty much disables itself at around 9V.
Tried the emergency switch trick via Thor's video, nope...nothing wakes the batteries up.
Called Relion, turns out Thor engineering geniuses they are, decided that Relion batteries can take the full 175amps (UHG output in practice probably around 150amps) from the UHG for any amount of time, hoping the BMS will kick-out due to over current. Well, guess what, Relion batteries kick out all right, by blowing up the BMS as they can't actually take a high current inrush. Apparently, the BMS might kick-out on slowly rising overcurrent, but more than likely blow up if the current spikes. As the person at Relion said, just the A/C coming on and increasing the RPM's could take a Relion out in the current design. Relion and Thor are working on solution.
Called Thor, they wanted me to take it to a dealer. I asked if I could remove the batteries and just take them to the dealer for warrantee handling. They said that was up to the dealer. I just didn't pursue it with them from there.
So, if you have 2 good batteries, no much of an issue. Current splits between them and they stay way under charge amps that will damage them.
But, let's say one goes to sleep before the other one, that means the other Relion gets the full charge - kiss it good-bye. Then the sleeping battery gets woken-up, guess what, since the first one is now dead, the second one gets the full charge amps...and now it's gone too. You probably should have a Balmar APM-12 installed, since when a battery abruptly disconnects the alternator field dumps - that dump can be way over 12vdc and could take out 12v devices in the coach.
More fun...after reviewing this YT (same exact issue I had) https://youtu.be/9WdCP0wZcIU?si=8x3CwRoASMdWHL9a
I decided to pull the batteries...more Thor genius at work.
Yes, you need to jack the frame up, to clear the rear axle to get 4 nuts off the battery cage - zero fun was had. Once, past that step, it's easy to get the batteries tipped and out - I used a floor jack to support them as in the video.
Once I got them tipped and started disconnecting...no surprises - true to Thor crap engineering. Thor wired the regulator power directly to one of the batteries vs. to the buss bars (that will be changed in the redesign). Not the end of the world, just poor choice.
This was my favorite find, the MRBF fuses on the + post...I would expect them to be 150amp as on the Thor schematics. Well they must have been completely out of stock, so what the heck...'let's just put in 300amp fuses they gotta be twice as good', what are the chances the 2/0 cable (rated under 195amps) will ever see that much current. Yep, both batteries had 300amp MRBF's on the posts. Complete and utter negligence.
Called Balmar, asked if they either had a regulator that could control current or how could I set the 618 to minimize the possibility of 150amp+ charging. Belt Load Management is the key.
I'm going to have to play with it, when I get batteries installed again, I'm thinking of lowering it somewhere between 85% - 75%. I was warned not to go below 65% as there needs to be some room for the regulator to lower the field as the alternator temp increases.
I'm good taking a bit longer to charge, vs. not having to replace another set of batteries.
I have 2 new replacement Relion's on the way, under warrantee...at least Relion stands behind their products very grateful for that. I should say most of the time Thor did their part in all my warrantee claims, but they should really re-consider their engineering choices.
Changes I'll make to the design:
Add 120amp breakers (bussman or blue sea - no knockoffs) vs. MRBF fuses- way easier to reset vs. drop the battery to get at them.
Move regulator power to buss bars vs. single battery
Change Belt Field Management between 85-75% to limit charge current.
Add a DPST switch on both the ignition sense and regulator power - so it can be completely disco'd from power. If disco'ed alternator just free spins. Can also be accomplished by pulling the black connector and the brown ignition sense wire.
Add warning light/audible alarm off regulator Dash Lamp pin
Find a way to run aux 12vdc to fridge from appropriate power bank in the case of battery failure.
Add switch to MV...MV guy was doing a SMH when he learned it wasn't installed by Thor. Saves a bit of power draw when not plugged in.
Adding 3 DC breakers to Solar Controller - 1 on incoming, 2nd on output to coach batteries, 3rd second output to chassis battery (I have a GoPower dual battery bank controller - solar charges both coach and chassis). All these circuits are appropriately fused, just adding breakers more as switches to disconnect loads that are currently hard wired.
Ron