Projecta 50 amp intellicharger broken

Snippy · Senior Member

Projecta 50 amp intellicharger broken

carpaidiem · Veteran Member

Sound like charger has not been working for properly a while, not fully charging the batteries will stuff them. also when you put in the 3 batteries were they all brand new, if not putting old AGM'S with new disaster. charge will only recognize older batteries and not fully charge any thing new to capacity. I found this out also the hard way. Auto electrician said all would work ok. Three years later my new batteries stuffed old battery lasted an extra 6 months. Some "experts" I now take with a pinch of salt. Do you own research some times need lots. I found this out when I changed to Lithium system. So much conflicting rubbish. Good Luck

Snippy · Senior Member

carpaidiem wrote:
Sound like charger has not been working for properly a while, not fully charging the batteries will stuff them. also when you put in the 3 batteries were they all brand new, if not putting old AGM'S with new disaster. charge will only recognize older batteries and not fully charge any thing new to capacity. I found this out also the hard way. Auto electrician said all would work ok. Three years later my new batteries stuffed old battery lasted an extra 6 months. Some "experts" I now take with a pinch of salt. Do you own research some times need lots. I found this out when I changed to Lithium system. So much conflicting rubbish. Good Luck

Been through all that, Aotolecky told me gel would work with my 2 agm's. Wrecked the lot. Existing batteries all matched been in 3 years.

The charger has been fine until these errors started coming up. Looking at replacing the Projecta with same and new AGM's. Hoping I can hold out until I get to the coast as prices are rediculous where we are now.

Possum3 · Guru

Try this lot www.aussiebatteries.com.au/batteries/deep-cycle-agm/2x-140ah-12v-agm-deep-cycle-battery

fwdoz · Guru

Try Victron. Long reliable history & ours have never missed a beat.

Enerdrive also have a great reputation but are more expensive.

kgarnett · Senior Member

The Projecta charger incorporates voltage sensing wires inside the charging cables.

These voltage sensing wires are insulated from the charging cables up to the point where they connect to the battery.

If the voltage sensing wires become broken or the charging cable has been cut or extended then the charger can't measure the battery voltage and an "OLC"error is displayed.

OLC is not generally a temp sensor error !

If you cut the charging cables (+ve and -ve) you should be able to see the insulated voltage sensing wire in the centre of the cut cable. You may need to strip back some of the insulation of the sensor wire to ensure that is able to contact and measure the battery voltage.

Quote from p13 of Projecta manual

Note: These battery chargers include sensor wires that run parallel to both the positive and the negative DC leads. This allows for accurate voltage measurements

to be taken directly from the battery. It is strongly recommended not to cut the DC leads during installation. However if the DC leads are cut, ensure that the sensor

wires are included in both positive and negative connections

Ken

-- Edited by kgarnett on Saturday 1st of August 2020 08:46:06 PM

Warren-Pat_01 · Guru

Snippy,
A couple of years ago I was looking for a good MPPT controller & tripped over this crowd - their prices were good. That is if you need to get new gear & Bob recommends the brand too.

www.keoghsmarine.com.au/SOLAR-PANELS_Solar%20Controllers/SOLAR-PANELS-and-WIND-GENERATORS-Solar-Regulators/SOLAR-PANELS-and-WIND-GENERATORS-Solar-Charge-Controllers-MPPT-Solar-Charge-Controllers/Victron_BlueSolar_Soilar_Controllers.

Before going elsewhere & as a temporary solution if all else fails, can you go back toward the charger/controller & jumper in new cables ie shift the battery connection point back towards the charger? The sensing may not work correctly & you will have to monitor the voltages more carefully with a multimeter.

PS - did your "Aotolecky" help with the cost?

fwdoz · Guru

Warren-Pat_01 wrote:
Snippy,
A couple of years ago I was looking for a good MPPT controller & tripped over this crowd - their prices were good. That is if you need to get new gear & Bob recommends the brand too.

www.keoghsmarine.com.au/SOLAR-PANELS_Solar%20Controllers/SOLAR-PANELS-and-WIND-GENERATORS-Solar-Regulators/SOLAR-PANELS-and-WIND-GENERATORS-Solar-Charge-Controllers-MPPT-Solar-Charge-Controllers/Victron_BlueSolar_Soilar_Controllers.

Before going elsewhere & as a temporary solution if all else fails, can you go back toward the charger/controller & jumper in new cables ie shift the battery connection point back towards the charger? The sensing may not work correctly & you will have to monitor the voltages more carefully with a multimeter.

PS - did your "Aotolecky" help with the cost?

Funnily enough Warren, I happened to get mine from Keoghs!

Snippy · Senior Member

fwdoz wrote:
Try Victron. Long reliable history & ours have never missed a beat.

Enerdrive also have a great reputation but are more expensive.

Not really interested in changing brands, all our gear is Projecta (Inverter, dc-dc etc) and not too phased re the charger as 4 years full time on the road isn't too bad.

Snippy · Senior Member

Warren-Pat_01 wrote:
Snippy,
A couple of years ago I was looking for a good MPPT controller & tripped over this crowd - their prices were good. That is if you need to get new gear & Bob recommends the brand too.

www.keoghsmarine.com.au/SOLAR-PANELS_Solar%20Controllers/SOLAR-PANELS-and-WIND-GENERATORS-Solar-Regulators/SOLAR-PANELS-and-WIND-GENERATORS-Solar-Charge-Controllers-MPPT-Solar-Charge-Controllers/Victron_BlueSolar_Soilar_Controllers.

Before going elsewhere & as a temporary solution if all else fails, can you go back toward the charger/controller & jumper in new cables ie shift the battery connection point back towards the charger? The sensing may not work correctly & you will have to monitor the voltages more carefully with a multimeter.

PS - did your "Aotolecky" help with the cost?

Re=did the connections as advised by Projecta, still no go.

Autolecky, no help there. I asked for a quote to do our electrics when we bought the rig. "Let's call it $3,000 and see how we go on the day." Not hard to work out my response to that one.

Whenarewethere · Guru

You obviously want to stick with Projecta, I have their solar panels which are brilliant. Victron (all my electronics) they do have a 50amp charger, maybe they have other models but I haven't looked thoroughly, that charges 3 batteries independently.

Don't know how you would wire that in!

-- Edited by Whenarewethere on Sunday 2nd of August 2020 08:06:12 AM

dorian · Guru

Snippy wrote:
Re=did the connections as advised by Projecta, still no go.
Autolecky, no help there. I asked for a quote to do our electrics when we bought the rig. "Let's call it $3,000 and see how we go on the day." Not hard to work out my response to that one.

I would follow the instructions of @kgarnett. Projecta's tech support doesn't appear to understand the problem.

See pages 13 and 18 of the manual (as already stated):

https://www.thebatterycellonline.co.nz/files/IC2500-800-24_Instruction_Manual.pdf

-- Edited by dorian on Sunday 2nd of August 2020 01:13:23 PM

laurieoz · Senior Member

kgarnett wrote:
The Projecta charger incorporates voltage sensing wires inside the charging cables.
These voltage sensing wires are insulated from the charging cables up to the point where they connect to the battery.
If the voltage sensing wires become broken or the charging cable has been cut or extended then the charger can't measure the battery voltage and an "OLC"error is displayed.
OLC is not generally a temp sensor error !
If you cut the charging cables (+ve and -ve) you should be able to see the insulated voltage sensing wire in the centre of the cut cable. You may need to strip back some of the insulation of the sensor wire to ensure that is able to contact and measure the battery voltage.
Quote from p13 of Projecta manual
Note: These battery chargers include sensor wires that run parallel to both the positive and the negative DC leads. This allows for accurate voltage measurements
to be taken directly from the battery. It is strongly recommended not to cut the DC leads during installation. However if the DC leads are cut, ensure that the sensor
wires are included in both positive and negative connections
Ken

-- Edited by kgarnett on Saturday 1st of August 2020 08:46:06 PM

Hi Ken

Now I am worried (I think)

In my motor home I have a Projecta IC2500

It was under the bed and difficult to get to and see what was happening

I cut the wires added anderson plugs to each end and when I need to connect, I connect from outside the bed and can also use the the projecta to charge other batteries .

I obviously did not read the manual about this sensor wire(I did it about 3 years ago)

I do not get a fault and seem to have no problems

What should I do about this sensor wire ?

Is it possible I have clamped the sensor wire when I added the anderson plugs and all is ok?

Laurie

Snippy · Senior Member

dorian wrote:
Snippy wrote:
Re=did the connections as advised by Projecta, still no go.
Autolecky, no help there. I asked for a quote to do our electrics when we bought the rig. "Let's call it $3,000 and see how we go on the day." Not hard to work out my response to that one.
I would follow the instructions of @kgarnett. Projecta's tech support doesn't appear to understand the problem.

Exactly the same instructions provided by Projecta tech support. (Also the manual).

Doesn't work.

Tony Bev · Guru

kgarnett wrote:
The Projecta charger incorporates voltage sensing wires inside the charging cables.
These voltage sensing wires are insulated from the charging cables up to the point where they connect to the battery.
If the voltage sensing wires become broken or the charging cable has been cut or extended then the charger can't measure the battery voltage and an "OLC"error is displayed.
OLC is not generally a temp sensor error !
If you cut the charging cables (+ve and -ve) you should be able to see the insulated voltage sensing wire in the centre of the cut cable. You may need to strip back some of the insulation of the sensor wire to ensure that is able to contact and measure the battery voltage.
Quote from p13 of Projecta manual
Note: These battery chargers include sensor wires that run parallel to both the positive and the negative DC leads. This allows for accurate voltage measurements
to be taken directly from the battery. It is strongly recommended not to cut the DC leads during installation. However if the DC leads are cut, ensure that the sensor
wires are included in both positive and negative connections
Ken

-- Edited by kgarnett on Saturday 1st of August 2020 08:46:06 PM

Hi kgarnett (Ken)

If the voltage sensing wires become broken or the charging cable has been cut or extended then the charger can't measure the battery voltage

Thanks for the above info, it is something that I shall remember

So this is why you people are techies, and I am just the oil rag, assisting the engine driver

I had an (expensive to me), Projecta 15 amp, 240 volt battery charger. It does not have a screen just a mode button

I had it hooked up to my house batteries, under a seat. As I was parked under a tree, with 240 volt available

I had the 12 volt wires going between the enclosure box, and the seat, while I was sitting on the seat, for nearly 10 days

Next time I used the charger, was on power mode, and it would not produce any more than just above 2 amps, same when I put it back to battery charging

I threw it away, as I assumed that the internals, were just not robust enough to travel in a motorhome

It now seems like I may have crimped the wires, and travelling had broken the sensing wire/s inside the insulation, of either 12 volt pos or neg

Jaahn · Guru

Hi smile

If it was mine and I was given the information given here about the sense wires, I would open up the unit and trace the internal connections for the sense wires at the control board. Then make up two new wires and run them to the battery terminals externally and firmly connect them. If that fixes the problem then make a permanent solution using that principle. If it does not then look for other problems. Any electrical tecko could do that for you.

Jaahn

-- Edited by Jaahn on Sunday 2nd of August 2020 06:47:12 PM

kgarnett · Senior Member

Here are a couple of photos of the voltage sense wire which is incorporated into the charger cables.

If the cable has been cut, you will need to strip back some of the sensor wire insulation so that the sensor wire is in contact with the current carrying wire. preferably close to or at the battery. There are sensors wires in both the +ve and -ve cables.

At the charger end the sense wires are drawn out of the current carrying cables and are connected to the circuit board. It would not be terribly difficult to install fully separate sensor cables. If it were me I would install a polarised two pin socket on the back panel of the charger so that I could run separate sensor wires direct to the battery.

Ken

Projecta cable 2.jpg Projecta cable 1.jpg

laurieoz · Senior Member

laurieoz wrote:
kgarnett wrote:
The Projecta charger incorporates voltage sensing wires inside the charging cables.
These voltage sensing wires are insulated from the charging cables up to the point where they connect to the battery.
If the voltage sensing wires become broken or the charging cable has been cut or extended then the charger can't measure the battery voltage and an "OLC"error is displayed.
OLC is not generally a temp sensor error !
If you cut the charging cables (+ve and -ve) you should be able to see the insulated voltage sensing wire in the centre of the cut cable. You may need to strip back some of the insulation of the sensor wire to ensure that is able to contact and measure the battery voltage.
Quote from p13 of Projecta manual
Note: These battery chargers include sensor wires that run parallel to both the positive and the negative DC leads. This allows for accurate voltage measurements
to be taken directly from the battery. It is strongly recommended not to cut the DC leads during installation. However if the DC leads are cut, ensure that the sensor
wires are included in both positive and negative connections
Ken

-- Edited by kgarnett on Saturday 1st of August 2020 08:46:06 PM
Hi Ken
Now I am worried (I think)
In my motor home I have a Projecta IC2500
It was under the bed and difficult to get to and see what was happening
I cut the wires added anderson plugs to each end and when I need to connect, I connect from outside the bed and can also use the the projecta to charge other batteries .
I obviously did not read the manual about this sensor wire(I did it about 3 years ago)
I do not get a fault and seem to have no problems
What should I do about this sensor wire ?
Is it possible I have clamped the sensor wire when I added the anderson plugs and all is ok?
Laurie

I took the wires out of the anderson plug today

Sure enough found the mentioned wires that I had not stripped back

The insulation was just broken from crimping the connectors, so I guess just making contact with the main wires so not giving a fault on the unit.

I will have to go back to reading manuals more carfully

Thanks for the information

Laurie

Snippy · Senior Member

What gets me is you pay good money about $700, from memory then you have to be a technical genius to keep it working.

Ripping the rubbish out and buying some decent gear.

Bagmaker · Senior Member

the issue only becomes apparent after modification from the existing supplied projecta wiring.
one needs to be aware of it if shortening/lengthening the cables or changing the terminals.

The IC range of projecta charges are excellent bits of kit, usually, with very fast voltage sensing and stable output.

That said, all machines fail eventually

Snippy · Senior Member

Bagmaker wrote:
the issue only becomes apparent after modification from the existing supplied projecta wiring.
one needs to be aware of it if shortening/lengthening the cables or changing the terminals.
The IC range of projecta charges are excellent bits of kit, usually, with very fast voltage sensing and stable output.
That said, all machines fail eventually

The cables weren't modified or lengthened, they simply failed. Problem started intermitently a few months ago and gradually got worse.

Cutting and replacing the lugs was advised by Projecta, and also others on this post.

I can't afford to run unreliable equipment.