One Year old van battery connections and workmanship.

Submitted: Monday, Dec 17, 2012 at 16:34

ThreadID: 99522 Views:3003 Replies:5 FollowUps:2

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GEMAC Solar and Power

Hi All,

I have just completed an inverter install in a van manufactured in SA.
The following photos show the standard of workmanship for this manufacturer.

The batteries had been relocated by the manufacturer earlier this year.
2 x 120AH located to the rear of the van. Where the batteries were located is where I found these connections.
It must be noted that there was NO FUSE or Circuit Breaker between the batteries and the connections shown.

There seems to be no Q.A. done on the 12VDC side of things and this is where the most current is able to flow. The four cables from the lug goto the Fridge, No Fuse Protection, The Anderson Plug no protection, the small CB Box and the supply from the Solar Panel regulator.

All this loading was taken on the 2.5mm overall diameter red wire that was not even crimped correctly.
Fire hazard ??? I leave it to you to decide.

The photo of the lug only was connected in a similar way. This was the Neg side of things. The 4 cables on this lug just pulled out of the lug as I was trying to unravel the tape hiding the bare metal.

At this stage I will not name the van manufacturer until I have spoken to the manufacturing association of Australia.

We have all spoken and talked about Q.A. on here and just how bad it is.
I recall last week Rebecca H saying and I will quote
"Few concerns with some finishes and they forgot to do a few things so fingers crossed they sort it out before it is shipped next week."
How do manufacturers just FORGET????

My van had a hot dip chassis as opposed to the standard one because the manufacturer forgot I had asked for a duragalve one?
And he wanted to charge me extra too as he tried to explain it was my fault for "not Reminding Him"

So All I am able to say is Be aware of BAD Workmanship by unqualified persons.

Battery Connection 2

Battery connection 1

Regards
Geoff

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Reply By: Member - Burto (NSW) - Monday, Dec 17, 2012 at 17:01

Monday, Dec 17, 2012 at 17:01

Sorry to hear about your problem, at least you found it before there was a serious escalation, in regards to the lack of fuses, I always use fuses of the correct amperage and have recently found fused positive battery terminals that I have now fitted to both batteries, works a treat, I have to just make sure to pack the spare fuses.

Hope all works out well for you.

AnswerID: 500548

Reply By: Member - Ed C (QLD) - Monday, Dec 17, 2012 at 18:06

Monday, Dec 17, 2012 at 18:06

What was the manufacturer's response when you spoke to them about it??

:)

Confucius say.....
"He who lie underneath automobile with tool in hand,
....Not necessarily mechanic!!"

Member
My Profile Send Message

AnswerID: 500551

Follow Up By: GEMAC Solar and Power - Tuesday, Dec 18, 2012 at 16:57

Tuesday, Dec 18, 2012 at 16:57

not our problem now as it has been changed/altered

FollowupID: 776653

Reply By: Millsy999 - Monday, Dec 17, 2012 at 19:16

Monday, Dec 17, 2012 at 19:16

It is pretty obvious looking at those lugs that they have not been crimped with the correct tool. As an auto electrician, I would say that it is totally unsatisfactory from a safety and performance point of view. You cant just crimp those style of lugs with an ordinary set of terminal crimpers. I use a $300 set of crimping pliers specifically made for this style of lug. You will also note that at the ring end of the lug the barrel has an opening. This is so that the lugs can be soldered if you do not have the proper type of crimper to do the job. Once again, a standard size soldering iron (50-100 watts) will not be sufficient. If for some reason I need to fit one of these lugs in a situation where the pliers cannot be used (tight spaces etc) I use a 250 watt soldering iron.

As a side note, each wire MUST be fused (alternatively circuit breakers) and each wire should be terminated individually.

AnswerID: 500561

Reply By: Member - Old Girl - Monday, Dec 17, 2012 at 20:38

Monday, Dec 17, 2012 at 20:38

You have to be on the look out for everything. Our van is 12 months old. Each trip lucky they were in winter i put the fridge onto dc. It wasnt until the last one in warmer weather i noticed the fridge wasnt all that cold. Just thought that i had it on the wrong setting, done that before. I was having a poke around and found wires going no where under the fridge. Had a certified van repairer out to do the usal bearing service and asked him what was the wire for. It turned out the andersen plug wasnt hooked to the fridge or battery. Now theres a monitor fuses, and all the safety requirements sorted. But gee we pay a hell of a lot of money only to find this. Not good enough.
However, now we are vary aware on what to look for and test.
Sharon

AnswerID: 500571

Follow Up By: GEMAC Solar and Power - Tuesday, Dec 18, 2012 at 16:56

Tuesday, Dec 18, 2012 at 16:56

Hi Sharon
Seems like this is a Nation Wide Issue and not just something local.
The more I read on here the more I am sure there is

NO QA.
NO Following of Drawings.
No Plans.
No Final Checking.
Just non trades people building vans

And yes we do pay these %$#& van builders a lot of money.
And who paid for your work or fixes???

Like this one The owner had to do so

Geoff

FollowupID: 776652

Reply By: Members Pa & Ma. - Tuesday, Dec 18, 2012 at 11:12

Tuesday, Dec 18, 2012 at 11:12

Hi Geoff,
I did send you my Email address but have found, now, that some of them aren't getting through due to a very regional area where we live.
I guess it was the same van we've spoken about before?
As for my question in the Email, I think Hubby has found some one to help him just out of our area. Thankyou.
Take care, safe travels. Ma.

AnswerID: 500611