Buying a Van Part 3
This is a continuation of the story of buying and modifying my Chasson Flash 02. For the earlier parts see:
franksblog.webnode.com/other-writing/buying-a-van-a-story-part-1/
24th Jan 2011
Again queries on why I was doing so much complicated work on an almost new van instead of buying one that was exactly right or sticking with the Renault.
My answer: None of the mods or improvements are in any way as complex as a whole van (many are in fact trivial) besides we needed the space of a coachbuilt and a fixed bed this time, and it had to be affordable and less than 6m long.
28th Jan 2011
Just an update. I am now in the situation defined by a version of Pareto's Principle:80% of the work required only 20% of the effort. I am having difficulties sourcing some minor items (Is that the recession reducing stocks?) also just adding one little bit of water hose has resulted in a major strip down of parts of the van.
Today's jobs involve adding two short bits of cable for the two new 230V sockets. This job so far has involved attempting to get switched sockets to match the decor only to fail, so I am spray painting the clip on surrounds to match. I have also cut holes for the sockets which involved removing quite a bit of stuff to get my saw in. To connect the sockets today I have to move the battery charger and ac and dc distribution boards and the surround over the grill to get to the other cable junction. When these jobs are finished they won't show any of the time and effort involved!
Improvements
1. Name Van: Chatham Completed
2. Add towel/drying rails. Completed
3. Design and fit cupboard shelving. Completed
4. Fit rubber glove and tea towel holder. Completed
5. Fit gas lighter holder.
6. Design and fit partitions under bed. Completed
7. Replace halogens with LEDs. Completed
8. Add shurflo accumulator to water system.Started
9. Soap dispenser in Bathroom (Fiamma) Completed
10. Awning Light. Prefitted Cables found
11. Extra mains socket Started
12. Bed end cupholders Re-Ordered
13. Front seat cupholder Re-Ordered
14. Hook for rubbish bag. Completed
15. Make fitted cover for bench seat. Completed
16. Get winter covers for fridge and grill. Completed
17. Cut up carpet to retain some.
18. Wet clothes hooks over door Completed
19. Fit solar panel Position decided panel to hand
20. Fit two larger batteries Completed
21. Fit Nasa BM1-C battery monitor. Completed
22. Make EHU cable stowage. Completed
23. Sound insulation for water pump.
24. Improve run of pipes and cables. Started
25. Replace luminaire over cooker for LED type Completed
26. Add Battery LED lights to door and rear locker Completed
27. Add boot/shoe storage to underbed area Completed
28. New Add Thermowrap insulation to front grp moulding (re 6 below)
Snags
1. Replace curtain hooks. (poor quality) Half replaced
2. Fix over bedhead shelf properly. Completed
3. Seal side of worktop
4. Get English language versions of some manuals. Asked Discover
5. Fit new outside door clip Completed
6. Investigate thin glass fibre
7. Investigate roof junction sealing. Temporary Repair done
8. Staple velcro for head rest. Completed
9. Charger repair. Completed
10. Check water pipe route and insulation near fridge. b]Completed[/b]
11. [Fix Fridge door lock Completed
12. Move lower Table support to correct position.Completed
13. New Side wall dowels not located properly LHS poor Chausson build.
31st Jan 2011
A major milestone today adding the pressure accumulator to the water system There were plenty of options, as it can be anywhere in the cold water system downstream of the pump. However I had to modify the pipework next to the pump anyway so by moving some of the electrics around I got a neat self draining position.
The accumulator acts as a sort of spring or damper, smoothing out the pressure variations that cause the pump to go on and off rapidly or 'pulse' which is noisy, and will damage the pump over time. Small water systems using semi-rigid pipework are most susceptible.
Also finished off one extra socket and the cup holders at the bed end of the van.
Photo above shows the original state. Cabling ducts and hot air ducts prevents access to the T joint in the pipework next to the output side of the pump. Part of the muddle is that the Webesto cabling loom is supplied with all terminations for a much larger vehicle (or boat!). Chausson didn't shorten the cables so they are stuffed in here. I was hoping to simplify this a bit. Chausson have mainly used 12.5 mm semirigid pushfit piping but with normal (not pushfit) joints and crimped hose clamps.
The accumulator could be put in the system anywhere downstream of the pump outlet. It can be Tee'd into the system and one end blocked or put into the pipe run. I looked at both options. Two other factors; from time to time it may have to be re-pressurised so the valve needs to be accessible and if you want it to drain freely when the system is drained it is better to orient it with the valve up and the hose connections down.
I found that by moving some of the electrical components I could mount it next to the pump as shown below. Shurflo provide a coupling with the accumulator for that purpose.
After cutting off the hose clips and warming the pipe up I still wasn't able to get the semi-rigid pipe off of the T joint. So I cut the short length of reinforced hose that went from that joint to the pump and replaced the hose clips. I then fitted a longer piece of reinforced hose and using a hair drier reformed it into an 'S' shaped loop to connect the existing T piece to the output side of the accumulator . Because I wasn't able to break the pipe at the T joint I wasn't able to do much about unwinding electrical cables that were caught up in the pipe run. This was a pity because the hot air duct is partially collapsed and wedged by the pipes and cables and I could have replaced it if I could have only got it free. The only other way was to remove the fresh water tank and as that is imprisoned by the metal framework of the rear seatbelt supports, so that looked like a dockyard job.
By moving the webasto fuses and terminal blocks and the split charge relay box to make way for the accumulator I was able to improve the wiring layout slightly but not as much as I would have liked.
The pump was noisy anyway but its mounting had been overtightened taking the 'give' out of the rubber mounts, it ran much quieter after I refitted it. The underside lid of the pump 'box' has had some sound absorbing foam glued to it, the sort that you put under laminate flooring.
1st Feb 2011
PHOTO UPDATE
The completed pump area
Cup Holders - Deployed
Cup Holders - Folded Away
Extra 13A Switched Sockets
1st Feb 2011
I have to say of all my mods the cupholders provoked the most excitement! I was asked where I got them from etc
There are some cheap and nasty ones on eBay but these came from a chandler they are about £5 each but they had a two for the price of one offer.
www.force4.co.uk/6511/Force-4-Folding-Cup-Holder.html
11th Feb 2011
Although I have been 'home alone' this week I didn't get much done (the dogs don't like me staying out in the van more than about 30mins at a time). so I managed to I finish three jobs and start another I have also added two more new ones due to my new astronomy hobby.
I'll add some more photos later
Improvements
1. Name Van: Chatham Completed
2. Add towel/drying rails. Completed
3. Design and fit cupboard shelving. Completed
4. Fit rubber glove and tea towel holder. Completed
5. Fit gas lighter holder.
6. Design and fit partitions under bed. Completed
7. Replace halogens with LEDs. Completed
8. Add shurflo accumulator to water system.Completed
9. Soap dispenser in Bathroom (Fiamma) Completed
10. Awning Light. Prefitted Cables found
11. Extra mains sockets [Completed
12. Bed end cupholders Completed
13. Front seat cupholder Re-Ordered
14. Hook for rubbish bag. Completed
15. Make fitted cover for bench seat. Completed
16. Get winter covers for fridge and grill. Completed
17. Cut up carpet to retain some.
18. Wet clothes hooks over door Completed
19. Fit solar panel Position decided panel to hand
20. Fit two larger batteries Completed
21. Fit Nasa BM1-C battery monitor. Completed
22. Make EHU cable stowage. Completed
23. Sound insulation for water pump. Completed
24. Improve run of pipes and cables. Completed
25. Replace luminaire over cooker for LED type Completed
26. Add Battery LED lights to door and rear locker Completed
27. Add boot/shoe storage to underbed area Completed
28. Add Thermowrap insulation to front grp moulding (re 6 below) Started
29. New Add mcb for battery charger Completed
30. New Add external dc socket for telescope electronics etc
31. New Add red interior lighting (for night vision)
Snags
1. Replace curtain hooks. (poor quality) Completed
2. Fix over bedhead shelf properly. Completed
3. Seal side of worktop
4. Get English language versions of some manuals. Asked Discover
5. Fit new outside door clip Completed
6. Investigate thin glass fibre
7. Investigate roof junction sealing. Temporary Repair done
8. Staple velcro for head rest. Completed
9. Charger repair. Completed
10. Check water pipe route and insulation near fridge. b]Completed[/b]
11. [Fix Fridge door lock Completed
12. Move lower Table support to correct position.Completed
13. Side wall dowels not located properly LHS poor Chausson build.
11th Feb 2011
PHOTO UPDATE
Finding suitable curtain hooks for the cab windows wasn't easy the cheap ones fitted were breaking and bending and also coming away from the gliders, there were 32 of them.
These locking clips from Leisureshopdirect come in packets of 10 for about £1.60. They come with gliders but I used my original ones. They are so good that I also used them to replace the ones on the shower curtains at home.
Wiring the first mains socket I added was just a case of extending a spur from a socket that won't be used. The second mains socket was easy to wire as far back as the ac distribution but I found that Chausson fit moulded plugs to their distribution systems and there were no spare ways. Also I wanted to be able from time to time to isolate the battery charger. As all ac is protected by a single 16A mcb I put a 6A mcb for the charger and extra terminals on the din rail to do both jobs.
15th Feb 2011
Finished one of the more time consuming jobs. The front compartment and two dead air spaces either side had no insulation and were just a thin badly finished grp shell. Using a roll of thermowrap (£12 Homebase) some spray PVA glue and some duct tape. I have insulated it and now the locker can contain clothes or bedding.
16th Feb 2011
I'm sure everyone feels some trepidation when they fill up with water for the first time after a winter layoff. I assure you its much worse when you have cut the system apart, introduced a new bit, moved stuff around and replaced a major three way joint.
Water peeing out the bottom of the van was the first result before I even switched on the pump. I thought "Truma mechanical drain" (I don't have an electric dump valve) but it was actually the fresh water tank drain I hadn't pushed it home properly
With the pump pressurising the system there were no more leaks so now that I had water I tested the Truma - All OK much relief
I then got my wife out to the van for her to show me what she thought was wrong with the shower - of course it worked OK but when the hose was pushed back into the tap I could feel it getting knotted. I have the type that functions as a tap but then you pull the spout out and it becomes a shower hose. A quick look in the under sink cupboard and I could see what the flexible hose was catching on.
The clowns who installed it cut much too big a hole in the top of the cupboard to get to the waste etc and the pipe was fouling on the edge of the hole.
At the same time as this was going on I had noticed a drip from under the van below the basin and the shower tray so when I removed the cupboard I found that the flexible hose assembly was very loose at its coupling. Now this in down stream from the tap so not pressurised when the tap is closed but it was leaking badly and the water going 'somewhere' under the tray. I can only hope its is leaking out by the side of the the waste outlet and not pooling somewhere.
Sorting this leak was easy but I shall have to figure out how to stop it catching. I might eventually replace the whole thing with a separate tap and a trigger operated shower.
The other snag?
Well the shower room door is closed by a push button catch but additionally the catch operates two more catches at top and bottom of the door using pieces of D section rod. The lower one hasn't been working. The fixing was too low by 5mm and the D drive wasn't engaging at the push button end. Fixed now and you can't see the D drive when its all together so no photo. Afternote this was to cause further problems later.
After Wednesday's post I have repaired the two new snags.
The hose snagging on the cupboard rear was easy to fix once I had looked more carefully. All I did was release the hot water hose connection and rearranged how it lay with the cold one and the waste. All three pipes then occupied much less room and adding a couple of cable ties ensured that they wouldn't foul the shower hose when retracted. There was still the possibility of fouling the cupboard rear and top cut out. I took a piece of silicon sheet (as used for baking trays) and used it to cover most of the hole and provide a super slippy rear to the cupboard. Alas no photo and I'm not stripping it down again just for you!
Improvements
1. Name Van: Chatham Completed
2. Add towel/drying rails. Completed
3. Design and fit cupboard shelving. Completed
4. Fit rubber glove and tea towel holder. Completed
5. Fit gas lighter holder.
6. Design and fit partitions under bed. Completed
7. Replace halogens with LEDs. Completed
8. Add shurflo accumulator to water system.Completed
9. Soap dispenser in Bathroom (Fiamma) Completed
10. Awning Light. Prefitted Cables found
11. Extra mains sockets [Completed
12. Bed end cupholders Completed
13. Front seat cupholder Re-Ordered
14. Hook for rubbish bag. Completed
15. Make fitted cover for bench seat. Completed
16. Get winter covers for fridge and grill. Completed
17. Cut up carpet to retain some.
18. Wet clothes hooks over door Completed
19. Fit solar panel Position decided panel to hand, mountings ordered
20. Fit two larger batteries Completed
21. Fit Nasa BM1-C battery monitor. Completed
22. Make EHU cable stowage. Completed
23. Sound insulation for water pump. Completed
24. Improve run of pipes and cables. Completed
25. Replace luminaire over cooker for LED type Completed
26. Add Battery LED lights to door and rear locker Completed
27. Add boot/shoe storage to underbed area Completed
28. Add Thermowrap insulation to front grp moulding Completed
29. Add mcb for battery charger Completed
30. New Add external dc socket for telescope electronics etc
31. New Add red interior lighting (for night vision)
Snags
1. Replace curtain hooks. (poor quality) Completed
2. Fix over bedhead shelf properly. Completed
3. Seal side of worktop
4. Get English language versions of some manuals. Asked Discover
5. Fit new outside door clip Completed
6. Investigate thin glass fibre Completed
7. Investigate roof junction sealing. Temporary Repair done
8. Staple velcro for head rest. Completed
9. Charger repair. Completed
10. Check water pipe route and insulation near fridge. Completed
11. Fix Fridge door lock Completed
12. Move lower Table support to correct position. Completed
13. Side wall dowels not located properly LHS poor Chausson build.
14. New Shower hose fouling rear of cupboard and other hoses, also leaking. Completed
15. New Shower door lower catch not operating. Completed
21st Feb 2011
DAMN
Bad News: Just found a water leak from the hot water system.
Good news: for a while there it looked like the water was coming from the fresh water tank. That really would have been a dockyard job.
Bad news: its in a tight area next to the Truma heater where the water splits to go to the bathroom and to the kitchen areas. The joint is obscured by cables.
Cables pulled aside for clarity
Null points to Chausson for using 12.5mm pushfit pipework but ordinary 1/2" joints and fastened them up with radiator hose clips of the non-adjustable crimped variety. I replaced the crimp clips with jubilee clips.
21st Feb 2011
It was basically the scuttle leaking, windscreen bonding problems, plus dual mass flywheels, clutch shuddering and burning out and the general unwillingness of FIAT to own up.
Plus I've owned the Renault Trafic and have driven and compared old and new Ducatos. Yes the new ones (X250) were much better than the old but FIAT was only playing catch up and they had a long way to go IMO.
My current Ford is probably no better a ride than the current FIAT (ie still worse than my Trafic was) but doesn't have the problems that FIAT owners still complain of.
25th Feb 2011
A week is a long time in motorhome ownership!
I noticed the lower fridge vent louvres flapping and found that the tiny piece of plastic that the catch engages with had sheared off. This was probably my fault as I opened it in the cold weather to investigate an insulation problem and again last week to look for a possible cable route. Having said that its an appalling design. Still the replacement came with a cold weather cover so now all three vents have covers.
On a a dry day I noticed another little bit of water on the floor, after much searching I found three leaks all near the Truma boiler. As I checked the hose connections one of them became a huge leak, the main connection to the truma boiler just leaked whenever it was touched.
Suffice to say several MHF subscribers came to my rescue with information and diagrams and it transpired that it had been put together wrongly from new. A quick call to the Truma helpdesk confirmed this and got me some gratis parts.
The other leaks were as befoe due to using crimped hose clamps over pushfit piping instead of using pushfit connectors. I guess I'm going to find these all over the place. I just spotted one that I won't be able to reach without dismantling woodwork.
Drying off the 12V distribution box, after the leaks, I opened it up for a look. (After all I want to add external dc sockets.) I was horrified to see how complex it was and have decided to add an extra fused distribution for new dc circuits and to enable me to bypass it if the control panel or dc distribution were to fail in the middle of a holiday. I made much more of this at the time starting another thread about the over complication of Motorhome electronics and of the risks of putting all the power onto one board which also has microcontrollers on it.
This thread will go quiet for a while as we are going to use it. Yes my motorhome is not just to give me winter employment we can have holidays in it as well.
Improvements
1. Name Van: Chatham Completed
2. Add towel/drying rails. Completed
3. Design and fit cupboard shelving. Completed
4. Fit rubber glove and tea towel holder. Completed
5. Fit gas lighter holder.
6. Design and fit partitions under bed. Completed
7. Replace halogens with LEDs. Completed
8. Add shurflo accumulator to water system.Completed
9. Soap dispenser in Bathroom (Fiamma) Completed
10. Awning Light. Prefitted Cables found
11. Extra mains sockets [Completed
12. Bed end cupholders Completed
13. Front seat cupholder Re-Ordered
14. Hook for rubbish bag. Completed
15. Make fitted cover for bench seat. Completed
16. Get winter covers for fridge and grill. Completed
17. Cut up carpet to retain some. Completed
18. Wet clothes hooks over door Completed
19. Fit solar panel Update: Position decided, panel and mountings to hand
20. Fit two larger batteries Completed
21. Fit Nasa BM1-C battery monitor. Completed
22. Make EHU cable stowage. Completed
23. Sound insulation for water pump. Completed
24. Improve run of pipes and cables. Completed
25. Replace luminaire over cooker for LED type Completed
26. Add Battery LED lights to door and rear locker Completed
27. Add boot/shoe storage to underbed area Completed
28. Add Thermowrap insulation to front grp moulding Completed
29. Add mcb for battery charger Completed
30. Add external dc socket for telescope electronics etc
31. Add red interior lighting (for night vision).
32. New Add fused supplementary dc distribution.
Snags
1. Replace curtain hooks. (poor quality) Completed
2. Fix over bedhead shelf properly. Completed
3. Seal side of worktop
4. Get English language versions of some manuals. Asked Discover
5. Fit new outside door clip Completed
6. Investigate thin glass fibre Completed
7. Investigate roof junction sealing. Temporary Repair done
8. Staple velcro for head rest. Completed
9. Charger repair. Completed
10. Check water pipe route and insulation near fridge. Completed
11. Fix Fridge door lock Completed
12. Move lower Table support to correct position. Completed
13. Side wall dowels not located properly LHS update and RHS perhaps its a feature and not poor Chausson build .
14. Shower hose fouling rear of cupboard and other hoses, also leaking. Completed
15. Shower door lower catch not operating. Completed
16. New New 'O' rings and hose clips fitted to Truma water boiler Completed
17. New New lower Fridge vent replaced holding catch broken Completed
25th Feb 2011
The photos (annotated)
28th Feb 2011
Had some more comments from people saying their van was perfect and doubting that I needed to do all this work, also saying that I shouldn't have bought a van that needed so much work - this was followed by people defending my approach and thanking me for the thread.
Just after we went on holiday I saw that I had received a comment on the thread about a fridge door that wouldn't stay locked (this was my response - snag #11)
The piece of plastic that you slide from side to side has probably come unshipped from the lever that closes the fridge. It will pull off in the direction about 45 degrees up and towards you from outside the door.
There is also a screw so you can take it all apartI live with it happening from time to time. I pm'd the questioner with a picture but don't seem to have it anymore
Busy just enjoying the van.
7th Mar 2011
Just spent a very satisfactory week away in Kent. The MH performed very well, I just found one or two improvements to make and a couple of little snags to add to the list.
As reported elsewhere the water pressure is too high for the thetford flush to work without splashing.
I noted a lump of mastic hanging down inside the water filler hose to water tank junction from an over-enthusiastic constructor.
Amperor are supplying me with a Power Integrator for evaluation. This saga was the subject of a seperate thread basically its a good bit of kit but difficult to retrofit into a modern Causson with Italian electronics. It performs the following functions:
MPPT solar regulator
Wind generator regulator
Vehicle battery trickle charger (similar to BatteryMaster)
Battery to Battery Charger
Also on the improvement side, when the wardrobe door is closed you have to push clothes out of the way of the latch as you close it. A simple 'L' shape thingy will hold the clothes clear of the door catch
One of the cupboards used for lightweight storage of doggy items could do with a mid-height shelf.
We have used a dog restraint harness for the first time. OK for one dog but the older one panics and gets caught up. I noticed that in their travelling position four side of a 'box' are formed by seats and bulkheads so as I already have some small mesh, marine grade, nylon netting I am thinking that I could make a bespoke dog travelling 'crate' by putting removable netting on the top and the remaining side. The soft materials consultant (Doreen) has been invited to come up with a design.
Improvements
1. Name Van: Chatham Completed
2. Add towel/drying rails. Completed
3. Design and fit cupboard shelving. Completed
4. Fit rubber glove and tea towel holder. Completed
5. Fit gas lighter holder.
6. Design and fit partitions under bed. Completed
7. Replace halogens with LEDs. Completed
8. Add shurflo accumulator to water system.Completed
9. Soap dispenser in Bathroom (Fiamma) Completed
10. Awning Light. Prefitted Cables found
11. Extra mains sockets [Completed
12. Bed end cupholders Completed
13. Front seat cupholder Re-Ordered
14. Hook for rubbish bag. Completed
15. Make fitted cover for bench seat. Completed
16. Get winter covers for fridge and grill. Completed
17. Cut up carpet to retain some. Completed
18. Wet clothes hooks over door Completed
19. Fit solar panel Position decided, panel and mountings to hand
19a New Fit Amporer Power Integrator
20. Fit two larger batteries Completed
21. Fit Nasa BM1-C battery monitor. Completed
22. Make EHU cable stowage. Completed
23. Sound insulation for water pump. Completed
24. Improve run of pipes and cables. Completed
25. Replace luminaire over cooker for LED type Completed
26. Add Battery LED lights to door and rear locker Completed
27. Add boot/shoe storage to underbed area Completed
28. Add Thermowrap insulation to front grp moulding Completed
29. Add mcb for battery charger Completed
30. Add external dc socket for telescope electronics etc
31. Add red interior lighting (for night vision).
32. Add fused supplementary dc distribution.
33. New Add wardrobe catch clothes protection
34. New Add shelf in 'dog cupboard
35. New Investigate dog restraint cage (homemade and bespoke)
Snags
1. Replace curtain hooks. (poor quality) Completed
2. Fix over bedhead shelf properly. Completed
3. Seal side of worktop
4. Get English language versions of some manuals. Asked Discover
5. Fit new outside door clip Completed
6. Investigate thin glass fibre Completed
7. Investigate roof junction sealing. Temporary Repair done
8. Staple velcro for head rest. Completed
9. Charger repair. Completed
10. Check water pipe route and insulation near fridge. Completed
11. Fix Fridge door lock Completed
12. Move lower Table support to correct position. Completed
13. Side wall dowels not located properly LHS Update: and RHS perhaps its a feature and not poor Chausson build.
14. Shower hose fouling rear of cupboard and other hoses, also leaking. Completed
15. Shower door lower catch not operating. Completed
16. New 'O' rings and hose clips fitted to Truma water boiler Completed
17. New lower Fridge vent replaced holding catch broken Completed
18. New Water pressure reducer required for Thetford flush
19. New Remove mastic from inside water filler hose.
7th Mar 2011
A couple of productive days
Offering up the panel and mounts
Marking the mount and cable entry positions
All positions roughened and prepared for adhesive
Mounts and cable gland box bonded to roof.
The final assembly.
Unlike the mount to roof joint I didn't rely on the adhesive for the panel to mount joint, as well as the adhesive there is a one small stainless steel screw on each mount. The cable run makes use of the bolts that were fitted for the previous owner's satellite system.
Whilst working on the roof I peeled off the original sealant on all seams and resealed with the quality marine adhesive/sealant used for the mounts: Körapur Marine. Note I did not need tools to remove the original sealant I just picked and peeled it off with my fingers.
I have also fitted a Thetford flush restrictor and a solar panel isolator switch as well as an external dc socket to power my telescope.
10th Mar 2011
Solar Regulator
I had planned to fit an MPPT solar regulator and extra dc distribution in the area shown below.
However I am being supplied with an Amperor Power Integrator which is a bigger thing altogether (and it does a lot more). I knew its dimensions from its specifications so I knew plan A wasn't going to work.
Well today I received the power integrator and its not until I saw it in the round that I realised fully how difficult it was going to be to fit it in.
The area pictured above is the best because:
A. Its adjacent to: the leisure batteries, the existing dc distribution, the prefitted solar panel cables.
B. Its near to the existing battery relays (vehicle and leisure battery).
C. Its a protected area effectively a large box.
The disadvantages were
X. It didn't fit
Y. Even if it was shoehorned in you wouldn't be able to get to the connectors or view the mode indicating and fault LEDs , press the reset button or check on the security of the connectors
Z. If you could overcome that there were temperature concerns such as cooling airflow and a clear path for its fan exhaust. The Truma water boiler is in the same area (to the right of the ac and dc distribution boxes.
So rather than start wiring it in I spent the afternoon trying other options but in the end realised that if I could sort out the problems the original area chosen was still best.
I started by seeing what could be done by moving existing units. I moved the battery charger a lot and the dc distribution a couple of centimetres to give new positions as shown.
I then realised that to gain access to every thing on the Amperor unit it would be better if it were raised to a higher level so after trying some ideas I ended up making a little (8-9cm high) ledge with a cut out so the battery charger socket and fuse could still be accessed. I made it longer than the depth of the unit to allow some flexibility in its mounting.
These last three photos show the ledge and the Power integrator offered up to its position.
One last thought about temperature. The charger and the solar regulator are unlikely to be working hard at the same time. I can arrange for a small thermostat controlled fan to come on if the whole area becomes too hot.
As previously stated the whole subject of the Power Integrator was covered in a seperate thread but for the sake of completeness I will cover the main things here.
Once the mechanical arrangement was sorted it had to be connected and here I met a few head scratching problems. In order to trickle charge the vehicle battery and also to do battery to battery charging a connection had to be made to the vehicle battery it but the Italian power systems were in the 'way'
The original system uses two relay boxes, one connects the habitation battery to the dc distribution and the other connects the vehicle battery to the habitation battery and between them they perform the function of a split charge relay. The habitation one is controlled by the power on switch on the control panel via the DC controller electronics and the other instead of being triggered by the "ignition light signal" is controlled by the rising voltage as the alternator comes on line after a start. This relay also 'tells' the dc distribution system to power the fridge with 12V.
An investigation of the relay system showed that these relays also provided a feedback system to the microcontroller board and in order not to confuse things had still to operate once the Amperor box was in circuit. It was straight forward to modify the prefitted Chausson wiring of the solar option to the solar input of the Amperor and run its output habitation terminal to the habitation battery. The solar power (if available) would charge the battery via the MPPT regulator and the relay box would control the battery output to the dc distribution as before.
To allow the vehicle battery to be trickle charged a connection had to be made that was independent of the vehicle relay box, but when the alternator was on line battery to battery charging had to happen and also the fridge had to be supplied with DC power. The end result was that the feed to the contactor in the relay box was removed at the box taken to a new fuse and the feed from the other side of the contactor moved to the new fuse and taken directly to the amperor starter battery terminal. The relay box stll worked as before but did not connect the vehicle battery to the habitation dc distribution.
This left one problem how to tell the Amperor to switch between solar and alternator power. It has an input that is supposed to be fed from the ignition light or the D+ terminal of the alternator (same thing) but no such output is readily available on the Ford Transit. One unconnected terminal in the middle of the DC distribution board was labelled D+ and when I measured it I found it that it went "high" when the alternator came on line. So I used that to switch the Amperor.
15th Mar 2011
I was asked several questions about my batteries and the supplier.
Two Powermax 110Ahr from Barden Batteries near J9 of M27. Got excellent service from them and they deliver in their own van so the batteries came the right way up! Wet unsealed they gave me free vent kits
Well the Amperor Power Integrator is in and working and yesterday I saw 4Amps going in from the solar once I had flattened the battery a bit to make room
I also did a couple of starts in quick succession to take some out of my vehicle battery and then saw the integrator start trickle charging the vehicle battery.
This part has continued the saga up to a little over the first 4 months of ownership.
Off to Scotland in a few days so I'll do one last update of my list before I go, and I think I better start part 4.
Part 4 franksblog.webnode.com/other-writing/buying-a-van-part-4/