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Old 02-25-2021, 01:35 PM   #1
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Coach battery issues

2007 Dynasty with Magnum MS2012 inverter. New Interstate 6 volt bank of four batteries installed in January. We are having an issue with the outside two batteries: one battery is overcharging with one undercharging, the other two in the system check out fine. Originally we had an issue with the one overcharging went dry in one month adding one gallon on distilled water before purchasing new. The problem still exists after installing all four, if we change the position of the batteries the same location of batteries causes overcharge or undercharge. Interstate dealer advised to disconnect the two batteries having issues, by doing this we have no issues with only two batteries in system working. We thought of purchasing a new Magnum ME-BTS25 battery temperature sensor to see if this might be the issue. I have disconnected the existing sensor from battery and does not make a difference. I'm currently located in an area with no luck finding a tech to evaluate the problem. Hope someone has an idea what might be the issue, we will be leaving in two months and will want all four batteries operating while returning home. Thank you, John
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Old 02-25-2021, 02:08 PM   #2
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First thing to look at is how they're wired. It's difficult to have a series-parallel set like that have issues with just two and not affect the other two. But if they're not wired right, or something went wrong with a cable, terminal or protection device then I guess anything's possible. Not impossible for "bad" batteries but being new I wouldn't put that high on the list (though they may be now if they've been wounded in the process).

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Old 02-25-2021, 02:09 PM   #3
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2007 Dynasty with Magnum MS2012 inverter.
High quality inverter/charger - not likely the cause. A defective charger would affect all batteries in the battery bank.

New Interstate 6 volt bank of four batteries installed in January.
Each set of two 6 volt batteries connected in series makes one 12 volt battery.
Two 12 volt sets connected in parallel double the capacity.

We are having an issue with the outside two batteries: one battery is overcharging with one undercharging, the other two in the system check out fine.
1) Battery cables are connected wrong. One is not connected. One is in parallel with the other set. New batteries were not connected the same as the old batteries.
2) One battery is defective. It has little or no capacity. It boils away water because the other battery in the set is not yet fully charge and continues to draw high current. This results in over voltage on the defective one and it "boils".

the other two in the system check out fine. Originally we had an issue with the one overcharging went dry in one month adding one gallon on distilled water before purchasing new.
Maybe the old batteries were not connected correctly either.

The problem still exists after installing all four, if we change the position of the batteries the same location of batteries causes overcharge or undercharge. Interstate dealer advised to disconnect the two batteries having issues, by doing this we have no issues with only two batteries in system working.
This indicates it is the cabling that is not connected correctly. Interstate dealer is correct. Correct cabling before using again. The battery that boiled dry is probably damaged, but may still work at reduced capacity. See wiring diagram in this web link:

https://www.survivalmonkey.com/threa...arallel.37039/

Pick a diagram that has 4 each 6 volt batteries producing 12 volts for the coach.

We thought of purchasing a new Magnum ME-BTS25 battery temperature sensor to see if this might be the issue. I have disconnected the existing sensor from battery and does not make a difference.
Lead acid batteries being charged at temperatures above 77 degrees F. need reduced input voltage while charging. In freezing temperatures voltage can be increased. It is hard to see the action of the temperature sensor.
The Magnum can be used without the sensor as long as temperatures remain moderate or low. See Magnum owners manual for exact temperature requirements.

When you get it fixed, I would be delighted to find out how. Please post results.

I wish you good luck and happy trails ahead!
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Old 02-25-2021, 03:53 PM   #4
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Take a picture of your cabling and post them here.

Something is wrong.
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Old 02-25-2021, 04:16 PM   #5
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Only a couple of things it can be, miss wired or bad cable. IMHO
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Old 02-26-2021, 08:45 AM   #6
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Battery issue reply

Thank you for all suggestions: 1) not sure if this helps however the issue occurred with old batteries last fall, batteries were 7 years old so thought replacing with new would solve problem. Two batteries were replaced under warranty a week ago, after installation of new batteries one day later checked the voltage and found the same issue of first battery (positive post) displayed 8.1 volts with next battery (negative post) showing 5.6 volts so disconnected before any damage occurred. Right now only two batteries are connected in the system. I ordered a new temperature sensor to install. Does anyone think the solar panel could cause this issue? If so any suggestions on how to verify proper voltage supplied to batteries? There is also a telephone type cable that is connected to the negative post of the battery that is overcharging, not sure what this does in the system. The picture is displays current hook up with unused cables laying on batteries as connected originally.
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Old 02-26-2021, 09:13 AM   #7
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You have both Positive and Negative lines that go to the chassis coming off the same set of batteries (back of the picture). this will cause the 2 batteries in the back to charge to a higher voltage. The simple solution is to move one of these lines to the front set of batteries......you will still leave the parallel cable in place but this will circulate the flow through all 4 batteries and not just the 2 in the back.

Easy peasy!!
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Old 02-26-2021, 09:18 AM   #8
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Old 02-26-2021, 09:25 AM   #9
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Quote:
Originally Posted by paul65k View Post
You have both Positive and Negative lines that go to the chassis coming off the same set of batteries (back of the picture). this will cause the 2 batteries in the back to charge to a higher voltage. The simple solution is to move one of these lines to the front set of batteries......you will still leave the parallel cable in place but this will circulate the flow through all 4 batteries and not just the 2 in the back.

Easy peasy!!
This would be a good practice in general, but it cannot be the cause of the front set "boiling". If anything the current wiring would make the rear set overcharge and the front set under charge.
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Old 02-26-2021, 09:55 AM   #10
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Put the unused cable on where marked.

Remove phone wire thing. Its supposed to be a battery temp sensor. The end is missing. Buy a new BTS and install.

The BTS battery temp sensor plugs into the inverter charger. The way its connected is causing the over charging of your batteries. Unplug it for default ( safe ) charging.
Here are two brands, Magnum and Xantrex, one should be yours.Click image for larger version

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Old 02-26-2021, 10:01 AM   #11
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They are boiling because the BTS is shorted. That causes overcharging.

The single battery is dying because the BTS is shorting it to ground.
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Old 02-26-2021, 10:03 AM   #12
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Strange little wire

Thank you for the picture. It helps a lot. All the cables look to be in their proper place. The only thing I can see that is out of place is the small wire connected to the jumper on the disconnected pair of batteries. There is also a spade lug there that has no apparent purpose.

Remove the small wire and see if it corrects the problem. The small wire seems too small to cause the problem, but is the only thing I can see out of place.

Usually nothing should be connected to the serial jumper terminals.

after installation of new batteries one day later checked the voltage and found the same issue of first battery (positive post) displayed 8.1 volts with next battery (negative post) showing 5.6 volts so disconnected before any damage occurred.

8.1 volts across the terminals of a 6 volt lead acid battery indicates gross overcharging. The maximum should be 7.2 volts while fast charging. 6.9 volts is normal charging.

This causes water to "boil" and grid corrosion. Check water level and leave it disconnected until a fully charged mate is available.

5.6 volts is deeply discharged (0% state of charge). It is not charging at all. There may be a load continuing to discharge it.

This battery must be fully charge for 14 to 18 hours soon. Letting it stay this way will result in accumulation of large sulfate crystals. The battery will cease to work. It must be charged separately from the remaining battery bank using a 6 volt charger.

Take it to a service shop to get it charged or get a portable 6 volt charger. Maybe the Interstate battery dealer you talked to will charge it for you. It needs to be charged for 14 to 18 hours and may benefit from "conditioning".

8.1 + 5.6 = 13.7 volts this is normal charging output from solar and/or converter/charger.

Does anyone think the solar panel could cause this issue?

It is highly unlikely the solar controller or the converter/charger could cause different results on different batteries in the bank. The solar charge system would affect all the batteries the same.

If so any suggestions on how to verify proper voltage supplied to batteries?


See voltages posted above.

There is also a telephone type cable that is connected to the negative post of the battery that is overcharging, not sure what this does in the system.

Remove this wire and see if it solves the problem. Usually no loads should be connected to the serial jumper terminals.

I wish you good luck and happy trails ahead!
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Old 02-26-2021, 10:54 AM   #13
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Quote:
Originally Posted by Persistent View Post
Thank you for the picture. It helps a lot. All the cables look to be in their proper place. The only thing I can see that is out of place is the small wire connected to the jumper on the disconnected pair of batteries. There is also a spade lug there that has no apparent purpose.

Remove the small wire and see if it corrects the problem. The small wire seems too small to cause the problem, but is the only thing I can see out of place.

Usually nothing should be connected to the serial jumper terminals.

after installation of new batteries one day later checked the voltage and found the same issue of first battery (positive post) displayed 8.1 volts with next battery (negative post) showing 5.6 volts so disconnected before any damage occurred.

8.1 volts across the terminals of a 6 volt lead acid battery indicates gross overcharging. The maximum should be 7.2 volts while fast charging. 6.9 volts is normal charging.

This causes water to "boil" and grid corrosion. Check water level and leave it disconnected until a fully charged mate is available.

5.6 volts is deeply discharged (0% state of charge). It is not charging at all. There may be a load continuing to discharge it.

This battery must be fully charge for 14 to 18 hours soon. Letting it stay this way will result in accumulation of large sulfate crystals. The battery will cease to work. It must be charged separately from the remaining battery bank using a 6 volt charger.

Take it to a service shop to get it charged or get a portable 6 volt charger. Maybe the Interstate battery dealer you talked to will charge it for you. It needs to be charged for 14 to 18 hours and may benefit from "conditioning".

8.1 + 5.6 = 13.7 volts this is normal charging output from solar and/or converter/charger.

Does anyone think the solar panel could cause this issue?

It is highly unlikely the solar controller or the converter/charger could cause different results on different batteries in the bank. The solar charge system would affect all the batteries the same.

If so any suggestions on how to verify proper voltage supplied to batteries?


See voltages posted above.

There is also a telephone type cable that is connected to the negative post of the battery that is overcharging, not sure what this does in the system.

Remove this wire and see if it solves the problem. Usually no loads should be connected to the serial jumper terminals.

I wish you good luck and happy trails ahead!
I guess you don't read other responses.

The shorted BTS is causing all of his problems.
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Old 02-27-2021, 10:56 AM   #14
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Battery issue reply

Good morning all, attached are pictures of all batteries hooked up. With all batteries together still having issue with overcharging and undercharging of the two batteries. I have read all suggestions but maybe not understanding all advise received. Is it possible to send a picture of your current batteries to compare. There was mention the batteries are not hooked up correct, if not correct I don't understand what to change. If possible can I call to discuss with this issue? My number is 608.837.3045 if no answer please leave a message and I will call back. Thanks everyone but still having issues, Jack
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