Tuesday 28 March 2023

Boring Bike Stuff!

After fitting the new lithium battery into the trailer I promptly forgot to take a photo. 

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My battery mounting frame.

The three Watt meters in the trailer electrical box were then checked to ensure they worked with the new battery.  I can monitor:

  • Solar power IN
  • Alternator power IN
  • Battery consumption OUT

You will have to wait for a photo <sorry!>

Today it was ebike cleaning time.  I've decided to wax the chain instead of oiling it.  Reputably this both reduces the frequency at which the chain gets dirty and extends its life.  Rather than buy bike chain wax I made some.  My technique was to use my pocket knife to shave a standard candle and then dissolve the shaving in Shellite.  After removing the chain from the bike it went into the ultrasonic cleaner for an hour before being placed in the wax solution.

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There's a chain immersed in that 'grey' solution.  The chain spent 24 hours in the solution before drying.  The process was then repeated.

During this time the Shimano Alfine internally geared hub was stripped and cleaned.  This was the first time I'd disassembled the hub.  In the past I've done the standard oil change and cleaning fluid routine.  I've actually been servicing the hub (doing oil changes) at four times the recommended frequency.

The rear chain sprocket looked dirty so that went into the ultrasonic cleaner for an hour.  It came out looking like new

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The oil on the outside of the hub internals looked reasonably clean.  But then I only changed it two months ago.

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The hub was placed in an empty soft drink bottle full of petrol which was then placed into the ultrasonic cleaner for an hour.

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Whilst the cleaner was doing its job I cleaned and inspected the interior of the hub.  Everything looked fine.

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After cleaning, the gears looked good.

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The petrol was black.  Obviously some impurities were removed

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I wanted to know if any swarf (metal filings) had been removed during the cleaning.  I placed some magnets into the container

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Oh Yes!  The magnets collected a significant amount.  I'm pleased they are no longer grinding away inside the hub.

Reassembling the hub took some time.  My old eyes can't pick out the fine details and I ended up using a magnifying glass.  The hub was then refilled with fresh gear oil.

Saturday 25 March 2023

It started Raining

Work on the battery modifications ceased when it started raining.  Autumn must be here!

The new lithium battery had been on charge for three hours when I went to check it.  The 15A charger was resting.

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This was a good sign as it indicated the lithium battery BMS had stopped the charger from over-charging the battery.  I then checked the amp meter which had been displaying 15 Amps going into the battery.  Now it was displaying 0.2A.  Another good sign.

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The last check was the battery voltage meter.

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When the battery is 100% whilst charging the voltage should be 14.6V

A 'rested' 100% charged battery should have a reading of 13.6V

If the meter is accurate then the voltage should slowly drop to 13.6V as the battery 'rests'.

The old battery was underneath the trailer whilst the new battery will be in the top compartment.  I'll need to extend the cables.  The cheapest price I could find for 2 metres of suitably sized red and black cables was $45.  Then I remembered seeing a set of 3.5 metre long 100A jumper cables at a special price of $39.95 in the 4WD Supacentre.  Better the $5 in my pocket.

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I made a short lead for the battery terminals with a Anderson Plug at the other end.

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The small black wire is the temperature sensor lead.

I could plug the supply positive and negative wire into one of the Anderson Plugs on top of the battery box rather than making a lead that fits to the terminals.  My reasoning for not using one of the top plugs is both top plugs could be used in the 4WD.  One to power the fridge and the other for the 12V oven.

No photos of the trailer wiring as it's still raining.

Friday 24 March 2023

Decision Made

Whilst driving home from my recent camper trailer snagging trip I considered the battery replacement issue.  The 'dead' 150Ah slim line AGM battery had been carefully mounted by me in a secure and sealed custom made case under the rear of the trailer.  The first two consideration were; should I replace it with another slimline AGM battery or opt for a slimline Lithium battery?

My electrical demand is rather modest.  The combined load for the fridge and freezer is less than 6 Amps.  Added to that is a small amount of LED lighting and the very infrequent use of the 500W 240V inverter.

When not moving, the single 150W solar panel provides sufficient energy to meet the requirements to power the fridge and freezer.   Assuming the panel can produce a max of 10 Amps and there are 15 hours of daylight then the production would be 150Ah.  This is probably optimistic.  Assuming the fridge/freezer consumes 6 Amps for 24 hours then the load is 144Ah.  Of course the fridge and freezer don't run continuously so the consumption will be less.  Assume the consumption is 100Ah. 

It's only possible to use 50% of an AGM battery before damaging it.  This means the old battery had 75Ah available.  This is insufficient if I was to rely on the solar panel.

Lithium batteries can provide 80% of their rated capacity.  Well they can provide 100%, but this significantly reduces the number of life cycles.  It stick with 80%.  Therefore, for the 24hr load of 100Ah a replacement Lithium battery would require a minimum capacity of 125Ah.

The price of Lithium batteries is slowly reducing.  A good quality 100Ah lithium battery costs approximately $1500 and the budget end around $4-500.  You get what you play for and if it was essential for me to have a very reliable battery system (ie, continuous cruiser) I'd opt for a more expensive quality battery.  However the camper trailer doesn't fall into that category and a budget battery should suffice.

There are three essential criteria with lithium battery construction

  • Quality of the assembly/construction
  • Quality of the lithium cells (some manufacturers use second hand or second quality cells
  • Quality of the inbuilt Battery Management System (BMS).  A poor BMS can result in cell imbalance leading to premature battery failure.

I'm not going void a warranty by tearing apart a newly purchased lithium battery to inspect the quality of construction.  Instead I will read the results of others who have done this already.

An initial search revealed Aldi has a 'VoltX' brand lithium 100Ah battery on sale this weekend for $449.  Purchasing an Aldi 'Special Buy' in Perth is very "hit and miss".  We're on the other side of the continent and often the special Buys aren't in stock.

Another option was a battery from iTechWorld.  They are a local, Perth company who design and develop lithium batteries.  Note they don't state 'manufacture'.  No doubt their batteries are made in China.

I've previously purchase a number of camping items from the 4WD Supacentre chain of stores.  they specialize in budget priced 4WD and camping equipment made in China.  Their website stated they had a current special on many items; including lithium batteries.

I could purchase a slimline lithium battery from the 4WD Supacentre and fit it into the old AGM battery compartment under the trailer.  That's when I realised it wasn't necessary to fit the replacement battery under the trailer.  If I purchased a lithium battery it would be lighter than the old AGM which would enable me to more easily move it around.  When I was going on a trip without the trailer I could place the battery in the rear of the 4WD, along with the fridge.  I'd need to make a battery box, but that wouldn't be too hard.  Then I realised the 4WD SupaCentre had a special on battery boxes.  They were selling them cheaper than I could purchase the components.

Off to the local 4WD SupaCentre

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Our new 120Ah lithium battery

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The battery box

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Internal 30A fuse. 

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Isolation switch, voltage meter and red 10A reset button.

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On the opposite side is a 12V cigarette socket and two usb charging ports

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On the top are two Anderson Plugs

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I fitted the battery inside the case noticing there was a gap on the side and end.  The last thing I want is the battery bouncing around inside the box and I fitted some packing to eliminate that from occurring.

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Then the cables were connected to the battery terminals and the lid fitted.

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The voltage meter was showing 13.2V which indicated the battery was approximately 70% charged.

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Accordingly to the battery specifications the maximum charging current is 60 Amps.  But the fuse in the box is rated at 30 Amps.  I elected to be cautious and used our 240V charger which has a maximum output of 15 Amps.

Whilst the battery was on charge I made a start on modifications to the trailer .

Thursday 23 March 2023

"Snagging Trip"

Those reader who have had a narrowboat built will likely know that at the end of the construction process it is usual to take a "snagging cruise".  This is when you find all the small issue that need rectifying by the builder before the boat can be consider completed.

After my recent alterations and additions to the camper trailer I decided to make a "snagging trip" to see if everything was satisfactory.  I also wanted to test the new 12V oven.  The trip proved to be a sound decision as I identified two important issues requiring rectification. 

My journey took me 200km south of Perth to the Collie Region.  I'd not previously visited the area and the snagging trip was a good opportunity to familiarize myself.

Rather than taking the southern Freeway (motorway) I opted to use the older Southwest Highway as it would provide a change in scenery.

After driving 30 minutes I stopped and turned on the new 12V oven before continuing on for another 30 minutes.  This time I placed three frozen sausage rolls into the now pre-heated over.  Jan had suggested I place the rolls in an aluminium tray instead of directly on the oven rack.  The idea was this would minimise crumbs.

After another 30 minutes I stopped for lunch at Waroona where I had piping hot rolls.   So hot that I needed my hat to get the tray out of the oven.

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Online oven reviews had suggested it would take an hour to heat pies and rolls.  However our oven does this in 30 minutes.  My belief is this is a result of the voltage step-up converter raising the voltage to 15V.

The oven is working well, although I discovered using an aluminium tray wasn't a good idea as the radiant heat had burned the bottoms of the rolls.

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Waroona is a quiet and tidy country town.

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Half an hour later I reached the town of Harvey.  This is another pleasant country town.

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Art Deco architecture?

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Parked in the main street

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My plan was to reach Wellington Dam and camp in Wellington National Park.  Entry to the park is free but camping fees apply.  Upon reaching the road into the park I noticed a sign stating there was no mobile phone coverage in the park and camping booking had to be made online.  That was annoying as I had anticipated the park would be like others I'd previously been to where there was a pay kiosk. 

Upon attempting to book online I discovered the National Parks booking website was overloaded with a message stating "try later".  That was no good to me as there was no mobile phone coverage further on.  In the end I decided to drive on and visit the dam.  The camping issue would be solved later.

Wellington Dam was constructed during the Great Depression.  It was one of the government public works projects designed to meet a need but also provide employment and an income for those who had lost their livelihood.  The dam and reservoir are named after the Duke of Wellington.

The original dam has been raised in height twice since first constructed.  Initially it's purpose was to provide water for local irrigation.  However as it was raised in height and capacity increased it also provide town water supplies in the region.

Whilst the reservoir has been a well know and used recreational area for locals, it was the painting of the mural on the dam that made it a major attraction.  The 8000sq mtr mural by Australian painter Guido Van Helten was completed in 2021.

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The northern half of the reservoir is in the National Park and the southern half in the State Forest.  As I was unable to pay of a campsite in the National Park I decided to do some "free" camping on the southern edge of the reservoir in the State Forest.  No facilities in the forest; but that didn't bother me. 

A 6km heavily corrugated dirt track led me through the forest to the water where I found an isolated campsite.

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I'm not the first to camp here as I found an old shelter and discarded broken folding chair.

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I immediately realised someone old; like me; with dodgy knees could make use of the broken chair.  Cutting a hole with my pocket knife and positioning the chair over a hole provided me with a "short drop" toilet.  

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Necessity is the mother of invention Smile

Initially I thought I was alone.

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However an evening walk revealed there were others in the far distance who had a similar idea.

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Dinner consisted of sausages, potatoes and mixed veg.  I retired to the rooftop tent at dusk and had a fitful night as it was hot and humid.  Too hot to sleep in the sleeping bag and too cold to sleep without it.

In the morning I woke to find my first major snagging issue.  The trailer battery was flat!  This wasn't exactly a surprise as I've had my suspicions about the AGM battery.  It hasn't been used much but is now at least five years old.  Last night I removed the contents of the freezer adding them to the fridge.  After turning off the freezer the electrical load was only 2.4A.  The battery had been fully charged before leaving Perth and the charge maintained by the vehicle during the trip.  Then the solar panel supplied it until dusk.  It should have been able to easily cope with the overnight load.

I need a new battery! Sad smile

There was little point in spending more nights away from home as the food in the fridge would likely start to go off.  After packing up I did my normal routine of checking the trailer lights.  That's when I discovered the left indicator light on the trailer had an intermittent connection.  Another issue identified!  A temporary repair fixed that and I started heading home via the town of Collie.

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Collie is mainly known for its coal containing the only coalfields in West Australia.   At one time there were four thermal power stations and two coalmines around Collie.   However the move towards "green energy" has seen all but one of the power stations be decommissioned, with the last to be decommissioned in the near future. 

Friday 17 March 2023

Camper Trailer Enhancements

A number of items ordered from China arrived today.  All of them are required for some enhancements I have planned for the camper trailer.

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Clockwise from the top left in the above photo.

  • Mounting bracket for an Anderson Plug
  • 12V to 15V DC converter
  • 10 Anderson Plugs
  • A Watt Meter.

These are required for three projects.  The first is to increase the voltage to the 12V oven in the back of the 4WD.  When running, the oven draws 15 Amps at 12V.  By increasing the voltage to 15V the heater element should get hotter.  The converter is rated at 30 Amps which should be sufficient to power the oven.

I've mounted the converter on the rear of the oven cabinet    

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The second project was to mount an Anderson Plug on either end of the Watt Meter.  This provides a handy meter to monitor the various power sources and consumers.

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The Watt Meter was plugged into the 4WD power supply to the oven with both the engine and oven off.

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No current (Amps) and the voltage was 12.53V.  That slightly concerned me as I'd only taken the battery off the 240V battery charger that same morning. 

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Then I started the 4WD with the oven still off.  The voltage rose to 13.63V and there was a very slight Amperage.  Probably due to power losses in the 12-15V converter.

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Then the oven was turned on.  The voltage dropped to 12.39V and the Amperage was 15.86A.  I'll get around to testing the voltage on the oven side of the converter.  It should be 15V

The third project is to fit a 12V Anderson outlet plug on the trailer.  I've decided to fit one in order to run the oven in the back of the 4WD from the trailer battery when camped.  This avoids the potential of inadvertently flattening the 4WD battery.  It also means the solar panel can be recharging the trailer battery whilst the oven is simultaneously drawing power from it.

The first step in this project has been to wire an Anderson plug into the trailer.  I've sealed the back of the plug with silicon as it will be slightly exposed to the elements. 

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The last part of this project is to fit a mounting bracket to the trailer.