Battery, Alternator or its cutout?

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Removed the +ve wire from alternator. This wire is found on top of alternator mounted by a nut. Using a mutimeter I found it to be passing +26Vxx (when taking metal body as ground). Still its 0.285 amps.

noticed one thing more. If I removed the +ve terminal and make a bridge using my own body (i.e. hold the terminal in one hand and touch the +ve terminal), it shows 0.2xx amps. Does that not mean that 0.2 amp is just too low to consider?
 
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Look for the control wires on the back of the alternator, remove them and see if you still have leakage..
 
Could not find anything on the back.

Do you have 3-4 wires coming out the alternator somewhere? These will be seperate to the large main power lead coming out.
 
I cannot seem to located additional wires.

Ok here is the new thing; With batteries fully charged (13.xxVolt each), when I start the motor and rev it up to 2000rpm, I get a reading of 26.xx volts across the battery terminals.

If the engine is idle 900-1000rpm, I get 25volts.

Do I need to increase the volts via alternator cutout?
 
I cannot seem to located additional wires.

Ok here is the new thing; With batteries fully charged (13.xxVolt each), when I start the motor and rev it up to 2000rpm, I get a reading of 26.xx volts across the battery terminals.

If the engine is idle 900-1000rpm, I get 25volts.

Do I need to increase the volts via alternator cutout?

The alternator is not charging enough according your reading. If you're sure the reading is correct (calibrated V-meter?) the reading should be at least 27.8 Volts a few minutes after starting.
A max of 28.8 Volts is allowable.
 
I have a digital Multimeter. It showed 26.xx when reved up. Went to 24 when idle (without load).

Did some adjustment to cutout, now its 25 idle and goes to almost 30 when reved up.
 
I have a digital Multimeter. It showed 26.xx when reved up. Went to 24 when idle (without load).

Did some adjustment to cutout, now its 25 idle and goes to almost 30 when reved up.

Low setting is fine, does not matter that much. But high setting is far too high. Do not exceed 28.8, better keep it near 27.6-27.8
 
I am sticking to 30V. Till date no problems and battery indicator is green. Its 12.5 volts when engine is not running, overnight.

Today something strange happened, when I step on brake paddle, I hear a click of the flasher (indicator/signal relay). With this ‘click’ the volts dropped (I could see it via the voltmeter in speed o meter). Removed and checked the flasher, flasher relay was fine.

I turned on lights to full beam and reved the engine a bit. Then I made it idle (900rpm) for a few minutes. Suddenly engine turned off. I noticed that the fuse box wire to the battery had burn out.

This wire was actually coming out of a grip, directly (seems someone hacked it since the grips wire was cut). Furthermore, it was a rather a thin wire compared to that of the other grips. I assume this grip to be of fuse box since ignition did not work after the burn. The clock did not give display as well.

I replaced the wire with a heavier gauge. Soldered it to the grip thus rendering the grip to do its proper job. I think there is a short but why did it now blow the fuse (instead of fuse box main wire?)

Everything seems to be in order now. I am keeping a fire extinguisher in truck, just in case...
 
I don't see a direct relation battery and today's problem.
Today was (is) maybe a temporarely short, probably in the wire you replaced.

In relation to the 30V system voltage. For your system this will hardly be a problem. It will handle that without a significant problem I think. But if the voltage is really 30V your batteries get overloaded, shortening their service-life.
At least check the fluis regularly because at this high voltage they will start 'cooking' thus spilling distilled water.
 
I cannot check fluids (acid) since its a sealed battery. I want it to be 30V (to be precise its 29.xx when reved up) since lights are brighter, AC airflow has increased and best of all; the battery low voltage issue is resolved.

The amp draw remains 0.275amp. I cannot locate the problem area. Battery voltage is 25.xx volts (when checked at morning before an engine start).
 
A draw of 0.275 amps during a night is no problem. Over a forthnight.......
But if you cannot locate the item that draws this, there is not mucht you can do to alter it.

If you want to keep the voltage that high......be my guest. ;)
But don't say you have not been warned.

No, seriously, that is all your choice. It's your truck and you can do to it whatever you want. I just wanted to warn. No hard feelings what so ever.
 
The voltage is dropping again (since I didnt use the truck for days). I can hear the decrease in crank sound.

Is there any way I can locate the problem? I am guessing perhaps it could be some relay fault since if it would be a bare wire, it should have oxidized by now. Furthermore, I was hoping for somthing to burn out but no luck so far.

Also when I hit the brake paddle I can hear a 'click' sound in car audio speakers. A sort of 'blink' of head light can also be observed.

I remember when I use to hit the brake, I could hear the flasher relay 'click'. This is no more the case now.

And yes, if I remove the terminal and then reconnect it, I can see a spark (higher than it should be) and the amp draw (with everthing off) is 0.279.
 
Start pulling fuses .. and get the circuit with the current draw. And then start searching in this circuit the problem
 
Ok I think I am near finding the problem area. Today the batteries went dead again. I pulled the fuses and removed wires from the batteries.

When I remove ‘dome fuse’ and the ‘wire’ that goes to one of the 15A converters (directly, since this converter supplies for anti-theft system, car audio memory and CB) the amp draw goes to zero.

If I only remove dome fuse and not this wire, amp draw goes from 0.27 to 0.23. If I remove the 'wire' and not dome fuse, amp draw goes from 0.27 to 0.25. Strange but this is the case.

So... I do not have a slightest clue what to do since I cannot compromise vehicle security and thus cannot remove the converter. ***Worth noting that any converter that I use with or without a 12V load, draw remains the same. Furthermore, it is a switching 24-12 converter.
 
See this thread.
https://forum.ih8mud.com/showthread.php?t=150018

That problem is comparable to your's.
A switching regulator will draw a fair amount of current even when there is no, or hardly any load.
Even worse, the lower the load, the worse the efficiency.
I had exactly the same problem as you seem to have now.
I created a small convertor that provides the current for my car-alarm and the car-radio memory.

I have posted a drawing about this convertor in posting nr 19 of the thread mentioned above.
Might be of some help to you.
Mind that if you use this setup, the convertor (switching regulator) you have in use now, no longer has to be connected to the battery directly but should be connected either to the ''accessory'' or the 'ignition' terminal.
 
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Ron R:

I do have some 7812 lying around. I do not have diodes and am going to skip on that part. Have some 0.22uF caps am going to use that. It is a nice 'trick' and the same idea once hit me. I have some questions:

a) Have you checked the draw of this circuit? You know that this is also a linear regulator.

b) 7812 is going to get pretty hot, have you mounted a heatsink?

c) LM7812 is made to withstand load of 0.5 ampere. Now the CD player memory and car alarm... I know just the loud speaker (thingy that make noise) is 50watts. Besides, anti theft system would also consume some amps. You really think just 0.5amp would do the trick?

d) You should not use the LM7812 and the 'big' converter on same rail. You must introduce a relay such that when your 'big' converter kicks in, the homemade one kicks-out. Else, since LM7812 is not load capable and produces say 12V (which is lower than your 'big' converter as usually they produce 13.8V or 14.4V, hence LM7812 at lower potential will result in current flowing towards LM7812 from the big converter. And I doubt the diodes would help much (suppose when there is no load i.e. CD player off).
 
Ron R:

I do have some 7812 lying around. I do not have diodes and am going to skip on that part. Have some 0.22uF caps am going to use that. It is a nice 'trick' and the same idea once hit me. I have some questions:

a) Have you checked the draw of this circuit? You know that this is also a linear regulator.

Yes I know it's a linear. But for this application it's an advantage. If you want you can also use a integrated switching regulator, the one I mentioned in my other posting.
Disadvantage of the switching regulator compared to the linear is that (at 24V) the swtiching can handle a max load of 0.5 A whereis the linear can handle at least 1.0 A.
Because this regulator only has to deliver current for the alarm and memory, 1.0 A is more than sufficient, at least in my setup. It's now in use for about 8 years.

b) 7812 is going to get pretty hot, have you mounted a heatsink?
Hm, not normally. The current for memory and alarm/anti-theft will be something like 40-50 mA. Taken into account that the efficiency is near the 50% mark, the draw from the battery will be in the 0.1 A range. Less than half the draw you have now.
The 7812 can even do without heatsink, but -as I wrote in my other posting - I've put the little circuit in a alumimum box. The 7812 is bolted to one of the walls of this little box. That box now acts as a heatsink.
The 'body' of the 7812 is mass, so you can bolt it directly to the alu-box and fix it onto the car-body.

c) LM7812 is made to withstand load of 0.5 ampere. Now the CD player memory and car alarm... I know just the loud speaker (thingy that make noise) is 50watts. Besides, anti theft system would also consume some amps. You really think just 0.5amp would do the trick?
The 7812 is available in various capacities. Even 3 A-versions are available.
At rest -when there is no alarm - a 1A version is more than sufficient. When the alarm is active the draw probably will be more than 1 A but only at short bursts. Keep in mind that although the speaker is rated at 50 Watts, that's only peak, I doubt it will really draw 4 A.
The 7812 has an internal protection so, even if overloaded, it won't get damaged.

d) You should not use the LM7812 and the 'big' converter on same rail. You must introduce a relay such that when your 'big' converter kicks in, the homemade one kicks-out. Else, since LM7812 is not load capable and produces say 12V (which is lower than your 'big' converter as usually they produce 13.8V or 14.4V, hence LM7812 at lower potential will result in current flowing towards LM7812 from the big converter. And I doubt the diodes would help much (suppose when there is no load i.e. CD player off).

You are right in saying that the two (the regulator and the switching convertor) should not be on the same rail. Never connect two powersources to each other.
But that's why I've used the diodes. They effectively 'disconnect' the two powersources because they work like a one-way valve. Current can travel from the source (the 7812) but not towards it.
Because the 7812 will effectively deliver ~11.3V (12V minus loss over the diode) the switching convertor will override it when it kicks in at ~14V. And because of the diode, no current will flow towards the 7812.

This 11 and a bit as voltage may seem to be low, but that is no problem at all to maintain memory and keeping the alarmsystem alive.
I found that, at a battery level where I was unable to start the engine, the memory was still alive and alarm was working properly. Of course, if the batteries get fully drained (i.e. several start-attempts) then story ends.
 
Sounds promising. A must do for every 24Volt system I would say.

If possible, using a multimeter verify that the 'switching converter' does not pass current towards this regulator. This I got to know. I am going to use cut off relay instead of diode. Switching regulator would kick in with ACC.

Also, what’s the amp draw with the regulator and without this regulator?
 
Sounds promising. A must do for every 24Volt system I would say.

If possible, using a multimeter verify that the 'switching converter' does not pass current towards this regulator. This I got to know. I am going to use cut off relay instead of diode. Switching regulator would kick in with ACC.
Keep in mind that a relay is slower than a diode!!

Also, what’s the amp draw with the regulator and without this regulator?

Hm, don't know or I understand this right.
If I measure the amount of draw from the battery, in my setup this is 85-90 mA (alarm not activated = not sounding the alarm but in 'guarded'- mode and memory for the radio/CDplayer connected) total. So that is included the loss over the regulator 7812.
If I would use the integrated switching regulator (very new on the market, still hard to find) the current would be in the 45-50 mA I guess, this because this regulater has an effeciency of about 95%!!
 

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