Stirling Advanced Regulator and Battery Maintenance

I last wrote about the advanced regulator was when I had a temporary connection to power the unit  cruising the Droitwich Ring. Since then I found a connection on the ignition switch that has power on only when the ignition is switched on. The unit it now wired in permanently. With this unit and the Smart Gauge I now confident that I've taken the guesswork out of managing battery capacity.

The only remaining 'management' issues are the state of the fuel tank and holding tank. We cruise hoping one is full and the other is empty, probably topping up and pumping out more often than needed. Management of the fuel tank will remain a broom handle but I may investigate a holding tank gauge.

Took out and check the domestic batteries … went to check the bow thruster batteries to find they are maintenance free!

Refleks Stove Dismantled

The guide on Canalworld.net proved very useful. I did not succeed, for whatever reason, in drilling out the rivets so ground them off. This was no problem for the rivals holding the outer case to the base as it can be done from the inside. This was not sufficient get the outer case past the flue outlet and fuel input. I had to grind off the rivets holding the top ring and fiddle rail. This had to be done very carefully as any over grinding will be seen. I also had to remove the large brass T piece from the fuel pipe and only then could the outer cover be lifted off.

Then, first grinding off the rivets fixing the inner case to the base, and then the rivets securing the burn pot, completed delicate work with the angle grinder. When grinding off the rivets from the face they need to be pushed back with a centre punch. After doing this to the 3 rivets holding the burn pot I placed the inner assembly on the bench and, using a piece of wood and a hammer eased the burn pot down and out.

The stove was now dissembled and the burn pot, apart from some surface dirt, was fine. All the holes were clear. Obviously this was not the problem! The only suspect part is the catalyst or burn coil. At nearly £100 I'll reassemble the stove and try lighting it again to see if the recent failure was just a one off. I'll reassemble the stove using no8 self tapping screws.

The regulator is not the same as the one described in the Canalworld.net post and a suggested alternative elsewhere on Canalworld is not the same so that will go back as it was taken off.

Neither the primary fuel fitter/water separator nor the filter in the stove regulator had any significant dirt trapped … not bad for over 10 years use.

I do need a new drill though. Trying to drill out the rivets, at some stage, I found that the drill was not working in 'forward'. So whether I had been trying to drill out the rivets using 'reverse' or whether the drill failed while I was using it I have no idea.

The Refleks Stove requires maintenance

There is a diesel Refleks stove in the main cabin. I have done nothing to it over the years than occasionally clear out the accumulated gunge at the bottom of the 'burn pot'. From time to time the stove has been difficult to light and has unexpectedly gone out. The last time we were onboard the stove failed to burn properly … the match continued to burn as a wick to a pool of fuel. Checking inside I could see part of the catalyst was corroded so guessed a replacement was required.

The problems started when I began to search online for spare parts. Not only can I not find a spares list  but it appears that maintenance was required! … 'the burner pot should be removed … every 2 years for a more thorough cleaning'. And there's a filter in the regulator! It seems a more thorough overhaul is required but no manufacturer/supplier details online. However, canalworld.net has a useful guide to servicing the heater and it needs rivets to be drilled out … not an onboard task. So next weeks a visit to the boat to bring home the stove.

Dunhampstead to Worcester Thursday 22 Aug - Saturday 25 Aug

Found a satellite TV signal on the nearly empty Dunhamstead permenant moorings. We having tried for fuel at Dunhamstead and failed, we eventually filled up at Hanbury before cruising on. After winding at the second lock we moored above Astwood bottom lock and after lunch walked to Hanbury Hall. Whilst there Brian phoned to ask where we were moored. He and Janet arrived at the boat having walked from the second lock minutes after we had got back. A pleasant afternoon tea catching up on family and boating news.

Left there to cruise to Droitwich. A slow cruise as a boat coming up the staircase lock had foundthe bottom lock empty and the upper chamber completely drained. Arriving just after midday we walked into the town and had a pleasant lunch at an Italian restaurant J had previously checked out on Trip Advisor. Shopping at Waitrose and a lazy afternoon.

Intending to switch off the fridge overnight, not to save power but because of the noise, I accidentally switched on the deep freeze. As a result the batteries were at 57% when we set out the next day. I had not intended to switch on the Advanced Regulator as we would be back on shore power that evening. However, given the lowish battery capacity it offered an opportunity to test out the regulator ...
Start           57%     13.7v
1 hr            67%     14.05v
2 hrs           82%     14.5v
3 hrs           94%      14.65v
3.5 hrs        98%      14.7v  .... success!

Need now to follow a battery maintenance routine, something I have never need before.

Back in Worcester by 1430, after a fast accompanied passage through the Diglis basin locks, and home for tea.

Droitwich Ring

With a forecast of good weather we've decided on a short break cruising the Droitwich Ring ... currently moored and it's raining!
Worcester Birmingham Canal is very quiet, met only 4 boats and one has passed us since we moored. The canal is not in a good state, water is low and in the five. Mile pound reeds are encroaching into the navigation. All locks have been set in out favour. Paddles vary, most are reasonable except for the top paddles on Offerton Bottom Lock are the hardest I've experienced for a long time. The top lock paddles were the easiest today!
Tried for fuel at Lowesmoor Wharf but the phone was not answered so did not bother manoeuvring into their basin.
Initially no need to use the Stirling Advanced Regulator as batteries were charged from the mains. However, stopped for lunch and watched the TV news by which time capacity dropped to 91% so connected the regulator and after a short half hour cruise capacity was back to 100% ... success! But still have to find an appropriate power point to power the regulator only when the engine is running.
Moored for the night just before Dunhampton Bridge.

The Stirling Advanced Digital Regulator

Although fitted I had not been able to get the advanced digital regulator to work for our Oxford and Sharpness cruises so today decided to investigate further by changing the 55 amp alternator for the 70 amp alternator. The former is has a field wire I fitted whilst the latter has one fitted professionally. Before starting though I would check the 12v supply to the unit using my 'universal' testing 'wire with bulb and clips' ... I had previously tested using a 12v meter ... result no power! Connected the unit directly to 12v supply and it worked. Did not fit the 70 amp alternator ... went for lunch out instead.

I don't think I'm a complete idiot. I'm convinced I had 12v on the meter and when first fitted the battery type LED on the unit was flickering. I have now to investigate whether the terminal on the ignition switch does not give 12v or whether there is a fault between the terminal and where I connected to the advanced regulator. Also want to be able to switch off the advanced regulator when a planned long cruise or a reasonable battery state make its use unnecessary, so some further work required. Until then we can cruise with the regulator operating and find out how effective it is at speeding up recharging the batteries.

Gifford Circus, Frampton upon Severn

Cruised to Gloucester stopping overnight at Upton upon Severn to meet daughter and granddaughter Sunday evening. They stayed with us overnight and we cruised to Frampton Monday morning.

Weather was forecast to be very wet but no rain while cruising. The unofficial moorings after the first Frampton bridge and now not available to cruised on and moored near second bridge. This meant a longer walk to the Green where the Circus was set up. Enjoyed a drink in the sun before lunch.

Splatt Bridge, Sharpness Canal

Heavens opened whilst having lunch but cleared up to restart 20 minutes before we needed to set out for the circus. Then stopped just as we prepared to leave. Longer walk then I expected but rain held off until we were in the tent.

Excellent performance but a child is needed to justify enjoying it! Good meal at the Bell before D and Grand D departed.

Decided to cruise on to Sharpness ... it has not improved since our last and only visit so years ago. Then back to Gloucester which was surprisingly quiet, just 5 boats on moorings overnight. Next day to Worcester ... 9 hours on the river ... too long.

Kingswood Junction - Oxford - Worcester

Have to admit that posting comments while cruising I have not done too well! Cruise to Oxford was marred by meeting a CRT volunteer on Hatton Flight who had detained a hire boat half way up the flight on the grounds of a water shortage. The boat was kept waiting about an hour to wait for a following boat ... untrue and officious. When the pair came out of the lock they were tied together. Crossing in a short pound meant that J in Ada was pushed to the side ... a new meaning to 'barging'! Before that, in third lock, engine stopped because of fuel starvation. Took about 30 mins to change the fuel filter but the boat we were travelling with went on without us so worked the flight alone.

Oxford was quite with plenty of moorings available opposite Oxford Boats. The city was crowded as it was the time for prospective students to look around the colleges ... an real flock of 'seagulls'. However, met up with friend, best man, and exchanged news over an excellent lunch at Conte, steak and chips done French style.

Cruise back, stopped a couple of nights at The Pig Place on the Oxford Canal. 240v connection but no water. Apparently they use a bore hole and there's none to spare but excellent bacon and sausages. Stopped below Hatton for an early start, no there boats to share the work and no sign of the CRT volunteers.

Returned via Stratford on Avon so met up with J's cousin Robert and enjoyed a very pleasant evening with them. Similarly at Tewkesbury, another cousin and another very pleasant evening. And so back to Worcester.

Started the cruise with cold damp weather and ended with a record breaking heat wave ... British weather.

Worcester to Kingswood Junction

Departed late after an unexpected lie-in onThursday, 13 June, heading in the general direction of Bath via Stratford Canal, Grand Union, Oxford, Thames and K&A. It seems some years since we last cruised this area.
Although there seemed a lot of water flowing down Offerton Locks, all pounds below Astwood Locks were 6-9" down. No problems after Astowwod so is all the water running down the Droitwick?
Moored for the night in Stoke Pound on pins. There a better moorings further on in the flight. Successfully used the digital 'stick' aerial very impressive for such a small, omi directional device.
Away early next day for Tadebigge. Entered bottom lock at 0800 and moored below top lock at 1230. We were teased at the start by the first 4 locks being set in our favour and the rest against until we met boats coming down just over half way through. Even then the last few locks were against us.
Not much water coming down except on one occasion when locks being emptied above must have come together to flow over the lock gates. Moored tired below top lock.
Pump out and fuel planned for today. Concerned being Saturday that the hire bases would be busy but first boatyard, Anglo Welsh obliged. Wast Hil Tunnel was surprisingly not especially wet and moored at Kings Norton for lunch. The Stratford Canal seems pleasanter than I recalled and moored just outside Hockley Heath for the night.
The new advanced digital alternator regulator is not working and we need about 6 hours crushing to fully recharge the batteries. The Smartguage is an invaluable aid to managing battery capacity. The unit, like the old one, is indicating correctly the battery type, which is set using dip switches, but nothing else indicated. I'm using the field wire I fixed when I bought the old unit many years ago. Is it connected correctly to the brushes? I will investigate but need to be cautious as no spare if I damage anything.
Next day stopped to shop in Hockley Heath. Al we remembered of the place was a rather iffy roast lunch at the pub by the canal. We were pleasantly surprised to find a good shop, Chinese and Indian restaurant/takeaway and a SteakHouse. Had a choice of NT properties to vist, Packwood House or Baddesley Clinton and decided on the latter so moored on the Grand Union to walk there along the Heart Of England Way. However, decided to leave the visit until tomorrow.
Poor or no digital TV signal so resorted to satellite as there was a clear Skye in that direction.

Shake Down Cruise

During half term holiday we took a few days to check how fit Ada is and have a few days away. We cruised North to the Staff and Worcs and then on to Stourton Junction and return. First 3 days of the Bank Holiday Weekend were brilliant, but cool, sunshine. After that it rained so much that the River Severn was threatening flood conditions. As we had a date with our Granddaughter, N, we returned a day early. In the event the rain stopped and the river was never Red.
Ada was mostly fit. However, the recently fitted advanced alternator regulator was not working. As this device is over 10 years old I'm assuming it's the unit and not how I fitted it. A new digital unit is on order and I'll fit it as we cruise next. The Smartgauge showed that we used between 40 and 50% battery capacity overnight and it took 4-5 hours of running the engine to get back to 100%.
Holding tank is giving us about 9 days endurance and the level can just about be made out through the natural plastic side. I'll have to mark off 'days to go to full' on the tank side!
I also tried a TV 'stick' aerial but in a cutting. The result was surprisingly good but not enough for comfortable viewing. I'll try it again when the surrounding countryside appears better for reception. The   advantage of the 'stick' aerial is that it does not consume battery capacity, unlike the satellite aerial.
Now provisioning Ada for our long cruise.

Diode fitted on Bow Thruster Charging Circuit

The bow thruster batteries now share charging from the 55amp alternator with the starter battery. There is a relay between the starter battery and the bow thruster batteries. I understand that there is a risk that the bow thruster will try to take power from the starter battery. As the rating of the relay is significantly less than the bow thruster this could cause the really to fail and cause a fire.

To prevent this a split charge diode can be used to replace the relay. This is what I planned to do. I was concerned as space there is limited. Also the diode needs to disperse heat and this would be impaired in the engine space. My solution has been to fit the diode at the bow thruster end of the charging circuit in the front locker with the batteries.

Taking voltages, there is a loss of 0.74v from the cable run from the engine space to the diode and a further loss of 0.79v across the diode, so a total loss of 1.5v.

Further battery update

After much frustration fitted the 70 amp alternator warning light. I put the cable through when first fitting the second alternator. The fustration was first trying to get it to work when there was a 'gap'  in the cable (intended but forgotten about!) then when there was no bulb in the new warning light.

Connected the shore battery charger to the bow thruster battery circuit. Unfortunately not neat but safe and out of sight.

Fitted the Sterling Advanced Regulator but no evidence from the SmartGauge of any effect. I'll investigate further when cruising after a night away using the domestic batteries.

Final outstanding task is to fit the Sterling Split Charge Diode, when it's received.

Front and back doors

When Ada was painted I asked that all the holes for the front and back door catches be filled and painted over. The catches were short cabin hooks. They pushed the doors away from the cabin sides and eventually wore away the paint.
I had some vague idea of using magnetic catches. This proved harder than I expected but today I fixed magnets to all doors and I'm very pleased with the result.

Keeper on front window frame

I eventually found rubber covered round magnets. Rubber covered to prevent damaging the paint where they strike. Off the boat they are very fierce but attached to the doors they apply just the right hold. The steel  back doors strike and hold to the cabin sides. the magnets are pushed out by 4 washers behind them to prevent the doors hitting the back cover fixings. The front doors have a keeper fixed to the wood window frame and the magnets on the doors. the thickes of these is sufficient to prevent the handles hitting the glass of the front windows.

Magnet with spacer washer behind

14 mm gap, just enough
to be clear of the cover
studs

Battery capacity update

Refitting the alternators in the reverse positions went very smoothly. I was concerned that I did not detect any output from the 55 amp alternator before taking it off. However, when refitted it in the primary position it worked perfectly.

The puzzle came as I could not detect any output from the 70 amp alternator in the secondary position. I've used an alternator in this position with the same cabling to charge the bow thruster batteries for 10+ years. After some investigation I found that fitting the warning light resulted in the alternator generating 14+ volts. So how have the bow thruster batteries been charging for the last 10+ years?!

So 3 outstanding tasks:
1. Fit warning light to 70 amp alternator.
2. Connect bow thruster batteries to shore charging cable.
3. Fit advanced alternator regulator to 70 amp alternator.
4. Fit split charge diode.

1. Wire to control panel already in place so need to order lamp holder and fix in place.

2. Currently cable is connected, as per instructions, to domestic batteries and I have no idea how to progress the task.

3. I've order from ebay a replacement regulator with the earth negative field wire already fitted. The wiring loom from my previous failed attempt will need modifying by shortening all the cables but should be a quick job.

4. A future task.

Overall a satisfying days' work.

Battery capacity

In 1997 Ada was fitted with a Lucas A127 55 amp alternator charging the domestic and starter batteries. A couple of years later when fitting the bow thruster I fitted a second alternator, also a Lucas A127 55 amp unit, to charge the bow thruster batteries. About the same time I bought a Sterling advanced alternator regulator but, although I modified the alternator to fit the -ve earth field wire, I did not fit it as there was no problem with the batteries keeping up with our use of 12v power.

With time we added more 12v equipment and began to have power capacity issues. When I got round to fitting the advanced alternator regulator it did not work. I have since realised that marine alternators have isolated returns so following the instructions and connecting the -ve of the advanced regulator to the alternator case does not make a working connection.

About this time we had a problem with the bearings of the domestic/starter alternator so I decided to replace it with a higher capacity alternator. I bought a Lucas A127 70 amp alternator and as the connections were different did some further research about marine alternators. (It was then that I realised my mistake when fitting the advanced regulator.) Fitting the new alternator was straight forward and marginally improved the battery capacity but there were still times when there was not enough battery power.

The original alternator was repaired and carried as a spare. Researching the replacement alternator I learnt that the A127 alternator case has 2 configurations left handed and right handed. As one fited alternator is LH and the other is RH I researched how to change from one to the other.

Latest idea is the realisation that it would be better using the 70 amp alternator to charge only the domestic batteries and to use the 55 amp alternator to charge the bow thruster and starter batteries. This invokes changing the handing of both alternators. Then moving the 55 amp alternator to the position of the original alternator and the 70 amp alternator to the auxcilary position. With the current cabling, the 55 amp alternator is charging domestic and includes a relay. The 70 amp alternator is charging the bow thruster.

All -ve connects are common so no changes to -ve cables. Disconnect the +ve cable from the domestic batteries to the relay. Connect the +ve cable of bow thruster batteries to the relay terminal formally connected to the domestic batteries. A new 10mm cable will be required. Connect the +ve terminal of the 70 amp alternator to the domestic batteries. A new 6mm cable will be required.

Finally, fit the advanced regulator to the 70 amp alternator. For about £10 I can purchase a replacement regulator with a -ve earth field wire already fitted saving modify the existing one.

The alternators are here at home. The major issue is, before taking off the 55 amp alternator I did not detect any output so may not be working. I've changed the handing and it's ready to refit and test. If it's not working I'll bring it home and replace the regulator and rectifier having already watched the online youtube training video! I'll change the handing of the 70 amp alternator when the 55 amp one is proven working as refitting the 70amp alternator to charge the domestic/starter batteries is the fall back position. When both are proven working I'll change the cabling. When that is done I'll change the 70 amp regulator, as this can be done without dismounting the alternator, and fit the advanced regulator.

Then the question will be, how long will it take to recharge the batteries to keep the deep freeze, fridge, satellite TV and inverter working!

Further thoughts now ... I will need to replace the relay with a split charge diode unit. This is to prevent the bow thruster drawing high amps, through 10mm connecting cables and the relay, from the starter battery if the bow thruster batteries are discharged. There is a fuses in the cable that should give protection but it's a bit crude.

LED Lighting

After what seems years of intention I eventually bought and fitted 2 trial LEDs, cool white 180 Lumens from Bedazzled. The issue was would there be sufficient light to read by and could I fit them into the existing light fittings of which I have 2 types. The oldest, bought from a chandlery, have bayonet bulbs,  and the newer from Screwfix, have G4 halogen bulbs, of which there are 2 types.
By taking out the reflectors, the 30.5mm LED units fit into the Screwfix fittings and, although we were not staying overnight, the illumination seems sufficient for reading. Advice from a friend is to use warm white as the closest to current lighting. However, it is only a matter of getting used to cool white.
I've now ordered LEDs for the remaining lights. I could have ordered complete units to replace the oldest light fittings but they seemed expensive. Screwfix no longer offer the units I previously bought and buying units with a G4 bulb seemed wasteful. However, searching the internet, buying new units fitted with G4 bulbs and removing these to fit LEDs saved about £5 a unit. As I need 5 units that saves £25 in what is an expensive upgraded.
The next problem is fitting the new units. The holes cut in the deck head are too big. I fitted the previous ones by cutting a wooden ring using 2 blades fitted to a hole cutter. As they were to fit in what had previously been cut with the large hole saw blade, they were a very loose fit and a fiddle to fix in place. I have a couple of weeks to think up a better solution as I plan to replace the oldest units while cruising over the Easter fortnight. Fitting the LEDs in the existing newer units is a couple of minutes per unit and will be done before we set out.