westy black box charger not working

[16vmini]

whats this part doing / does ? (circled in red ) .. basically the charger is getting 240v , through fuse and into this component... i then dont get any voltage on the other side (other leg) so there is no voltage going to the coil.

is this component blown ? or am i missing something ? ( this charger has two coils as it charges the 2nd battery in my camper as well )

any help fixing would be ace



cheers
Matt

[16vmini]

email from my friend

Hi Matt

From your description and the photo it sounds as though this mystery component is wired in series with the fuse before it gets to the transformer.

Presumably the “neutral” side of the mains supply is connected to the other end of the transformed primary coil.

If this is the case, then I strongly suspect that it is a thermal fuse.

Is the text you’ve put on the screen shot in red what is written on the item itself ? If so, then its definitely a thermal fuse.

They do sometimes die of old age without actually having detected a “real” fault – as they can’t be reset then the thing to do would be to short it out in the first instance so you can charge the car again.

They aren’t expensive to replace – Maplin do some which are 240v 10 amp rated which are under a quid each. Stock code RA15R is 128 degrees which is near enough, the temperatures aren’t that accurate really, anyway !

http://www.maplin.co.uk/thermal-fuses-470" onclick="window.open(this.href);return false;

Hope this helps

Cheers

Pete F.

[16vmini]

yep just bridged thermo fuse and its all working .. will order some replacements up

regards

Matt

[California Dreamin]

Rather than a 'fuse' this looks like a thermal 'cut out' to offer protection from over heating. As users of Westfalia's can testify, these get pretty warm in operation.

Same result tho...needs changing.

As a side note...I am very tempted to retrofit a 92 or even a 120mm fan in the lid somehow to lower mines operating temp.
low speed quiet fan.....running off the 12- 15 volt output.
Martin

[AdrianC]

Lob it. Gain space and a more intelligent charger.

[16vmini]

Lob it. Gain space and a more intelligent charger.

was an option , but for 99p vs £££ .. those pounds can go towards a weekend away now...

Matt

[Ralf85]

On an associated point, is there a switch anywhere to turn the charger off if you want to? And what is a better option than the standard westie black box?

Patrick

[California Dreamin]

The main drawbacks with the Westy BBB charger are: size/relatively low power output/heat & their inability to 'switch to float charge' which means you shouldn't leave it plugged in for very long periods as they can 'boil the battery dry'.

This is not to say that they don't do a reasonable job, just that technology has improved and better units are available that can be left permenantly turned on.

There are also alternative 'methods' of charging but at a cost.

If you are just taking about a replacement, look at leisure chargers from Amperor/sterling/Numax.....8 amps or higher.
Remember that the BBB had two outputs (charges the starter as well as the leisure batteries)
To be honest, if you carry out the well documented interior light/radio mod (see on Wiki) there there will be no need to have the starter battery being charged as there shouldn't be anything using starter battery power.
Therefore, a single output type charger would be fine supplying just the leisure battery.
If you want to charge both then there are ways and means (again look on Wiki for a Sterling system that was modded with relays to charge both batteries).
Having said this; I reckon it would be just as easy and cheaper to fit two charges... (something like the low powered Ctek clone that often comes up for sale at Lidl for £14.99) This would be ideal for the starter battery.
And
A higher powered unit (maybe the Numax Connect and forget 10amp...about £59.00) to take care of the leisure side.
Total price £75.00 and both batteries being charged seperately and smartly with no worries about over charging.
http://www.tayna.co.uk/Numax-Leisure-Ba ... P6127.html" onclick="window.open(this.href);return false;
Martin

[Ralf85]

That is a really useful bit of info. Thank you for that.

Patrick

[16vmini]

when i have some spare money i will replace , for now the 99p thermal fuse seems to be working that arrived today...

good info though...

Matt

[DaveyP2004]

Hi,
Just in case you need it in the future there is a full circuit (see last page of linked document) and wiring diagram for the Westfalia BBB here:

http://www.westfaliat3.info/WestfaliaBa ... erLG20.pdf" onclick="window.open(this.href);return false;

It does show the thermal fuse but doesnt give any more info than you already have ie: 130 degrees.
Cheers,
Dave
(http://www.vwT25camper.info" onclick="window.open(this.href);return false;)

[16vmini]

Hi,
Just in case you need it in the future there is a full circuit and wiring diagram for the Westfalia BBB here:

http://www.westfaliat3.info/WestfaliaBa ... erLG20.pdf" onclick="window.open(this.href);return false;

It does show the thermal fuse but doesnt give any more info than you already have ie: 130 degrees.
Cheers,
Dave
(http://www.vwT25camper.info" onclick="window.open(this.href);return false;)

why did i not even look on that site .. did a search on google thats it ....cheers

Matt

[JerseyMike]

Thermal cut out. Breaks the circuit at temperature.

Replace it or remove the unit and get some shiny new stuff.

http://www.ctek.nu/gb/en/chargers/rvs" onclick="window.open(this.href);return false;

[16vmini]

Thermal cut out. Breaks the circuit at temperature.

Replace it or remove the unit and get some shiny new stuff.

http://www.ctek.nu/gb/en/chargers/rvs" onclick="window.open(this.href);return false;

i have some other ideas ... but thats later on in the year

<Matt

[mioba]

This is a Great Post. I have exactly the same problem. I was on the verge of replacing my BBB until I read this. I had even tested with a multimeter and found the same. I never had an I incling to change the thermo fuse - that just me being a numpty with electrics.
I guess this is a real big reason the BBBs fail and people don't realize it is this little part.
I will replace this part once I source it here in Munich.
Thanks for the great tip really appreciated.
Rock on!