Thinking aloud.....
Moving the caravan today, the mover showed it had a bit of an issue, so now I am trying to diagnose it 'at a distance' from the obvious symptoms, before delving in...
It is run from the 12v leisure battery, via wireless remote control. It drives the tyres via rollers, driven by two heavy duty motors, one to each tyre, which have to be manually engaged, against the tyres. It's not a soft start, rather the 2 motors are powered by 4x Omron relays, two forward, two back. A 5th HD relay, is the master relay, which powers the entire system. The master relay is turned on via a power button, on the remote. On pressing the power button, you hear the master relay click on, then it goes through a rapid sequence of testing the other 4 relays operate, and none of them are suffering welded contacts, or it shuts back down and shows a fault condition.
Now for the problem - After pressing the power button, I hear the diagnostic sequence, then sometimes all works as it should. Other times, the master relay reopens, then closes and runs the diagnostics again, then a random few seconds later - again, and so on repeating. I don't need to touch the power button, for it to do this. When it reacts like this, if I try to drive it, it drives stop start. When it doesn't do it, it drives absolutely fine.
The behaviour is similar, whether the rollers are engaged to the tyres (under load) or not.
It's not a wireless remote problem, because if I go out of range, it just switches off the drive relays. Leisure battery shows 13v, and not much less when powering the motors. Remote has a new good PP3.
I'm thinking to get the PCB out, and on the bench, powered with 12v, then check that master relay's coil is getting close to 12v, and the relay coil is good. I don't have a circuit for it. Has anyone got any other suggestions for this intermittent behaviour?
Moving the caravan today, the mover showed it had a bit of an issue, so now I am trying to diagnose it 'at a distance' from the obvious symptoms, before delving in...
It is run from the 12v leisure battery, via wireless remote control. It drives the tyres via rollers, driven by two heavy duty motors, one to each tyre, which have to be manually engaged, against the tyres. It's not a soft start, rather the 2 motors are powered by 4x Omron relays, two forward, two back. A 5th HD relay, is the master relay, which powers the entire system. The master relay is turned on via a power button, on the remote. On pressing the power button, you hear the master relay click on, then it goes through a rapid sequence of testing the other 4 relays operate, and none of them are suffering welded contacts, or it shuts back down and shows a fault condition.
Now for the problem - After pressing the power button, I hear the diagnostic sequence, then sometimes all works as it should. Other times, the master relay reopens, then closes and runs the diagnostics again, then a random few seconds later - again, and so on repeating. I don't need to touch the power button, for it to do this. When it reacts like this, if I try to drive it, it drives stop start. When it doesn't do it, it drives absolutely fine.
The behaviour is similar, whether the rollers are engaged to the tyres (under load) or not.
It's not a wireless remote problem, because if I go out of range, it just switches off the drive relays. Leisure battery shows 13v, and not much less when powering the motors. Remote has a new good PP3.
I'm thinking to get the PCB out, and on the bench, powered with 12v, then check that master relay's coil is getting close to 12v, and the relay coil is good. I don't have a circuit for it. Has anyone got any other suggestions for this intermittent behaviour?