Blue Sea ACR not combining

Hey guys,

I think I've narrowed down my problem but just wanted some feedback in case I am missing something.

I installed a dual battery system in my 2016 Tacoma back in 2017. Up until tonight I have had absolutely zero issues with it functioning. Here is the system:

Dual AGM group 27F batteries (X2 power)
Blue Sea ACR 7622: https://www.bluesea.com/products/76...rging_Relay_with_Manual_Control_-_12V_DC_500A
100amp breaker between house batt and aux fuse panel
100W solar tied directly to house batt
ZAMP solar charger

Post 238 shows my setup: https://www.tacomaworld.com/threads/off-grid-engineering-dual-battery-system-q-a.468553/page-12

Current accessories are just extra outlets in the bed for charging electronics and my ARB fridge.

The problem is that my ACR is not combining.

Truck off - Main at 12.5V, House at 11V
Truck on - Main at 13.8V, House at 11V (ACR should combine)
Truck on - Main at 13.8V, House at 13.8 after I physically combine the batteries by depressing the ACR
Truck off after physically combining the batteries and the ACR does not isolate them like its supposed to.

I've checked voltages on both sides of the ACR back to the ground so I know the connections are good.

Do these ACRs go bad over time? Any idea why this might be happening? I'll be calling Blue Sea tomorrow but any input is appreciated.

 

Can't answer your question, but jealous of your setup. Did you build your own tray to fit the second 27F? Haven't seen one for sale anywhere that would take a battery that big.

 

Do you have the ACR yellow switch in lockout mode by mistake?
Do you have the interior switch wired to be on "isolate"?

Other than that, I'd imagine there can be an issue where the potential sensing device inside the ACR drifts or fails, causing the conditions you are seeing.

 

Update - called Blue Sea and spoke with a technician. He gave me a couple of documents to help troubleshoot the issue but advised that they would send me a replacement ACR (free of charge) if needed.

One of the first things I wanted to ensure was proper ground of the system so I cleaned the common chassis ground location for the batteries and ACR. Issue not fixed. Next I moved onto checking the battery voltages and saw my house battery oscillating between 9V and 12V pretty quickly. Strange... the only thing that could be effecting the charge was my solar panel. I took the in-line fuse out of the positive lead and the battery voltage stabilized. The fuse had a bit of crud built up on it so I cleaned the prongs. Replaced the fuse and the voltage kept steady. Turned the truck back on and everything works - ACR clicks over and both batteries are at 13.8-14V.

I honestly hate electrical issues as they can be a nightmare to figure out. A lot of it comes down to properly checking the system and making sure connections are good and the voltages look reasonable.

This is the battery tray that I'm using. Kind of pricey but does the job. I also bought the replacement tray for the stock battery location as it holds the ACR. Everything else I did on my own - including making my own cables... but you can buy complete systems from the website if you choose.

https://www.**************/collections/battery-trays/products/toyota-tacoma-auxilary-battery-tray

(not sure why that link is broken but the website is offgridengineering)

ACR switch was in the correct location and I never wired up the interior switch so no issue there.