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Old 04-01-2018, 07:48 AM   #1
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Default Safety hazard in Aktiv and EcoTrek

I think this group will find this interesting too.

Thanks for your help finding regulatory authorities. RVIA should help get these hazards fixed too.
The safety code violations descriptions are in laymen's form so owners can understand the risk.
https://sites.google.com/view/shoot-...afe?authuser=0
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Old 04-01-2018, 12:27 PM   #2
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Seems like you're an unhappy customer.

Did you take it back to the dealer? Did they not fix the issues? Did you report your concerns to the safety organizations?

What do you want the members of this forum to do for you? Or are you just trying to get back at Hymer?
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Old 04-01-2018, 01:32 PM   #3
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I think I would point out that the 18ga grounding wire, useless as it is, is connected to the NEUTRAL buss bar, and not the ground buss bar.

In mobile applications, the "normal" rules would say that neutral/ground bonding like that should only be done at the power source, and you often have 3 different sources in an RV, shore power, generator, and inverter. The should never be more than one bonded location in the circuit at a time.

The shore power is bonded at the power pole, so good that way. The generator is bonded internally in most cases so good. The automatic transfer switch switches between them, so only one at a time like it should be. The tough one is the inverter because you want it bonded when inverting but not bonded when bypassing shore power to the van if it is an iverter/charger. If it is an inverter only, it needs to disconnect the bonded connection from the van when not in use. Good inverter chargers switch between bonded and not bonded with the inverter on and off and take care of the problem.

The system shown, with neutral and ground bonded at the breaker panel is incorrect ALL the time as it adds a bonded connection at a place away from the power source.
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Old 04-01-2018, 01:51 PM   #4
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Quote:
Originally Posted by booster View Post
I think I would point out that the 18ga grounding wire, useless as it is, is connected to the NEUTRAL buss bar, and not the ground buss bar.

In mobile applications, the "normal" rules would say that neutral/ground bonding like that should only be done at the power source, and you often have 3 different sources in an RV, shore power, generator, and inverter. The should never be more than one bonded location in the circuit at a time.

The shore power is bonded at the power pole, so good that way. The generator is bonded internally in most cases so good. The automatic transfer switch switches between them, so only one at a time like it should be. The tough one is the inverter because you want it bonded when inverting but not bonded when bypassing shore power to the van if it is an iverter/charger. If it is an inverter only, it needs to disconnect the bonded connection from the van when not in use. Good inverter chargers switch between bonded and not bonded with the inverter on and off and take care of the problem.

The system shown, with neutral and ground bonded at the breaker panel is incorrect ALL the time as it adds a bonded connection at a place away from the power source.
pretty sure he has an UHG and not an ONAN
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Old 04-01-2018, 02:11 PM   #5
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pretty sure he has an UHG and not an ONAN
In this case that makes no difference, I think, as a generator and shore power do their bonding before the transfer switch, so removing the genny and transfer switch won't do anything odd. The engine generator just works as a 12v source, like a battery, so it also will not affect anything related to the inverter or bonding The issue shown is on the110v side.
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Old 04-01-2018, 02:30 PM   #6
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Quote:
Originally Posted by booster View Post
I think I would point out that the 18ga grounding wire, useless as it is, is connected to the NEUTRAL buss bar, and not the ground buss bar.

In mobile applications, the "normal" rules would say that neutral/ground bonding like that should only be done at the power source, and you often have 3 different sources in an RV, shore power, generator, and inverter. The should never be more than one bonded location in the circuit at a time.

The shore power is bonded at the power pole, so good that way. The generator is bonded internally in most cases so good. The automatic transfer switch switches between them, so only one at a time like it should be. The tough one is the inverter because you want it bonded when inverting but not bonded when bypassing shore power to the van if it is an iverter/charger. If it is an inverter only, it needs to disconnect the bonded connection from the van when not in use. Good inverter chargers switch between bonded and not bonded with the inverter on and off and take care of the problem.

The system shown, with neutral and ground bonded at the breaker panel is incorrect ALL the time as it adds a bonded connection at a place away from the power source.
DIY community often discuss this bonding connection, it is in Magnum manual, so it is a little surprising for manufacturing company is not doing it correctly.
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Old 04-01-2018, 02:47 PM   #7
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Yep, we have a Magnum and that is some of the best information and easiest to understand around. When I went to hook it all up, I checked a lot of places in out Roadtrek to make sure there were no extra bonds. The Magnum is one of the brands that bonds and unbonds based on pass through or inverter on use.
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Old 04-01-2018, 03:52 PM   #8
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Without seeing the complete wiring diagram for the van (which we know Roadtrek will never, ever, provide, it is a bit hard to determine if the way they have, legal or not, is safe.

Many of the lower end inverter/chargers don't bond and unbond, and it appears they make the setup safer by putting the "inverter" outlets in as GFCI outlets. AFAIK, this will make it safe. If Roadtrek has the entire van on GFCI, it likely would be safe, although the wire sizing is still iffy and we don't know if the inverter is bonded, not bonded, or switches. Regardless of how it is the bonding at the box is not correct, IMO.

The whole idea of 110v power in a van is a very tough application to make safe all the time, as you don't have access to earth ground unless on shore power for zero reference.

As a final precaution, when I upgraded our system, I put in GFCI breakers in the main box, so everything is protected. Cheap insurance.
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Old 04-01-2018, 03:56 PM   #9
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We love our Aktiv and want to keep it forever. Unsolicited, Jim Hammill has three times offered to buy it back. It seems he would rather get rid of the customer than fix the problems. We've told the dealer but our Aktiv is built per Hymer and a dealer can't start inventing solutions. I'm reporting to many agencies
but the government safety organizations are not sure which has jurisdiction. Do you know a government official who can investigate. I'm posting so owners will be warned about the hazard. I want Hymer to succeed and these hazards must be addressed for them to succeed.
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Old 04-01-2018, 04:27 PM   #10
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Quote:
Originally Posted by booster View Post
I think I would point out that the 18ga grounding wire, useless as it is, is connected to the NEUTRAL buss bar, and not the ground buss bar.

In mobile applications, the "normal" rules would say that neutral/ground bonding like that should only be done at the power source, and you often have 3 different sources in an RV, shore power, generator, and inverter. The should never be more than one bonded location in the circuit at a time.

The shore power is bonded at the power pole, so good that way. The generator is bonded internally in most cases so good. The automatic transfer switch switches between them, so only one at a time like it should be. The tough one is the inverter because you want it bonded when inverting but not bonded when bypassing shore power to the van if it is an iverter/charger. If it is an inverter only, it needs to disconnect the bonded connection from the van when not in use. Good inverter chargers switch between bonded and not bonded with the inverter on and off and take care of the problem.

The system shown, with neutral and ground bonded at the breaker panel is incorrect ALL the time as it adds a bonded connection at a place away from the power source.
Thanks for the thoughtful response. I've opened the Inverter. The 18 guage wire is connected to the ground return to the campsite. It is the only wire connected to that return. Internal to the inverter, another 18 gauge wire is connected to the inverter's output to the breaker box. That 18 gauge wire is the breaker boxes only connection back to the campsite's shore power.

I agree that one one bonding location is best. Code also says it should be as near to the source as possible. In the Aktiv the inverter is the source of all 115 VAC so that could be the bonding location. I included pictures of the two "bonding pointsf" in the Inverter, both painted.

I'm OK if Hymer wants the breaker panel to be bond point but they first ran the 30 amp service shore power bond though an 18 gauge wire in the inverter. I'm also not happy that the 30 amp shore power only goes to the inverter that doesn't have a main switch or circuit breaker. Isn't a main switch a code requirement?
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