Category Archives: Electrical System

All Inspected and Ready to Go

The state inspection on the Airstream ran out in August but I decided to wait until September in order to gain a couple of months on the sticker — and then got busy and it slid to October. I don’t know if police check trailer stickers but my mechanic friend says that he’s seen inspectors wander around gatherings of trailers at a county fair looking for outdated rigs — so even though I really only need it for a day next January when we head out of the state, I decided to schedule the inspection at a local RV dealer that I like, M’s RV in Berlin, VT. It’s a mom and pop operation but the owners are very knowledgeable and they’ve helped me with several problems: every time I go there I learn something.

The co-owner Marcel gives me heat for owning an Airstream – alluding to the “glamping” aspect of Airstream owners – knowing all along that our rig is modest and priced less than many of the trailers and fifth-wheelers he has for sale on the lot. Plus, I found out that he is quietly restoring an old Airstream Caravel in his work space.

Last week, I took the ten mile drive down through Montpelier, outdated sticker and all, and we got started on the  inspection. Lights good, tires etc fine, but when we tested the brake controller, I got a “disconnected” signal. We tried and tried but nada. I explained that I had changed the 7-pin plug a while ago after problems and during our last trip, had a couple of “trailer disconnected” signals after a tight turn or a sharp bump. Everything seemed to work fine all the way home and since then – but we talked about how tough it is to connect each thick wire to the screws in the plug and how prone to coming loose they seem to be. We decided to try a better setup.

It's not easy connecting 18 year-old wires to screws in a replacement plug.

It’s not easy connecting 18 year-old wires to screws in a replacement plug.

Joanne, spouse and co-owner, took me into their parts department and showed me the setup that Marcel could install to fix the problem. (I could do it but it seemed smart to let a pro handle it.) It involves using a new plug already molded into a long lead and a junction box to hold all the wires, getting away from the “rat’s nest” of wires in the plug. I left the rig and while they had a lot of winterization of trailers to do (It got down into the 20’s this weekend), they called the other day to say that it was ready to go.

The molded plug comes with a long cord whose wires are connected in a terminal box.

The molded plug comes with a long cord whose wires are connected in a terminal box.

I wish I could say that I did this wiring but after seeing the quality, am glad that I left it to Marcel.

I wish I could say that I did this wiring but after seeing the quality, am glad that I left it to Marcel.

So I don't mind if he slapped a sticker on the waterproof cover.

So I don’t mind if he slapped a sticker on the waterproof cover.

Yesterday everything checked out great, Joanne slapped on a new inspection sticker, I paid the bill and was on the way. But first, Marcel gave me a lesson in using the brake controller to change settings as we travelled.

Wouldn’t you know, I went by three police cars waiting beside the road in the first three miles back to Montpelier. While no one seemed interested, it was nice to know that the Airstream was legal. More importantly, it was nice to know that the trailer brake system is working as it should as we face an 8,000 mile trip with some challenging climbs and descents. (Mendon Mountain, you’ll be the first.)

New Battery System

As I noted last week, I have been looking at options to strengthen our electrical system for those times where we are not hooked up. I decided to install two AGM batteries and a new controller under our couch which would double our capacity and also give us room for further expansion.

So I went down to my friends at Vintage Trailer Supply and talked to them about converters. Steve, the owner, thought that my existing converter would probably work ok but I opted to buy a new INTEL-POWER 9200 which “monitors the battery voltage then automatically adjusts the converter output voltage to provide the proper charging voltage for fast recharge and long-term maintenance.”

I felt that the expensive AGM batteries needed a state-of-the-art converter.

I felt that the expensive AGM batteries needed a state-of-the-art converter.

I had pretty much narrowed my battery choices down to 105 AH units from Fullriver or Lifeline which sell for over $300 per unit. I went with Lifeline because they are American-made and I got a good price from Powerstride Battery who got them here in four days with free shipping.

The installation of the converter was relatively smooth with just two leads to change – but of course it wasn’t that easy – the grounding wire was almost too short because it attaches on the far end of the unit. I got it going and soon was testing it on my existing battery, which it brought up to full charge over a day or so.

The major project while I awaited the new batteries was to move all the wires into the trailer. First, from inside the trailer, I labeled all the wires since some stay as is (the solar lines) and others (the wire for the tongue jack) have to be extended to come inside.

I reluctantly the terminal clamps off (the new units don’t use posts) and used my torch and solder to attach two new leads. Since I did it outside right near the tongue, I disconnected and moved the two propane tanks far away. I pulled all the lines inside, brought my old battery inside, and hooked it up to test the new setup. I got it done on a sunny day just before a front brought an all-day rainstorm.

Testing out the new wiring with my old battery. The container will be under the couch - it's there for spacing. We are sacrificing the middle storage unit for the batteries.

Testing out the new wiring with my old battery. The container will be under the couch – it’s there for spacing. We are sacrificing the middle storage unit for the batteries.

The Lifeline batteries came UPS yesterday afternoon and soon I was moving them into place. They have a 6mm terminal and a positive 8mm one. I knew that but it turned into a hassle as all my positive fittings had holes that were too small. I reamed and drilled out a couple, with some colorful language but I wired them up in parallel and while several leads are too long, the system seems to be in good shape. The converter started polishing off their charge right away.

The two Lifelines in parallel with a wiring setup that could use some cleanup - although no one will see it under the couch.

The two Lifelines in parallel with a wiring setup that could use some cleanup – although no one will see it under the couch.

I need to build a containment system around the batteries to keep them from moving. I have the materials and then it’s just moving the couch back, fastening it down, and cleaning it up. I think that this is going to be a good project to give us more flexibility in camping sites – and it is nice to have it done.

Electrical System Issues

We seldom spend much time “boondocking” with the Airstream and one reason is that we just have one battery. Over the years, we have taken some steps to improve our sustainability: we carry an 80w solar panel and have a small Honda generator, which we use mainly in the Northeast where trees and cloud cover often make solar problematic. Since the propane furnace is such an energy hog, I installed a catalytic heater which Penny certainly enjoys, since it is at her end of the trailer. I have also switched out most of our lights to LEDs and fixed a battery-draining function in our new refrigerator.

One of the reasons I have not moved ahead is that our battery area, on the tongue of the unit, only has room for a Type 27 battery. We’ve used Costco deep cell batteries which are reasonable but we only have room for one without major work to the frame and added tongue weight. So I have been looking at putting one or more batteries inside the Airstream so it requires pricey AGM units and a new controller — to replace the single-stage one that is now nearly old enough to vote.

So, the project began with exploration: removing the couch to get a better look at the electrical system.

It helps to have long arms when crawling under the couch to remove screws.

It helps to have long arms when crawling under the couch to remove screws.

These came out hard - it's time for stainless steel replacements.

These came out hard – it’s time for stainless steel replacements.

Once the couch was pulled out, the jumble of wires, insulation, and mouse droppings made cleanup task number one. Task two was to open it up more and try to figure out which wires were the ones I might need to move.

Lots of wires there - wonder where they all go?

Lots of wires there – wonder where they all go?

A closer look allowed me to identify the major wires to the battery.

A closer look allowed me to identify the major wires to the battery.

One of the issues to deal with if I’m planning to install new sealed (expensive) batteries is to upgrade the converter to a multi-stage unit which will charge but later on, float to keep from cooking the batteries.

This converter which takes 110 v and changes it to 12 v has had a good run. Should be easy to replace.

This converter which takes 110 v and changes it to 12 v has had a good run. Should be easy to replace.

The next steps: first go down to Vintage Trailer Supply and talk to them about a new converter — and probably buy a 60 amp unit.  I also need to get some replacement battery connectors because I’ll remove the existing ones in order to snake the two battery lines into the Airstream. I’ll also pull in the lines for the solar controller and the tongue jack.

I plan to replace the converter and temporarily install my battery inside and test out the charging system through the new converter and then the solar setup.

Then I will finish my research on AGM batteries and take a deep breath and order a couple. They are costly but should be good for some time and also provide the staying power we need while camping away from hookups. Stay tuned.