Category Archives: battery

Here Comes The Sun

As I get ready for a long trip, I am trying to address one of the issues that Interstates like mine have – which is weak electrical systems for camping in spots without hookup aka as boondocking. It is a problem I knew about and frankly, don’t anticipate long stints in non-electric situations. However, many state parks and federal sites are definitely non-utility.

The problem comes primarily from the refrigerator, which is electric only. Most trailers have a dual-option system where you can run on just propane but the wizards at Airstream decided, probably for venting issues, to opt for an electric-only. I can hear the design team: “They have an onboard generator, no problem.”

I had a small solar panel that we logged with the Safari trailer and decided to use that if I could. There’s really no room on the roof for panels without a lot of time and expense so I studied things a bit and to use a pun, a light bulb went off. I had two new deep cycle batteries – about 150 amp-hours total – which was less capacity than I wanted. They also had a vent tube going out to the side of the van. Voila! I could used AGM batteries, which require no venting, and run the line from the solar panel in through the vent. Of course, it sounded easier than it was.

I bought two 6 volt Lifeline golf cart batteries which fit into the limited space, connected them to get 12 volts and 220 amp-hours. Here’s a shot of the rabbit’s warren of wires – I’ve got a little finishing work to do.

My brother Barry suggest that I use a quick disconnect plug like he has used – and ordered me one. I bought the charge controller for the solar panel (to avoid overcharging the batteries) and some wire and fittings. Of course, the ground to the battery box snapped off when I tried to use it and I must of dropped some of the small screws for the disconnect several dozen times. The finished project looks pretty good.

I got everything ready, plugged in the panel, and we had liftoff. It’s not a big solar gain, probably 4 amps in full sunlight, but it will help nicely.

I have a good place to stow the panel inside the van so we’ll see how things go. The van has its own battery for the engine but while travelling, I should get some charging of the house batteries. I’ll test this out over the next few months and see if I need more capacity. For now, it was a relatively inexpensive do-it-yourself project (with technical assistance from my brother) that seems to be a good start to energy independence. Nothing like seeing that panel just sit there and quietly crank. Stay tuned.

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.

Getting Ready For Winter Traveling

With the exterior polishing project shut down due to my knee operation, there’s been a hiatus of sorts on Airstream work until the last few weeks, when I started to get serious about readying the rig for our upcoming trip.  Last week, with cold weather forecast, I drained the water system and winterized it with RV anti-freeze.  There is a sequence of isolating and draining the hot water tank, switching a valve so that the water pump pulls from a gallon jug, and then the pumping until pink liquid comes out the fixture.  I think everything is set — we will find out in late December when we hit warmer weather and get the water running (and hopefully not spraying through cracked pipes or joints) again.

In spite of only getting about 1/2 of the polishing process, the old girl looks ok. I'll bring the polishing gear and perhaps work on it in the SW -- otherwise next summer.

In spite of only getting about 1/2 of the polishing process, the old girl looks ok. I’ll bring the polishing gear and perhaps work on it in the SW — otherwise next summer.

Last trip, I built some shelving for the shower — which we seldom  use — and we found it handy for storing clean and dirty laundry.  This trip, we decided we might want to use the shower (rather than always relying on public facilities) so out the carefully-built wood came and I stored it overhead in the garage in case we change our mind after this jaunt.

I ordered a new latch, and a new air-relief valve for the shower from Out-of-Doors Mart, a fine mail order place for Airstream gear, and after those little tasks were done, I tackled some of the safety systems.

Checking fire extinguishers, smoke alarms, and LP detectors, I found that our aged LP unit was intermittent.  It was also too close to the door so I bought a new one and installed it in a better place — after quite a time finding 12v lines available to extend.  Now we need to look at CO monitors and buy a new smoke alarm.  (A lot of the gear is original which means it is 14 years old.)

LPDetectorW

We stopped using the gas furnace system several years ago because the electric blower was a real energy hog and drained the battery quite fast.  We installed a catalytic heater to take its place and it works quite well.  However, as we found in 2012, the first few nights in Walmart lots can be pretty cold — so I decided to see if we could resurrect the old furnace.

I’ve had really good success getting repair work done at Mekkelsen RV, a local dealer who seldom services an Airstream.  Systems are systems though and they are pros so next week, off we go to get furnace work done.  I also thought, “You know, I don’t want to be driving in West Texas thinking, ‘I wonder if I should have gotten those bearings greased?’ so that’s on the list as well.  They tuned up the rest of the gas system this spring so with this, we should be all set.

The game plan is to move the ‘stream to Merrimac, MA at Thanksgiving and launch from there right after Christmas.  Stay tuned, it’s always an adventure.

Portable Solar


After a lot of discussion with Airstream owners, we decided not to mount the solar panel on the unit but rather, set it up manually so as to better capture the sun’s rays. So far, so good.

Installing the controller involved disconnecting and removing the refrigerator (to be able to snake wires alongside it) and cutting an opening in the wall. Everything went well until I went to close the cupboard over the refrigerator, and the arm hit the controller unit. Too late to move things so I moved the arm to the other side of the door.

I put on a quick disconnect near the hitch and ran enough wire to be able to move the unit around to either side of the trailer. When I first tried everything, I got nothing, even though the controller was reading battery voltage. After reading the instructions again (what a concept!), I realized that the leads to the solar panel were on the wrong contacts — a quick switch and we were in business.

It’s a great feeling to see that controller registering 4 amps of current or so in full sun. It’s almost easy to feel smug — sort of “take that, power company” feeling. The unit topped off the battery, shut down, and came on periodically as I used a little power for things.

The setting, with trees and intermittent clouds (as you can see in the photo), was not ideal but it was a great start to getting more independent energy-wise.

Off To Massachusetts

Having worked some on installing the solar controller and wiring up the solar panel, I tested it yesterday and it was great to see the meter registering 3 to 4 amps as the sun came out from behind the clouds. For now, I’m planning to use the panel up against a sawhorse, positioned to catch the sun — and not mount it on the roof. Several friends (and my brother) set it up that way and like the versatility.

We packed up and headed out today — still winterized — to visit our daughter and family in Merrimac, MA. We’ve set up a nice little parking area off their long driveway so Penny (the Vizsla) and I boondock out there. It saves a lot of hassle since Jen has an old cat and Penny is terrible with felines.

The trip down was uneventful — aside from the fact that our running lights still do not work. It was rainy and foggy the first hour and while not dark enough to require lights — they would have helped from a safety factor. Next week’s project.

The site here, as you can see in the photo, is pretty wooded so the use of solar is going to be iffy. Right now, the leaves are not out so there’s hope — but the forecast is for rain. I’m on a limited electrical budget and monitoring the battery with the new controller. I ran the old furnace with the blower for just a bit and saw an immediate drain. Fortunately, the catalytic heater is cranking and should take the chill off. Penny plants herself about a foot from it.

Being further south, the birds are more plentiful and active. On a walk with the dog just before dark, I saw about a dozen or more species including a lovely pileated woodpecker. Hope to do some serious birding tomorrow or Saturday at Plum Island.

The Ongoing Saga

I somehow got both the furnace and the refrigerator running — and just in time for heat as the weather turned even colder. I’m still not sure what the problem was — I removed the exhaust system and banged on some things, wiggled some electrical leads, and probably for other reasons, the heating system kicked in and stayed lit — operating normally.

So it’s been comfortable in the Airstream. Last night, as I returned from the house, I found that the lights were dim and the blower was laboring. Dying battery! I guess it’s not surprising given the draw of the blower motor. (I’m planning to have at least one more battery for boondocking — so this confirms that plan.)

It was late so I nosed the truck in toward the trailer, hitched up some jumper cables, and got juice flowing so that the heating system and lights worked.

You can guess the rest of the story: this morning, the truck battery was too low to turn the engine over! Fortunately, a quick jump start from my daughter’s Jetta got the Ford going, and we’ve got the trailer battery on a charger. We’ll be all set and have new impetus to set up a better system for future boondocking.