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Old 03-27-2016, 02:17 PM   #1
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Location: Santee, CA
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TS / Power Problems

Hello All,

Last August I posted a thread about a battery draining issue and added a post about having no power from our genset:

Troubleshooting Chassis Battery Drain Questions

Finally got around to looking at the problem and we're lucky to have a motorhome still!

So, what we have in the coach is the Todd TS50 TS with the respective cables from the generator and a shore power reel.

When I pulled the cover off the TS this what I saw:



And:





Note the "slightly" cooked neutral on the neutral relay and the bared and corroded conductor on the hot relay. The shore conductor was bared for about an inch in the middle of the conductor and is the black leg off the shore power.

Obviously I need to do a little repair work. I'd like to add a surge protector in front of a new TS and have done a little searching on the forum for what folks are using, but any quick recommendations are welcome! One thing I would like is a TS with more room to work in...

One thing has me curious about my existing setup -- the incoming conductors from the genset and the shore reel are #6AWG and are wire nutted to #10AWG conductors which then go to the relays. Now I'm not an EE, but in my limited experience working with power, downsizing conductors usually isn't a good thing. Is it typical to downsize in the TS?

Thanks in advance!
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Old 03-28-2016, 01:30 PM   #2
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Join Date: May 2005
Location: Santee, CA
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Hmm, can't seem to edit my own post...

Anyway, in doing some research it appears the #10AWG conductors are normal -- I had thought someone had 'jury rigged' the connections, but apparently not.

I also spoke with one of our EEs (my wife is one of the owners of a MEPT engineering firm -- I'm the 'T' guy...) -- he says #10 with 90 degree insulation is rated to 40A in a free air environment (not in conduit). I suppose we'll be ok...

I ordered the Lyght LPT50BRD transfer switch to replace the Todd TS and also a Progressive Industries EMS-HW50C surge protector and will install it before the TS with the remote display located in the systems bay.

Hope this info helps somebody down the road.
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Old 03-28-2016, 03:36 PM   #3
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Good choices on both the Lyght and Progressive products--have had both in my 03 for years now and think highly of both. While you are digging around on electrical, there is/should be an electrical junction box on the ceiling of the generator area [connects the cable from the genset to the one leading to the x-fer switch]. WRV was known to have used undersized wire nuts in that junction box and over the years, owners have reported near fires as a result of loose connections......
PS--believe the BRD model TS you ordered has the DC contactors [Vs AC current]--supposed to be much quieter, both now and later
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Old 03-28-2016, 04:39 PM   #4
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Quote:
Originally Posted by Old Scout View Post
Good choices on both the Lyght and Progressive products--have had both in my 03 for years now and think highly of both. While you are digging around on electrical, there is/should be an electrical junction box on the ceiling of the generator area [connects the cable from the genset to the one leading to the x-fer switch]. WRV was known to have used undersized wire nuts in that junction box and over the years, owners have reported near fires as a result of loose connections......
PS--believe the BRD model TS you ordered has the DC contactors [Vs AC current]--supposed to be much quieter, both now and later
Thanks. I'll take a look while I'm in there...
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