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08-10-2013, 06:43 AM
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#1
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Senior Member
Workhorse Chassis Owner
Join Date: Oct 2009
Location: On the Road
Posts: 452
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Burned generator wires in transfer switch.
Our Onan 5500 stopped powering the camper yesterday but still ran ok. I opened the transfer switch today and found the neutral and aux wires from the generator badly burned and broken off at the buss bar.
Yikes, thank God we didn't have a fire. The wires look pretty light compared to the shore line wires.
__________________
2003 Itasca Suncruiser 38G
1998 Jeep Cherokee. Ready Brute Elite tow bar and brake. Tow Mate wireless light bar.
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08-10-2013, 11:53 AM
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#2
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Senior Member
Monaco Owners Club
Join Date: Mar 2000
Location: Yuma Arizona USA
Posts: 2,996
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Had you ever checked the tightness of the wire connectors on the transfer switch? This is something we all need to be doing as part of our maintenance checks. Loose connections will cause high current draw and enough heat start a fire.
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Brian, Loretta & Lucy (Golden Retriever)
2008 HR Endeavor 40 PDQ , ISL 400
2010 Dodge Ram 1500 Toad
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08-10-2013, 03:37 PM
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#3
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Senior Member
Workhorse Chassis Owner
Join Date: Oct 2009
Location: On the Road
Posts: 452
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No I never checked that but I should have.
__________________
2003 Itasca Suncruiser 38G
1998 Jeep Cherokee. Ready Brute Elite tow bar and brake. Tow Mate wireless light bar.
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08-10-2013, 03:59 PM
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#4
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Senior Member
Damon Owners Club Workhorse Chassis Owner
Join Date: Mar 2009
Posts: 24,024
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If the wires are too small, that can cause overheat.. But I too suspect a loose screw. That is the #1 cause in these cases.
I am fond of saying that many RVers have a few screws loose.. and those are some of the very screws I'm talking about. (The ones in the breaker box also fit this statement just so you know) Suggestion.
With generator off (Which it will be till you replace the transfer switch) and shore power off (UNPLUGED and plug where you can see it) Tighten all electrical screws.
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Home is where I park it!
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08-10-2013, 04:23 PM
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#5
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Senior Member
Monaco Owners Club
Join Date: Mar 2000
Location: Yuma Arizona USA
Posts: 2,996
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We purchased our coach new but, it had set at the dealer for awhile. I checked all the connections before our first trip and I was able to tighten some of them as much as half a turn.
__________________
Brian, Loretta & Lucy (Golden Retriever)
2008 HR Endeavor 40 PDQ , ISL 400
2010 Dodge Ram 1500 Toad
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08-11-2013, 06:44 PM
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#6
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Senior Member
Workhorse Chassis Owner
Join Date: Oct 2009
Location: On the Road
Posts: 452
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After finding this problem I checked the other connections and found a few that would turn 1/4 turn.
__________________
2003 Itasca Suncruiser 38G
1998 Jeep Cherokee. Ready Brute Elite tow bar and brake. Tow Mate wireless light bar.
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08-11-2013, 06:47 PM
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#7
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Moderator Emeritus
Ford Super Duty Owner
Join Date: Aug 2000
Location: Bryan, TX when not traveling.
Posts: 22,948
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Loose connections will cause the overheating and burning. You should check the tightness of the wiring on a yearly basis.
Ken
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Amateur Radio Operator (KE5DFR)|No Longer Full-Time! - 2023 Cougar 22MLS toted by 2022 F150, 3.5L EcoBoost Tow Max FX4 Lariat Travel with one Standard Schnauzer and one small Timneh African Gray Parrot, retired mechanical engineer
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08-11-2013, 06:49 PM
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#8
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Senior Member
National RV Owners Club Workhorse Chassis Owner Ford Super Duty Owner Carolina Campers
Join Date: Aug 2011
Posts: 2,266
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Quote:
Originally Posted by wa8yxm
If the wires are too small, that can cause overheat.. But I too suspect a loose screw. That is the #1 cause in these cases.
I am fond of saying that many RVers have a few screws loose.. and those are some of the very screws I'm talking about. (The ones in the breaker box also fit this statement just so you know) Suggestion.
With generator off (Which it will be till you replace the transfer switch) and shore power off (UNPLUGED and plug where you can see it) Tighten all electrical screws.
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Don't forget to turn off the inverter too!
__________________
2002 National Dolphin LX 6356
Workhorse W-22 chassis
Don't believe everything you think.
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08-11-2013, 06:59 PM
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#9
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Senior Member
Join Date: Feb 2002
Location: bel air, md
Posts: 822
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My wife started smelling something like a chemical smell this morning and I traced it down to the transfer box. After taking the cover off found the input wires burnt and melted. The bus bar mounting plastic bar was melted and distorted. I checked the bus bar wires and all the screws were very tight. I will have to replace the box. This is the second major problem this week.
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09 Winnie 32 h adventurer towing '18 Malibu
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08-11-2013, 10:18 PM
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#10
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Senior Member
Monaco Owners Club
Join Date: Mar 2000
Location: Yuma Arizona USA
Posts: 2,996
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Quote:
Originally Posted by billyb
My wife started smelling something like a chemical smell this morning and I traced it down to the transfer box. After taking the cover off found the input wires burnt and melted. The bus bar mounting plastic bar was melted and distorted. I checked the bus bar wires and all the screws were very tight. I will have to replace the box. This is the second major problem this week.
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Bummer! Any chance you have the IOTA 50R transfer switch? They have been recalled.
__________________
Brian, Loretta & Lucy (Golden Retriever)
2008 HR Endeavor 40 PDQ , ISL 400
2010 Dodge Ram 1500 Toad
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08-12-2013, 04:23 AM
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#11
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Senior Member
Join Date: Feb 2002
Location: bel air, md
Posts: 822
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Yes that's what it is
__________________
09 Winnie 32 h adventurer towing '18 Malibu
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08-12-2013, 11:17 AM
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#12
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Senior Member
Monaco Owners Club
Join Date: Mar 2000
Location: Yuma Arizona USA
Posts: 2,996
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Do a search on IOTA 50R transfer switch there is tons of information on these things burning up. Not sure if your coach manufacturer was one of the companies who voluntarily recalled the IOTA 50R transfer switch or not. You may want to contact your dealer to see. IOTA filed for bankruptcy and from what I understand whoever is running the company now will not cover the recall. There are several other transfer switches that are recommended as replacements somewhere in the $200 range if you are comfortable changing it out yourself.
__________________
Brian, Loretta & Lucy (Golden Retriever)
2008 HR Endeavor 40 PDQ , ISL 400
2010 Dodge Ram 1500 Toad
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08-13-2013, 06:36 PM
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#13
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Senior Member
Join Date: Feb 2002
Location: bel air, md
Posts: 822
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Got my wfco box today, and it has 8 gauge wires in it rather then the 10 gauge that was in the old box. The 10th gauge is why the old wires were melting.
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09 Winnie 32 h adventurer towing '18 Malibu
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08-13-2013, 07:22 PM
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#14
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Senior Member
Join Date: Mar 2010
Location: Fowlerville, Mich.
Posts: 606
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Besides the xfer switch don't forget to check the 120 volt breaker box connections.
__________________
2000 Monaco Diplomat 40PBD
2012 Grand Cherokee Limited
2008 FatBoy, three spoiled Great Danes and a cat.
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