Electrical Connection Maintenance - Lesson Learned

[TucsonJim]

Our 2017 Reflection 297RSTS is wired for 50 amp service. But our house is only wired for 30 amp. So I use a 30 amp to 50 amp adapter to plug our rig in while at home. I also use the 30 to 50 adapter when running off generator power.

This has worked well for may years, but even though I know better, I have been neglectful in maintaining my electrical connections over time. As corrosion builds up, so can resistance. And when you get excessive resistance, you can get heat which can damage electrical connections. This photo shows evidence of excessive heat near the neutral terminal between the shore power cord and the 30 to 50 amp adapter.



In order to prevent this in the future, I'd recommend the followint maintenance:

1. Place a light coating of oxidation guard on the terminals before plugging in, and any time the cord has been exposed to rain.
2. If the terminals show any sign of oxidation, clean them with emery cloth and recoat.
3. I'd recommend you replace an adapter every 2-3 years. It's cheap insurance.
4. If your shore power cord is showing any sign of damage, replace the damaged end before using it again. I replaced mine today, and it was a 20 minute job.

Safety Note: Do not attempt any electrical repairs if you do not specifically know what you're doing and how to test the results. If there is any doubt, contact an electrician or replace the entire cord.

Steps to replace the 50 amp cord end.

1. Turn off all power at the breaker and verify it's off. Unplug from shore power.
2. Cut off the damaged terminal
3. Strip the wiring back in accordance with the instructions provided with the new terminal.
4. Coat the bare wires with oxidation guard, insert into the new terminal, and tighten per instructions.
5. Reassemble the new terminal, and perform a continuity test with the other end of the cord.
6. Coat the plug ends on the cord and the trailer with oxidation guard.
7. Plug in the cord, turn on the breaker, and test to verify connections.







Sources:

50 Amp Terminal
https://www.amazon.com/dp/B07DVZFBPM...roduct_details

30 Amp to 50 Amp Adapter
https://www.amazon.com/dp/B08CGLRRB5...roduct_details

Oxidation Guard
https://www.amazon.com/Gardner-OX-10...s%2C132&sr=8-2

Jim

[howson]

TucsonJim -- I'm sure you'd agree that the same maintenance applies to maintaining the electrical connections on the 7-way. Keep those connections clean and shiny!

[TucsonJim]

howson

Excellent point Howard. If it plugs in, clean and protect it!

[Jomani]

TucsonJim
Very clean install - obviously you’ve done that before. Have you considered using ferrules on the wires? I have started using these anytime I terminate stranded wire to a screw terminal that doesn’t fully capture the wire.



I used to service equipment that was manufactured in the Netherlands and found these types of ferrules on all of the terminals that used stranded wire. Note - in the picture above, I just slid the ferrule on a piece of 4 AWG welding cable as an example. The wire is not cut to the correct length and the ferrule is not crimped.

[TucsonJim]

Jomani

What a great idea. I'm going to do that in the future!

Jim

[Cate&Rob]

Jomani

I really like this crimped ferrule idea! I found the box of ferrules shown in your picture, online. Can you advise on the best crimper? I have jaws for my connector crimper that look like they might work but online also shows a 4 sided crimp. Ruikarhop seems to make ferrules but not crimper.

Thanks
Rob

[Country Campers]

TucsonJim

Thanks for the tips, I need to give my adaptors a good looking over.

I would however change the order of #5 from "Reassemble the new terminal, and perform a continuity test with the other end of the cord." to "Perform a continuity test and then reassemble". I would reassemble and then test and then disassemble to fix and reassemble again, haha.

Always good to get reminded of things that we do not think about too often until they go bad or do not work.

Brian

[Scott'n'Wendy]

I use one similar to this by iwiss
https://www.amazon.com/IWISS-End-sle...07LCF39W9?th=1

I use ferrules myself on stranded wire. It doesn't seem that popular in North America, but a lot of my wiring experience was influenced by Finland and ferrules were definitely to be used. So I use them. And once you remove a fine stranded wire from a screw lug connection that didn't use a ferrule, you will see why ferrules are good to use.

[Jomani]

Jomani

I really like this crimped ferrule idea! I found the box of ferrules shown in your picture, online. Can you advise on the best crimper? I have jaws for my connector crimper that look like they might work but online also shows a 4 sided crimp. Ruikarhop seems to make ferrules but not crimper.

Thanks
Rob

There are a bunch of crimpers out there like the one @Scott’n’Wendy posted the link to. I have one similar to that - it only goes down to 6 AWG wire. I use my lug crimper for anything bigger than that. These ferrules are very thin and easy to crimp. Sometimes you have to get creative - the square crimp doesn’t always work.