Tag Archives: safari-condo

Dining Table Reinforcement

The stock dining table on my 2023 Safari Condo (SC) Alto F1743 was coming unmoored from the base. I tightened the screws a couple of times but they just loosened back up and a couple were stripped. I also discovered the pedestal flange was cracked at one of the screws.

I did a quick search for this pedestal flange at Camping World hoping to find something local but didn’t. There were many possibilities on Amazon and this one seemed like a direct replacement. It does look identical– thin aluminum with chrome plating. And just as likely to crack, so good that it came with two pieces so I have a spare. But the hole pattern is slightly different as shown below. It isn’t that SC just drilled the holes slightly wrong– when the old and new parts are placed back-to-back the difference is obvious.

Slightly different hole pattern

I wasn’t sure what the material of this base board was until I began drilling into it. Some theories were an outer veneer around particle board or high density foam. But I think it’s actually plywood with a veneer. I’m not a fan of using wood screws to fasten the pedestal flange to any of these materials given how much force it sees when sliding that table back and forth or bouncing down the highway. My original thought was to use through-bolts but that would require counter-sinking on the bottom to recess the bolt head so the base board will still slide along the floor.

A helpful Altoiste recommended using T nuts. Brilliant. I wasn’t sure if they would recess enough to allow the base board to still slide but gave it a try. They work beautifully. The aluminum bracket on which the base slides is slightly thicker than the exposed edge of the T nut, so it still slides.

T nuts protruding on the bottom

I used M5 T nuts and M5-0.8 16mm stainless steel flat head socket cap machine screws. The holes in the pedestal flange have a counter-sink taper. I think the taper in the screw head better matches the pedestal flange than the round-head screws with no taper that SC used and may be less likely to crack it. A 16mm screw length uses all of the threads of the T nut without protruding past the edge. To install the T nuts I used a long M5 bolt through a piece of scrap aluminum and tightened the nut until it was pulled tight against the base board. Note the picture below shows a 12mm screw length, before I switched to 16mm.

Machine screw and T nuts

The trim around the edges of the base board is offset so the original bottom was flush with the board and the top had some trim overhang. I figured this must have been intentional so mounted the pedestal flange on the same side. I now think it probably doesn’t matter. Because the hole pattern was slightly off I couldn’t just drill out the the existing holes so I used the new pedestal flange as a template. I drilled out one existing hole and secured the flange with screw and T nut, then drilled the remaining holes through the flange. I thought I might destroy the flange in the process so was happy to have a spare, but it survived. It might have been a better idea to simply rotate the pedestal flange and drill entirely new holes, but this worked.

In the final assembly I added blue thread locker to the machine screws. I also considered adding adhesive between the base board and pedestal flange. SC had used some sort of silicon adhesive but I don’t think it really adhered– I had no trouble separating the two parts. I decided against adhesive. I don’t think the combination of T nuts and machine screws with thread locker will be coming loose any time soon and I don’t want to make things harder if I ever need to revisit this. I think the weak point now is the pedestal flange itself.

When I initially disassembled the table I had a hard time separating the table leg from the bottom pedestal flange. I ended up unscrewing the flange and banging it off with a rubber mallet. I don’t know if it will help but I added a tiny bit of ant-seize compound to both the bottom and top of the table leg. We never convert the table into a bed so not a big deal for us if it seizes again.

For now the table is as solid as ever.

Flippin’ Shades

Today I flipped the shades on the Big Front Window (BFW) so that the blackout shade is on bottom and the bug screen is on top. I did this to improve airflow between the shades and the window in an attempt to avoid excessive heat buildup that could warp the window, apparently a thing with the BFW. The idea is to set the shades for 80% blackout on bottom and 20% bug screen on top and use convection (hot air rises) to vent heat buildup out the bug screen on top, pulling in cooler air at the bottom to replace it (crack open the BFW). Then aid the process by pulling out the hot air with the trailer’s roof fan. This helps keep the interior of the trailer cooler without cooking the window in extreme conditions. The orientation has the added advantages of somewhat increased privacy when partially deploying the blackout shade and putting the heavier blackout shade on the bottom where the wall is more vertical, reducing the tendency for the shade to sag.

Flipped, in convection mode

All of the shades in earlier Altos were oriented this way but sometime before my 2023 F1743 was built, Safari Condo (SC) began flipping them on all of their trailers. SC confirmed that Horrex is the manufacturer of my shades. The Horrex manual clearly states that the blackout shade should be on the bottom. SC told me the orientation is personal preference and that they flipped them for convenience. That doesn’t make a lot of sense to me considering the guidance from the manufacturer and the considerations listed above, but OK. Easy enough to flip them back.

And it was pretty easy. I was initially unsure whether the curvature in the frame is symmetrical but it clearly is. This means I could flip the entire assembly, frame and all, vs. swapping the cartridges that hold the blinds. It took me about an hour to do this job solo. A second person might have helped or more likely would have just been in the way. Judicious placement of seat cushions and pillows doubled for a second set of hands. Here are the steps:

  1. Remove the front table
  2. Pop off the four plastic covers at each corner of the frame by pulling them from behind
  3. Prop the bottom of the frame with cushions and pillows to keep it from flopping down when screws are removed. The top of the frame is held in place by two brackets so it stays put without the screws.
  4. Remove the two sheet metal screws at each corner that secure the frame to the wall of the trailer.
  5. Carefully slide the whole frame up slightly to detach the top frame from the brackets. The clearance between the frame and the light switch assembly is tight, I had to “bend” the switch assembly slightly to free the frame. There is enough natural play in that assembly, nothing was bent permanently.
  6. Carefully rotate the whole blind assembly 180 degrees. The frame is fairly solid when detached from the wall but can’t withstand too much sideways force.
  7. Hang the top of the frame on the brackets, again “bending” the light assembly slightly. Prop up the bottom of the frame with cushions and pillows to hold it to the wall of the trailer.
  8. Re-attach the two sheet metal screws at each corner. As with every other sheet metal screw in this trailer, be careful to avoid stripping it while tightening. So.many.sheet.metal.screws :(.
  9. Replace the plastic covers at each corner. The trick is to slide the pointy part of the cover over the inner corner of the frame first, then push it on the rest of the way from the outer part of the frame.
  10. Reverse the plastic clip that joins the two shades
  11. Behold the now upside-down and out-of-sight warning label
Two sheet metal screws at each corner
Tight clearance
Prop bottom with cushions and pillows
Removed, ready to rotate
Bracket, one of two
Brackets

If I had stripped one of the sheet metal screws in this process I would have replaced them all with rivet nuts and stainless steel machine screws. If I had the rivet nuts on hand I would have done this proactively, but I was impatient.

Rather than “crack open” the window using the built-in detents on the left and right latches, it has been suggested more airflow is needed, maybe a 1/2″ to 3/4″ gap. It’s difficult to measure but using the detents, the gap between window and seal seems slightly less than 1/2″. A fellow Altoiste pioneered some blocks that will hold the window out further. These would be simple to create and could potentially hold the window more securely: Three attachment points instead of two, at the bottom of the window instead of the sides, and more difficult to break in from the outside. Here’s a post showing his design https://www.facebook.com/groups/Altoistes/permalink/1204161736285064. And another where STL files were uploaded that can be used to 3D print the spacer blocks. https://www.facebook.com/groups/Altoistes/permalink/24523360507271858

Now I need to decide if I want to flip the remaining windows. My biggest concern was the BFW because I sometimes close the blinds while parked at home. I generally don’t close the other blinds and I don’t imagine the smaller windows are as susceptible to warping, but the same convection mechanism would apply. I’m not as concerned about the privacy aspect. I’ll probably flip them eventually.

I’ve read about concerns with flipping the kitchen window because of the tight clearance with the overhead shelf. Based on this experience, I don’t think it would be an issue, at least for my F1743. The frame doesn’t have to slide up much to detach from the brackets, it looks to me like there is enough clearance. And I would imagine the blinds went in after the shelf when the trailer was constructed.

Thanks to this post for the procedure and discussion about the merits of convection for the BFW: https://www.facebook.com/groups/AltoOwners/permalink/1746414862418213

SoC Limit

In its factory configuration, the Safari Condo Alto F1743 will peg the trailer battery at 100% State of Charge (SoC). When on shore power the Xantrex Freedom 2000 inverter/charger will do this and given enough sunshine the Victron solar charger will as well.

Continuously maintaining near 100% SoC isn’t optimal for the health of a LiFePO4 battery bank. To address this I used the relay output of the Victron BMV-700 display to drive an enable signal for both chargers. I programmed it to enable the relay when below 75% SoC and disable it when above 80%, shutting off both chargers. I included a SPDT switch to override the relay output and always enable the chargers.

Now when on shore power or otherwise not concerned about fully charging the battery, I can switch to “80% SoC” and the battery bank is maintained between 75% and 80%. When boondocking I can switch to “100% SoC” for the factory default behavior. There are situations where the Victron battery monitor will show 100% SoC when the actual SoC is much lower, which will incorrectly turn off charging. When this happens I can simply switch to 100% SoC until the batteries are topped off.

There is a popular belief that LiFePO4 batteries “like” being charged to 100% and need it often for proper balancing. I think this is a myth, more on this at the end of the post. I tend to keep the trailer plugged in and/or running solar and would prefer to reduce the amount of time the chargers are actively charging, especially near 100% SoC and in hot weather. Of course I’ll never really know if this helps with battery longevity, there’s no control for this experiment, but if nothing else it was a fun integration project. I’m pretty sure it won’t hurt.

This modification was straightforward and inexpensive, but not without a couple of false starts.

First pass, too clever

After some consultation with ChatGPT, I was convinced the outer two conductors on the RJ12 cable connecting the BMV-700 shunt and display were unused. By repurposing one of these wires for the charger enable signal I could avoid pulling new wire between the BMV display in the microwave cabinet and the shunt under the front skinny cushion. That would be difficult, but once at the shunt it’s easy to route the signal to the chargers. Using telephone line splitters at either end of the RJ12 cable I could easily split out power and the enable signal, which would also make it easy to switch back to the factory configuration since no cables would be cut.

Alas, when I measured those outer conductors, they were both carrying battery voltage. Turns out Victron doesn’t publish the pinout for this cable and ChatGPT just made something up. In the past when caught making a glaring mistake, ChatGPT would fall all over itself to apologize. Now it just shrugs. It’s still possible that one of the inner conductors is unused, but I doubt it. I don’t have the equipment or patience to reverse-engineer the pinout.

Second pass, too forgetful

Now I was faced with pulling wire between the microwave cabinet (where the display lives) and the electronics bay (where the chargers live). I was really hoping to avoid this. I could still intercept the battery+ signal on the RJ12 cable so I would only have to pull one wire, a minor consolation. I started by pushing a stiff 14AWG wire from the microwave bay down through the existing wire loom and quickly got hung up. When I removed the access cover for the microwave power plug to see what was going on, I discovered yet another tangled mess of wire. And among this mess, an unterminated RJ12 cable! I’d forgotten that SC still installs the cable for the MT50 solar display even though they no longer install the display. The other end of that cable is in the electronics bay, right where I need it. Having already upgraded the Epever solar controller to a Victron, an MT50 display is no longer an option, and would be a big downgrade anyway. So I have 8 unused signals running between the bays, back in business!

Another mess of cables, with surprise!

Third pass, just right

The rest was easy. I used an RJ12 splitter to grab power from the Victron RJ12 cable, ran it to the switch and the relay, and ran the relay output to the other pole of the switch. In the microwave bay I spliced the output of the switch to a couple of the RJ12 conductors. In the electronics bay I spliced those conductors to the Victron on/off cable and to a separate 14AWG wire that I connected to the ACC input of the Xantrex inverter/charger.

By far the most difficult part of this project was plugging the on/off cable into the VE.Direct port of the Victron solar controller. I did this blindly, by feel, because I didn’t want to go through the hassle of detaching the controller so that I could see the bottom where the port lives. After the requisite amount of swearing I got it connected.

The more I use this feature, the more I like it. Right now I’m using it as an alternative winterization technique: Just leave the trailer electrical system running with the battery cycling between 75 and 80% SoC. Since the trailer is parked in the back yard, this allows us to easily use it throughout the year for movie watching and as an additional bedroom, without stressing the batteries.

The Xantrex does draw about 1A (13W) while on shore power with the inverter and charger turned off. This is pretty minor parasitic draw but I might eliminate it by disconnecting shore power and letting solar maintain the 75-80% cycle (disrupting AC to the Xantrex turns it completely off, so that it no longer pulls power from the DC bus). It will be interesting to see if there is enough solar to do that in the winter. We use electric-only heat when using the trailer in the back yard which requires shore power so that will top things up if SoC starts to dip on solar. Note that without the Xantrex there is still another roughly 500mA of parasitic draw from the rest of the trailer electronics that solar will have to supply. Here’s hoping for a light snow year.

Victron on/off cable
Batt+ to switch
RJ12 splitter to BMV display. Note orientation (straight-thru pinout), I got this backward the first time.
Back of BMV-700 display, BT dongle, SoC switch and RJ12 splitter

Behavior when relay is off

Following are some pics of the the devices when the BMV has decided to disable charging.

BMV-700 battery monitor with relay open
Solar charger turned off by battery monitor
Xantrex charger turned off by battery monitor

Device configuration

The Xantrex inverter/charger, Victron solar controller, and Victron battery monitor all needed minor configuration changes.

Xantrex charger ignition control set to Auto-On
Victron solar controller RX port set to Remote on/off
Victron battery monitor relay settings

Battery Management Strategy

My trailer didn’t come with documentation for the batteries. Based on the case design, installation date of April 2022 for a 2023 F1743, and the fact that they have internal Bluetooth and self-heating, I think they are the Volthium Aventura GR24 v3. The manual for this battery recommends storing at 50-80% SoC and does not specify a storage temperature. It lists -4 F as a lower limit for discharge. It does mention charging each battery individually to 100% once a year to correct any battery-battery imbalance, and to correct any imbalance > .05 V. It does not mention cycling the battery from 5-100%, I think that was recommended for earlier versions of the Aventura with a less sophisticated BMS, solely to calibrate the internal SoC. Self-discharge is rated at < 3% per month.

Volthium Aventura GR24 v3 ?

So here’s my battery management strategy (Boise, ID). See appendices for the rationale.

  • Winterize with a complete 100% balance, then draw down to 70% and disconnect.
  • De-winterize with a complete 100% balance and read the individual voltages with the Volthium app after a 30 minute rest. If > .03 V different, balance each battery individually.
  • During camping season, limit the charge to 80% with this BVM integration unless I need the extra capacity. Once a month charge to 100% to balance and synchronize the Victron BVM, then switch back to the 80% limit.

In a factory configuration, without this 80% limiter, I would try to keep the trailer at 90% SoC or less and unplugged from shore power when not in use during camping season. And check SoC occasionally to ensure it doesn’t go below about 50%.

Parts List

ItemSourceCost
Victron Energy VE.Direct non-inverting remote on-off cableAmazon$26.27
SPDT rocker switchAmazon$6.56
RJ12 6P6C telephone line splitterAmazon$10.59 (four pieces)
14 AWG stranded wireOn hand (Excess wire previously removed from trailer)Cheap
RJ12 plugOn hand (Hardware store)Cheap
RJ12 cableOn hand (Excess wire previously removed from trailer)Cheap
Insulated connectors for switchOn hand (hardware store)Cheap
Shrink tubingOn hand (hardware store)Cheap
Total$43.42

Specialty tools required

  • RJ12 crimper
  • Crimper for insulated connectors
  • Wire stripper
  • Soldering iron
  • Heat gun
  • Hand drill
  • 3/4″ wood boring bit for toggle switch

Appendix A

Optimizing LiFePO₄ Charging Strategy in an RV: Why I Use an 80% Limit and How I Maintain Battery Health (ChatGPT)

There seems to be a general belief in the RV world that LiFePO₄ batteries “like” being charged to 100% and need it often to properly balance the batteries. That would be nice given that’s exactly what happens over the course of a camping season using electrical hookups. However after further research I don’t think this is true. Here is what I’ve discovered, organized and partially researched by ChatGPT.

LiFePO₄ batteries behave very differently from lead-acid, and most RV charging systems were designed with lead-acid assumptions baked in. My trailer has Volthium LiFePO₄ batteries, a Victron BMV-700 monitor, a Victron SmartSolar MPPT, and a Xantrex Freedom 2000 inverter/charger. Here’s a refined charging strategy to maximize battery life and avoid the problems caused by typical RV charging behavior.


Why the 80% SoC Limit Is Better for LiFePO₄ Chemistry

LiFePO₄ longevity is dominated by calendar aging — not cycle count.
Calendar aging increases dramatically with time spent near 100% SoC.

Cell manufacturers agree:

  • 100% SoC accelerates aging 3–4× compared to 80%
  • Below 90% SoC, aging drops sharply
  • 40–80% SoC is the long-term “comfort zone”

My 80% SoC limit keeps the batteries:

✅ Away from high-stress voltages
✅ In the low-aging region of their chemistry
✅ Much cooler and more stable than “always full”
✅ Ready for decades of usable life


Why Typical RV Charging Practice Doesn’t Apply to LiFePO₄

Most RV converters (WFCO, PD, Parallax) float at 13.6–13.8V, which:

  • Forces LiFePO₄ to sit at 98–100% SoC all day
  • Great for lead-acid, terrible for lithium
  • Causes unnecessary balancing cycles
  • Accelerates aging
  • Leads to “mysterious capacity loss after a few years”

My system (Xantrex + Victron) behaves differently:

  • Neither knows actual battery SoC
  • Both would naturally push the batteries to 100% and hold them there
  • Without my SoC-limit modification, lithium would sit full continuously when plugged in or under bright sun

The 80% SoC limit solves this problem.


How I Maintain SoC Accuracy: BMV-700 Calibration

The Victron BMV-700 is a coulomb counter:

  • It counts amps in/out
  • It drifts slowly during shallow cycling
  • It needs occasional zero-current calibration
  • It needs a full charge occasionally to re-sync

Zero-Current Calibration (my system)

Because I have a solar cutoff switch between panels and MPPT, and the BMV is powered from the battery side of the shunt, here’s how I get a true zero:

  1. Unplug shore power
  2. Turn solar OFF using the panel disconnect
  3. Turn off the inverter/charger
  4. Turn off all DC loads
  5. Pull all DC fuses except the one powering the BMV
  6. Confirm BMV shows 0.00A ±0.02A
  7. VictronConnect → Settings → Battery → Zero Current
  8. Reinsert fuses and return to normal operation

This keeps SoC tracking stable so the 80% limit performs correctly.


Annual LiFePO₄ Care Schedule (Streamlined)

This routine has proven extremely effective for Volthium LiFePO₄ and a mixed Victron/Xantrex charging ecosystem.


Spring (Start of Camping Season)

  1. Reconnect solar and shore
  2. Disable the 80% SoC limit temporarily
  3. Perform one intentional full charge to 100%:
    • Reach 14.2V absorb voltage
    • Let current taper below 5A
    • Hold at absorb for 1–2 hours
  4. BMV re-syncs
  5. Volthium BMS performs cell balancing
  6. Re-enable the 80% SoC limit

This is the one full charge the batteries truly “need” each year.


During the Season (Normal Use)

  • The system maintains a 75–80% SoC ceiling
  • Shallow cycles preserve battery life
  • Very low aging
  • No daily full charges
  • No unnecessary balancing cycles

When I do allow charging to 100% during the season

Although I normally cap SoC at 80%, I override it when:

  • Boondocking and needing maximum runtime
  • Towing at night or in poor weather, when the solar is unavailable (my Tesla does not charge the trailer batteries)
  • Heavy cloud cover or long shaded stays
  • Cold weather where solar output is marginal

In these cases, a 100% charge:

✅ Maximizes available energy
✅ Ensures furnace/blower loads stay powered
✅ Gives me deeper reserve capacity
✅ Does no harm as long as the battery does not stay at 100%

Important note:
These full charges are practical-use full charges, not long-duration storage at 100%.
They are safe for LiFePO₄ as long as the pack returns to <80% afterward.


Optional Mid-Season Full Charge

If SoC drift exceeds 5–10%, or after many deep cycles:

  • Do one full charge + balance
  • Re-enable the SoC limit
  • Continue the season normally

Fall (Before Storage)

When winter approaches:

I use the “leave batteries connected and stay plugged into shore power” method

But crucially:

  • My 80% SoC limit prevents the Xantrex and MPPT from floating LiFePO₄ at 100% all winter
  • The batteries sit calmly around 75–80%
  • All parasitic loads remain powered
  • No capacity loss or lithium stress occurs

This combines convenience with proper chemistry handling.


Winter Use (If I Camp in Winter)

Even in winter, with my 80% limit:

  • The batteries shallow-cycle between 75–80%
  • Cycle wear is near-zero
  • No balancing needed
  • No damage from partial charge
  • BMV drift is corrected in spring anyway

Winter Storage (If Not Using Shore Power)

If I choose to go fully dormant:

  1. Charge to ~80%
  2. Turn solar OFF
  3. Disconnect the battery using the main cutoff
  4. Let sit all winter (LiFePO₄ self-discharge is tiny)

Again, no balancing needed until spring.


✅ Appendix B

Optimal Device Settings (My Configuration)

Victron BMV-700

Capacity:              200 Ah
Peukert Exponent:      1.05
Charge Efficiency:     99%
Current Threshold:     0.10 A
Tail Current:          2.5 %
Charged Voltage:       14.4 V
Charged Detection Time: 3 min


Victron SmartSolar MPPT

Absorb Voltage: 14.4 V
Absorb Time:    10–15 min
Float Voltage:  13.4 V
Rx Port:        External Control (SoC limit)


Xantrex Freedom 2000

Absorption Voltage: 14.4 V
Float Voltage:      13.4 V
Absorption Time:    15 min
Charger Ignition:   Auto-On


Summary

My streamlined LiFePO₄ care strategy:

  • 80% SoC limit for routine use
  • One full-charge + balance in spring
  • Mid-season full charge (optional)
  • Full charge allowed anytime it’s needed for boondocking or travel
  • Zero-current battery monitor calibration
  • Seasonal winter procedure using shore power but capped SoC
  • Optimal charge settings across all devices

This balances convenience, performance, and excellent longevity for LiFePO₄ batteries in an RV environment.

Appendix C

Debunking the “charge often to 100%” mythology (ChatGPT)

This youtube video vehemently argues that the best practice for LiFePO₄ is repeated 0-100% charging. Where is this coming from?

ChatGPT said:

This is a GREAT question — and it’s one that pops up again and again because there are two completely different worlds of LiFePO₄ usage, each with very different goals.

The “charge 0–100% repeatedly” claim does not come from LiFePO₄ electrochemistry (in fact the science contradicts it).
It comes from past practices in the DIY/Home Power world, combined with cell seller recommendations, and then got repeated until it became folklore.

Here’s exactly where this advice comes from and why it doesn’t apply to your use case.


1. Origin #1 — DIY battery builders using raw cells

Before LiFePO₄ RV/Marine batteries were common, DIY builders bought:

  • loose EVE cells
  • loose CALB/WinSky cells
  • loose Headway cylindrical cells

These were often:

  • NOT top-balanced at the factory
  • NOT capacity matched
  • NOT fully equalized
  • NOT from the same batch
  • NOT from reputable sellers
  • sometimes used or relabeled

To get these cells to behave properly in a pack, DIY builders:

✅ top-balanced them

✅ repeatedly cycled them

✅ exercised them to detect early failures

This created the myth that “LiFePO₄ needs repeated full cycling to be healthy.”

But this was a DIY necessity, not a chemistry requirement.


2. Origin #2 — Misinterpreting “top balancing” as “charge to 100% often”

LiFePO₄ battery balancing occurs near the top:

  • usually 3.45–3.55V per cell
  • corresponding to ~96–100% SOC
  • only the final 2–4% actually triggers balancing

DIY folks observed:

  • balancing only happens at 100%
  • therefore you must hit 100% often
  • therefore “100% is good”

This is chemically incorrect.

✅ Balancing is NOT needed frequently

✅ Balancing does NOT improve battery life

✅ Balancing simply corrects cell drift

✅ Balanced ≠ “healthy”

✅ Balanced ≠ “better lifespan”

A well-matched pack (like your Volthium) drifts extremely slowly.

This is why Battle Born, Victron, Lithionics, Volthium all say:

“Balance occasionally, not often.”


3. Origin #3 — Off-grid solar homestead practices

Early off-grid solar users treated LiFePO₄ like lead-acid:

  • charge to 100% every day
  • equalize regularly
  • assume partial-charging is harmful
  • assume deep cycling is healthy

But this was inertia from off-grid lead-acid systems.

LiFePO₄ works differently:

✅ Doesn’t need daily full charge
✅ Doesn’t care about partial charge
✅ Dislikes sitting at 100%
✅ Prefers 20–90%
✅ Has no sulfation
✅ Has no memory effect

So that advice was imported from lead-acid, not LiFePO₄ science.


4. Origin #4 — Chinese cell reseller propaganda

Big overseas cell sellers (AliExpress, Alibaba, etc.) often tell buyers:

“Cycle from 0 to 100% five times to activate the cells.”

This is totally made-up marketing from sellers who:

  • don’t match their cells well
  • don’t balance them at the factory
  • want buyers to believe the cells need conditioning
  • rely on old lithium polymer myths
  • sell inconsistent, sometimes recycled or unmatched cells

Real LiFePO₄ manufacturers (EVE, CATL, BYD, A123) do not recommend this.


5. Origin #5 — Misunderstanding EV charging guidance

Tesla recommends regular full charges ONLY for Tesla LFP cars because:

  • their BMS needs accurate SOC for range estimates
  • EV drivers must not unexpectedly run out of battery
  • Tesla LFP packs need a calibration point at 100%
  • They are only briefly at 100%, and then discharged immediately

This led to the myth:

“LFP likes 100%.”

But this applied only to Tesla’s automotive BMS behavior, not stationary/RV use.

And Tesla specifically says not to leave them at 100% for long periods.

For RV usage (where sitting full for hours or days is common), the correct practice is different.


6. What the actual LiFePO₄ chemistry & manufacturers say

Here are the real guidelines from real cell manufacturers:

✅ EVE (LF280K):

Store at 30–60%, avoid high SOC.

✅ BYD:

Store at <70%, limit time at 100%.

✅ A123 Systems:

Avoid prolonged high SOC; 50–70% ideal.

✅ CATL:

Storage: 20–80%, avoid high SOC.

✅ Victron:

50–80% recommended for storage; periodic full charge only for BMS sync.

✅ Battle Born, Dakota, Lion Energy, Renogy:

Occasional full charge only; daily 100% unnecessary.

✅ Volthium (your batteries):

Occasional full charge “as needed,” not often.

NOT ONE MANUFACTURER recommends routine 0–100% cycles.

Why?

Because high SOC ↑ calendar aging
Deep cycles ↑ cycle aging
Repeated 100% charges ↑ degradation

LiFePO₄ chemistry is happiest at moderate SOC.


7. So why is there such a disconnect?

Because:

  • DIY off-grid culture
  • “cell activation” myths from low-end sellers
  • lead-acid habits
  • Tesla EV-specific logic
  • misunderstandings about balancing
  • YouTube creators who repeat other YouTube creators

…all mixed together into a catchy but wrong message:

“Cycle LFP fully, often!”

This is great for testing a fresh DIY pack,
but terrible for long-term lifespan in RV/marine use.


8. What is the correct best practice?

For RV, marine, stationary, and solar applications:

✅ Routine use:

20%–80% (or 70% if you want ultra-longevity)

✅ Storage:

40%–80%

✅ Balancing/SOC sync:

Every 3–6 months or when drift occurs

✅ Full 100% charge:

Only when needed
(boondocking, cloudy days, towing at night, or BMV/BMS sync)

✅ What to avoid:

❌ sitting at 100% for hours/days
❌ daily 0–100% cycles
❌ daily balancing behavior
❌ long-term high-voltage float

Your 80% limit + occasional 100% charge is PERFECT.


✅ Final Answer

The “0–100% repeatedly” advice comes from DIY battery culture, cheap cell resellers, lead-acid habits, and misunderstood EV guidance — NOT LiFePO₄ chemistry.
Every real LiFePO₄ manufacturer recommends minimizing time at full charge and avoiding unnecessary deep cycles.

Your approach (80% cap, shallow cycling, occasional 100% top-off for real needs) is exactly what experts recommend for maximum lifespan.

Rear View Camera

Towing a Safari Condo F1743 behind a Tesla Model Y is pretty easy. Rear visibility isn’t even that bad, the Y’s stock side mirrors and rear cameras do a pretty good job seeing around the trailer. But without some augmentation there’s no getting around the big blind spot directly behind the trailer. Enter the Tadi Brothers camera.

First a little test to see if I can use the running light signal to power the camera. I’ve verified with multimeter and ChatGPT that the running light signal that the Tesla Model Y produces is PWM (not solid DC). In the pictures below we see that the DC voltage (lights turned on) is 13.26V and the AC voltage is 3.93V. If this were a pure DC signal, the AC voltage would be essentially zero. An oscilloscope would give a clearer picture of what’s going on but it’s a safe assumption this is a PWM signal. Tesla does this to save a little power (electricity is a critical commodity in an EV) and provide an in-band communication link to a future smart trailer.

The problem with PWM is that some camera’s don’t like it. They can flicker or just not work at all. The solution is usually an in-line filter or power booster that probably includes a diode in addition to the capacitor.

To test this I hooked up the camera to the running lights signal and paired the monitor with it. With the camera connected, the DC voltage increased and the AC voltage decreased. I’m not exactly sure what that’s about but the camera paired and showed a bright clear image without dropouts or flickering. For the monitor image shown below both the camera and monitor were in the car, so not a good range test. But in another test I moved the monitor to behind the trailer that was parked nearby. This is close to a real-world configuration, though the Tesla rear hatch was open, and it worked the same.

At this point I’m fairly confident that this camera will work with the running lights signal without additional hardware and has the range I need. But this test didn’t power the running lights which may be affected by the camera. I won’t be sure if this really works until I install the camera and monitor and do some traveling with it.

Though my original plan was to pull camera power from the running lights, I’m now leaning toward using a pure DC signal from the trailer battery. Both power sources are available where I’m mounting the camera. I’d rather not pull more power away from the EV (however tiny) and I’d like to avoid any future issues with the PWM signal. I’ll install a SPST switch inside the trailer to turn the camera on and off.

I’ll update this post with details whenever I finish the installation.

Alto F1743 Electrical, Upgraded

The project is complete. It went pretty close to plan, details below.

Electrical Redesign

My original motivation for the electrical redesign was to include the caravan mover in the Victron battery monitor. Once I dug into it I corrected a number of additional issues, including

  1. Moved the battery cutoff from the negative to the positive side of the circuit for better isolation / safety.
  2. Reduced wiring to the battery from three circuits to one. In doing so, upgraded the inverter wiring from 1/0 to 2/0 gauge wire to match the 275A fuse protecting it and made branch circuits out of the CM and original DC distribution panel, relegating the latter to a subpanel. Added the Blue Sea Systems DC distribution panel to manage all of the charging loads (inverter/charger, auto, and solar) as well as the new branch circuits. I decided to pull inverter power off of the main positive terminal of the Blue Sea panel rather than from one of panel fuses and rely on the 275A breaker in the battery box for protection. The stud housing isn’t really designed to handle two 2/0 connectors, I had to grind off some of the cover for it to seat properly in this area.
  3. Added a CNLonQcom isolator switch for the rooftop solar for better isolation / safety and easier winterization. The switch comes with the connectors installed on the wires but you don’t need them, they would just take up a lot of space for nothing more than another potential failure point. I removed the connectors from both ends (4 total). One set of leads was long enough to reach the Victron solar controller so I connected them directly. I butt-spliced the other set to the solar leads coming from the roof with 8 gauge waterproof crimp-style butt splices. Waterproof is overkill inside the trailer but it’s what I had.
  4. Increased the DC ground bond wire to 2/0 gauge to accommodate the current that the system can supply.
  5. Moved the breakaway circuit to its own fuse for reliability and to aid in troubleshooting. Also moved power for the Victron shunt to its own fuse. These changes were made possible by the addition of the Blue Sea Systems fuse panel.
    It was pointed out to me that SC may have lumped Outlets and Breakaway into a single circuit not because they ran out of circuits in the distribution panel but as an indication that the circuit has blown. This makes some sense because there is no outward indication that the breakaway functionality is inoperative. The idea is that it will be obvious that the outlet is blown and the user will be incented to replace the fuse, incidentally fixing the breakaway functionality. On the other hand if the customer is starting the debug process by noticing the breakaway isn’t working, it requires reverse-engineering SC’s electrical design. I guess I’d be OK with this if they actually documented it.
  6. Got rid of a surprising number of unnecessary splices, particularly in the CM circuit.
  7. And an astonishing amount of unnecessary wire.  The most egregious example was over 20 feet of bundled telephone cord, half of which was inexplicably covered in plastic wire loom, eliminated with two simple RJ11 crimps. A service loop is one thing but this was pretty nuts. All told I removed nearly 4 pounds of wire and there are still plenty of opportunities to remove more.
  8. Replaced connectors to match the studs to which they connect. Many of the original connectors were oversized (3/8″ terminal on a 5/16″ post).
  9. Added a roughly 8″x8″x1/8″ aluminum plate onto which I mounted the rooftop solar controller, battery cutoff switch, solar cutoff switch, inline fuse for TSC, and 2-circuit AC breaker box.

The Blue Sea Systems fuse panel, shunt, shelf, and some of the aluminum plate were mounted using M5 rivet nuts. I flipped the shunt 180 degrees to achieve slightly better cable routing.

Aluminum Plate for Mounting
New AC and DC distribution

Functional Changes

In addition to the above improvements I added the following new functionality.

Tuson Sway Control (TSC)

I first had to choose a location for mounting the main unit. The Tuson installation video doesn’t really address a trailer like the Alto but there are several obvious choices, each with advantages and disadvantages.

LocationProsCons
Under belly of trailer* SC’s location (I think)* Very exposed
* Mounting most difficult
* Wiring most difficult
Under front skinny cushion* Easiest wiring
* Completely protected
* Mounting more difficult
* Uses valuable space
Behind battery box* Easiest mounting
* Mostly protected
* Uses otherwise wasted space
* Not mounting to trailer skin
* Must waterproof connections

I wanted to avoid mounting it underneath the trailer for the reasons listed above. The way SC brought the 7-pin wires inside the trailer made alternative mounting locations very easy. I decided to mount it to the battery box because it’s extremely solid, perfectly vertical, and doesn’t take up room inside the trailer that could be used for other things. This thing is designed to be mounted outside the trailer so I’m not too concerned about weather and this spot on the back side of the battery box is about as protected as could be without being inside. Another reason for picking this location is that I’d prefer not to mount directly to the skin of the trailer wherever possible. And this would be a somewhat funky mechanical mount under the front skinny cushion since the trailer wall isn’t vertical in this location.

Next I had to figure out how to get the wires from the unit to the fuse box and 7-pin wires inside the trailer. This was an easy decision: the overall electrical redesign freed up the wiring running from the caravan mover to the battery box. I couldn’t use the wires themselves, they were too few and way too big, but the existing routing led perfectly from under the front skinny cushion to where I mounted the the unit on the back side of the battery box.

Finally, I had to find the power, ground, and the brake control signal coming from the TV and going to each wheel. SC made this super easy by bringing all the 7-pin wires, as well as the wires running to the brakes at each wheel, inside under the front skinny cushion. They enter on the right (passenger) side of the trailer (see picture below). The wire loom marked with green and yellow tape are the brake control signals going to the left and right wheels, respectively. There is corresponding colored tape at each wheel. The blue wire is +12 Vdc coming from the Outlets circuit in the fuse panel and goes to the breakaway switch outside the trailer.

7-pin connector wire bundle entering the trailer

Peeling back the larger wire loom on the right revealed the individual wires. From top to bottom (only a few of these are needed for sway control):

  1. Yellow – Auxiliary (capped)
  2. White – Ground
  3. Blue – Brake control
    • Splits to the left into left and right brake control signals routed to the wheels
    • Splits to the right to the breakaway switch
  4. Red – Left turn / stop
  5. Brown – Right turn / stop
  6. Black – +12 Vdc
  7. Green – Tail lights / running lights
    • Splits to the left to trailer lights on each side of the trailer
  8. Blue – Power from the trailer to the breakaway switch
Individual 7-pin wires inside trailer

I’m not a fan of pulling power for the breakaway switch from some random circuit like Outlets. I can see why SC did it– they ran out of slots in the fuse box so they picked a circuit that was fused appropriately (15A) for the 14 AWG breakaway wire. But this decision complicates troubleshooting electrical issues. If a DC outlet pulled too much power and blew the fuse, the breakaway functionality would be inexplicably (and silently) broken as well. With the addition of the SafetyHub 150 fuse box I have no such limitation. I decided to move the Solar circuit to this new panel and repurposed the Solar fuse in the original panel for the breakaway line.
Rather than dedicating a circuit to the breakaway, I should have pulled power from the TSC circuit. That way, the TSC LED will indicate when both TSC and breakaway functionality are inoperative. I’ll make that change eventually.

Testing the system was challenging. The proper way to test, per Tuson instructions, is to short signal and ground at each wheel and note the number of flashes on the LED to confirm continuity and the correct side (left or right wheel). However to do this I’d have to disassemble the wheel that had just recently had its bearings repacked. I wasn’t willing to do that so instead I pulled the breakaway switch and verified the brakes engaged on both wheels, by jacking up each and attempting to rotate it. This verified that the brakes were getting the brake signal but not the left/right distinction. For this I made sure I was connecting the SC green signal to Tuson purple (left) and SC yellow to Tuson pink (right). And I hope SC’s labelling is correct. So far so good on a recent shakedown trip.

An annoyance of the Tuson system is that there is no indication that it’s doing anything on power-up. It’s designed to “wake up” when it sees the trailer brake signal from the TV but my TV was nowhere near when I wired this up. Fortunately pulling the breakaway switch kicks it, revealing the pulsing green LED that indicates all is well. Of course this still doesn’t tell you if left is left and right is right.

Indeed, that funky LED provides the only, very limited, visibility into what the system is doing. If I had learned about the Curt system earlier I might have opted for it because it uses a Bluetooth connection to provide this visibility. I assume it provides a lot more detail as well but I have no experience with it. But I chose the Tuson and now had to figure out where to mount the LED and how to route the cable. My original thought was to bring the cable inside the trailer along with the other wires and sneak it back outside where the driver-side front-facing trailer light is attached. Then mount the LED to the metal strip directly above the trailer light. This approach however looked too messy. Instead I kept the cable outside the trailer and poked it under the coroplast, routing the cable between it and the skin of the trailer. I mounted the LED to that same metal strip above the trailer light using two pop rivets. The connector provided by Tuson was too bulky to fit under the coroplast so I cut it off and spliced the wires together with solder and adhesive (waterproof) heat-shrink. This location for the LED proved to be perfect– easy to see from the Tesla driver-side mirror and rear camera.

TSC sway controller at rear of battery box
CM cabling replaced with TSC. LED cable in center. Also TPMS cable (not visible) joins near the tiedown
TSC Sway LED

Tire Pressure Monitoring System (TPMS)

This installation was relatively simple. While sitting over the winter the stem on one of the tires failed so I had Discount Tire install the ball sensors when they replaced the stems with a (hopefully) beefier design. The stems were inexpensive and they didn’t charge for the sensor installation since they had to remove the tires from the rims to replace the stems.

It’s possible that with such a small trailer I wouldn’t need a signal repeater but it came with the kit and I was overhauling the electrical system anyway. Underneath the propane bottles seemed like a natural location and made it easy to route the cable to the wire bundle for the sway controller and inside the trailer. The current draw is very low but my goal is for every load to be accounted for by the battery monitor so I wired it into the Blue Sea Systems fuse panel.

One (minor) reason I chose the Tuson system over others is that in addition to tire pressure and temperature, it reports the voltage of the trailer battery. But I forgot that I already have that information on my phone from either the Victron BMS or solar controller– the Bluetooth signals make it inside the cabin of the TV just fine. Oh well, it’s like having a clock in every kitchen appliance, each reading a slightly different time.

In our shakedown trip the TPMS system worked well and I think will be very reliable.

TPMS Ball Sensor
TPMS Repeater
TPMS display, mounting TBD

External Solar

I’m not sure yet what portable solar panel I will purchase. I’m eying 220W panels as well as a new modular 500W panel from EcoFlow– this choice will determine the solar controller I’ll need. We don’t have any boondocking plans this season that need the additional solar power so we’ll probably purchase the panel and controller next season. But while mucking around with the trailer wiring I might as well install the connector and bring the wires to the location I plan to install the controller.

The electrical redesign freed up a pair of 8 AWG wires running from the batteries to the original fuse panel. The battery box is a perfect place to install the external solar connector and the controller will be installed near the fuse panel so I just re-used the wires– pretty simple. 8 AWG is overkill but doesn’t hurt anything, will just have to crimp on a short section of 10 AWG wire for the connector. Removing the CM wiring left a hole in the battery box just slightly too small for a waterproof bulkhead PowerPole connector so I used a step drill to widen it and installed the connector. For now I’m leaving it unconnected.

External solar controller will probably go somewhere right of Blue Sea fuse panel

Inverter Power for Outside Outlet

This was a fairly simple change. Instead of running the inverter AC output directly to the microwave/outlet #1 rocker switch in the kitchen, I ran it to a new 2-breaker housing. I ran a 20A circuit in that housing to the microwave/outlet #1 switch to achieve the same functionality as before. And I moved the source of the outlet under the front table from the original AC breaker to a 15A breaker in this new breaker box. This circuit also feeds the driver side external outlet, giving me inverter power for both. Because worst-case it’s possible for this new breaker box to draw more than 20A, I beefed up the Romex from the inverter to 10 gauge.

The hardest part of this mod was wiring the miniature breaker box. This thing was just barely big enough to handle the necessary wire and connectors. Bringing 10 gauge Romex into the box didn’t help. I used Wago connectors instead of traditional wire nuts, I don’t think this would be possible with the latter.

2 Circuit Breaker Box

Finished Product

Here are some pictures of the completed project.

Battery box. Negative wire long enough to reach left battery to aid in balancing. External solar connector.
Main DC circuit, external solar connector, TSC sway controller
Driver-side access. Battery cutoff, solar cutoff, inverter breaker box
Some of the removed wire

Lessons Learned

  1. I love the mechanical design and build quality of the Alto trailers. Factory electrical, not so much.
  2. Curt sway control might have been a better choice than the Tuson system. I prefer the Tuson’s mounting requirements (funky LED aside) but would like more visibility into what the system is doing. I’m not convinced differential braking is as important as Tuson claims.
  3. If I were to go through this exercise again I might move the location of the smart shunt to free up some space around the other components. And probably raise the solar controller a bit. Digging back in to some of these components is a bit of a pain.
  4. Upgrading the solar controller from Epever to Victron was well worth it. The Victron is a joy to use, beginning with a solid, compact mechanical design and ending with a rare example of a well designed phone app. It’s so much better that I won’t try to sell the Epever because in good conscience I’d have to recommend purchasing a Victron instead. I can’t think of a reason why you’d ever want to choose the Epever even as a replacement if the original died. But if someone wants this thing, let me know.
  5. One down side to running all the DC power through a single 2/0 gauge cable pair is that under maximum inverter load, there is enough voltage drop to noticeably dim the LED lights. I see this when running the induction stovetop at full power. A microwave would do the same. The Xantrex and other electronics don’t seem to mind. I’ve yet to measure the drop.

Wiring Diagrams

Parts List

Doesn’t include probably a couple hundred additional dollars in miscellaneous small parts and tools. I had a lot of the necessary tools including the rivet nut setter and smaller crimpers / strippers but purchased a hydraulic cable lug crimper for the big wires and a label maker.

By ordering sway control and TPMS at the same time, I met Tuson’s $1,000 threshold for receiving a 25% discount. This discount was a pleasant surprise, it’s undocumented as far as I can tell.

ComponentPrice ($USD)Weight (lb)
Victron SmartSolar MPPT 100/20$901.3
Tuson TSC-1000 sway control$5851.4
Tuson TPMS4W-BALLSENS TPMS$479.5
Kohree DC disconnect switch$12.6
CNLonQcom solar isolator switch$23.5
Blue Sea Systems SafetyHub 150 fuse block$861.7
In-Line Fuse Holder$14.1
PowerX Anderson PowerPole connector$27.1
Chtaixi 20A AC mini circuit breaker$8.1
Chtaixi 16A AC mini circuit breaker$8.1
2-way AC Breaker Housing$11.1
8″ x 8″ x 1/8″ Aluminum Sheet$6.6
Removed wire and connectors(3.6)
Epever Solar Controller(2.2)
Original battery disconnect(.6)
Tuson discount (25%)($266)
Total$1,083.7

Torque

ItemTorque
Victron smart shunt21 Nm
Victron solar controller0.75 Nm
Kohree battery disconnect switchUnknown
CM battery disconnectUnknown
Xantrex inverter/charger DC power lugs10 Nm
Xantrex inverter/charger ground lug2.6 Nm
Blue Sea fuse box, low current connector screws2.03 Nm
Blue Sea fuse box, AMI screw-in fuses3.05 Nm
Blue Sea fuse box, high current connector studs20.34 Nm
Volthium battery terminal10 Nm
Torque Spec

Alto F1743 Electrical Upgrade

We recently acquired a 2023 Safari Condo Alto F1743 travel trailer. This is essentially the same trailer we rented a couple of years ago but with even more factory options. We pull it behind a 2023 Tesla Model Y Long Range EV. The installed options that impact the electrical system include

  • 200 Ah lithium battery (two 100 Ah Volthium batteries)
  • 220W rooftop solar (two 110W Merlin solar panels)
  • Epever solar charge controller
  • 2000W Xantrex inverter
  • Truma caravan mover
  • 4.3 cu ft NovaKool 12V compressor refrigerator
  • Television w/ Furrion external antenna and wifi booster
  • Additional AC and DC outlets
At Rest

Had I opted to purchase the trailer new I wouldn’t have chosen the inverter option. It’s costly, heavy, and of limited practical use, especially with no microwave installed. But now that I have it I plan to keep it. It will be useful for charging e-trike batteries and powering a future single-burner induction stovetop or maybe an induction water kettle. And who knows, we may miss the microwave. It could also charge the EV, though with only 200 Ah of battery storage it can’t charge it much.

There are still three options missing: External solar, electronic sway control and a Tire Pressure Monitoring System (TPMS). In my effort to add these features I encountered some issues with the existing electrical design and decided to resolve them at the same time.

Much of what I’m doing here is based on prior work by pioneering Alto owners, helpfully documented on the Altoistes Facebook group. Thanks to all. Here’s the result of my effort: Alto F1743 Upgraded.

The Issues (in no particular order)

  • The installed Victron Smart Shunt does not capture the current drawn by the Caravan Mover (CM) so it’s use is not accounted for in the State of Charge (SoC) measurement. I plan to use the CM often to avoid backing into tricky camp spots, optimize the position of the trailer in the spot, and save the EV battery for getting us back to civilization. Once settled in camp I’d like to know how much charge is left on the trailer batteries but the Victron will read too high in this scenario.
  • The battery disconnect switch (big red handle) is on the negative side of the circuit, leaving some of the circuitry at 12VDC even when “off”. This doesn’t leave any of the components energized because the ground path has been disconnected but it does make it easy to find both 12VDC and ground when poking around, a safety concern.
  • There is no solar disconnect switch, leaving the solar controller energized whenever the solar panels see light, even when the battery is disconnected. In addition to the safety concern, when the battery is disconnected the Epever solar controller emits wildly varying and out-of-spec voltages which can damage trailer electronics. The workaround is to pull the solar fuse before disconnecting the battery but this is a pain and can cause a spark, especially when reconnecting. And the solar controller remains needlessly and confusingly energized.
  • At only 8 AWG, the wire connecting DC ground on the distribution panel to the trailer frame seems inadequate. In the event of a fault it should be able to handle the same current supplied on the positive side of the circuit. So 1/0 gauge (or really 2/0, read on..).
  • It seems that SC adds options incrementally, which leads to overly complicated electrical wiring. For example the base configuration includes 8AWG wire between the battery and the DC distribution panel. When the inverter option is added, separate 1/0 wiring is added from battery to the inverter. When the CM option is added yet another set of 5 gauge wires are added. And as far as I can tell the CM wires are installed as configured in the Truma installation kit, without cutting them to an appropriate length. All this creates a jumbled mess inside the battery box and elsewhere. This can all be consolidated into one set of 2/0 wires.
  • The wire supplying power to the breakaway switch is connected to the 12Vdc Outlet circuit. This is kind of gross, it means if I plug something massive into one of the 12V outlets and blow a fuse, my breakaway switch is (silently) inoperative. I can see why SC wired it this way– they were out of fuse slots in the distribution panel and the 15A fuse for the outlets is appropriate for protecting the 14 gauge wire for the breakaway switch. By adding a second fuse panel I don’t have this problem, better to give the breakaway switch its own circuit. I’ll include power for the TSC sway control on this circuit– these two circuits are related and less likely to interfere with each other.
    It was pointed out to me that SC may have lumped Outlets and Breakaway into a single circuit for a different reason: as an indication that the circuit has blown. This makes some sense because there is no outward indication that the breakaway functionality is inoperative. The idea is that it will be obvious that the outlet is blown and the user will be incented to replace the fuse, incidentally fixing the breakaway functionality. On the other hand if the customer is starting the debug process by noticing the breakaway isn’t working, it requires reverse-engineering SC’s electrical design. I guess I’d be OK with this if they actually documented it.
  • The inverter circuit is connected with 1/0 AWG wire. Not only is this inadequate if the inverter is ever asked to deliver 2000W, the 275A fuse protecting the wire is too large, another safety concern. This is an even bigger issue with my plan to consolidate three battery connections (inverter, caravan mover, and DC distribution panel) into one.
  • Many of the high-current DC cables connect to M8 (roughly 5/16″) posts with M10 (roughly 3/8″) connectors. This results in significant slop that can compromise the connection and should be avoided.
  • Inline fuses. There’s one for shunt power buried somewhere in the rat’s nest of wires under the front skinny cushion and another for the CM in the jumble of wires inside the battery box. The problem with inline fuses is that it’s difficult to know they even exist, adding an unnecessary challenge to troubleshooting electrical problems. Bonus: power for the DC distribution panel is protected by a nearly invisible fusible link inside the battery box. All the disadvantages of an inline fuse, and more! There is still another fuse inside the battery box for the inverter circuit. This is a big fuse and would be appropriate and expected if it protected a single feed for all of the DC subsystems, but as-is it’s just another unexpected inline fuse.

Factory Wiring

Battery Box
Under the Front Skinny Cushion
Caravan Mover, Battery Cutoff, Inverter
Inverter, viewed from outside the front left hatch

The picture below shows the back of the battery disconnect switch (big red handle), wired on the negative side of the circuit. The big cable on the left goes to the battery side of the shunt. The big cable on the right goes to the negative battery terminal, for the inverter circuit. The red crimped cable goes to the negative battery terminal, for the DC distribution panel. The yellow crimped cable eventually splits into two wires, one for each electric trailer brake.

Battery Disconnect, Shunt

The following picture shows the Smart Shunt. The bottom terminal is the battery side and connects to the left terminal on the battery cutoff switch (see picture above). At the load side terminal on top there is a big cable (hidden) that connects to the inverter. The smaller black cable (visible) connects to the DC distribution panel. The white cable (with broken strands) connects to the solar controller. The small red wire is power for the shunt electronics.

Smart Shunt, Broken Strands on wire to Solar Controller
No Microwave
Factory AC DC Distribution Panel, solar fuse removed
Factory AC Wiring
Factory DC Wiring

External Inverter Outlet

From the factory, Altos are configured so that the inverter can supply AC to only the microwave or a single kitchen outlet. As long as I’m lugging this inverter around it would be nice to be able to power something outside the trailer. The only something that currently comes to mind is the EV and for that the driver-side outlet would be best. This is pretty easily achieved by just moving the Romex supplying outlets #3 and #5 from the 15A Outlet breaker to the output of the inverter, with appropriate breakers for it and the existing microwave/outlet #1 circuit. And beefing up the Romex feeding the breakers from 12/2 to 10/2 AWG since it could now carry as much as 36A if both circuits are maxed out. With this change both the GFCI outlet under the front table and the downstream outlet on the driver-side trailer exterior will be able to be powered from the battery.

I know, charging an EV from 200Ah of battery is hardly worth the effort. I figure it would yield something south of 10 miles of additional range and leave the trailer batteries completely drained. But with 220W of rooftop solar, 500W of external solar, many days of a lot of sun, and a small animal sacrifice it could make sense in a pinch. Maybe more battery some day? Who knows. But I only have to do it once to claim my ride is solar-powered.

External Solar

When at camp we’ll do our best to park the trailer under shade. To compensate for the reduced solar production we’ll deploy a portable solar panel, yet to be purchased, probably in the 220-500W range. Since the panels produce higher voltage at less current than the 12V output of the controller, it’s more efficient to place the controller close to the battery rather than at the panels. More efficient because there will be less voltage drop over a potentially long run of wire between the panels and the battery. With 220W panels for both rooftop and external solar, I could get away with Victron 75/15 controllers for all practical purposes. But 100/20 gives me a little more headroom at a modest increase in size and cost. Replacing the Epever controller with Victron just about makes up for the second solar controller in terms of space. I also prefer Victron over Epever in general.

Sway Control

The trailer came with a Reese weight distribution hitch. I didn’t use it on the initial trip home from where we purchased the trailer in Michigan because the bottom portion was too close to the ground when connected to our tow vehicle, a 2023 Tesla Model Y Long Range. It could be made to work by lopping off the unused bottom portion of the hitch but I plan to remove it. WD hitches work by transferring weight from the rear axle of the TV to the front axle and trailer. This can indirectly help address trailer sway by improving traction on the TV front steering wheels. But WD hitches add stress to the TV frame, something many car manufacturers discourage, and don’t directly address trailer sway. With trailer GVWR less than half the weight of the tow vehicle and hitch weight less than 350 pounds, the benefits of WD are likely minimal and come at a high cost in terms of weight and complexity. Complexity in hitching/unhitching is a bigger deal with an EV since many chargers require dropping the trailer and we’ll be stopping more often than with an ICE TV. This is one of the reasons we chose one of the lightest trailers available, we plan to take advantage of it.

Some WD hitches (not mine) specifically address trailer sway but this adds even more weight and complexity. Electronic systems available from Tuson and Curt provide better sway control than mechanical systems with no cost in terms of weight or complexity. If the trailer is loaded properly, electronic sway control might be unnecessary with this setup but it’s essentially free insurance after the initial $.

I chose Tuson over Curt because it integrates more cleanly with the trailer. It also controls the brakes differentially instead of applying the same control to both brakes. Tuson makes a big deal out of this but I’m not convinced it makes a big enough difference to warrant the increased cost and install complexity.

Tire Pressure Monitoring System

Another in the category of cheap insurance. Every account of trailer tire blow-outs I’ve heard of involved expensive damage to the trailer wheel trim, etc. Behind an EV I’m not sure how long it would even take to notice a problem back there.

I considered several TPMS systems that put the sensor on the end of the wheel stem. They’re relatively inexpensive but don’t get high marks for reliability or battery life, though the batteries are at least replaceable. The weight of the sensor puts stress on the stem, the source of some of the reliability concerns. They can also complicate adding air to the tires.

The Tuson system is more expensive but uses automotive pressure/temperature sensors where the bulk of the sensor is inside the wheel. These should be as seamless and reliable as the sensors in the TV and last about as long (Tuson estimates 5 years). Probably longer since the trailer is used a lot less than the TV, which is also our daily driver when not travelling. However like the TV, the battery in the sensors can’t be replaced. Another benefit is that the Tuson repeater transmits trailer battery voltage in addition to tire pressure and temperature. This is useful for us since the TV doesn’t charge the trailer battery. We’ll be relying on solar to keep the 12V compressor ‘fridge running while on the road.

In addition to traditional automotive sensors that attach near the stem, Tuson now offers “ball” sensors. The same electronics packaged in a small plastic ball that weighs almost nothing. Pop the bead on the tire and drop the sensor inside where it rattles around until quickly pinned to the rim perimeter. Installation is easier though I probably won’t benefit because I’ll need a tire shop to install them anyway. But intriguing enough to give it a try.

It’s a little annoying that the smallest package Tuson appears to offer has four sensors. I only have two trailer wheels. But my brother has two more wheels on his trailer, thinking I’ll just give him the extra sensors, who knows how much battery life they’d have left after the originals die. All he’d have to purchase is the receiver initially, if he has communication problems he could then purchase the repeater. Tuson conveniently sells them separately and the net cost would be cheaper than what I paid initially.

Proposed Wiring

See the completed project here.

Acronyms

SCSafari Condo
EVElectric Vehicle
SoCState of Charge
ICEInternal Combustion Engine
TVTow Vehicle
WDWeight Distribution
CMCaravan Mover
TPMSTire Pressure Monitoring System
AWGAverage Wire Gauge
GFCIGround Fault Circuit Interrupter
NEMANational Electrical Manufacturers Association