Potential Electrical Fire Mitigated

[Irontent]

In addition to the floor flooding from the water heater (previously posted), I found and fixed an electrical problem today.

A couple of weeks ago, we were watching TV in the evening, and suddenly the TV, Stereo, and Fireplace went off. My first thought was that the circuit must have been overloaded for some reason, notwithstanding that we have used the exact same configuration for a couple of years.

I checked the breakers, and none were tripped. Oh well — I thought, probably a breaker failed. To isolate which one, I checked the AC output of each breaker to ground using my Fluke meter. All showed expected good voltage. In the process, I found three instances of white wires that were loosely laying in the neutral bar with very loose screws, which I re-torqued to a proper force. VERY POOR WORKMANSHIP FROM DRV.

When the circuit initially failed, i thought I smelled ozone, but i could not track-down the source.

After thinking about it for a few days, I decided that either a wire in the wall had been stapled/screwed into, or a bad splice had opened in the AC boxes in the living room slide. There are sets of boxes on the trailer frame (which presumably transition the trailer Romex into flexible SO cords and back to Romex).

The SO cords are terminated in two boxes (a two gang one and a three gang one) mounted under the living room slide outer wall. I guessed that the SO cords were spliced back into Romex which is then run in the walls of the slides to power the receptacles for the TV, stereo, appliance garage, and fireplace, as well as the dishwasher, microwave, and GFI plugs around the kitchen sink.

I removed the cover of the two gang box, to inspect the wiring. All looked fine, but as I wiggled the wires, I found that several were improperly crimped, and the wires came out of the crimp splice. I used new crimps, and set them with a suitable crimp tool. I was sure that this was the problem, but after reapplying power, the dead receptacles persisted.

So, I opened the three gang box, and saw that another bad crimp had allowed a hot wire to contact a neutral wire. Amazingly, there was enough instantaneous current to melt the splice, but not trip the breaker. Upon closer inspection, I noticed a small spot of green suggesting that there was some corrosion which became a high-resistance connection point, causing the over heating. I re-crimped both black and white wires, and inspected all other wires in the box to make sure no other wire had become too hot to melt their insulation. Upon applying power again, all receptacles are properly powered.

I think I dodged a major bullet brought on by another occurrence of sub-standard workmanship by the DRV Mobile Suite manufacturing crew. Fortunately they used a non-metallic box, and the sparks were properly contained in the box. But, it could have been much worse.

We have had numerous other electrical, water, and hydraulic system problems (including a slide that came out while we were driving at 60 MPH due to a failed hydraulic valve) which have been fixed by the selling dealer.

I plan to continue to document these issues so perspective buyers know what they are spending their hard earned money for!

A couple of pics are attached showing the failed wiring.

[Squerly]

That's some scary stuff and yes, I believe you dodged a bullet this time. Can't help but wonder what other electrical gremlins await you?

[16ACE27]

Originally Posted by Squerly

That's some scary stuff and yes, I believe you dodged a bullet this time. Can't help but wonder what other electrical gremlins await you?

Looks like standard Thor electrical work. Its not limited to the DRV crew, its a common occurrence where the electrical elements of water heaters and Automatic Transfer Switches are installed in all Thor RVs. Must check areas if you own one.

[Bob Denman]

It's a shame that you HAD to catch this before it became a real disaster...

But it's a really good thing that you did!

I'm glad that everything turned out okay...

[Cummins12V98]

EVERYONE should disconnect power from RV and tighten EVERY electrical connection from the cord reel to the breaker boxes.

[Bob Denman]

Amen...
It's better to take the time checking these things over; than wasting it while talking to the Fire Marshals!

[rynosback]

Stop giving me things to do guys. I sold my stick and bricks home so I could stop working on it. My life is full of relaxing, seeing things and having fun.

[Squerly]

Hey Irontent, it might be my imagination, but you don't seem to be to impressed with Thor?

[rynosback]

Originally Posted by Cummins12V98

EVERYONE should disconnect power from RV and tighten EVERY electrical connection from the cord reel to the breaker boxes.

Even the breaker boxes?

[Bob Denman]

And clean the wax out of your ears also!

[rynosback]

Has anyone thought of using these connectors?
https://www.homedepot.com/p/Ideal-32...-202894308-_-N

VS what DRV used.

https://www.amazon.com/Closed-Crimp-...15478728&psc=1

[10scDust]

Scary just thinking about what could have happened!
Good thing you were around when it happened and have the where with all to correct it.

Not sure how anyone else feels about it, but I use a de-oxidizer grease on connections, once I have been to them.
Is that a good idea?

[The Gritz Carlton]

Originally Posted by 16ACE27

Looks like standard Thor electrical work. Its not limited to the DRV crew, its a common occurrence where the electrical elements of water heaters and Automatic Transfer Switches are installed in all Thor RVs. Must check areas if you own one.

Thor purchased DVR in January 2015. This was designed and built by DRV, not Thor. Probably one of the many reasons DRV failed. Other than a bail-out, I believe DRV's as still being manufacturer in the original facility with the same crews and management teams used prior to the acquisition.

[16ACE27]

Originally Posted by The Gritz Carlton

Thor purchased DVR in January 2015. This was designed and built by DRV, not Thor. Probably one of the many reasons DRV failed. Other than a bail-out, I believe DRV's as still being manufacturer in the original facility with the same crews and management teams used prior to the acquisition.

The OP has a 2016 model. They had been assimilated by then.

[The Gritz Carlton]

...."I believe DRV's as still being manufacturer in the original facility with the same crews and management teams used prior to the acquisition."....

[Porkchop]

They are in the original facility with the original people, They were not "bailed out" nor failed. They were a very profitable company still owned by the founders of the company and sold for a very attractive price. The American dream. They kept the management team because they were effective for the company. You should check the facts before posting stupid stuff.

Bill

[The Gritz Carlton]

For a company that generated $135M per year to sell out for $47M...The American Dream for sure!!! LOL

[Cummins12V98]

Originally Posted by rynosback

even the breaker boxes?

every single connection!!!