Connecting the Battery Box; Power Sourcing

Having the batteries in the tongue box and the Xantrex converter in the front of the trailer requires three 2/0 wires between the two locations.  To accomplish this we are connecting the box to the trailer with a 1-1/2" conduit and a "pattern sweep" to turn the cables up into the cavity where the Xantrex converter will be mounted.

First, we had to drill a hole in the tongue box, which required that we unbolt it from the frame.  See the hole below:

Next we drilled a hole through the front skirt of the trailer and the 2x6 inside frame member:

Here is a view of the conduit connector fitted into the tongue box; note that the final fitting will include a rubber washer to seal against the diamond plate:

This is a view of the fitting through the trailer skirt, which will also have a rubber washer in the final form.  A length of PVC conduit will connect the tongue box with the trailer.

Finally, once inside the trailer, a pattern sweep will lead the cables upward into the Xantrex cavity.

 

The top of the sweep will be extended with a coupler and a length of pipe as needed through the plywood floor of the Xantrex cavity via a bored hole.  It will be held in place with another coupling to fair the end of the run.

The Xantrex converter, to review, will:

1. Charge the battery (via inversion) when connected to "shore power" 
2. Provide 120v AC direct from "shore power" when connected
3. Provide 120v AC converted from the batteries when "shore power" is not present

DC power is always supplied directly from the batteries.  There is also a provision to trickle-charge the batteries from the car's alternator when underway.

The Xantrex has an AC end and a DC end.  The AC end will be oriented to port side where the shore power link will be installed.  The DC end will be to starboard, and that is the side to which the above detailed conduit link will be positioned.

The AC output from the Xantrex will be fed to an AC breaker panel for distribution.  The DC connection to the batteries will be fed to a DC breaker panel for distribution.  A pair of DC meters (voltmeter and ammeter) will be connected to observe the battery status.