Problem with Waeco 12V plug in battery box socket

Thanks Alan. Your diagnosis could be correct. To work in the adaptor outlet the Waeco plug has to be pushed in hard and easily pops back out to the point where it doesn't work. But a new problem has arisen. After about 2 hours the error light on the Waeco started flashing so I moved the Waeco plug to another adaptor (I think it came with the inverter) that has alligator clips that I have clipped onto the main terminals of the battery box. Fixed the problem immediately. That suggests to me that the wires to the socket in the battery box are too small. Perhaps the battery box is not up to scratch.
I wondered if the Waeco 12V lead could be modified by fitting a different fuse and + and - leads with battery terminal ends on them for a permanent fit to the battery box. THat would be much more secure than plug and socket.
Kevin

Kevin, if the plug pops back out it suggests that the side (negative) contact on the plug is not applying sufficient force on the sides of the socket. This would not only allow the plug to become disengaged but also will not be making a good electrical contact. With a poor contact here the voltage available to the Waeco would be reduced and result in an error signal. It is not necessarily so that the wires are "too small". Study this dodgy plug and compare it to others. Possibly it can be corrected by judicious resetting of the side contacts.

Cigar plugs are by nature unreliable electrical connectors and changing to Anderson plugs can be a good move. You just need to be able to make the cable connections within the Anderson plug either by crimping using a correct tool or by soldering. If you go this way you will find the + and - connections marked on the Anderson plugs and in the case of the flexible Waeco cable the negative conductor is denoted by fine ribs moulded onto the PVC insulation of the cable. Be sure to get this polarity correct.

I eliminated plugs altogether on my fridge and wired the Waeco cable directly to the battery supply (via a fuse of course). I then purchased a replacement Waeco cable for using the fridge out of the vehicle, such as when being supplied from 240v via the mains module.

I have found a need to retain several 12v cigar plugs within the vehicle to supply those devices that have voltage reducers (5v) within the cigar plug. By selecting the cigar sockets carefully I have had no trouble with these, but they draw much less current nor are as critical as the fridge.

Sounds like Anderson plugs and a spare Waeco cable are the way to go. I've been a bit concerned about cigar plugs as they can easily be dislodged on rough road if gear starts moving around. I think a cable from the battery (with fuse) to an Anderson plug fixed to my storage unit right beside where the fridge goes on the car is the most secure arrangement. We don't want to have a hot fridge at the end of the day, do we?
Thanks for your help.
Kevin

I did the same as Alan B, permanently wired to screw terminals and a spare lead.

Kevin,

Had the same problem. Ditched the cig. and put Anderson plug in place. No more hot fridge on a rough road. Get a second cord for times you need the cig end. I take my fridge out of the ute when camping for a coupla days so that it can be plugged into the trailer.

Cheers

Greg

Hi Kevin,
Dont forget to add an inline fuse as well.
Cheers
Bushpig51

Thanks Bushpig. That was my next question. Does it matter which side of the Anderson plug that the fuse is fitted?
Kevin

Hi Kevin,
I have a 50 amp fuse between the battery and Anderson plug and a 10 amp blade fuse between the next Anderson plug and the fridge plug.
Cheers
Bushpig51

Hi Bushpig. Two of you are saying much the same thing. Must be right. It's a problem when you become more confused from conflicting advice.
Thanks,
Kevin

Kevin, your'e right about "conflicting advice".
Mind you, there are always alternate viewpoints.
It's just that some are more alternate than others! LOL

Interesting point, Barry. The ones that work are those with a smooth tube. One of those was a bit dicey but the second one worked but may not continue to do so under gravel road conditions.
The socket in the battery box has a full circle if contact material inside the entrance but this then breaks up into 4 equally spaced "fingers" of metal, each about 12.5% of the circumference. Could be that the contacts on the side of the cigar plug are going past the initial ring and need to be twisted to get a good contact on the fingers. But with Anderson plugs none of this matters, does it?
Cheers,
Kevin

That makes a lot of sense, Bill. I am a customer of Sidewinder and know what a Merit plug is and does. I have just had Derek's battery isolator fitted to my Jackaroo to charge the battery the use of which has spawned there problems with plugs and sockets. Tanks for your input.

Hi Bill. I'm not Familiar with the Engel plug but heat does seem to be an issue. I brought the Waeco and battery inside where I could watch it easier to try to run it from the cigar socket again. It would run for about 90 minutes and then disconnect its self. When I pulled the plug out to check it, the centre contact was too hot to touch.
I intend to talk to my local Waeco service agent this morning to get his take on it.
Cheers,
Kevin

Hey Kev, ....."the centre contact was too hot to touch."

There's your answer. If the contact was hot it was because of a poor connection causing a voltage drop at the contact and, with the current flowing through it, producing heat.

This same voltage drop would be subtracted from the nominal 12v and rob the supply to the fridge, causing it to disconnect itself.

Remedy? Change the plug and socket.

Kevin, The front of an Engel plug unscrews to reveal 2 prongs & a groove. These fit into corresponding spots in the socket so the polarity is correct. The cover then screws in to keep it all together. The Engel socket comes labelled + & - & fused with ends ready to attach to your battery. I drilled a hole in the top of the box & attached the provided bracket. The main thing is not to lose the front part of the plug. Bill