Truck Camper Wiring Guide: How Much Does It Cost?

Truck camper wiring is typically split into two subsystems: the 110-volt appliance system and the 12-volt chassis system. The 110-volt system is designed to power high-drain appliances such as air conditioning, televisions, and microwave ovens. The 12-volt system, on the other hand, is connected to the vehicle and serves the taillights and interior lighting. The wiring standards for these systems differ, with distinct wire colours designating a black or white negative ground.

Truck camper electrical systems have five primary power sources: 110-volt power (shore power), 12-volt power from batteries, solar power, power from gas or propane generators, and power from the truck's alternator(s). Shore power, also known as 110-volt or AC power, utilises a three-prong 15 or 30-amp power cord, which is plugged into a corresponding outlet. It can operate all systems in the truck camper, including the microwave, lights, fans, furnace, water pump, jacks, air conditioner, television, radio, slides, and appliances.

Battery power, also referred to as 12-volt or DC power, operates 12-volt appliances and systems such as lights, water pumps, and 12-volt televisions and entertainment systems. Some camper systems combine 12-volt power with propane for functions like the furnace and hot water heater. It is important to note that battery power typically does not run AC power appliances like microwaves and air conditioners.

Truck power is facilitated through a seven-way plug and umbilical cord installed by the dealer, connecting the truck's electrical system to the camper's. This setup operates the camper's turn signals, brake lights, and clearance lights, and includes a power wire that charges the camper's batteries while driving.

Generator power, derived from propane or gasoline, produces 110-volt AC power and essentially offers the same benefits as shore power when the generator is operational. Truck campers with generators can utilise them in remote locations without access to shore power, allowing full use of AC-powered appliances like microwaves and air conditioners.

Solar power involves 12-volt electricity collected by solar panels and stored in camper batteries. This option trickle charges the batteries during daylight hours, and its benefits vary based on the size and quality of the solar panels, controller, and batteries.

110-volt appliance system

Truck camper wiring is split into two subsystems: the 110-volt appliance system and the 12-volt chassis system. The 110-volt system is designed to power high-drain appliances such as air conditioning, televisions, and microwave ovens.

The 110-volt appliance system is an essential component of any truck camper setup, allowing users to power a range of appliances and devices. Here's a detailed guide to help you understand this system better:

Understanding the 110-Volt System

The 110-volt system, also known as shore power, operates on alternating current (AC) and utilizes a three-prong 15 or 30-amp power cord. This system is designed to power high-drain appliances, ensuring you can use modern conveniences while camping.

Wiring and Connections

When wiring the 110-volt system, it's crucial to follow safety guidelines and electrical standards. The wiring for this system typically involves a white/green/black tri-wire design, similar to the wiring in an average home. This allows users to power small appliances by simply plugging them into the camper's outlets.

Power Sources

The 110-volt system draws power from shore power connections, which are standard household outlets providing 110-120 volts of AC power. It's important to note that when using a 15-amp outlet, you may not be able to run high-drain appliances simultaneously without potentially blowing a fuse or damaging the electrical system. For simultaneous use, a 30-amp outlet is recommended.

Junction Box and Fuses

Truck campers typically have a power junction box that contains a fuse panel and power connections. This panel usually has an interior fuse block and an exterior 110-volt connection box with a cable. The fuse panel resembles a home's fuse block, with colored switches or screw-type fuses, and it's important to keep it free of debris to prevent electrical issues.

Safety Considerations

When working with the 110-volt system, always ensure that the wiring is secure and properly connected. Wiring the 110-volt and 12-volt systems together at any point other than the designated junctions can lead to severe damage and safety hazards. Additionally, always use stranded wire in a camper to prevent wire breakage due to vibrations.

110-Volt System Applications

The 110-volt system enables you to power a range of appliances and devices, including:

• Air conditioning
• Television
• Microwave oven
• Computers and cell phones
• Lighting
• Fans
• Furnace
• Water pump
• Jacks
• Radio
• Slides

The 110-volt appliance system is a crucial component of a truck camper's electrical setup, allowing users to power essential appliances and devices during their camping trips. By understanding the system's wiring, connections, and power sources, you can safely and effectively utilize the conveniences of modern appliances in the great outdoors.

12-volt chassis system

A 12-volt chassis system is an essential part of any camper van electrical setup. Here's a detailed guide on how to install and wire a 12-volt system in your truck camper:

Step 1: Understanding 12-Volt Power Sources

Firstly, it's important to understand the different power sources available in your truck camper. Typically, there are five primary power sources: 110-volt shore power, 12-volt battery power, solar power, power from generators, and power from your truck's alternator. For the 12-volt chassis system, we'll be focusing on battery power.

Step 2: Identifying 12-Volt Devices

Before you begin wiring, it's crucial to determine which devices in your truck camper will be powered by the 12-volt system. These typically include lights, water pumps, entertainment systems, furnaces, and certain types of refrigerators.

Step 3: Calculating Power Requirements

Now, you need to calculate the total power requirements of the 12-volt devices you've identified. This involves finding the amperage draw of each device and then summing them up. This calculation will help you choose the appropriate wire sizes and fuses for your system.

Step 4: Choosing the Right Wire Size

Selecting the right wire size is critical for the safe and efficient operation of your 12-volt system. The wire size depends on the amount of electrical current (amps) that will flow through them. As a general rule, thicker wires are required for higher amperage. You can refer to wire sizing charts, such as the one provided by Blue Sea Systems, to determine the appropriate wire size for your specific application.

Step 5: Connecting to the Battery

When connecting your 12-volt devices to the battery, it's important to use the correct type of wire and ensure proper connections. It is recommended to use pure copper wires with high strand counts for maximum flexibility and temperature resistance. Additionally, always include an appropriate in-line fuse in the positive lead to protect the circuit.

Step 6: Fuse Selection and Installation

Fuses are essential for safeguarding your 12-volt system. The fuse size should be based on the wire size you've selected. A fuse with a higher amperage rating than the wire can handle should be avoided, as it could lead to unsafe conditions. Install the fuse as close to the battery as possible, ensuring easy access for future maintenance.

Step 7: Grounding the System

Proper grounding is crucial for the safe operation of your 12-volt system. Consult your vehicle's user manual to identify an appropriate ground point on the chassis. Connect the negative terminal of the battery to this ground point using an appropriately sized wire and terminal.

Step 8: Wiring Devices to the System

Now, you can start wiring your 12-volt devices to the system. Ensure that each device is connected through a fuse or a circuit breaker to protect against short circuits and overcurrent situations. Use the correct wire size for each device, referring to the wire sizing charts as needed.

Step 9: Testing and Safety

Once your 12-volt system is wired, it's important to test it thoroughly. Use a digital multimeter to check voltage levels, continuity, and current draw. Always follow safety precautions when working with electricity, and if you're unsure, consult a professional.

Step 10: Maintenance and Troubleshooting

Regular maintenance of your 12-volt chassis system is important to ensure its longevity and reliable performance. Keep an eye on battery health, clean and tighten connections as needed, and periodically inspect wires for any signs of damage or corrosion. If you encounter any issues, refer to troubleshooting guides or seek assistance from a qualified technician.

12-volt power

When adding a 12-volt device or outlet to your camper, it is important to consider the available power sources. Here are some options for connecting a new 12-volt circuit:

• Direct connection to the batteries: This method is useful for circuits with heavy loads or charging needs, such as a solar panel charging system. It is important to include an appropriate in-line fuse in the hot (+/positive) lead for safety.
• Distribution bus: Some truck campers have a separate distribution bus with heavy-gauge connections to a distribution panel, generator, or other major connections. This can be another location to add a 12-volt circuit, provided it has an inline fuse.
• Existing circuits: Power can be redirected from an existing circuit with accessible wiring to the desired location. This approach is suitable for low-current devices such as cell phone chargers, LED lights, or small fans. It requires knowledge of the fuse size and the current draw of the new device.
• Empty distribution panel slots: If there are empty slots in the existing distribution panel, a new 12-volt circuit can be added, and the fuse will be installed in the panel.

It is important to note that running certain appliances, like a furnace blower or a refrigerator, solely on 12-volt power can quickly drain your batteries. To conserve 12-volt battery power, it is recommended to use propane or shore power whenever possible.

Solar power

Solar panels are wired in series, parallel, or a combination of the two. When wiring solar panels in series, the voltage of the panels adds up, but the amperage stays the same. When wiring solar panels in parallel, the amperage adds up, but the voltage stays the same. When wiring solar panels in series-parallel, the amperage and voltage of the panels add up.

Solar panels are wired in series when the solar array voltage is too low for an MPPT charge controller to operate optimally. Solar panels are wired in parallel when the solar array amperage is too high.

Solar panels are connected to solar charge controllers, which are connected to the battery bank. The solar charge controller regulates the voltage from the solar panel array down to a usable voltage for the battery bank.

Solar panels are connected to each other and to the solar charge controller using MC4 connectors.

Solar panels should be tilted toward the sun to maximize energy production. The angle of the tilt depends on the time of year and location. In the summer, the tilt angle should be equal to the site latitude minus 15 degrees. In the winter, the tilt angle should be equal to the site latitude plus 15 degrees.

Solar panels should be mounted securely to the roof of the truck camper. The mounting hardware should be strong enough to withstand the weight of the solar panels and the force of the wind. The mounting hardware should also be corrosion-resistant to prevent rust.

Solar panels should be mounted with a gap between them to allow for airflow and prevent overheating. The gap between the panels should be at least one inch.

Solar panels should be mounted with a tilt to shed water and snow. The tilt angle should be at least 10 degrees.

Solar panels should be mounted with a gap between the roof and the panels to allow for airflow and prevent moisture buildup. The gap between the roof and the panels should be at least one inch.

Solar panels should be cleaned regularly to remove dirt, dust, and debris. The panels can be cleaned with a soft brush or cloth and a mild detergent.

Solar panels should be inspected regularly for damage. Any damaged panels should be replaced immediately.

Solar panels should be grounded to prevent electrical shocks. The grounding wire should be connected to the negative terminal of the solar panel and to a grounding rod driven into the ground.

Solar panels should be fused to prevent electrical fires. The fuse should be sized according to the amperage of the solar panels. The fuse should be installed between the solar panels and the solar charge controller.

Solar charge controllers should be mounted in a dry, ventilated area. The charge controller should be mounted with screws or bolts to a solid surface. The charge controller should be mounted within easy reach for monitoring and maintenance.

Solar charge controllers should be fused to prevent electrical fires. The fuse should be sized according to the amperage of the solar panels. The fuse should be installed between the solar panels and the charge controller.

Solar charge controllers should be connected to the battery bank using appropriate gauge wire. The positive lead from the charge controller should be connected to the positive terminal of the battery bank. The negative lead from the charge controller should be connected to the negative terminal of the battery bank.

Solar charge controllers should be programmed according to the manufacturer's instructions. The charge controller should be set to the correct battery type and voltage. The charge controller should also be set to the appropriate charging algorithm for the battery type.

Solar charge controllers should be monitored regularly to ensure proper functioning. The charge controller display should be checked to verify that the solar panels are producing electricity and that the battery bank is charging. The charge controller settings should be adjusted as necessary to ensure optimal charging.

Solar batteries should be mounted securely in a ventilated area. The batteries should be mounted with brackets or straps to prevent movement. The batteries should be mounted off the floor to prevent moisture buildup.

Solar batteries should be connected in parallel to increase amp hours. The positive terminals of the batteries should be connected to each other and to the positive terminal of the solar charge controller. The negative terminals of the batteries should be connected to each other and to the negative terminal of the solar charge controller.

Solar batteries should be fused to prevent electrical fires. The fuse should be sized according to the amperage of the battery bank. The fuse should be installed between the solar charge controller and the battery bank.

Solar batteries should be monitored regularly to ensure proper functioning. The battery voltage should be checked with a voltmeter to verify that the batteries are charging and discharging properly. The battery fluid level should also be checked to ensure that the batteries are not overfilled or underfilled.

Solar batteries should be maintained according to the manufacturer's instructions. The batteries should be cleaned and inspected on a regular basis. The battery terminals should be cleaned and tightened to prevent corrosion and ensure proper conductivity. The battery fluid level should be checked and adjusted as necessary.

Solar battery banks should be sized according to the power requirements of the truck camper. The battery bank should be able to provide enough power to run all the electrical appliances and devices in the camper. The battery bank should also be able to store enough power to last through periods of low sunlight or high power usage.

Solar battery banks should be monitored and maintained to ensure optimal performance. The battery bank should be checked regularly to verify that all the batteries are connected properly and that there are no signs of corrosion or damage. The battery bank should be charged and discharged regularly to prevent sulfation and maintain the health of the batteries.

Solar battery banks should be upgraded as needed to meet the power requirements of the truck camper. Additional batteries can be added to the battery bank to increase the amp hours and power capacity. Higher-capacity batteries can also be substituted for lower-capacity batteries to increase the power capacity of the battery bank.

Power from gas or propane generators

If your camper features a built-in or portable generator, your generator uses propane (built-in generators) or gasoline (portable generators) to produce 110-volt AC power.

If you are looking for a quiet generator, the Yamaha EF2000iSv2 is a great option. It is a small and lightweight generator that produces 2,000 watts of peak power and 1,600 watts of continuous power. It has a patented and helpful 'Oil Watch' warning system and an 'economy' mode switch. It runs on gasoline and has a tank capacity of 1.1 gallons.

Another quiet generator is the WEN 56200i 2000 Watt Portable Generator. It is a lightweight generator that produces 2,000 watts of peak power and 1,600 watts of continuous power. It has an 'eco mode' switch and runs on gasoline with a tank capacity of 1 gallon.

If you are looking for a more powerful generator, the Honda EU3000iS 3000 Watt Generator is a good option. It is a quiet generator that produces 3,000 watts of peak power and 2,800 watts of continuous power. It has an eco mode and an oil sensor which will shut the unit off if the oil is too low. It runs on gasoline and has a tank capacity of 3.4 gallons.

If you are looking for a more affordable option, the Champion 75531i 3100 Watt Generator is a good choice. It is an inverter generator that produces 3,100 watts of peak power and 2,800 watts of continuous power. It has an economy mode and weighs only 80 lbs. It runs on gasoline and has a tank capacity of 1.6 gallons.

Frequently asked questions