2024 Interstate with Volta E1 - Failures

[Boxster1971]

Originally Posted by m210658

I was shocked when I looked at the wiring mess under the CS ottoman. My conclusion was:

The front of our Interstate 19 has been designed by German engineers - the back has been built by Airstream's carpenters. . . .

Agree with StogieMan - a great comment. I've always thought that Airstream does not have electrical engineers on staff.

Sound like you have a great project. I did something similar to my old 2013 Interstate but stayed with AGM batteries back in 2014.

I didn't want to spend all my time rebuilding another van. I started to go custom with Advanced RV, but it got too expensive at 2-3 times the cost of a new Airstream Interstate.

Now I'm slowly rebuilding the things that need improvements in between my road trips.

[Rocinante]

Yeah, we've had a desire for an Advanced RV unit for years, but every time I look at the likely cost, I decide to upgrade something on our van that's been annoying me. Much less expensive that way, hah!

[Boxster1971]

Originally Posted by Rocinante

Yeah, we've had a desire for an Advanced RV unit for years, but every time I look at the likely cost, I decide to upgrade something on our van that's been annoying me. Much less expensive that way, hah!

Agree - that's why I bought another Airstream Interstate. Like the artistic design and can fix the shortcoming in the electrical and plumbing myself.

[m210658]

Hi StogieMan,
as you noticed, I'm new to the forums and quite busy right now. My wife wants her garage back and the backyard cleared out

Unfortunately I didn't take a lot of before-after pictures, it kind of interferes with the workflow when you do things alone. I have a few shots though and may take up your suggestion in a week or two.

Not sure how many people are crazy enough to buy a 1 year-old RV (got a good deal on our 2022 Interstate 19) and immediately rip it apart. Just FYI, our generator had 6 hours on the clock, the Van had driven 2400 miles when we got it. But it became quite obvious on the first short trips that starting the generator every time we needed to use the microwave for 30 seconds was not a good option - now the generator has run a total of 16.8 hours and is sitting in a corner of the backyard. Sigh!

I guess, I will write up the entire story when I'm done with the upgrade - the box is almost finished, time to wire it up and then mount it.

:-) Michael

[AJDurr]

Originally Posted by Boxster1971

StogieMan - I agree 100% and can see myself opening up the Volta PDH at some point as it contains the Inverter/Charger, DC-DC converters, SmartSolar controller and numerous fuses. I would not open the FlexPack as it is at another level of complexity. I do plan to do a FlexPack firmware update soon. They have the firmware loader software on the Volta web site. It only requires a laptop connected to the internet and a USB-B to USB cable that I have in my collection of old cables. Image of loader start page attached - FYI.

I replaced the Volta display sent as retrofit of E1. Trick is (not to yank on the dispay) to pry the panel out of the latches and then you have full access to unscrew the old display and attach the new display. Takes about 20 minutes doing for the first time. I have uploaded photos of the process in tge Airstream Interstate FB group. If anyone has replaced AC Detect harness in PDH, I would like to know how to access PDH to save some time.

[Rocinante]

Looks good! Are you putting these batteries where the generator used to be? Such a tempting idea, though I suppose they would be more exposed to a wider range of temperatures. Definitely looking forward to reading more about your project(s) here when you have time.

Originally Posted by m210658

Hi StogieMan,
as you noticed, I'm new to the forums and quite busy right now. My wife wants her garage back and the backyard cleared out

Unfortunately I didn't take a lot of before-after pictures, it kind of interferes with the workflow when you do things alone. I have a few shots though and may take up your suggestion in a week or two.

Not sure how many people are crazy enough to buy a 1 year-old RV (got a good deal on our 2022 Interstate 19) and immediately rip it apart. Just FYI, our generator had 6 hours on the clock, the Van had driven 2400 miles when we got it. But it became quite obvious on the first short trips that starting the generator every time we needed to use the microwave for 30 seconds was not a good option - now the generator has run a total of 16.8 hours and is sitting in a corner of the backyard. Sigh!

I guess, I will write up the entire story when I'm done with the upgrade - the box is almost finished, time to wire it up and then mount it.

:-) Michael

[m210658]

Yes, I build a custom box that mounts directly to the structure that held the generator - the box is made from 5 mm Aluminum. I found a company in Utah that took my drawing and bent the sheet metal, I did the rest.

The EPOCH batteries I use have a heater, just like the BattleBorn batteries (2x 100 Ah) that came with the Interstate 19. The two BB batteries were mounted under the chassis, right under the steps on both sides - so I don't think the operating conditions will be significantly different. The EPOCH batteries' BMS automagically handles the heating, the OEM batteries had an additional signal to turn on heating. The signal is controlled by a key switch.

[Rocinante]

That sounds like a great solution. Please do share when it's all done. We currently have 400Ah of LifeBlue lithium batteries under the rear lounge on the passenger side, along with our 3kW Victron inverter/charger. The gear is safe in there, but it sure would be nice to have that space back and to have it all outside so that when the batteries are discharging and the inverter is generating heat they all do that outside the van.

[m210658]

Update - I finished the box and, with the help of my son, installed it under the van. After connecting all the wires, it just works! It has been a 7 week project and it finally reached the state where it can be used. The last two days the sun helped increasing the SoC of the batteries from 84 to 92 %, everything works

[SunnyApp]

Since the work done by Volta on our system, things have been 100%. Not 100% better - totally 100%.

For three weeks our Volta system has been turned on.

On and off shore power about 10 times. Zero confusion in either Volta or the Firefly.

Boondock - 9 nights. Never got below 40% on the batteries. AC used the whole time.

Travel time: 2 hours min each day and the batteries have fully charged. This is quite honestly why we bought this because we never stay put in one place for more than a night.

New features:

- the Volta now shows how long it will take to charge (assuming you have more current coming in than going out).
- system goes into a ‘bypass’ mode display when plugged in
- no longer have to flip to tell it how many amps coming in when on shore power
- Volta app seems to work without disconnecting

____

If you have got your AS IS in for the ‘upgrade’ have you had the same improved benefits?

[Boxster1971]

Originally Posted by SunnyApp

. . . If you have got your AS IS in for the ‘upgrade’ have you had the same improved benefits?

I called Volta two weeks ago and had them send me the new display, PDH patch cable and link to the firmware uploader. Last week I did the firmware update myself using a laptop and proper USB cable to the battery under van. Installed the new display and returned the old one with Volta provided return label. Also installed the PDH patch cable.

My Volta system was working OK before these upgrades. The PDH was replaced by dealer back in February as the alternator charging never worked. I have boondocked in early July using the A/C on Volta battery several nights when traveling to and from our destinations. This is also the reason I got the E1 option with large Volta battery.

With new firmware I no longer get the false alarms in the Volta app that the system needs to be reset. It also does not randomly turn on the inverter as it did before. Noticed that the alternator charging now will go to 98% SOC, compared to only 95% before the firmware update.

The Volta app on my iPhone is still a little flakey and often has to be restarted to work. That is an app problem and Volta needs to update the app.

Now I just hope that my Volta system keeps working as designed.

[AJDurr]

What does the PDH patch cable and does it work for you? I have changed the PDH patch twice and both times the system starts charging and shuts down. I have used different shore powers, 20 and 30 amps, same result. Frustrated with the harness patch. Any thought except keep pushing Volta.

[Boxster1971]

Originally Posted by AJDurr

What does the PDH patch cable and does it work for you? I have changed the PDH patch twice and both times the system starts charging and shuts down. I have used different shore powers, 20 and 30 amps, same result. Frustrated with the harness patch. Any thought except keep pushing Volta.

When you say the system starts charging and shuts down do you mean the charging shuts down? Or does the entire Volta system shut down, disabling all electrical power on the coach side?

I don't exactly know what Volta intended to fix/change with this PDH patch cable. I suspect it changes some function of the Inverter/charger.

Today I noticed some unusual behavior. Don't know if this is new or something I just never noticed before.

I was testing the hot water heater after re-plumbing the water lines to remove the hot water mixing valve. My AI19 has the Truma Combi D unit which is different than the Elwell unit on your AI24GT.

I set the Truma for maximum electric heating of the water, which draws 1700 watts. I was plugged into 30A shore power. Volta battery was at 85%, set charging to 10A and then noticed it was not putting power into the battery, it was showing -45 watts power flow on the Volta display. Then I upped the charging to 15A and the battery started to get a charge, positive power flow on display.

There appears to be some form of power management being done by the Volta inverter/charger depending on other component power consumption. I thought that only the FireFly EMS managed power use.

It was too hot for me to do more investigation of this observation. I'll try looking at it again later this week.

[AJDurr]

When I insert the AC detect harness patch and connect the shore power, Volta display and Firefly turn on, batteries begin to charge for about 10 seconds (I see the flow), then Volta abruptly shows the message “System shutting down” and everything turns off including the power switch. Used a new patch sent to me and it did the same thing. . I called Volta to speak with Jon Myer, the tech support who has been helping me, was on leave. However, the Volta phone tree now has an option for AC Detect patch problem which of course goes to a voice mail. Without the patch, charging works fine and alternator doesits job. I am puzzled about the purpose of this patch.

[Boxster1971]

Originally Posted by AJDurr

When I insert the AC detect harness patch and connect the shore power, Volta display and Firefly turn on, batteries begin to charge for about 10 seconds (I see the flow), then Volta abruptly shows the message “System shutting down” and everything turns off including the power switch. Used a new patch sent to me and it did the same thing. . I called Volta to speak with Jon Myer, the tech support who has been helping me, was on leave. However, the Volta phone tree now has an option for AC Detect patch problem which of course goes to a voice mail. Without the patch, charging works fine and alternator doesits job. I am puzzled about the purpose of this patch.

Yikes! That is a serious issue. Forget the patch cable and enjoy your van.

I've noticed that Airstream seldom builds these vans the same way in a given model year. This makes a vendor like Volta at the mercy of varying configurations in the electrical system. I've asked Volta why they didn't have an Airstream Vehicle-Specific How-To Guides on their support page. They said they do not have any Airstream units at Volta, and would need one for the guide.

Does your Interstate have the Dual RIB Box installed?

The wiring diagrams in the owner's manual for my 2024 AI19 w/E1 indicate there is a Dual RIB Box in the 30-Amp 120-Volt Schematic. But there is not one installed in my van. The 120VAC wiring in my van is correctly wired to separate the two shore power circuit breakers from the inverter output that has all the other system circuit breakers.

Airstream has messed with the 120VAC neutrals wiring that I'm convinced has caused issues, especially the Volta equipped vans.

Today I did more testing of the Volta Charge Rate Selection. It sets the limit of the shore power independent of the shore power setting on the Firefly system. I was plugged into 30A shore power with the Firefly set to 30A shore power but had the Volta charge rate set to 10A. When running the A/C drawing about 11A the Volta display indicates -50W as seen in attached photo. This seems weird to me because I've told the FireFly system that there is 30A of 120VAC power available, but the Volta system does not use that 30A source and instead starts drawing from the battery to power the 12VDC circuits. When I increased the Volta charge rate to 15A, 20A, 25A or 30A it would allow more power to come in from shore power to run the A/C and charge the Volta battery.

[AJDurr]

Originally Posted by Boxster1971

Yikes! That is a serious issue. Forget the patch cable and enjoy your van.

I've noticed that Airstream seldom builds these vans the same way in a given model year. This makes a vendor like Volta at the mercy of varying configurations in the electrical system. I've asked Volta why they didn't have an Airstream Vehicle-Specific How-To Guides on their support page. They said they do not have any Airstream units at Volta, and would need one for the guide.

Does your Interstate have the Dual RIB Box installed?

The wiring diagrams in the owner's manual for my 2024 AI19 w/E1 indicate there is a Dual RIB Box in the 30-Amp 120-Volt Schematic. But there is not one installed in my van. The 120VAC wiring in my van is correctly wired to separate the two shore power circuit breakers from the inverter output that has all the other system circuit breakers.

Airstream has messed with the 120VAC neutrals wiring that I'm convinced has caused issues, especially the Volta equipped vans.

Today I did more testing of the Volta Charge Rate Selection. It sets the limit of the shore power independent of the shore power setting on the Firefly system. I was plugged into 30A shore power with the Firefly set to 30A shore power but had the Volta charge rate set to 10A. When running the A/C drawing about 11A the Volta display indicates -50W as seen in attached photo. This seems weird to me because I've told the FireFly system that there is 30A of 120VAC power available, but the Volta system does not use that 30A source and instead starts drawing from the battery to power the 12VDC circuits. When I increased the Volta charge rate to 15A, 20A, 25A or 30A it would allow more power to come in from shore power to run the A/C and charge the Volta battery.

Thanks for your response. I am not sure if I have the dual RIB. I tried the harness patch again, it chages from the shore power when the power button is on and shuts down when the power button is off or tirned off during charging. It supposed to go into bypass mode, but it suts down instead. Any guess!

[Boxster1971]

Originally Posted by AJDurr

Thanks for your response. I am not sure if I have the dual RIB. I tried the harness patch again, it chages from the shore power when the power button is on and shuts down when the power button is off or tirned off during charging. It supposed to go into bypass mode, but it suts down instead. Any guess!

Ok - that is more interesting information.

Now I understand with the PDH patch cable your Volta system charges properly on Shore power. That is good.

However, when you turn the Volta system OFF while connected to shore power it shuts down completely rather than entering the Shore Power Mode. I assume that is what you have called "bypass mode".

Normally when in Shore Power Mode, the Pushbutton LED flashes green continuously. Then the Volta system should only shut down fully when shore power is disconnected or lost for other reasons like a tripped circuit breaker.

My AI19 with the new PDH patch cable does properly go into the Shore Power Mode. I tested it yesterday. I even got a notification from the Volta App that the system had shut down due to loss of shore power.

One tip is to be sure you only push the Volta Pushbutton once briefly when turning it ON or OFF. Holding the button or pushing it more than once can cause unusual conditions. The Flex-Pack User manual even cautions about repeatedly pressing the Pushbutton with this caution:

"Do not repeatedly press the pushbutton. After pressing the button, wait 30
seconds for all system checks to occur before pressing the button again."

[Rocinante]

Gotta say, if Airstream ever delivered an E1 to Volta, it's more likely Volta would have to produce a document for Airstream on how to never ever install their gear.

[Cuervo]

2024 Interstate GT E1 here -- traveled coast to coast US, up to Alaska and final failure mid BC headed to Anchorage. Had intermittent E1 failures and solved with SunnyApproach fix on YouTube until it stopped working - was in Alaska - nearest Airstream dealer in Edmonton so now AirBnb here - almost fixed, but shorepower not charging - transfer switch issue- harness and touchscreen etc replaced. Been 2 weeks. Hoping for final fix in next few days. Wiring is different each year it seems in AS coaches leading to confusion for installers - a rats nest of wires and fuse boxes and PDH etc. They must get approval from Ohio factory and Volta before performing changes. But. Sunny got his fixed, so hope for me! Appreciate your comments all of you - been ghosting forum - but in the stew here. An American in Canada - but the service dept is excellent - I don't blame them. I run a music studio off my E1 off grid - when it works, it's amazing. Along with Starlink - incredible internet in the wilds. I am reminded of the early days of computers and blue screens of death - now - things work. This is a transistional period for this stuff. Overall though, feel lucky to be off grid for a week or more with internet and AC luxuries. Bonus - Canadian dollar is 72% of US - so - nice to pick up goodies at Canadian Tire etc on the cheap!

[Boxster1971]

Cuervo - thanks for sharing your experience. You are correct that there are a lot of wiring variations in every Interstate built by Airstream. The messy wiring approach doesn’t help the assembly workers get the job done right.