PD4635 converts and charges, but no AC to coach

[nicaland]

Three years ago or so I replaced my crappy stock converter/charger with Progressive Dynamics PD4635. I'm in no way an electrician, but it wasn't a difficult job to do correctly, same with other electrical projects such as installing solar panels and a charge controller for them, installing an inverter, etc. so I have a pretty good grasp of most electrical principles.

This converter has been functioning perfectly since, and for that matter is still producing a clean 12V supply and properly charging my batteries, so it's obviously still getting 120V from both shorepower as well as my generator from the AC transfer switch, but no AC to any AC required devices or outlets. The main AC breaker and all of the other ones have not tripped. I do have one gfci equipped outlet and it has not tripped. I do notice a faint hum coming from the box that houses everything (old Parallax/Magnateck enclosure) that I don't remember hearing before.

I just don't get it. Anybody got an idea what could be going on here?

[booster]

Originally Posted by nicaland

Three years ago or so I replaced my crappy stock converter/charger with Progressive Dynamics PD4635. I'm in no way an electrician, but it wasn't a difficult job to do correctly, same with other electrical projects such as installing solar panels and a charge controller for them, installing an inverter, etc. so I have a pretty good grasp of most electrical principles.

This converter has been functioning perfectly since, and for that matter is still producing a clean 12V supply and properly charging my batteries, so it's obviously still getting 120V from both shorepower as well as my generator from the AC transfer switch, but no AC to any AC required devices or outlets. The main AC breaker and all of the other ones have not tripped. I do have one gfci equipped outlet and it has not tripped. I do notice a faint hum coming from the box that houses everything (old Parallax/Magnateck enclosure) that I don't remember hearing before.

I just don't get it. Anybody got an idea what could be going on here?

It sounds like the main breaker for the AC is tripped and PD is not wired through it, just straight off the mains.

[nicaland]

Thanks Booster, but no, the main AC breaker has not tripped. When I installed the PD I'm sure I did it by the book; I can't remember but apparently the converter/charger section receives AC before the main AC breaker, because when I flip it off the converter is still getting AC power. I'm contacting Progressive Dynamics today and will report their response.

[mkguitar]

flip your AC main breaker to "off".


If the PD still has power, you have a wiring fault.


If you don;t have power- good.


You must now trace your power system to find the fault


check the transfer switch, check each breaker and the panel

[booster]

Since this is not a standalone PD system and goes into and older control center box, just check for 110v power at the input to the control center and output of the control center. If you have power in and no power out, you have an issue with the PD.

[nicaland]

Thanks guys very much for your input. Turns out that an automatic transfer switch (a GoPower MC-30) that I installed when I mounted an inverter to avoid everything potentially turning to smoke if I inadvertently had the inverter running when on shorepower or genny power is defective. The buzzing I was hearing was coming from it, and lightly tapping on the contacts stopped the buzzing and viola I had AC power in the coach again, but after carefully cleaning it's contacts with a bit of emery cloth it stopped functioning completely, which is just weird, but replacing it with a new one is simpler and cheaper than buying a new PD4635 for sure!

[nicaland]

Correction: The tranfer switch I installed is a Powermax PMTS-30, not a GoPower MC-30. Sorry 'bout that.

[booster]

Originally Posted by nicaland

Thanks guys very much for your input. Turns out that an automatic transfer switch (a GoPower MC-30) that I installed when I mounted an inverter to avoid everything potentially turning to smoke if I inadvertently had the inverter running when on shorepower or genny power is defective. The buzzing I was hearing was coming from it, and lightly tapping on the contacts stopped the buzzing and viola I had AC power in the coach again, but after carefully cleaning it's contacts with a bit of emery cloth it stopped functioning completely, which is just weird, but replacing it with a new one is simpler and cheaper than buying a new PD4635 for sure!

Generally, in systems that have a genny, shore power, and the 110v output from an inverter, it would be done with two automatic transfer switches because you have to handle 3 inputs.



The first ATS would switch back and forth between shore power and generator and the second would use the output from the first ATS and the inverter output and switch between them. The output of the second ATS would go to van 110v circuits.


They used to make 3 input ATS switches but I haven't seen one in a long time.

[nicaland]

Yes Booster, I do have two ATS as you have described. I bought this one at Amazon, and should have read the reviews a bit more thoroughly as many of these have failed in the exact same way as mine. I ended up with this one because it's dimensions allowed me to place it in the only spot available (and it was pretty cheap too....)

[lejeep]

Originally Posted by nicaland

Three years ago or so I replaced my crappy stock converter/charger with Progressive Dynamics PD4635. I'm in no way an electrician, but it wasn't a difficult job to do correctly, same with other electrical projects such as installing solar panels and a charge controller for them, installing an inverter, etc. so I have a pretty good grasp of most electrical principles.

This converter has been functioning perfectly since, and for that matter is still producing a clean 12V supply and properly charging my batteries, so it's obviously still getting 120V from both shorepower as well as my generator from the AC transfer switch, but no AC to any AC required devices or outlets. The main AC breaker and all of the other ones have not tripped. I do have one gfci equipped outlet and it has not tripped. I do notice a faint hum coming from the box that houses everything (old Parallax/Magnateck enclosure) that I don't remember hearing before.

I just don't get it. Anybody got an idea what could be going on here?

Hello nicaland,
I hope you are still around.
I also have the old parallax 7300 on my 2003RT. It never worked and for the heck of it, I decided to repair it with no results so far.

Would you happen to still have the old one you removed?
If so I would be very interested if you could post a couple pictures of the board. I have the feeling someone worked on it before me and could have replaced some components with less than ok substitutes.

Thanks in advance!
I am running out of ideas...

[nicaland]

I threw the original converter away after installing the Progressive Dynamic unit, and resolved the issue with it so it is still in use. I'm not sure which one you are asking if I still have, but if you are talking about using the old single charging stage type of converter/chargers I strongly recommend not to do so!

[GallenH]

I also replaced the converter portion on my Magnetec unit in 1997 PW. It was working ok but I, like nicaland, wanted a multiple state charger. The Progressive Dynamic conversion was pretty easy and allowed me to retain the distribution portion (DC routing/fuses and AC routing breakers) from the old Magnetec.

[nicaland]

The advantages of installing the PD charger/converter over the puny stock unit are huge and so very worth it's cost and installation work. I built in the option of powering my TV with AC or DC, which was impossible with the old unit because it's DC output was too dirty for the TV to recognize, and when plugged into shorepower or running the genny, battery charging time is massively reduced. Additionally, I keep my unit plugged into shorepower all of the time at home; doing that with your old charger would definitely over time cook your batteries. The charging unit on the PD is so good that after 6 years (maybe more, can't remember exactly) of use, my current set of cheapo Walmart flooded lead acid deep-cycle batteries are still going strong, and I've only had to add a little water one time since installed!

[lejeep]

Ok. Thanks for looking anyway.
I know the original is less than perfect, but as I wanted to test my repair skills with this unit.
Since I already pitched around $100 in it, might as well finish the job.

[lejeep]

Hello GallenH,
Would you happen to still have the old Magnetec lying around.
If so, I would appreciate if you could post some pictures.
As I mentionned to Nicaland, I suspect the previous owner(untraceable) replaced some components with innapropriate stuff.
There is no schematic to be found so only pictures can confirm this.
Thanks in advance.
Daniel

[GallenH]

Sorry. Wish I could help you out but I did the PD conversion about 7 years ago and don't have any of the old components.

[lejeep]

Thanks anyway.
Gotta be someone with the old one laying around.