power converter replacement

Sounds like you have it under control
I have pictures and schematics if need be
Send me a PM if you need additional help

Posted By: dryfly on 01/10/15 06:41pm

KJINTF wrote:

"Any tips on what might be the culprit on the WFCO board. I'm told the capacitors frequently develop leaks. What else."

The majority of the time a small 220ufd 25Vdc cap located by the two large series resisters develops excessive ESR. The symptom is that the converter will output the proper Voltage without any load, once a load is applied the voltage quickly drops. Suggest an ESR meter across the cap or simply replace the cap and hope for the best.


That is exactly the symptoms the converter is experiencing. For some reason it's been an intermittent problem. It would reduce output voltage then later would return to full voltage output.

I don't have an ESR meter but may well have a capacitor of that value in the junkbox. I'll look for the large series resistors and hopefully the cap is labeled so I can find it. I'm not too terribly concerned about replacing the unit with the PD4655 as I feel I'll have a lot better power converter. Thanks for your advise.

j-d wrote:
Pic of a PD 4655

Am I correct in thinking that it replaces a PORTION of one or more popular Makes/Models of Converter/Charger?

We have an IOTA that I'd describe as All-In-One. It's OEM, no doubt cheap, and it comprises:

AC Breaker Panel
DC Fuse Panel
Power Converter 120VAC >> 12VDC
House Battery Charger

I can DO Wiring, Cutting, Fitting, Trimming. I anticipate a total nightmare swapping out the IOTA because all the related wiring is cut short. I can barely replace a Breaker let alone connect the wiring we have to a new unit with a different layout.

How do I get that done?

First make sure you have the IQ4 for the Iota if it has the jack for it. Then you don't need to swap it out.

Yes, the whole thing is called a Power Centre and just the converter can usually be swapped out. Or leave it there and install a deck mount converter elsewhere (closer to the batteries is good)

dryfly wrote:

jrnymn7 wrote:
If all one is in need of accomplishing is simple conversion from 120v to 12v, wouldn't a simple psu work? (Just figure out max load draw and size accordingly). They come in both adjustable and fixed voltages.

~$60 for 40a, ~$110 for a 60a.

You also need a means of charging and regulating the battery, other than that, Yes. Most converters have 3 or 4 stages of charging from max to maintenance modes.

Indeed, but I got the impression you had a separate charger in place. I now see you had the battery disconnected for troubleshooting.

Nevertheless, as BFL alluded to, if you dry camp a lot, you may be best to go with two separate switching power supply units. Most have adjustable voltage. You can set one to a suitable voltage, i.e; 12v plus circuit voltage drop, for powering the rig's electrical, and the other to suitable charging voltages. This can work out very well, especially if the battery is a long ways from the 12v distribution. Just something to possibly consider.

Pic of a PD 4655

Am I correct in thinking that it replaces a PORTION of one or more popular Makes/Models of Converter/Charger?

We have an IOTA that I'd describe as All-In-One. It's OEM, no doubt cheap, and it comprises:

AC Breaker Panel
DC Fuse Panel
Power Converter 120VAC >> 12VDC
House Battery Charger

I can DO Wiring, Cutting, Fitting, Trimming. I anticipate a total nightmare swapping out the IOTA because all the related wiring is cut short. I can barely replace a Breaker let alone connect the wiring we have to a new unit with a different layout.

How do I get that done?

wa8yxm wrote:
YOu have two options.. OEM and Progressive Dynaics 4600

Personally I would inspect and very likely fix the one you have (Can do that if you are near Darian, GA) but if you replace, go with the PDI 4600 This is one of the Wizard controlled units and .. I'm still looking for something that's better than the charge wizard. Have yet to find one.. Some as good, or very close, but non better.

I replaced mine with a Powermax Boondocker. Direct replacement. Call Randy @ bestconverter

smkettner wrote:
Progressive Dynamics will serve you well.

www.bestconverter.com

Powermax main board assembly is probably the most direct replacement.

x2. That is what I have.

KJINTF wrote:
"Any tips on what might be the culprit on the WFCO board. I'm told the capacitors frequently develop leaks. What else."

The majority of the time a small 220ufd 25Vdc cap located by the two large series resisters develops excessive ESR. The symptom is that the converter will output the proper Voltage without any load, once a load is applied the voltage quickly drops. Suggest an ESR meter across the cap or simply replace the cap and hope for the best.

That is exactly the symptoms the converter is experiencing. For some reason it's been an intermittent problem. It would reduce output voltage then later would return to full voltage output.

I don't have an ESR meter but may well have a capacitor of that value in the junkbox. I'll look for the large series resistors and hopefully the cap is labeled so I can find it. I'm not too terribly concerned about replacing the unit with the PD4655 as I feel I'll have a lot better power converter. Thanks for your advise.

"Any tips on what might be the culprit on the WFCO board. I'm told the capacitors frequently develop leaks. What else."

The majority of the time a small 220ufd 25Vdc cap located by the two large series resisters develops excessive ESR. The symptom is that the converter will output the proper Voltage without any load, once a load is applied the voltage quickly drops. Suggest an ESR meter across the cap or simply replace the cap and hope for the best.

Depends on equipment and camping style. For most RVs 35 amps is plenty.

It is like a converter war in the brochure specs. With WFCO it is only a couple $$ more for 65 over 35. In some ways the 35 will actually operate better because it is far more likely to actually switch to boost mode when expected.

wa8yxm wrote:
YOu have two options.. OEM and Progressive Dynaics 4600

Personally I would inspect and very likely fix the one you have (Can do that if you are near Darian, GA) but if you replace, go with the PDI 4600 This is one of the Wizard controlled units and .. I'm still looking for something that's better than the charge wizard. Have yet to find one.. Some as good, or very close, but non better.

Any tips on what might be the culprit on the WFCO board. I'm told the capacitors frequently develop leaks. What else.

AS far as the Progressive Dynamics unit, the largest PD46xx is rated at 55 amps. My current WFCO is rated at 65 amps. I doubt that this would create a problem as I doubt I ever need that much capacity in the charging system. Any comments??