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Old 05-09-2012, 04:26 PM   #31
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Default Re: Total Electrical Upgrade

Nice! glad you got on top of your hum issue. Electrical hum just about drives me crazy, Hmmm well the rest of the way to crazy anyway.
Pictures are always nice
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Old 05-11-2012, 09:07 PM   #32
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Default Re: Total Electrical Upgrade

An update on the replacement PD4045 converter from Progressive Dynamics.
This unit won't go into storage mode. It is stuck on 13.6 volts after being on for 4 days.

My batteries were fully charged when I installed the the replacement PD4045 converter from Progressive Dynamics.
The initial output from the replacement converter was 13.6 volts (normal mode). That is exactly what it should have been according to the owner manual.
After approx 24 hrs, with no load, the output voltage should have dropped to 13.2 volts (storage mode) according to the owner manual.

The PD4045 just won't go into storage mode and 13.6 volts is too high for storage use.

The original PD4045 dropped down to 13.2 volts after approx 24 hours when I installed it. It stayed at 13.2 volts all week after that except for a 15 minute period every 24 hours when it went to 14.4 volts in desulfation mode.

I called Progressive Dynamics today but it was too late to speak to a technician. The person I spoke to did give me troubleshooting info but that hasn't helped.
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Old 05-11-2012, 11:03 PM   #33
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Default Re: Total Electrical Upgrade

That sucks! you might have to get yet another board.
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Old 05-12-2012, 12:12 AM   #34
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Default Re: Total Electrical Upgrade

Yeah, I doubt that speaking to a tech will solve the problem. There's just nothing to field adjust on these as far as I know.
I rechecked all connections already. Disconnected the batteries. Went through the steps in the troubleshooting guide. And I used a second volt-meter to be sure.
I'll call them next week.
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Old 09-03-2012, 11:22 PM   #35
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Default Re: Total Electrical Upgrade

Just an update and maybe a work-around. I spoke to a tech at Progressive Dynamics on May 14 about the PD4045 not going into storage mode. He confirmed that there was nothing I could fix and that replacing the board was the only option. I told him I'd test it one more time. After 39 hours the PD4045 was still in normal mode (13.6 volts). I called the tech back and he agreed to send me a replacement board. I asked that they pack it a bit better than the last one as it was loose in the shipping box and would have been bounced around quite a bit in transit. He said it wouldn't be shipped right away because he was going to test it first to make sure that it was (1) quiet and (2) operated according to their specifications.

Well, the replacement board never arrived. I have seen the PD4045 in storage mode (13.2 volts) over the summer but I don't know how long it took for it to get in that mode. The tech probably forgot to send it or it got lost. I should have followed up after a month.

Today, I decided to put in a switch to change the output voltage to a Gel battery charging profile for when I want to reduce the voltage. The PD4045 has two charging profiles. Wet cell and AGM batteries have Boost Mode at 14.4 volts, Normal Mode at 13.6 volts for 30 hours and Storage Mode at 13.2 volts. The Gel battery profile reduces each of those voltage by approximately .4 volts. There are two pins on the board that you short with a jumper to change the PD4045 to use it with Gel batteries. Wet or AGM is 14.4v / 13.6v / 13.2v. Gel is 14v / 13.2v / 12.8v.

A properly operating PD4045 uses time to determine when to go into storage mode. It could be sitting there at 13.2 volts in Storage Mode for a week but if you disconnect from grid power and drive to the store and back home and plug in again it will go straight into Normal Mode (13.6v) for 30 hours. I don't like that. The batteries are fully charged so I think it is unnecessary to have them at 13.6 volts again.

I wanted to be able to lower the voltage at will without having to take off the cover of the PD4045 so I installed a small switch instead of just using a jumper to drop the voltage by .4 volts. I can now change the charging profile whenever I want to by sliding the switch on or off. If I've been driving for 6 hours (after leaving home with fully charged batteries) I can now set the PD4045 to 13.2 volts when I plug in at a campground instead of it being at 13.6v for 30 or more hours.

For most RV'ers automatic operation of the charger is best. I closely monitor my batteries so this added level of control is beneficial to me.

The two pins to be shorted to reduce output voltage by approx .4 volts:


I soldered the wires to the switch and protected it with heat shrink:


The wires are long enough to allow me to unplug them if I need to remove the PD4045 cover:


The installed switch:


Closeup of the switch:


The switch is not visible when the access door is closed:
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Old 09-05-2012, 04:29 PM   #36
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Default Re: Total Electrical Upgrade

Nice and simple mod, the best kind!
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Old 09-06-2012, 08:20 PM   #37
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Default Re: Total Electrical Upgrade

I checked today and saw that the PD4045 output voltage in Gel battery charging profile had dropped (as it should) to 12.8 volts. I don't know when it changed though. I moved the selector switch to put it back into the Wet or AGM charging profile and the voltage went back up to 13.2 volts as expected. So, this little mod is working as I hoped.
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