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Old 03-29-2012, 05:37 PM   #1
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Default Total Electrical Upgrade

I'm planning to upgrade the electrical system in my van and have most of the parts I need. New fuses, wire, AC panel, DC panel, Converter / Charger, Inverter and automatic transfer switch. This project could end up costing about $1,000 by the time I get new AGM batteries even though I'm choosing the most economical items I can find.

The heavily modified existing charger is a 1970's model in the van and it includes the DC panel. It is overdue for an upgrade.

The limiter fuse, circuit breakers, fuse holder, Progressive Dynamics PD4045 45 Amp Inteli-Power Mighty Mini Power Center converter/charger and the Xantrex Prowatt SW Inline 15 Amp Transfer Switch were all ordered from Best Converter. http://www.bestconverter.com/ The Pure Sine Wave inverter came from Canadian Tire. http://www.canadiantire.ca The Xantrex Prowatt SW Inline 15 Amp Transfer Switch for the Inverter is larger than I thought it would be.



I got 50 ft of 3-wire 10 gauge flexible wire rated for 30 amps from a local marine store for about $80. I'll cut it into the lengths I need but will keep the heavy insulation on it. I'll make up a spare shore power cord from what is left over. I need the 10 gauge wire because the new AC panel will be near the front drivers side just behind the drivers seat and the old panel is in the rear passenger side and is only accessible through the rear doors. I'll be installing a Roof Top air conditioner so I'll probably use the 10 gauge wire for that run also. It is marine grade wire and flexible so it should not be affected by any vibrations from driving.



I'm hoping to use the short run 2/0 gauge cable that I've had for a while with the new inverter. It is very thick cable.



My garage is not heated so the warmer weather means I can now get started on this project. I'll post updates as I make progress,
Attached Images
File Type: jpg DSCN0210.JPG (428.5 KB, 2328 views)
File Type: jpg DSCN0213.JPG (243.7 KB, 2329 views)
File Type: jpg DSCN0214.JPG (182.3 KB, 2328 views)
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Old 03-30-2012, 11:34 AM   #2
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Default Re: Total Electrical Upgrade

Sounds good. I'll be looking forward to reading about it.
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Old 04-17-2012, 12:29 AM   #3
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Default Re: Total Electrical Upgrade

This is turning out to be a much more difficult and time consuming job than I thought it would be. I have started though and some of the hardest stuff is done.

The most difficult thing so far has been running the 30 amp cord from the front, just behind the drivers seat, to the rear passenger side. The well insulated 3 x 10 gauge wire cord is 5/8" in diameter. DW helped with the pushing and pulling.



I decided to remove the old electrical panel and instead run the 30 amp cable all the way from the inlet to the new converter/charger.





I'll trim off the excess butyl rubber that I used to form a gasket.



The new converter charger will be installed where the old one was.





I've cut lots of holes for ventilation and also for access. I kept the 6" diameter hole cutout and will use it as a removable access hatch.



I have also run wire for a 110 volt circuit and made some brackets to attached to the van floor to hold down the 2 AGM house batteries.

Attached Images
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File Type: jpg DSCN0247.JPG (182.5 KB, 2186 views)
File Type: jpg DSCN0210s.JPG (283.6 KB, 2186 views)
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File Type: jpg DSCN0230.JPG (265.6 KB, 2187 views)
File Type: jpg DSCN0254.JPG (231.5 KB, 2187 views)
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Old 04-17-2012, 10:00 AM   #4
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Default Re: Total Electrical Upgrade

Apparently some can see your pictures but I don't even get a clickable link. I can see the pictures in the photo gallery but yours don't seem to be there. At least it SOUNDS (or rather reads) like a good project.

Any ideas?

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Old 04-17-2012, 11:58 AM   #5
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Default Re: Total Electrical Upgrade

My photos are attached to the post. They're not in the gallery. Maybe they are just slow to load because they big.
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Old 04-18-2012, 11:52 AM   #6
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Default Re: Total Electrical Upgrade

No, they're not loading or anything. The line that looks like it should be a link is just a light grey (?) on the blue background. It's not "clickable" and "mousing" over doesn't do anything.

Oh well, thanks anyway.

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Old 04-18-2012, 12:12 PM   #7
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Default Re: Total Electrical Upgrade

To anyone - let me know if you see (or don't see) the photos in the posts above.
To fleamarketeer - do you see other photos on the forum? There are lots here. I can recreate what I think you see when "load images automatically" is turned off in Firefox. Same when "show pictures" is turned off in Internet Explorer.
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Old 04-19-2012, 03:36 PM   #8
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Default Re: Total Electrical Upgrade

I'm new to the forum, using a mac with firefox and the photos are loading beautifully for me.
Thank you for the detailed instruction.
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Old 04-20-2012, 02:15 PM   #9
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Default Re: Total Electrical Upgrade

Subscribed to watch and learn... just realised I need to know this for whether I do my own conversion or get an older one. Photos showing great here, XP + firefox.
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Old 04-22-2012, 01:02 AM   #10
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Default Re: Total Electrical Upgrade

Quote:
Originally Posted by markopolo
To anyone - let me know if you see (or don't see) the photos in the posts above.
To fleamarketeer - do you see other photos on the forum? There are lots here. I can recreate what I think you see when "load images automatically" is turned off in Firefox. Same when "show pictures" is turned off in Internet Explorer.
Pics are visible here. Also on either XP or Win7, with Firefox or Google Chrome or IE7 as browsers.
Maybe it's the anti-virus software stripping/blocking the .jpeg files on open?
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