| 45 Amp Intelli-Power Converter Conversion Questions [message #313928] |
Wed, 01 March 2017 08:57  |
pnbarber
Messages: 11
Registered: June 2016
Location: Raleigh, NC
Karma: 0
|
Junior Member |
|
|
I posted the following at the back of the recent converter discussion but I thought I might get a response quicker if I started a new thread.
First a little background on the coach, it is a mid 90's Clasco conversion and has all the wiring connected to a distribution panel and then to power circuit panel. The old converter is under rear cabinets and only accessible from the side and I will be reinstalling the new one there.
The linked photos shows my current converter connections. I identified the red power and ground wires that will connect to the new converter and the receptacle for the plug. I haven't removed it so I don't know for sure if it has internal fuses but I've included an interior shot for discussion.
http://www.gmcmhphotos.com/photos/old-converter/p62204-old-converter.html
http://www.gmcmhphotos.com/photos/old-converter/p62205-inside-old-converter.html
If a fuse is needed, is a 40 Amp inline type adequate protection or is there another type that I should get. Also, the new converter instructions indicate a separate chassis ground is required which I will install.
Thanks in advance.
P. Barber
Raleigh, NC
1978 GMC Royale - 1995 Clasco Upgrade
|
|
|
|
| Re: 45 Amp Intelli-Power Converter Conversion Questions [message #313929 is a reply to message #313928] |
Wed, 01 March 2017 09:43  |
JohnL455
Messages: 4447
Registered: October 2006
Location: Woodstock, IL
Karma: 12
|
Senior Member |
|
|
A better picture would be showing not the old unit that is being removed, but the hook up points. I would run new wires as those appear to be old cloth type. I think 6 ga would suffice but check instructions as you may have a longer run and need 4 ga. Check lug size on your converter as well for max size fit. Disconnect all negative cables at batteries before starting project. As a note on the old converter, that metal strain relief is meant for armoured cable clamping, not individual wires as it could eventually wear through and short out. That type of short has the full brunt of the house battery and a serious fire hazard as it will get red hot before burning away. DC Negative and chassis ground are the same on our coaches but feel free to run them both. There should also be an AC ground through the AC cord ground which eventually ends up the same potential but through a different path via the AC electrical wiring.
John Lebetski
Woodstock, IL
77 Eleganza II
|
|
|
|
|
|
| Re: 45 Amp Intelli-Power Converter Conversion Questions [message #313949 is a reply to message #313930] |
Wed, 01 March 2017 14:36 |
pnbarber
Messages: 11
Registered: June 2016
Location: Raleigh, NC
Karma: 0
|
Junior Member |
|
|
1. The new converter is an Inteli-Power PD9145A and it's output terminals are rated for 2 to 14 ga. copper or aluminum wire.
2. Our coach has rear twin beds with a builtin cabinet between. The existing buzz box is mounted in the base of this cabinet, approximately 4 to 5 feet from the house battery bank which is aft of the Onan.
3. The existing ground wire is old cloth type and will be replaced. The red wire (unknown gauge) is plastic coated and I am hoping it can remain as I am find it difficult tracking it's route through the coach as some areas are not accessible.
P. Barber
Raleigh, NC
1978 GMC Royale - 1995 Clasco Upgrade
|
|
|
|
|
|
| Re: 45 Amp Intelli-Power Converter Conversion Questions [message #313972 is a reply to message #313949] |
Thu, 02 March 2017 10:02 |
 |
Matt Colie
Messages: 8547
Registered: March 2007
Location: S.E. Michigan
Karma: 7
|
Senior Member |
|
|
pnbarber wrote on Wed, 01 March 2017 15:361. The new converter is an Inteli-Power PD9145A and it's output terminals are rated for 2 to 14 ga. copper or aluminum wire.
2. Our coach has rear twin beds with a builtin cabinet between. The existing buzz box is mounted in the base of this cabinet, approximately 4 to 5 feet from the house battery bank which is aft of the Onan.
3. The existing ground wire is old cloth type and will be replaced. The red wire (unknown gauge) is plastic coated and I am hoping it can remain as I am find it difficult tracking it's route through the coach as some areas are not accessible.
Perry,
Grab a drink of something and hang on.
If I loose you through all this, just come back and say so and I will try to fill in what I will probably have forgotten to say.
A PD9145 is a great box (I have one), but it really needs the pendant to shine. It can make your house bank last for a very long time.
With the distance to the house bank and the cable I see, your charge rate will limit at about 35 amps and there is nothing you can do about that without shorter and/or cable. And I mean much shorter and much heavier. I did all the calculation about this because my 9145 maxed out at 27 amps and that meant a long/lot of generator time to bring the bank back up.
About the cable:
- The woven jacket looks to be a wire type SM. That is high temperature and there is no reason to replace it unless it is damaged more than shows in the pictures. It may be marked. If it is #10 AWG, leave it there. SN cable has never been readily available in SAE gauges, but it could be.
- The red (orange) cable looks light to me, but I can't read numbers on it. You should try to find some.
A Caution Here...
If the wire says #10, try to find where is says #10AWG or #10SAE. SAE wire is only ~90% the area of AWG. Thought the Ampacity (current carrying capacity) as for heating will not be an issue, voltage drop will be. Do not look at a table that gives voltage drop as a percent because in this application, that is garbage. If you loose 0.5V on the way to the house bank, you will cut the charge rate from a maximum or 40~45 to less than 30amps and that makes a big difference. If you want to upgrade this conductor, look up "marine" wire suppliers. Marine wire has some real advantages. Not only is it tin plated for corrosion, but it is finer strand even than SAE. This makes it way easier to pull and handle. If you choose to replace it, do a wrapped and soldered splice to the end of the original cable and use that to pull it into place.
The PD9145 can and will - given the chance - deliver 45 amps to a depleted pair of GC2s. It will still take a while to get back to even 90% SOC no matter what you do. The battery chemistry becomes the limiting factor there.
It is proper practice to protect wire connected to a primary power source (like a battery) from an over current situation. In this case, if you can find a 50 circuit breaker, (self resetting or not) that would be a good application.
As I am hopping you have one of the better sliding battery racks, the cable length gets to be more of an issue because of the additional cable required to slide the bank out to check the level in all 6 cells. I am also hoping that the house bank is a pair of GC2s or the like and not 12s in parallel.
Matt
Matt & Mary Colie - Chaumière -'73 Glacier 23 - Members GMCMI, GMCGL, GMCES
Electronically Controlled Quiet Engine Cooling Fan with OE Rear Drum Brakes with Applied Control Arms
SE Michigan - Near DTW - Twixt A2 and Detroit
|
|
|
|
| Re: 45 Amp Intelli-Power Converter Conversion Questions [message #313977 is a reply to message #313972] |
Thu, 02 March 2017 12:03 |
pnbarber
Messages: 11
Registered: June 2016
Location: Raleigh, NC
Karma: 0
|
Junior Member |
|
|
Thanks you for your replies Matt and John. They are really helpful.
Matt, first of all, I do have the Charge Wizard for the 9100 converter and will be installing it also. I believe I am able to follow and understand the information you supplied but had a few additional questions. I also know that there are limitations on what I can do to have an optimal charging set-up but if I can move the converter closer to the battery bank should I explore that option?
If I replace the positive red wire, what gauge of marine wire should I purchase? There is a West Marine store in town and I believe they should have what I need.
They also show to have a 50 amp manual reset circuit breaker that I will pick up. https://www.westmarine.com/buy/motorguide--50-amp-manual-reset-circuit-breaker--10352748
P. Barber
Raleigh, NC
1978 GMC Royale - 1995 Clasco Upgrade
|
|
|
|
| Re: 45 Amp Intelli-Power Converter Conversion Questions [message #313984 is a reply to message #313977] |
Thu, 02 March 2017 14:09 |
|
Matt Colie
Messages: 8547
Registered: March 2007
Location: S.E. Michigan
Karma: 7
|
Senior Member |
|
|
pnbarber wrote on Thu, 02 March 2017 13:03Thanks you for your replies Matt and John. They are really helpful.
Matt, first of all, I do have the Charge Wizard for the 9100 converter and will be installing it also. I believe I am able to follow and understand the information you supplied but had a few additional questions. I also know that there are limitations on what I can do to have an optimal charging set-up but if I can move the converter closer to the battery bank should I explore that option?
If I replace the positive red wire, what gauge of marine wire should I purchase? There is a West Marine store in town and I believe they should have what I need.
They also show to have a 50 amp manual reset circuit breaker that I will pick up. https://www.westmarine.com/buy/motorguide--50-amp-manual-reset-circuit-breaker--10352748
Perry,
Glad that both you have the Wizard and that I did not manage to loose you along the way. (I hate to admit how often that happens because I skip something.)
Anything you can do to shorten the run (both cables) to the bank will improve the situation.
A cable size of 8AWG is where the return of the gain starts to diminish, and at 6AWG, that is about all you can get with a 45 amp charge. People will think you are overboard with either, but that means they don't understand the loss with any voltage drop.
Realize that the current goes both ways and the loss accumulates both ways. So match the cables sizes. Also be sure that any other connections are sound.
The breaker at Waste Marine looks like a good bet.
It looks like you are off to a good start.
Matt
Matt & Mary Colie - Chaumière -'73 Glacier 23 - Members GMCMI, GMCGL, GMCES
Electronically Controlled Quiet Engine Cooling Fan with OE Rear Drum Brakes with Applied Control Arms
SE Michigan - Near DTW - Twixt A2 and Detroit
|
|
|
|
GMCforum
Search
Help
Register
Login
Home
