[mjlaupp]

PD4600 3 of 3 - or - Installation is NOT the Reverse of the Removal

I decided to upgrade the power converter in my 2004 3326. The included instructons (as modified) are reproduced below:

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Intelli-Power PD4600 Series Converter Replacemant: Modified

Power: (page 1)
Disconnect all power sources prior to removal of the old converter. Power sources may include, but are not limited to:
• 120VAC shoreline power (unplug shoreline power cords)
• Onboard generator (disconnect per manufacturer’s instructions)
• 12VDC battery power (disconnect negative terminal(s) from battery(ies) ) I pulled the battery fuse.

Removal: (page 2)
See prev. post

Installation: (page 2) - renumbered
9. Strip branch circuit wires, install a spade lug on each wire and connect to the barrier strip on new DC board.
Circuits 1 - 9 on the old board are installed to terminals 4 - 12 on the new board. Don't forget to transfer the fuses. Note: Terminal #1 and fuse #1 on the new DC board is located behind the mounting box framework.
10. Butt splice additional 6 inches of wire to the battery wires removed from the old DC board (black to black, yellow to white). Replace white wire from neutral buss with longer 8 inch yellow wire.
11. Connect 2 black battery wires to Bat+ terminal on DC board. Connect 2 white battery wires and neutral buss wire to Bat- terminal on DC board.
12. Slide new converter into power center. Route black/white/green wire-set into AC power section, and black/ white wire-pair into DC section. Secure using (4) screws removed in step #8. OK
13. In the AC power section, connect new converter neutral (white) wire to neutral distribution block, and converter ground (green) wire to ground bar. Connect hot (black) wire to AC fridge/converter breaker. Need to but splice in the old splitter for fridge power.
14. Replace AC power section cover and secure using (2) screws removed in step #3. OK
15. In the DC power section, route new converter DC wires behind new DC power distribution board. Connect new converter power (black) wire to the new DC power distribution board terminal labeled “CONV POS+”. Connect the negative (white) wire to the DC board terminal labeled “CONV NEG-“. OK
16. Connect 4-pin header on DC board to 4-pin header on converter assembly using the 4-wire harness (included). OK
17. Making sure new DC feed wires remain behind DC board, secure DC board to power center using (2) screws removed in step #5. OK
18. Transfer DC Distribution branch circuit information to the new label provided with the retrofit kit, and adhere label over existing label on the inside of the power center cover. Affix green Replacement Notice label in any unused area of the power center cover. Do this before installing the cover, it's easier.
19. Replace power center cover using (4) screws provided with kit. OK


Additional tools used:
Allen wrench for batt connections on new DC board
Wire strippers
Wire terminal crimpers
Ink pen
Multimeter

Additional materials needed: (not included in upgrade kit)
Black #10 insulated automotive wire (battery wire extension)
Yellow (or white) #10 insulated automotive wire (battery wire exxtension)
1 - blue 18-14 awg butt splice connector (for AC power wire)
4 - yellow 12-10 awg butt splice connectors (for battery wires)
2 - red 22-18 awg spade lugs (for branch circuits #1 & #2)
7 - yellow 12-10 awg spade lugs (for branch circuits #3 through #9)

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Ok, it's done! The converter is quieter, the charge wizard is blinking fast mode indicating normal mode charging, the 12v fans in the TM are quieter with the filtered DC and only time will tell about the battery life. I can now leave my TM plugged into shore power without fear of cooking the batteries. Now it's time for some LED bulb replacement.

Time investment: 8 hours.

DC output voltage: 13.96v

Pictures will follow.

Mike