Replacing the power converter - dimensions

SH

Shaihulud2090

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Location
Florida
I need to buy new batteries for my 2206T. Given the cost of lifepo4's and the weight & shortcomings of lead acid, I've decided to upgrade the power converter to a lithium compatible power converter.

For the cost of two decent deep cycle 100AH lead acid batteries plus about $40 I can upgrade the power converter and get a lifepo4 100AH battery reducing the tongue weight by 90lbs.

I've measured the space for the existing power converter. It measures 5" L x 5" H x 12" W. I've not pulled out the distribution panel (DP) to examine it in depth, but I am wondering how I'm going to accommodate a new power converter. The ones I've seen mentioned in other posts do not match the dimensions of the space for the existing power converter. Boondocker 35A, PD4045, PD9145A.

I don't want to replace the DP if I can help it. Can anyone offer advice here? If I have to replace the DP, I will.
 
Shaihulud, there are certainly converters that allow you to keep your existing DP, but I chose to replace my Elixir converter with one that includes the DP. It was the PD4045 and I've posted a thread on the replacement here: https://www.hilotrailerforum.com/f28/elixir-converter-replacement-7659/ It is smaller than the OEM Elixir converter so space is not an issue and I like the fuse layout on the DP MUCH better than the one that the Elixir had. Specifically, the pesky two 30A battery charging fuses are now on the FRONT of the panel, rather than hidden behind it and there is a LED on the panel that tells you if one of those fuses has blown.

If you haven't seen them, the LiTime LiFePO4 Group Size 24 batteries look a good choice now. They have low temperature charging protection as well as the normal high temperature and short circuit protection and are will liked in several reviews I've read. Additionally, they are very affordable.

- Jack
 
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Thanks Jack. I have read your thread about the installation of the DP you posted. It was very informative. But if I could find a drop in replacement for the PC I'd rather go that route.if I can't do that I will certainly follow your steps.
 
Best Converter.

Look up Best Converters Phone #. You will be able to speak with a tech. I have ordered two converters from them. They ship out fast. EC customer service.
 
Do we have any long-term info on LiFePO4 batteries being used in our trailers with the demands of the hydraulic lift system? After installing my Renogy ammeter, I was seeing a max of about 96A of current to lift the top. Would this rush of current cause any issues to a LiFePO4 battery or its BMS? I'm seeing some with 100A max discharge rates, others with 150A. I think it's a pretty unique power demand in the camping trailer industry, but I suppose some rigs have their electric or hydraulic slides, too.

-Nick
 
Nick, my LiFePO4 battery system has worked perfectly for the year that I've had it. I think I've probably raised the top at least 20 times during that period and I know this is hardly a "long term" report, but so far, I'm very happy with the batteries.

- Jack
 
JackandJanet said:
Nick, my LiFePO4 battery system has worked perfectly for the year that I've had it. I think I've probably raised the top at least 20 times during that period and I know this is hardly a "long term" report, but so far, I'm very happy with the batteries.

- Jack
Click to expand...

Thank you, Jack! :)
 
Jack, I'm getting ready to pull the trigger on a new power converter purchase. I was wondering if you could share your insight on why you chose the PD4045. It looks like a good unit and I've read enough of your posts to know you like it. I'm torn between it and the BD 1245PC. The advantage for me is the BD1245PC looks like it's a drop in replacement and won't require any modification to mount it.
 
I think the main reason I chose the PD4045, was that it was significantly cheaper than the BoonDocker unit I was seeing at that time. Now, it's only $1, cheaper, so they're a wash. I know Boondocker makes good converters, but I'm pleased with my PD one too.

I'd say go with the BoonDocker if it looks easier to install. Like in my installation, you should be able to simply transfer the CBs and fuses to the new unit, so I wouldn't pay for new ones.

I DO like the LED in the PD that tells me the status of those pesky 30A fuses, and it was simple to convert it to a LiFePO4 battery charger.

Can you download a user/installation manual for the BoonDocker before you order it? I did that for the PD and it helped me decide to get it.

- Jack
 
Yes, it looks like they have a drop in replacement for the Elixir. I looked at the documentation for it. I'm concerned that it doesn't specifically discuss lifepo4 charging that I could see. Technically the Elixir will charge lithium batteries, just not very well.

Are you using it with lifepo4 batteries Sam?
 
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And, Shaihulud - I DO have LiFePO4 batteries now (as you probably know) and my PD converter works well with them.

I would not trust any converter not specifically designed foe LiFePO4 batteries to work with them. Yes the charging algorithm is different and that DOES make it "not work very well", but LiFePO4 batteries have very low internal resistance and that means they can draw excessive current that overloads the charger. This would probably just blow the charging fuses in the Elixir, but it wouldn't work.

Surely, Best Converter could tell you if the one they recommend would work with LiFePO4 batteries?

- Jack
 
I called Best Converter and spoke with Randy. He said that the BD 1245PC has a switch on the board to switch charging modes for lithium. So, I ordered it a couple of days ago. Waiting for it to come in.
 
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Installing your converter.

When I ordered from them it came fast and in EC. Should you have any questions during the install just call Randy.
 
Hey all. I'm finally getting round to installing the new BD1245PC power distribution panel, but I've ran into a road block.

I don't know where the negative wires on the DC side from the Elixir 45 go in the new panel, BD1245PC. I've transferred and wired the AC side of the panel. However, where the Elixir 45 has two wiring blocks on the DC one for positive and one for negative, the BD1245PC doesn't have any wiring blocks. Instead, it has wires coming out of the back of the panel for the positive wires which I can buttsplice. But that still leaves me wondering where to connect the negative wires.

I have a graphic which I put together that I hope is helpful. Panel Install 2.png


I've reviewed the documentation, but it's not clear to me where these wires would go. Documentation is found here: https://www.bestconverter.com/assets/images/Powermax/BPC/1200PCmanual.pdf


Please let me know what you think, because I'm out of ideas.
 
Since I don't have the same converter, my thoughts are just a guess. It appears your new converter uses the "Ground" buss bar as the DC Negative terminal bar. If so, all the negative wires would go to it.

And, looking at the .pdf you link to, it appears that heavy white wire is the "neutral" AC wire.

But, since you are able to talk to folks at Best Converter - you should verify this with them.

- Jack
 
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Converter install.

I second Jack's recommendation to speak with the tech at Best converter. They give excellent customer service. Recently I tried to talk to someone at Ryobi about getting a part for my Ryobi string trimer. Impossible. I will never buy anything from them again!! Internet reviews say the same thing. Maybe if i call them in the middle of the winter i will get the part i need. In the mean time I bought another brand of trimmer.
 
Thanks Jack and Sam. I appreciate the replies. I plan to call BestConverter Monday.

An interesting side note, I uploaded the manual to chatgpt and asked where to connect the negative DC wires. It pin pointed the OUTPUT-GND. So I think I'm going to do as Jack has done and borrow the wiring block from the old Elixir. But, after confirmation.

Once I get it done and working I'll do a proper write up to document the entire process.
 
Hey Sam or Jack. I am in need of your experience. I called Best Converter and they could not advise me.

I'm trying to understand how to connect a couple of wires.

The 10 gauge DC Black wire that is labeled as the charge line is going to connect to the wire on the panel labeled 12v charge line. Please correct me if I'm wrong.

The 10 gauge DC Red wire is a bit of a mystery. If I'm reading the schematics correctly this goes to the master (black by the door) switch. I'm thinking I can connect it also to the black wire and put an inline fuse on it. And that should be it. Jack let me know what you think.

I'd really like to know what Sam's husband did on his BD1245PC.
 
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