PD 4045

[tscarbroughdc]

First, let me say that I am CLUELESS about electrical stuff, but I have a few people who know quite a bit...But Im still trying to learn.

If I buy the PD 4045, what else would I need to buy?

it is my understanding that you plug up at a campsite and this thing converts your AC into DC for lights and all? Would I still be able to have a plug in for tv/cpap? How bout plugging my air conditioner into it?

Im about ready to put the roof on my build and trying to figure out what kind of wire I need to run and lights I need to buy and all!

Can someone show me a schematic of what wires go into this box and what wires come out?

Anyways, any info would be appreciated...

Thanks!

[GuitarPhotog]

The company provided wiring diagram is pretty pathetic, but it can be set up easily. This page has all the specs and a link in the bottom right corner to the manual.

In addition to the converter, you are going to need a 12 V battery to run things when you aren't connected to shore power, some ATC-style fuses for your DC circuits, and some (minimum one double) 120 VAC circuit breakers.

You wire 120 VAC, through 2 or more circuit breakers to power the converter, and additional 120 VAC loads like an air conditioner, etc.

One of the circuit breakers is internally wired to the Converter/Charger section and, when connected to a 12 V battery, provides a 4-stage smart charger and up to twelve 12VDC outputs.

I have a simple DC system with 4 circuits: lights, fans, USB, and accessory outlets. I have built in a 12 VDC to USB power supply so I can charge my phone easily.

On the AC side, I have 4 circuit breakers: one is the Main breaker and disconnects everything from the shore power inlet. In addition, one circuit powers the converter, one powers a duplex receptacle in the cabin, another powers a duplex receptacle in the galley (handy for plugging in electric appliances).

As for wire size, if you search here you'll find a Wire Gauge - Amps chart that will tell you how large your wires need to be. They must be sized for the load, so for example the outlet for your air conditioner will require heavier wire than will your lights.

<Chas>

[les45]

If you are not experienced in AC or DC wiring then you definitely need to draw on the help of friends who are. Wiring the PD and the various AC/DC circuits is kind of like wiring a house and a car. Use this as a learning opportunity.

In addition to the wire, lights, outlets, and fixtures that will form the various AC/DC circuits, you will need four AC circuit breakers and enough DC fuses for each DC circuit that you plan to run (plus spares). Info on what kind of circuit breakers to buy is found in the PD manual.

The best wiring information for the PD is the Detailed Wiring Diagram that is in the manual that comes with it. The manual is a bit fuzzy sometimes and you may have to call a technical rep with the PD company for assistance. I did and I found them quite helpful. One of the problems I found were some minor changes made from year to year that do not get incorporated into the manual.

One of the primary reasons for using the PD converter is to keep a battery charged and to have a fully charged battery should you lose AC shore power (or just decide to go camping where there is no campground power). Unless you carry a separate generator, you will not have AC power when boondocking. The PD then only serves to distribute your DC battery power.

Keep in mind that the manual only tells you how to terminate wires within the PD cabinet. You will have to design how your circuit wiring will be run through your cabin and galley, including your AC primary inlet and your DC primary wiring from the battery. A good source of this type of information would be found by searching this section of the forum (Electrical Secrets) and in the various build journals. You can find basic schematics and questions and answers about anything you might run into with your wiring.

I strongly suggest that you do your research in advance and plan out all of your wiring and fixture locations before you get too far into the structural part of your build.

As you work on your wiring and issues arise, just keep asking questions here and you will get lots of help.

Good luck.

[tscarbroughdc]

Thanks y'all.

Would I be best to run the wire around my spars or through my spars? The spars are 1x2 and seem pretty flimsy.

ImageUploadedByTapatalk1378346592.220598.jpg (63.08 KiB) Viewed 3213 times

[les45]

A few small holes through the spars will not hurt a thing. The whole structure will be plenty strong when all the insulation and skins are installed. I ran my wiring in the ceiling for my inside lights, porch lights, and fan as you can see in these pics.

[Shadow Catcher]

One thing I will add is have more outlets both AC and DC than you think you need, it is amazing how quickly they find uses. i.e. recharging cell phone(s) camera battery, laptop. We have two external duplex plugs for the air-conditioner, fan... inside DC outlets for charging cell phone... when not plugged in.

[tscarbroughdc]

Thanks y'all.

I ordered a bunch of stuff yesterday from vintage technology:
2 porch lights
6 interior lights
1 PD4045
1 Fantastic fan 5000
1 marine shore power outlet for the side of the camper

I'm hoping to get the inside roof on this weekend!

[tscarbroughdc]

That looks good Les!! My work certainly isn't as neat as yours!

Two questions:

1. What wire do I buy to run it through the spars? I've been told Romex 12 gauge which is fairly good size. Plus I'm using the PD4045 so I think I'd want to wire the camper for dc. Right?!?!

So if I go to Lowes what do I ask for?

2. What steps did you use to paint you camper yellow?!?! I really like that and would like to paint mine yellow. Did you. Just wipe it down with a wet cloth and slap yellow paint on it?

[les45]

I used Romex 12/2 for my AC inlet and outlets but did not have to run it through the spars. My PD 4045 is in a cabinet between the cabin and galley so all my AC wiring is essentially inside the cabinet coming from the inlet to the PD and then going to one standard outlet on the cabin side and two GFCI outlets on the galley side.

I used 12 ga stranded wire for all my DC fixtures inside the cabin (lights and fan) and my porch lights. That is what you see running through my spars. You can buy this at Lowes or any automotive store, but you can usually get a better deal by buying it in larger quantities on Ebay. Here is a link to one convenient source with the black and red already paired: http://www.ebay.com/itm/100-FT-12-AWG-G ... 35c7249ce6
I ran a hot and a ground wire pair to each fixture but I happened to have an old unused dune buggy wiring harness so I was able to use several different colors for my hot wire and black for all my grounds. I used a #10 black and red pair for my primary wire from the battery (on the trailer tongue) to the PD.

I have some fairly detailed descriptions and pics of my electrical installation in my journal (see link below) and one really good pic of the inside of my electrical cabinet showing how the back side of the PD 4045 looks after it was wired up.

Painting the outside was not so simple. All my skins are plywood so I started by sealing everything, including all edges, with CPES. I then used an epoxy filler to fill all the little imperfections, screw and staple holes, etc. in the plywood. This involved lots of sanding, filling, and sanding again. I used 4" fiberglass tape on all corners and joints embedded in up to three coats of Aeromarine epoxy. I then applied two coats of Zinsser oil based primer (with more filling and sanding) and then three top coats of Rustoleum Sunburst Yellow. The final coat of Rustoleum was applied thinned by 25% with mineral spirits in order to get the smooth sprayed on look. Again, details of my paint job are in my journal also.

[Esteban]

Delcity.net http://www.delcity.net/ is a good electrical supplier I have used. They were suggested by Steve Frederick.
If you use them and order online I suggest clicking on live help/chat. They really are helpful and may offer you a discount code. To chat with them be online with a shopping cart during their business hours M-F.

Here are some things you may use/need:
duplex brake cable http://www.delcity.net/store/Duplex-Brake-Cable/p_354.h_180698.t_1 for 12 volt circuits. For higher amp draw circuits use 12/2
wire http://www.delcity.net/store/Wire-&-Cable/ your pick
terminals http://www.delcity.net/store/Terminals/ ring terminals, butt terminals
junction box http://www.delcity.net/store/Stud-Type-Junction-Box/p_790202 helpful for under the trailer wiring
terminal blocks http://www.delcity.net/store/Screw!Type-Terminal-Blocks/p_73274 between pd 4045 and 12 volt circuits
fuses http://www.delcity.net/store/ATC-&-ATO-Fuses/p_11503 for pd 4045
fuse holders http://www.delcity.net/store/Fuse-Holders-&-Adapters/p_178 maybe a maxi near battery
electrical repair kit http://www.delcity.net/store/The-FixIt%C2%99-Electrical-Repair-Kit/p_714604 for construction and on road repairs
trailer connectors http://www.delcity.net/store/Molded-Trailer-Connector-Loops/p_8592 detachable plugs & wires for wiring the hatch
battery switch http://www.delcity.net/store/Battery-&-Ignition-Switches/p_4792 master switch to turn off battery power
battery cables http://www.delcity.net/store/Lead-Battery-Cables/p_371 from battery to master battery switch and to pd4045
maybe a circuit breaker on battery hot http://www.delcity.net/store/Hi!Amp-Surface-Mount-!-%3Cbr%3EManual-Reset-%28Switchable%29/p_193073 near battery on hot battery cable, or as an alt. use a fuse
shrink tube http://www.delcity.net/store/Shrink-Tube-&-Tape/ to protect wire and terminals
so much to choose from.

Using Romex is controversial because it is solid wire more prone to fatigue. Better to use stranded wire which is more flexible. Your local hardware store may carry what you need sold by the foot. 10/3 stranded wire for 30 amps 120 volts between your power inlet and the PD4045 like this http://www.wesbellwireandcable.com/SJOOW/10_3.html

[tscarbroughdc]

Thanks so much guys! I'll be looking into all of this this weekend. I'm finishing up my spars and painting the inside.

I also bought a pneumatic staple gun to help with putting the Luan on.