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Old 10-31-2021, 10:58 PM   #1
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Electrical Conversion

Started the electrical conversion to lithium today.

The first thing I had to research was to figure out if I could reuse the Progressive Dynamical PD 4000 120 volt to 12 volt converter with integral fuse panel that I installed when I built out the interior. It has worked flawlessly for the past four years. It has a built in battery charger and 120 volt breaker panel for use when plugged into shore power. The only problem is that my version is not setup to charge lithium batteries.

I looked at the unit wiring diagram and figured out that I could eliminate the battery charger function by removing two wires. This will allow me to connect the lithium battery directly to the fuse panel. The only draw back is that I will not be able to charge the lithium battery via the 120 V system in the PD unit.

Once I figured that out it was time to start the demolition. Today I emptied some cabinets move some things around and then pulled all the wires that ran from the old house batteries, located on the passenger side frame rail, to the PD4000.
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Old 11-01-2021, 07:39 AM   #2
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You could replace the charging unit for the PD4000 with the LiFePO4 unit:

Replacement Lithium Converter for Progressive Dynamics 4000 Series RV Power Control Center - 60 Amp Item # PD4060LICSV

or

Replacement Lithium Converter for Progressive Dynamics 4000 Series RV Power Control Center - 45 AmpItem # PD4045LICSV


-greg
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Old 11-01-2021, 10:43 PM   #3
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I thought about replacing the PD unit with the one you mention. Since I already have a standalone Kisea DC to DC charger with built in MPPT solar controller it did not make sense to replace the PD unit. The only thing I lose by disconnecting the PD charger is the ability to charge the lithium battery from shore power. If I find I need to charge from shore power I can always add separate 120 V to 12 V lithium charger.
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Old 11-02-2021, 10:40 PM   #4
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Dropped the old house batteries off the frame today. Not the easiest thing to do. There was lots of corroding on the terminals. Glad the new battery will be inside and easier to access and visually monitor.
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Old 11-19-2021, 10:39 PM   #5
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The new lithium battery fits nicely in the back drivers side corner of the van between the outside wall and the dinette. The angle brackets attached to the backside of the cabinet hold the board that the charger is bolted to.





Both the battery and the charger are easily removable so that I can move them to the milk crate when need the system in the Jeep. The circuit breaker and fuse block are mounted to the battery with VHB tape. The fuse block is used in the Jeep as there is already one in the van.
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Old 11-19-2021, 10:53 PM   #6
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The last piece that I need to figure out is where to get the key switched power for the trigger wire that tells the charger to start charging. Thought I could use the cigarette lighter power. Unfortunately it is powered all the time on my 2002.

Looked under the hood and found three unattached wires that I could not find on the wiring diagram that I have. They are just below the cowl and slightly to the left of where the steering column comes through the fire wall. Does anyone know what they are for?

Wire on the right; dark red with green stripe with a damaged label that reads LOW. Has 6 volts with key on. Zero with key off.
Wire in the center; brown with blue stripe with a damaged label that reads PT??
Wire on the left; yellow with a red stripe with a damaged label that reads CTO. Has 12 volts with key on. Zero with key off. This is the one I want to connect to.

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