Converter Section Replacement Instructions

Do not replace the converter section unless the following checks have been completed:

1. Remove the front cover.
2. Connect unit to a 120 VAC power source.
3. Use a digital voltmeter to verify proper voltage at the 120 VAC breaker that the converter is connected to. This voltage should be between 105 and 130 volts.
4. Disconnect all AC power to unit before continuing: Verify the reverse battery fuses have not blown. These fuses will only blow if the battery or DC output leads were connected in reverse, even for a moment.
   • PD4500 series - If they are blown, check the wiring to the battery before replacing fuses with same type and rating.
   • PD4000 series - If LED indicator is NOT illuminated continue to step 5. If illuminated, verify wiring to the battery is correct before replacing fuses with same type and rating.

PD4000 Reverse Battery LED Indicator:

1. With AC power disconnected, remove the reverse battery fuses.
2. Reconnect AC power and check the converter output from the CONVERTER GND/WHT to the CONVERTER POS/BLK terminals on the DC board. This should be 13.6 +/- .3VDC (14.6 +/-.3VDC for LI models).
3. Check for any inline fuse in the positive lead near the battery and verify it has not blown. Replace if blown.
4. If the converter output is not present and there is AC power to the converter, the converter is defective. Contact your dealer for return instructions. 1541A

Removing the Converter Section: (Do not remove the entire AC/DC distribution panel. Only remove the converter section)

1. Disconnect all AC power to the unit.
2. Disconnect the (3) AC wires from the circuit breaker, neutral and ground buss bars. Remove AC hot (black) wire first, then AC neutral (white), and finally AC ground (green).
3. Disconnect DC converter output wires from the DC distribution pcb.
4. Remove and retain hold down screw(s).
5. Remove converter section.
6. For factory repairs, return only the converter section. Make sure you use proper packaging to ensure the product’s safe arrival.
7. Reverse steps to install new converter section.

Verifying Converter Function:

1. Turn off breaker supplying power to the converter.
2. Verify proper battery connection: Using a digital voltmeter, measure voltage across converter output wires/lugs.
3. Turn on breaker supplying power to the converter.
4. Using a digital voltmeter, measure voltage across converter output wires/lugs. If the voltage has increased from step 2, the converter is supplying power to the DC circuits and charging the battery.