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Old 10-17-2015, 12:50 PM   #15
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An otherwise simple task becomes difficult or impossible when you cant put your hands on the right tools.

Been there done that...




Brevi tempore!
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Old 10-18-2015, 06:15 PM   #16
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In response to the OP title...."A long, long way from home."
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Old 10-18-2015, 08:07 PM   #17
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Well, this replacement has turned out to be "interesting". Yesterday I got slammed with family stuff and couldn't get to the trailer to work on it, but. Had high hopes for today. When I started I found out the cover is NOT using t 20 screws, but something smaller. So off to Home Depot on a Sunday afternoon to buy more tools. An hour later and I'm back at the trailer with a combo folding torx tool and t15 does the trick. The couver is off. For those keeping score this has only taken me three days.

Getting the Parallax out was pretty easy, and the connections look straight forward, so, ummm, why does the P unit have four wires and the PD five. Hmmm. Oh well, onward and upward. Taking off the DC board was easy, writing down the color of the little cd wires so I can put them back in order.

Unfortunately, this is where I ran into the problem. The thick DC negative cable is a titch too short to routed to the new board. PD moved the attachment point just enough to make it impossible, unless you take the whole freaking top part of the electrics out so you can access the strain relief and get another inch or so of wire. To do this you really want your electric drill/driver, which I did not have with me. And buy now it was getting late and my wife called wondering when I would be home. So...I will try to find the time to finish it up this week. I'm thinking this might be a three week job. :/

Mike
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Old 10-18-2015, 09:29 PM   #18
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Make sure the batteries are disconnected.... Please. ... And disconnect AC POWER FROM THE CONVERTER..'please.
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Old 10-18-2015, 09:43 PM   #19
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CWF, thx for worrying. The batteries are disconnected, the trailer is not plugged in to shore power, and neither converter is connected right now. I want to finish getting the new DC board right before I install the converter. I just need to access the strain relief thingie which is impossible without taking out the upper part of the unit. Once I can get access to the screws that hold the wires it should be cake. If it isn't I'll probably send an SOS out to Lew.
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Old 10-18-2015, 10:05 PM   #20
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CWF, thx for worrying. The batteries are disconnected, the trailer is not plugged in to shore power, and neither converter is connected right now. I want to finish getting the new DC board right before I install the converter. I just need to access the strain relief thingie which is impossible without taking out the upper part of the unit. Once I can get access to the screws that hold the wires it should be cake. If it isn't I'll probably send an SOS out to Lew.
Definitely remove the entire package from the wall. Should be 4 screws.....no biggie! This will give you access to the strain relief and allow for more DC power cable to come forward. You should find a substantial amount of surplus cable behind the unit.
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Old 10-22-2015, 07:14 PM   #21
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Well, finally progress. Sort of.

Today I had the afternoon off work so I went out to the storage unit with all my tools figured I'd get'r done. Ahh, the naivety of old age. I unscrewed the top unit from the wall, easily gaining access to the strain relief, and carefully routed the wires to where they needed to be.

The thick wires are very thick and not easily coaxed into a new position, but with perseverance, I succeeded. Then I mounted the DC board in its place. Next came the seven colored DC circuit wires, screwed into their places. Time to remount the top unit, and I got that done.

Starting to get excited now. All that's left is to slide in the new converter, connect five wires, and I'm done! So I get the converter, slide it in place run the wires, which takes a little time, but not too bad, then I start to screw new converter to the upper units frame.

Umm. The holes don't line up. #*%+!

So I have to disconnect the converter, take it home, and drill or roto zip out a quarter inch of extra space in the sheet metal so all the holes will line up. I should be able to finish this off on Saturday.

The good news is I tested the unit as long as it was connected. Seems to work perfectly, goes through all the charge states, and is dead quiet. So I got that working for me.

If anyone wants any advice about doing this, you can pm me. I thnk I've made enough mistakes doing this that I may be able to save you some grief. But it feels good to know I won't be frying my batteries any more.

Mike
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Old 10-22-2015, 07:21 PM   #22
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Well, finally progress. Sort of.

Today I had the afternoon off work so I went out to the storage unit with all my tools figured I'd get'r done. Ahh, the naivety of old age.......
Umm. The holes don't line up. #*%+!

.....

If anyone wants any advice about doing this, you can pm me. I thnk I've made enough mistakes doing this that I may be able to save you some grief. But it feels good to know I won't be frying my batteries any more.

Mike
Mike, that's really great news! Thanks for checking back.
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Old 10-22-2015, 07:27 PM   #23
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Good info
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Old 10-22-2015, 11:09 PM   #24
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Originally Posted by Caffeinated View Post
Well, finally progress. Sort of.

Today I had the afternoon off work so I went out to the storage unit with all my tools figured I'd get'r done. Ahh, the naivety of old age. I unscrewed the top unit from the wall, easily gaining access to the strain relief, and carefully routed the wires to where they needed to be.

The thick wires are very thick and not easily coaxed into a new position, but with perseverance, I succeeded. Then I mounted the DC board in its place. Next came the seven colored DC circuit wires, screwed into their places. Time to remount the top unit, and I got that done.

Starting to get excited now. All that's left is to slide in the new converter, connect five wires, and I'm done! So I get the converter, slide it in place run the wires, which takes a little time, but not too bad, then I start to screw new converter to the upper units frame.

Umm. The holes don't line up. #*%+!

So I have to disconnect the converter, take it home, and drill or roto zip out a quarter inch of extra space in the sheet metal so all the holes will line up. I should be able to finish this off on Saturday.

The good news is I tested the unit as long as it was connected. Seems to work perfectly, goes through all the charge states, and is dead quiet. So I got that working for me.

If anyone wants any advice about doing this, you can pm me. I thnk I've made enough mistakes doing this that I may be able to save you some grief. But it feels good to know I won't be frying my batteries any more.

Mike
Sorry to jump on this so late, but the sidewalls of the metal box have some flex in them.......no drilling really required!

I've encountered this situation a number of times.
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Old 10-23-2015, 07:58 AM   #25
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Lew, I screwed in one side, and for the life of me cannot get enough space to get the other 2 screws in. It's off by at least an 1/8 of an inch, maybe a bit more. Maybe if I really reefed on it, but I can't do that and hold my drill at the same time. I'm thinking at the factory their template might have slipped a bit.

Mike
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Old 10-27-2015, 07:33 PM   #26
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We'll, I finally finished this job today. I never did get out to the storage unit last weekend, but I made some time today and finished up. I had to take the converter back out and use my roto zip tool to gain a extra quarter inch of wiggle room to get all four of the screws to line up, but that was relatively easy, aside from the re-threading the ac and DC wires back in and out of the unit. While it was out I used a fine file to round off all the sharp edges of the sheet metal frame, so if I ever have to mess with it again it should lessen the chances of getting cut by the frame. The original t-15 torx screws that stymied me in the beginning? They don't fit the new PD frame but PD sends their own that do, and they are Phillips head. The PD screws paint does not match the dark brown Parallax paint so I'm sure my wife will have me remedy that in the future, but for now, it's in, it's working, and it's all good.

Mike
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