Replace wfco converter controller

[Henry1011]

Hi all,

I would like to know if had anyone replaced the wf-8735p with the progressive dynamic pd4135K ("Progressive Dynamics RV Power Control Center with AC/DC Panel and Converter/Smart Charger - 35 Amp Progressive Dynamics RV Converters PD4135K" https://www.etrailer.com/RV-Converters/Progressive-Dynamics/PD4135K.html). I am interested in lithium battery charging and this unit is advertised of having that capability.

Please note that a similar unit on Amazon pd4135KV doesn't support lithium charging.

The model's names are so similar and the price is also the same. I wonder if they are the same so I thought that it is better to ask.

Thank you for your help.

Henry

[pgandw]

I have replaced the WFCO 8735P with the PD4135 twice - in 2016 and then in my 2nd A-frame in 2019. In both cases, I replaced the WFCO because it never changed from 13.7V. Which caused too much battery evaporation when left plugged in while in the garage. Because of the dates, and because I use 2 Costco/Interstate GC-2s for batteries, I have no idea if the PD4135 is LiFePO-compatible. The PD4135 works very well with my battery setup in all 3 charge modes.

I suggest contacting Progressive Dynamics directly for specifics on their 4135 models.

Details of the converter/panel replacement are in my thread: https://www.forestriverforums.com/fo...er-114528.html

Fred W
2019 Flagstaff T21TBHW A-frame
2008 Hyundai Entourage minivan
camping Colorado and adjacent states one weekend at a time

[TitanMike]

Originally Posted by Henry1011

Hi all,

I would like to know if had anyone replaced the wf-8735p with the progressive dynamic pd4135K ("Progressive Dynamics RV Power Control Center with AC/DC Panel and Converter/Smart Charger - 35 Amp Progressive Dynamics RV Converters PD4135K" https://www.etrailer.com/RV-Converte...s/PD4135K.html). I am interested in lithium battery charging and this unit is advertised of having that capability.

Please note that a similar unit on Amazon pd4135KV doesn't support lithium charging.

The model's names are so similar and the price is also the same. I wonder if they are the same so I thought that it is better to ask.

Thank you for your help.

Henry

I would contact Progressive Dynamics before purchasing the Converter from ANY supplier. When reading on PD's site they don't appear to offer a converter that will charge EITHER lead acid OR Lithium IN THE SAME MODEL.

In fact most of their literature warns that a Li converter/charger is NOT to be used on a lead/acid battery.

Only exception to this, and it's not advertised even though the PD tech supports acknowledges that it will work fine, is to use the Charge Wizard feature to force the converter into Boost Mode which then provides a 14.4 volt output which will complete the charge in a LiFePo4 battery and balance cells.

Not sure but it is possible that the e-trailer information was written by someone who took some creative license in describing the capabilities so contacting PD for the correct info is highly recommended.

[Henry1011]

Originally Posted by TitanMike

I would contact Progressive Dynamics before purchasing the Converter from ANY supplier. When reading on PD's site they don't appear to offer a converter that will charge EITHER lead acid OR Lithium IN THE SAME MODEL.

In fact most of their literature warns that a Li converter/charger is NOT to be used on a lead/acid battery.

Only exception to this, and it's not advertised even though the PD tech supports acknowledges that it will work fine, is to use the Charge Wizard feature to force the converter into Boost Mode which then provides a 14.4 volt output which will complete the charge in a LiFePo4 battery and balance cells.

Not sure but it is possible that the e-trailer information was written by someone who took some creative license in describing the capabilities so contacting PD for the correct info is highly recommended.

Thank you for the boot mode 14.4v info. If it can be set at this mode then it will work with lithium since the battery already has a battery management system (bms) for charging. Would you know how to set the pd4135k in boot mode? Is there a physical switch to enable boot mode?

[TitanMike]

Originally Posted by Henry1011

Thank you for the boot mode 14.4v info. If it can be set at this mode then it will work with lithium since the battery already has a battery management system (bms) for charging. Would you know how to set the pd4135k in boot mode? Is there a physical switch to enable boot mode?

I would contact Progressive Dynamic's for details.

[pgandw]

The PD 4135 is a "drop in" replacement for the WFCO 8735P combination distribution center/converter. In both the WFCO and PD, the 35 amp converter is built into the distribution panel, and the converter is NOT a removable board. These converter/panels are built for smaller campers with 6 half width circuit breaker slots, and 6 DC circuits/fuse slots. There are no external controls or adjustments on either converter, at least on the 2018 and prior models I have worked with.

The PD 4135 automatically puts out 14.2 - 14.4V when it senses battery SOC below 90%. At 90% SOC (approximately), the PD4135 shifts to 13.7V which it maintains for 44 hours or 100% SOC is reached, whichever comes first. Then, trickle mode at 13.2V. Both my PD4135 units appear to use this concept of operations based on observed voltages of battery when disconnected from shore power, and of converter when connected.

My PD4135 units do not have any model number letters after the 4135, so changes may have been made since 2018 when I bought my last 4135. That's why I would call Progressive Dynamics about any changes in models and model numbers.

Fred W
2019 Flagstaff T21TBHW A-frame
2008 Hyundai Entourage minivan
camping Colorado and adjacent states one weekend at a time

[camaraderie]

It appears to me that the K designation in the model number simply means that the unit does NOT come with input power wires...merely terminals where you can connect your wires. I don't believe there's any version which supports lithium available.
If you are looking for the ability to charge either lead acid OR LifePO in your next converter....suggest you look at ANY of the Iota DLS series which are well built CONVENTIONAL single stage charges accompanied by YOUR CHOICE of plug in dongles which drive the charger to multi stage charging appropriate for YOUR batteries of the moment. They have about a half dozen dongles called IQ4 modules including one for LiFePO drop in batts that you can get for under $20



As you can see...installation is merely plugging in a telephone jack wire between dongle and converter.

[Henry1011]

I found out that the PD4135K sold by etrailer.com does have a physical switch to support lithium battery charging. I have ordered the unit already. When I got it then I will take a few pictures to update the thread. I think it may help other users who might want to convert to lithium battery for their camper.

[camaraderie]

Thanks for the resolution Henry! Interesting that this is nowhere on PD's website & manuals...look forward to hearing HOW it works!

[bcramer]

I switched to lithium batteries a couple of months ago and looked at both the PD and WFCO modules for my WFCO converter. I was going to get the PD, but every supplier had long lead times. So, I got the WFCO module from a local RV dealer. It works great with fairly simple installation.

[NMWildcat]

Call Randy at http://www.bestconverter.com
They are an excellent source of information and well respected. They sell PD, as well as other brands.
They are a very responsive Mom and Pop shop and will get you fixed up.

[Henry1011]

Hi all
I received the pd4135k unit from etrailer.com today. I took some pictures so that you can see what it looks like. Note that on the unit there is a note saying that it supports both lithium and lead acid battery via a switch. That confirms that the unit support lithium battery charging.

Note I just have to wait for a warm day to go and replace the wfco unit in the trailer. That could take a few months as I am living in the north east of the country.

[KyDan]

I know I'm late to the party but couldn't you much more easily have just changed the charger board and kept your existing 12v fuses?
I changed mine that way and it was all of a 10 minute job.

[Henry1011]

Originally Posted by KyDan

I know I'm late to the party but couldn't you much more easily have just changed the charger board and kept your existing 12v fuses?
I changed mine that way and it was all of a 10 minute job.

May be it would help if you can provide some diagram of how you hook up the charger board to your unit. And a picture or two of the device that you are using. Do you have the model of the part and where to get it? It is hard for someone who is new to this to picture what to do without more information.

[pgandw]

Originally Posted by KyDan

I know I'm late to the party but couldn't you much more easily have just changed the charger board and kept your existing 12v fuses?
I changed mine that way and it was all of a 10 minute job.

The OEM WFCO8735P does not have a way to replace the converter separate from the panel. I sure couldn't find it if it does exist. That's why the PD 4135 is a complete panel/converter replacement also. Both are used on smaller trailers - there are 6 half-size AC circuit breaker slots, and 6 fused DC circuits.

Fred W
2019 Flagstaff T21TBHW A-Frame
2008 Hyundai Entourage minivan
camping Colorado and adjacent states one weekend at a time

[BarabooBob]

I have changed out two WFCO converters because neither one of them would go to the 14.2 volt fast boost charge mode. They both stayed on 13.4 v all the time. I owned the first TT for 6 weeks and sold it because it did not work for us. We have put over 12,000 miles on the second TT in the last two years. The PD 4135K works great. It charges quickly and has not resulted in water lose in my batteries.

[TitanMike]

Originally Posted by pgandw

The OEM WFCO8735P does not have a way to replace the converter separate from the panel. I sure couldn't find it if it does exist. That's why the PD 4135 is a complete panel/converter replacement also. Both are used on smaller trailers - there are 6 half-size AC circuit breaker slots, and 6 fused DC circuits.

Fred W
2019 Flagstaff T21TBHW A-Frame
2008 Hyundai Entourage minivan
camping Colorado and adjacent states one weekend at a time

Also, if the wires to fuses and breakers are properly marked when removed, reinstalling isn't a terrible task.

Amazon sells a wire marker "book" for ~$8 that you use to number the wires. Write the number and circuit served on a piece of paper and when reinstalling wires you have your map.

[nayther]

Originally Posted by NMWildcat

Call Randy at BestConverter - Converters, Inverters, Electrical Supplies, Electronics
They are an excellent source of information and well respected. They sell PD, as well as other brands.
They are a very responsive Mom and Pop shop and will get you fixed up.

2nd.3rd and 4th for Randy and Best Converter. Upgraded two RV's with his parts and advice and been perfect. Prices are right in line with ebay, etc. and they stand behind their products. Bought transfer switch and inverter and converter and with Randy's advice it all fell into place perfectly. Then the remote control panel for the Samlex inverter crapped out, called them and they sent me a replacement no questions asked and did not want the old one back. First class

[Henry1011]

It has been relatively warm (45+F) here the last few days. So I ventured out to the trailer trying to replace the wfco unit with the pd4135. I got it done today but I can tell you that it wasn't a walk in the park. I am an electrical engineer so I am familiar with circuit and that helped me a bit but it took me a good two days to get it done.

Here are some of the problems that I encountered, hopefully my experience could help someone else out there:

1. First I tried to take the easy way of pulling out the wfco charger main board and replace it with that of the pd4135 but that didn't work. The boards are not of the same size and their screw holes for tying down to the housing unit are not the same. So I abandoned this approach.
2. I removed the wfco unit entirely and rewired everything to the pd4135. That was such a pain. Especially with the AC wiring. The wires are so stiff and there was only a tiny space to make them bend and go-to where I wanted them to go. This took the most time for me.
3. The DC wiring is relatively easier. All I had to do was cutting the old connections and transferred them over to the new connections using twisted connecting caps. The confusing part here was that the pd4135 has two red wires. One connect to the battery + and the other one I am not sure what it is used for. May be the second red wire is for connecting to a second battery system? I left it alone unconnected.
4. The pd4135 housing is slightly smaller than that of the wfco so I had to cut a small piece of wood and glued it to the side of the opening to make it fitted.

Now that everything is working, I think the pd4135 is probably a good replacement unit but the instruction manual is just down right disappointing. For example it provides you with a lithium switch but it wouldn't tell you, up or down, to set it for lithium battery. It has no description for the LED light so when it is flashing you just don't know what it means. It have descriptions like 'wire 001' and 'wire 002' but you look everywhere and don't see any thing labeled 001 or 002.

I am including a few pictures so you see what the upgrade process look like.

Good luck if you decide to do the upgrade.
Henry