DIY Network

Power System A new power converter is installed on the Airstream. From "Classic Rides" episode DCLR-209

Host Kevin Tetz is joined by Jeff McCoy, an electrical engineer, who installs a new power converter that converts AC 120-volt power to DC 12 volts when the coach is hooked up to city power.

On the project trailer the original MagneTek 40 amp power converter had been badly modified by the previous owner and was unsafe and not up to codes.

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	Jeff helps Kevin install a new power converter to the Airstream coach.
	Figure A
	Figure B

Install New Power Converter

Note: You need a converter to replace the battery in the electrical system when you hook up to shore power. The converter basically assists the battery in the coach by converting power.

1. First open up the old converter and remove the DC distribution wires.

2. Disconnect and remove electrical pieces as necessary. Remove the DC negative wires and the old converter is removed.

3. Sort the wires and select the DC negative lines that will go to the DC negative terminal bar. (The terminal bar--figure A--is mounted to the trailer floor.)

4. Cut the old wires to expose good copper, strip the ends and the clean negative wires should be installed to the terminal bar.

5. Get connections as tight as possible.

   Note: The project Airstream has a split system, which means it consists of both AC and DC currents, so Kevin and Jeff next install a fuse panel, which contains over the current protection devices.

6. Route the wires through and make connections to the branch circuits as necessary.

7. Fuse the wire based on the wire gage, not based on the equipment it's running. Cut and strip each wire and install them to the fuse panel (figure B) as needed. Follow manufacturer's guidelines for connections and make sure connections are tightened.

8. The fuse box is secured to the floor and the wires are bundled together using zip ties. The installation of the fuse box is complete.

9. To move in the converter, keep the leads as short as possible and cut and strip the black DC negative wire that comes from the terminal box, which was installed earlier.

10. Insert into the new converter box and screw it down until secure. Do the same with the red positive lead.

11. Secure the box to the floor and plug it in.

Note: When you plug the trailer into AC power, check the connections to make sure everything is correct. Use a voltage meter to check the converter system.

In the next segment Kevin installs a new "deep cycle" battery and completes some electrical projects.

RESOURCES :

Dremel Tools
Website: www.dremel.com

Aluminum Wheels
Alcoa Wheels
Website: www.alcoawheels.com

Marathon Tires
The Goodyear Tire & Rubber Co.
1144 E. Market St.
Akron, OH 44316-0001
Phone: 330-796-2121
Fax: 330-796-2222

Electric Dump Valve
Phase Four Industries
Website: www.drainmaster.com

SeeLevel Tank Monitor System
Garnet Technologies Inc.
125 M and M Ranch Rd.
Granbury, TX 76049
Phone: 877-668-7813
Fax: 817-573-0005
E-mail: sales@rvgauge.com

Power Converter
Parallax Power Supply
425 Sycamore St.
Anderson, IN 46016
Toll-free: 800-443-4859
Fax: 765-608-5235

GUESTS :

Gary Bunzer
The RV Doctor
Bunzer Consulting
PO Box 2074
El Cajon, CA 92021
E-mail: gbunzer@cox.net
Website: www.rvdoctor.com

Terry D. Cooper
Instructor
Recreational Vehicle Program, Industrial Maintenance Engineering
Texas State Technical College
Waco, TX 76705
Phone: 254-867-4878 (office)
Fax: 254-867-3570
E-mail: terry.cooper@tstc.edu

Jeff McCoy
Parallax Power Supply Expert
4118 E. 900 St.
Warren, IN 46792
Phone: 260-519-2799
E-mail: jmccoy@parallaxpower.com