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Old 10-22-2014, 04:34 PM   #15
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Whenever you have an electricial problem make sure you have clean tight contacts and look for overheating from your plug through to your outlites

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Old 10-22-2014, 05:09 PM   #16
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In your picture of the breaker box it appears that it is a ground fault breaker, are you sure it is wired correctly? I can't really tell by the picture. Any short no matter how small will pop a gfci does it happen more often when it's raining or damp?

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Old 10-24-2014, 07:51 AM   #17
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Opinions are like noses....everyone has one.

My observation is that (as others have said) the converter is much too old. That type uses a ferro-resonate transformer to stabilize the voltage. They are loud, inefficient and prone to failure. A new solid state unit (about $150) will work better anyway.

The problem with transformers is that they can get damaged over the years and have internal shorts that draw too much current. The short circuit can often be intermittent, so you never know what will happen.

The previous suggestion of using an external battery charger to keep the batteries up and act as a converter will allow you to disconnect the converter from the breaker. Then you can have a chance to determine if the converter is the problem. If the breaker settles down, then replace the converter with a new solid state unit. Amazon has lots of really good ones listed.

Tom & Jan ---- Westwing43
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Old 10-26-2014, 07:18 AM   #18
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Well everyone, it took a LOT of testing and redoing but we got it!

In the 5th pic down you can see the main power feed to the hot plate the breakers mount to was melted. This was the big clue that I didn't pick up on.

You can see the lug it screws into is cocked and not at a 90^ angle in relation to the hot plate.

Because this part is notched on the side (to butt up against the hot plate) being cocked meant that only the SCREW was transferring power between the wire and plate!

I took it all apart, put it back together properly, and tried it... but the breaker still popped.

Not to be discouraged I swapped the AC and Main breaker wires (to use the AC breaker for the mains) and guess what... it's been fine since!!!

So I think the excessive heat from the bad mains connection made the P120GF breaker pop too frequently and ruined it.

Only issue now? That breaker is $130 new! And no chance I'm getting a used one!

That can wait though... we don't need the AC till next year

So thank you everyone for all the suggestions and help!!!

Full timing in a 1979 Dodge Sportsman Shasta 22' - 440 power in a little package!
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