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Old 10-29-2011, 05:24 PM   #15
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The noise makes me think that you have some kind of arcing. Try an locate where that sound is coming from as that should be a big hint. You may want to start the gensset and then locate as close as you can to where it seems the sound comes from and then have a helper shut down the genset while you listen. If something is arcing, you will probably be able to see signs of something burned from where it arcs to. Arcing is not a good thing and can cause a fire.
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Old 10-29-2011, 06:57 PM   #16
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Here is a PDF of what the insides of the 12V fuse board may look behind it.
The heavy wire lugs maybe where your having a problem.
Here is a operators manual.
You do have a auto relay thats suppose to cut in your batteries if no shore power or Gen.
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Old 10-29-2011, 08:03 PM   #17
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Wa8yxm and 007 have it right. The 6300 does have a relay in it that selects between battery and converter output (PPS LINEAR CONVERTERS TECHNICAL). When 110VAC is available, the relay energizes and selects Converter output. When the 110VAC is removed, the relay de-energizes and selects the battery as the source for coach 12VDC. The relay is sticking and not de-energizing properly (most likely burnt contacts). The zapping noise is most likely from the burnt contacts.

The 6345 is an older linear style converter that with only a 5 amp battery charge capability. As Wa8yxm said, you will get better performance from one of the newer 3 stage converters. It does connect a little differently but that is simply combining the battery B+ red wire and converter output blue wire shown in the 6345 schematic together. Newer converters do not use a relay.

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Old 10-29-2011, 08:51 PM   #18
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No lights with the engine running would be another issue.

Depending on your coach, your system may look something like this

Shore power goes to a automatic transfer switch
Generator power also goes to this switch.

From there it goes to the Magnetek 6300 where it branches out to assorted places INCLUDING the back side of the box which houses the converter

Battery power both goes to and comes from a 30 amp or a pair of 30 amp fuses in the Magnetek,,,

When on shore power LIGHTS and other 'non senistive" loads are powered by the converter,, to the exclusion of all other sources.

Radios and "Senistive" loads are powered by the charger section of the 6300 in parallel with the battery which is charging. A relay isolates these two 12 volt systems

Loose Shore/Generator power and the relay is supposed to close, connecting the battery to both systems.

The engine, has yet another isolator, may be a relay or may be a "Brick" with diodes in it (Fairly large brick) Relay, actually a solenoid, looks like a Ford Starter Solenoid, makes the connection between the two batteries,, BEFORE the Magnetek 6300 however, and should not be affected by it. So why starting the engine would kill the lights I don't know.

My reasons for always recommending replacement of a 6300 (Well at least the electronics behind the fuse/breaker panels) has to do with it being a rather poorly regulated (Ferroresonate) single stage charger... I much prefer a proper 3-stage converter.

And to Dave (Who kept saying I have it right) Thanks.. I do my research as it happens, and I've designed and built power supplies for other uses (They major difference between a "Power Supply" and a "Converter" is... Who you are talking to... They do exactly the same job, Convert one power to another, Usually 120vac for devices made in the US, into some DC voltage, 5 (plus or minus) 12, 15, 18, (All common voltages in computers) and I've designed for most of those. Built and used till I went full time.. (I use the Progressive Dynamics 9180 for 12 volts now)
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Old 10-29-2011, 09:09 PM   #19
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No lights with the engine running would be another issue.
The relay in the 6345 is causing all this. Like a ATS selects between shore or generator power as the 110VAC source, this relay selects between converter or battery as the 12VDC source. The alternator connects to the isolator relay which connects to the coach battery which connects to the problem relay.

I had the same problem with the old PD system in my 78 Chieftain when I bought it in 2003. I cleaned up the contacts and got it working. Used it up until this year when I upgraded both the AC/DC panel and PD9260 this year.

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Old 10-29-2011, 10:39 PM   #20
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I can't thank all of you enough for all this extremely good information and all the PDF files and schematics. I'm SURE that it is probably the contacts on the relays...I'll try cleaning them and get back to you all...soon!!! I would also like to clarify that when the lights are off (probably due to the relays not working) when I start the coach up it doesn't power up the coach lights....obviously because the relays haven't kicked in so the circuit is not closed...so the relays definitely sound like the culprit!!! I will try to get it working for now but I think that I will upgrade it in the near future to a 3 stage converter without the relays..
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Old 10-30-2011, 12:25 PM   #21
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One thing I will add.. Often there is a "Delay" on the engine's isolator (And the Generator transfer switch on the A/C side) If someone (My wife for example) has all the patience of iIm (Get it, Impatience) they don't wait for engagement.

I have had to reset things because of that more than once.
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Old 11-02-2011, 04:17 PM   #22
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The relay in the 6345 is causing all this. Like a ATS selects between shore or generator power as the 110VAC source, this relay selects between converter or battery as the 12VDC source. The alternator connects to the isolator relay which connects to the coach battery which connects to the problem relay.

I had the same problem with the old PD system in my 78 Chieftain when I bought it in 2003. I cleaned up the contacts and got it working. Used it up until this year when I upgraded both the AC/DC panel and PD9260 this year.

Dave
How did you go about cleaning up the contacts on the relays in the 6345?? Is it possible to purchase ..just the 2 relays?
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Old 11-02-2011, 06:26 PM   #23
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I had a Progressive Dynamics (PD) converter. I was able to clean the relay contacts with a automotive ignition points file. Inside of yours looks simular to this http://www.parallaxpower.com/6300/6300Qinternal.pdf

Transfer relay is shown on right side. As far as relay replacement, you would have to see if there is P/N information on the relays themselves and the google them. They are high amp DPDT 12VDC relays. When the unit is plugged in, the relays energize allowing converter current to flow. They use 2 relays to handle the current load. When 120VAC power is removed, they denergize and pass battery voltage.

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Old 11-07-2011, 03:02 PM   #24
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so you figure that it is the relay in the converter? This is what I was suspicious of. So the whole converter should be replaced? Would this also be a reason for no power to the coach lights when the engine of the motorhome is running?
Not sure why a delay, but the 6345 doe NOT have a relay in it. I have taken one apart and rebuilt and still using it, no relay in there at all.

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Old 11-07-2011, 09:44 PM   #25
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The PDF picture shows two transfer relays????
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Old 11-07-2011, 09:58 PM   #26
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Yep, the schematic also (http://www.parallaxpower.com/6300/6300.PDF). I think they divide the amperage between the 2 relays. The relays are no where near as big as the one that was in my old Progressive Dynamics unit.

Dave
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