Replacement 45 Amp Converter Section for RV Panel  

I installed the original PD4045 in my camper about 16 years ago, and it worked flawlessly with the 2x 100Ah LeadAcid deep-cycles. I then, 2 yrs ago, upgraded a 420Ah LiFePO4 LiTime battery and the PD4045CSV. took 10minutes to swap out the charger chassis. I now have over 3 days of power, vs the 15-20 hours of the LeadAcid. I left all the original wiring in my trailer the same. But.... I did go through ALL existing wiring again to make sure I didn't have any issues. Most common thing I see in all trailers is poor grounds. Or maybe a cheap butt-wire connector came loose and/or shorted. My camper is 100% 12VDC w LED lights, DC fridge, DC fan, etc. As I have no need for an DC/AC inverter. I charge the battery with both house-120VAC and using a 2500W gas generator. ZERO problems in 2 years of camping. I also added a Victron SmartShunt to the circuit. BEST upgrade I have ever done to my trailer. I can fully monitor everything (charging and discharging) from my smartphone via bluetooth. I have only found one issue. When charging this new 420Ah LiFePO4 battery when it is down to 10% remaining charge the PD4045 DOES allow for using all 45AMPS of rated charging power. (Note-LeadAcid batteries will never allow this much charging current.) So, what I found was that the single 30A fuse was blowing every time it tried to charge. The unit came with only ONE fuse. So, i added a second 30AMP fuse in the empty slot next to it. I could find NO information as to the wiring of the unit itself in the manual or online. BUT, once i had 2 30AMP fuses installed, it charged at 40-45Amp draw with no problems. The charger in the PD4045Li works as designed. As the battery gets charged from 10 to 100%, it does reduce the current lower and lower. Also, the BMS of the battery is doing its job to protect the battery during charging. My LiTime battery is rated up to 200Amps of charging current. So it does take every bit of current that the PD4045 puts out. What is the max charging current rating for your 2 40Ah batteries? Now as to your issues you are seeing. If I have change any part more than once, i would immediately realize that it may not be the PD4045, but something else in the circuit that is causing the problem. How many new chargers have you purchased?? I treat the repair of my trailer, my truck, and my jeep with all the same logic. So with 1000s of happy PD4045 users, I would lean towards something else is causing the issues you are seeing. The odds of having multiple PD4045s, in a row, coming out of the box all "bad" is not very probable. I have only seen good results with people using the PD4045. But yes, I have been fighting various electrical problems in trailers for 25 years, and i can be VERY frustrating.....

I have had and continuously have great results with this product. I love it.