Updating Magnetek 6325 - Fiberglass RV



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Old 05-26-2019, 08:54 AM   #1
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Updating Magnetek 6325

I'm going to update my batteries soon (probably Gel) and have heard horrible things about the Magnetek charging/power system. I don't want to update the batteries and have the Magnetek ruin them in a year or two. It appears that it would be much simpler to buy one of the PD 4600 kits to convert it to a smart charger. Does anyone have any experience with this? Is this a good way to proceed? Are there better/more modern units that have come to the market since the PD 4600 series were introduced?

Also, my unit is 25 amps. The smallest PD 4600 I've found is 35 amps. Would it be okay to go to a higher amperage and if so what limitations do I have going up to say a 45 or 55 amp unit? I've been pricing them and have actually seen some of the higher amp units selling on sale for cheaper prices.
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Old 05-26-2019, 09:27 AM   #2
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I just updated a WFCO converter bottom to a PD4635LIV (the lithium version). The instruction sheet has a page for the Magnetek 6336, which I suspect is the 35 amp version of the Magnetek. If so, the replacement doesn't look all that difficult. If the physical dimensions of the 6325 are different from the 6336, that could be a problem. I'd contact PD. They were very helpful with my replacement choice.

If Bonair went with the minimum wire size between the converter & battery, you should replace it. For 35 amps, I'd use at least #8 wire for both the + & - connections. If you go larger, use wire size tables to determine what size wire you need.
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Old 05-26-2019, 09:40 AM   #3
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Thank you Jon. You are always a great resource for pertinent information. I've been reading your Lithium battery conversion with interest. I'd love to go the Lithium route but at approx. $1000 each I'd be afraid of screwing something up and ruining my investment.
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Old 05-26-2019, 09:43 AM   #4
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Originally Posted by Jon Vermilye View Post
If the physical dimensions of the 6325 are different from the 6336, that could be a problem.
One of the reasons I want to do the conversion rather than replacement is the physical dimensions of the Magnetek are huge and I'm have trouble finding a unit that will take up all that space. Hopefully there is enough room in there.
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Old 05-26-2019, 02:27 PM   #5
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Does anyone have any experience with the "Boon docker" brand of convertors?
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Old 05-26-2019, 06:04 PM   #6
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you can have a face plate adapter made for a smaller unit. A sheet metal shop can handle that job as can a cabinet maker. Just depends if you want wood or metal.
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Old 05-26-2019, 06:57 PM   #7
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I'm pretty sure I could handle a face plate. The main thing with going with the conversion is it is only a few wires compared with having to rewire the whole box. In the conversion you leave everything connected to the fuses and only change the guts that is the convertor/charger. I think I have plenty of room to put the new "guts" in.
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Old 05-28-2019, 01:22 PM   #8
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My PD4635 update kit included a new 12 volt fuse panel so there were some wires to change.
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Old 05-28-2019, 02:16 PM   #9
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My PD4635 update kit included a new 12 volt fuse panel so there were some wires to change.
How was it? LOL What was the degree of difficulty? I did a full convertor once and it was pretty difficult.
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Old 05-28-2019, 03:25 PM   #10
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How was it? LOL What was the degree of difficulty? I did a full convertor once and it was pretty difficult.
Pretty straight forward. Just write down all the colors and positions before you start. No need to remove the wires, just disconnect then from the old fuse board.
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Old 05-28-2019, 03:40 PM   #11
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Take pictures too maybe.
Friend of mine built his house from pictures of display model.
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Old 05-28-2019, 03:59 PM   #12
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And follow the instructions to mount the new fuse board before changing over the wiring. I thought I'd save some time on my stomach by switching the wires before exchanging panels. Bad move - the branch wiring made the board too stiff to attach. Nothing like doing the same job twice!
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Old 05-28-2019, 04:31 PM   #13
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Take pictures too maybe.
Friend of mine built his house from pictures of display model.
Excellent idea!
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Old 06-01-2019, 04:46 PM   #14
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I'm pretty sure I could handle a face plate. The main thing with going with the conversion is it is only a few wires compared with having to rewire the whole box. In the conversion you leave everything connected to the fuses and only change the guts that is the convertor/charger. I think I have plenty of room to put the new "guts" in.
I replaced the unit in my 1998 Casita with a WFCO WF8735 converter that was quite a bit smaller, but had a 3 stage charger required for the new AGM battery. I fabricated a face plate from 0.125 aluminum and had enough room to add a battery monitor and a switch to select between the solar controller and the converter. I have sense added 2 additional switches to turn off the hot water heater and a rear view camera.
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