PD-5100 Automatic Transfer Relay - Loose connectors

[Wayfinder]

During my full-time adventure, I discovered this in the Progressive Dynamics ATR.  I was not happy to see that the two connector screws indicated in picture were VERY VERY loose.  Had to turn several times to snug them up good.  Now I need either a new ATR, or at least figure out how best to change those two half-melted wires.  The busbar plate, or ledge (black), is secured to the box with two rivets. 

Has anyone ever see this before?

Also, while looking closely, I noticed the front 30 AMP receptacle on the trailer is not protected by the EMS, only the driver-side 30 AMP connector is protected by the EMS.  

Any thoughts or teachings on the differences between the two 30 AMP receptacles?

Thanks,

[dewdev]

Since these wires were loose it caused a build-up of heat which may have caused the melting.

Is the copper leads melted or just the insulation that is around the copper leads?

If just the insulation is melted (which it looks like in your picture), you can purchase a can of rubberized (paint-on) electrical coating material which comes in a can with a brush attached to the cover. Just disconnect the wires, move them so you can get at each side and put the new rubberized coating on the damaged part of the wires.

If the copper is melted, then you are probably correct that they need replacement. 

[Wayfinder]

Wires looked okay when I pulled them out from connectors to inspect, just dark colored, but no melting at all.

[Steph and Dud B]

Several turns doesn't sound like they just wiggled loose. Hate to see sloppy work on 120v electrical systems. That, and propane, really need to be done right.  Interesting that the front receptacle is not protected by the EMS. I suppose that's OK of you're only feeding it with a generator? Haven't people had trouble with the EMS balking at generator power, it was that just because there was no ground bonding plug installed?

[Rivernerd]

On 12/18/2021 at 2:55 PM, dewdev said:

If just the insulation is melted (which it looks like in your picture), you can purchase a can of rubberized (paint-on) electrical coating material which comes in a can with a brush attached to the cover.

I have had good results with this Gardner-Bender Liquid Tape product:

https://www.amazon.com/Gardner-Bender-07315001126-LTB-400-Electrical/dp/B000FPAN2K/ref=asc_df_B000FPAN2K/?tag=hyprod-20&linkCode=df0&hvadid=198096571354&hvpos=&hvnetw=g&hvrand=10257715978080992862&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9029558&hvtargid=pla-350654169801&psc=1

 

[dewdev]

On 12/18/2021 at 5:50 PM, Steph and Dud B said:

Several turns doesn't sound like they just wiggled loose. Hate to see sloppy work on 120v electrical systems. That, and propane, really need to be done right.  Interesting that the front receptacle is not protected by the EMS. I suppose that's OK of you're only feeding it with a generator? Haven't people had trouble with the EMS balking at generator power, it was that just because there was no ground bonding plug installed?

Yes, based on these forms, it was only the  ground bonding plug needing to be installed.

[Wayfinder]

Just in case someone finds this old thread.  Many of us have since upgraded to the latest version o fthe Progressive Dynamics Automatic Transfer Relay (ATR) Switch box (Part # PD5110010Q). It can still be found at eTrailer.com (as of December 2025).

This new part is a far superior model using Wago connectors.  PLEASE GET THE OLD-STYLE ATR BOX UPGRADED IMMEDIATELY!!!!!

My #110 is wired differently than other trailers of the time period in regards to the front generator power receptacle, it by-passes the EMS altogether.  Other trailer owners have the front shore power line going through the EMS too, via the ATR box.

[Galway Girl]

My original was subbed out by PD as a warranty claim.

Now the second one has the issue with the Neutral leads both in the box and from the street side.

I'll be buying a new version of this box PD5110010Q.

[jd1923]

1 hour ago, Galway Girl said:

Now the second one has the issue…

Our original PD ATS went out last year, a burnt wire or two. I decided to bypass the ATS. One cable now goes from the side 30A receptacle to the PI EMS and then to our Victron MP2 inverter and finally to the 120VAC breaker panel. 

We never use the 30A inlet up front, since we never use a generator. So no need for an ATS!

We’ve had 3 RVs and the PD 5100 had failed in all three. If you must have an ATS, it’s time to upgrade to a better product!

Edited 38 minutes ago by jd1923