ENGLISH BATTERY-POWERED SYSTEMS FOR DOMETIC AUXILIARY AIR CONDITIONING SYSTEMS INSTALLATION GUIDELINES Dometic Corporation, Environmental Division Rev.
WARNING: Only trained technicians should perform these checks and tests. These units contain voltage of 12VDC, 24VDC, 115VAC and/or 230VAC. Some of these voltages can be lethal. These units also contain refrigerant under high pressure. Refrigerant circuits should only be accessed by licensed technicians. COPYRIGHT © 2009 Dometic Corporation, Environmental Division, All Rights Reserved.
Battery-Powered Systems Installation Guidelines CONTENTS NOTES AND WARNINGS 4 UNDERSTANDING LOW VOLTAGE DISCONNECTS (LVD) 4 INSTALLING THE BATTERIES 5 INSTALLING ADDITIONAL BATTERY BOXES 6 WIRING THE NEW BATTERIES 6 INSTALLING THE BATTERY FUEL GAUGE 7 INSTALLING THE INVERTER 7 OPTIONAL: INSTALLING THE INVERTER/CHARGER 7 INSTALLING THE INVERTER CONTROLS 8 INSTALLING THE ALTERNATOR 9 DASH CHARGE LIGHT (VOLVO) 10 – 11 TESTING THE ALTERNATOR 12 WIRING THE "IGNITION INTERLOCK" ON THE HV
Battery-Powered Systems Installation Guidelines NOTES AND WARNINGS IMPORTANT The Dometic battery-powered air conditioning system is an integrated package of components which have been carefully selected and tested to work together for proper performance.
Battery-Powered Systems Installation Guidelines INSTALLING THE BATTERIES You will replace the standard lead-acid batteries with absorbed glass mat (AGM) batteries (Fig. 1) and also add extra AGM batteries to get extended time running on battery power. The first step is to find space for the extra batteries and inverter. Note that whenever possible the inverter should be mounted in the same box with the batteries.
Battery-Powered Systems Installation Guidelines INSTALLING ADDITIONAL BATTERY BOXES Boxes should be mounted with cabling in mind. The shorter the cables the less voltage drop and the less chance for chafing and rubbing. Mount Dometic battery boxes with four bolts, either supplied with the box, or Grade 8 fasteners of at least 5/8" diameter. Some battery boxes come with a clamp-on mounting solution.
Battery-Powered Systems Installation Guidelines INSTALLING THE BATTERY FUEL GAUGE INSTALLING THE INVERTER Follow the manufacturer’s instructions to install the battery fuel gauge. Follow the manufacturer’s instructions. Here are some other suggestions: The shunt must be connected between the last battery and the inverter negative post. You may install the shunt at the battery or at the inverter. The aluminum bar may be moved to accommodate either.
Battery-Powered Systems Installation Guidelines INSTALLING THE INVERTER CONTROLS The inverter controls should be mounted in an easily accessible place, probably the same area in which you will mount the HVAC controls (Fig. 5). Consider first the area at the head of the bed (driver’s side of the truck). Usually the truck’s HVAC controls are mounted here and provide a wire chase for your use.
Battery-Powered Systems Installation Guidelines INSTALLING THE ALTERNATOR Follow the instruction manual included with the alternator/regulator. Here are a few additional tips. The new alternator should directly replace the existing one (Fig. 6) (i.e., pad mount or J180 mount). If not, you need to request the correct model. The alternator amp rating is based on the number of batteries in your system and may be different on different applications. You will have to reuse the alternator pulley.
Battery-Powered Systems Installation Guidelines DASH CHARGE LIGHT Note for all Volvo Trucks: If your existing alternator has an "I" terminal with wire attached, you may need to add a relay to make the “Alternator” or “Charge” dash light work correctly. One way to tell is if the existing alternator has a wire hooked to the "I" terminal. If the new alternator does not have this terminal, then you will need the charge light relay. If you do not already have the charge light relay, request Dometic P/N 4163717.
REV. - DATE Wire Labeled "Ground" Wire Labeled "Stator" Back of Alternator DC Negative 30 REVISIONS DESCRIPTION + 85 DC Positive MADE BY 87 APPR BY 86 Relay Terminal No. 30 85 86 87 Connection Point Charge Lite Wire Stator Tap Ground (-12vdc) Positive (+12vdc) DOCID Sheet 1:2 02/25/09 SCALE: DATE: SIZE: A VENDOR NO. APR BY: DWG BY: 1 of 1 KEA 080418 PART NUMBER: SW Cruisair O.I.
Battery-Powered Systems Installation Guidelines TESTING THE ALTERNATOR Alternator voltage test. Connect the test leads of a volt meter to the alternator output terminals. Note: Most Leece Neville alternators have isolated ground rectification. Always connect tester/volt meter directly to the negative output terminal of the alternator or your test will be inaccurate.
Battery-Powered Systems Installation Guidelines OPTIONAL: INSTALLING 120VAC OUTLETS INSIDE THE SLEEPER If so equipped, the system will have 120VAC outlets that can be installed inside the sleeper for accessory use. The outlets may be installed anywhere inside the sleeper, however, they should be installed in an area that makes sense for the loads the driver will be applying (i.e., probably near one cabinet or the other).
Alternator - + - Battery 1 + AC Wiring DC Wiring + Battery 2 - Factory Negative alternator lead Factory Positive alternator lead Add a 2/0 cable from positive alternator stud to positive starter stud. 3/8" ring terminal for the alternator, 1/2" for the starter. + + Battery 3 Starter - THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF DOMETIC CORP. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF DOMETIC COR IS PROHIBITED.
ENGLISH + + Primary (OEM) Box - - + Start Battery 2 Start Battery 1 Factory Positive Alternator Cable Factory Negative Alternator Cable + Battery Separator Factory Starter Cable Starter Add at least a 3/0 cable from the alternator positive to the starter positive lug. 3/8" ring terminal on the alternator, 1/2" at the starter. NOTES: 1) House Batteries must be of the AGM deep cycle type 2) Alternator shall be upgraded. Discuss with Dometic Applications Department for recommendation.
- Start Battery 1 + Factory Positive alternator cable Factory Negative alternator cable - Start Battery 2 + Factory Starter Cable Starter Add at least a 3/0 cable from the alternator positive to the starter positive lug. 3/8" ring terminal at the alternator, 1/2" at the starter. NOTES: 1) House Batteries must be of the AGM deep cycle type 2) Alternator must be upgraded. Discuss with Dometic Applications Department for recommendation.
ENGLISH - Start Battery 1 - Start Battery 2 + Primary (OEM) Box + Factory Positive alternator cable Factory Negative alternator cable Factory Starter Cable Starter Add at least a 3/0 cable from the alternator positive to the starter positive lug. 3/8" ring terminal at the alternator, 1/2" at the starter. NOTES: 1) House Batteries must be of the AGM deep cycle type 2) Alternator must be upgraded. Discuss with Dometic Applications Department for recommendation.
+ - Battery 1 + Factory Positive Alternator Cable - + Factory Starter Cable Battery 2 + Primary (OEM) Box Factory Negative Alternator Cable - - Battery 3 + - - THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF DOMETIC CORPORATION. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF DOMETIC CORP IS PROHIBITED.
ENGLISH - Battery 1 + Factory Positive alternator Cable Factory Negative alternator Cable - + - + - Battery 3 + - + - THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF DOMETIC CORPORATION. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF DOMETIC CORP IS PROHIBITED.
- - - Battery 3 + OEM Battery Disconnect Switch OEM Fuse Block + + + NOTES: 1) House Batteries must be of the AGM deep cycle type 2) Alternator shall be upgraded. Discuss with Dometic Applications Department for recommendation. 3) Inverter must be of approved type by Dometic in order to insure proper operation of system. 4) Cable size is choosen based on voltage drop and load. All cables shall be 2/0 unless otherwise noted on drawing.
ENGLISH Left Front Tire Factory Positive B New Positive 3/0 cable to Starter Positive Engine Block Factory Positive Starter Field Wiring NOTES: 1) Batteries must be of the AGM deep cycle type 2) Added cables must be 2/0 or larger. 3) Add a positive cable from positive on the alternator to the positive post on the starter. 4) Add a negative cable from the Frame Ground Post to the Truck side of the Negative Fuse (not the battery side.
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Dometic Corporation, Environmental Division P.O. Box 15299 I Richmond, VA 23227 USA I 804-746-1313 I Fax 804-746-7248 www.dometictruck.com I sales@dometictruck.com UNITED STATES & CANADA SERVICE ONLY Weekdays 8:00 am to 5:00 pm (Eastern Time) 804-746-1313 All other times 888-440-4494 L-2597 Rev. 20091009 For all other areas visit our website to find your nearest distributor.
