400 70 69-00, Rev.2 DOMETIC AB INSTRUCTION FOR INSTALLATION TRAVEL POWER® 230 V AC, 16 A CONTENTS Page 1. GENERAL INFORMATION 3 2. BEFORE INSTALLATION 4 3. INSTALLATION 10 4. CHECK BEFORE USE 18 5. TECHNICAL DATA 19 6. FAULT TRACING 21 7. WIRING DIAGRAM 25 (991 00 10-06) - Read and follow these instructions carefully when installing Travel Power. - A qualified electrician must do the 230 V AC installation. - The power box cover is not to be removed at any time.
ENGLISH Instructions for installation NOTE Travel Power is not intended for powering life support systems. The instruction for installation is intended for installation engineers and maintenance people of the Travel Power®. NOTE that using this instruction for installation require necessary authorization and knowledge to work with the Travel Power®. Read these instructions before and during the installation of the Travel Power®. Use this instruction for fault tracing. Save this instruction for later use.
1 GENERAL INFORMATION 1.1 SAFETY PRECAUTIONS The output voltage from the Travel Power generator is considerably higher than the output voltage from a regular vehicle alternator. WARNING! No extra connections are to be made to the Travel Power generator under any circumstances. The Travel Power unit must never come into contact with the regular 230 V network or the 12/24 V system of the vehicle.
2 BEFORE INSTALLATION Make sure that the product is complete and undamaged. PLEASE OBSERVE! In the event of damage caused by transportation, the buyer must immediately report this to the company responsible for the transport. Before beginning the installation of Travel Power check that no parts needed for a complete installation are missing. 2.
2.3 IF NO CUSTOM-MADE INSTALLATION KIT IS AVAILABLE, FOLLOW THESE INSTRUCTIONS For a complete mounting kit, brackets, pulleys and other parts have to be produced. Please observe that the assistance of a service station or similar facility experienced in designing belt transmissions and manufacturing-mounting brackets is strongly recommended.
PLEASE OBSERVE ! It is of greatest importance that the generator pulley is mounted in parallel to and aligned with the crankshaft pulley as shown in Figure 1. If the pulley installation is not made correctly problems due to belt wear are likely to occur. Figure 1 Figure 2 To ensure good performance, the area of contact between the belt and the pulley should be as large as possible.
To obtain as good alignment as possible between the drive pulley and the generator pulley it can be necessary to put washers on the generator shaft behind the pulley, see Figure 3. For this purpose following washers are included: 2 pieces of 3 mm washers 1 piece of 1 mm washer 3 pieces of 0.5 mm washers Washers to align the pulley. Relative position between T = 0 washers .5 is unimportant. T = 3 Remaining washers are placed ) outside of the T here, = 0 between . 5 ( 2 xthe pulley T =and 1 the throat nut.
2.4 PULLEY DIAMETER DESIGN Tabulated below is the approximate generator rpm corresponding to the available power: 3000 rpm - 1000 W 3600 rpm - 1800 W 5500 rpm - 3500 W The generator rpm is dependent on crankshaft rpm and the pulleys have to be dimensioned carefully to keep the rpm within the allowed limits for the generator and to ensure that the engine does not have to be over-revved to achieve proper function.
Check the choice of pulleys according to the following instructions: - Find out the maximum rpm for the engine (Max). - Find out the engine's rpm when traveling at maximum, continuous velocity (Maxcont). - Divide the diameter of the large pulley (Dlp) with the diameter of the small pulley (dsp). Multiply the result with the maximum rpm for the engine (Maxrpm). This result must not exceed 18 000 rpm. If it is larger a smaller pulley should be chosen for the crankshaft.
3. INSTALLATION Installation of Travel Power must be made by an authorized Travel Power workshop. See section 7, Figure 11, for wiring diagram. Before the installation is started make sure that the vehicle is parked on level ground with the parking brake engaged, the ignition off and all connections to the battery disconnected. 3.1 INSTALLATION OF THE GENERATOR AND PULLEYS If a custom-made installation kit is used, please proceed according to the instructions accompanying it.
3.2 INSTALLATION OF THE POWER BOX WARNING! HIGH VOLTAGE! The cover of the power box must not be removed at any time. To cut, drill into, or in any other way damage the product may result in poor performance and cause danger and will therefore invalidate the warranty. If the cover has been removed or if the product has been willfully damaged the warranty will no longer be valid. - Mount the Power box in a dry, well-ventilated space protected from strong vibrations.
Note to locate the Power box in horizontal position leads to higher risk for liquid to trickle through the air inlet. Be therefore observant when to choose location of the Power box so it not will be exposed to unnecessary external influence that can limit the function of the Power box.
3.3 INSTALLATION OF THE SHIELDED CABLE Please observe! The output voltage from the Travel Power generator is considerably higher than the output from an ordinary 12 V or 24 V vehicle alternator. The cable is delivered with two pre-mounted connectors in one end, to be mounted in the Power box. The other end with the pin-socket connectors is to be mounted in sockets on the generator, se Figure 5. Power box connectors Generator connectors Figure 5.
The cable is to be mounted in the sockets on the generator as shown in Figure 7. Each cable conductor is marked with a number between 1 and 5. These shall be mounted in the socket plug corresponding to the same number as the generator cables. Greatest carefulness should be taken when mounting the cables into the socket plugs. As a result of a faulty connection the rotor will be demagnetized and must be re-magnetized, see further section 6. Figure 7.
3.4 ON-OFF SWITCH The on-off switch is delivered as standard in the cover of Travel Power box. If another location of the on-off switch is requested please contact you retailer for an extension cable. 3.4.1 Location of the on-off switch different from standard When mounting the on-off switch in different place than standard, the following instructions should be noted. 1.
Figure 8 Figure 9.
3.5 INSTALLATION OF 230 V AC An authorized installer must do the 230 V AC installation Connection to the 230 V is made on the socket shown in Figure 10. Socket for 230 V connection From the generator 230 V cable Figure 10. Connection to the Power box The connection to the 230 V circuit is made in the 3-plug socket on the power box. Screws do the plug connection in the socket. Be sure that the cable is properly and safely connected in the socket and that the cable is fixed with the cable clamp.
4. CHECKLIST BEFORE USE Do not turn on the ignition and do not use Travel Power before a thorough check of the installation has been made! 4.1 Mechanical control - Check the generator and make sure that it is securely mounted on the engine. - Check the pulleys and make sure that they are parallel and aligned. Make sure that the belt and the pulleys can run without obstruction and that the belt is tightened according to manufacturer's instructions.
5. TECHNICAL DATA 991 00 10-06 TRAVEL POWER 230 V AC, 16 A Power box Output voltage Output power continuously Phase Voltage type Wave from Frequency Max current continuously Max start current during 5 s.
Figure 11.
6. FAULT TRACING 6.1 SCHEME FOR FAULT TRACING Use caution when fault tracing on Travel Power. Please observe that this is a 230 V installation. Is there voltage in the 230 V-outlet? NO Is the red LED lit? Yes Go to paragraph 6.
6.2 TRACING SCHEME WHEN RED LAMP LIT Use caution when fault tracing on Travel Power. Please observe that this is a 230 V installation. Red LED is lit YES Have several connections and disconnections of large loads within a short interval occurred? YES Turn off the engine for 1 minute and then restart the Travel Power without load. Avoid such behavior in the future.
6.3 FAULT TRACING BEFORE CONTACTING THE RETAILER To prepare before contacting the Travel Power representative the points below should be worked through: 1. Are all connectors in connection and all socket screws well tightened? It should be noted if there is a voltage drop at smaller loads the shielded cable connectors could be unproperly connected. 2. If point 1 is considered to be sufficient, loosen the cable (the 2 and 3-pole connectors) from the Power box.
5. If none of the above points gives any indication on faults it may be possible that the generator has been demagnetised. To check this follow the points below. 5.1. The measured and faultless shielded cable shall be mounted properly according to Figure 7 on the generator. It shall be de-mounted from the Power box. OBSERVE if the shielded cable is connected to the Power box during the magnetisation process the Power box may be damaged. 5.2.
7. WIRING DIAGRAM FOR TRAVEL POWER, 230 V, 16 A To be used with Travel Power 991 00 10-06 230 V, 16 A outlet 1,2,3: Connection of 3-pole shielded cable connector 4,5: Connection of 2-pole shielded cable connector A: Switch device for external power Shielded cable External power 3-pole generator socket 2-pole generator socket B: RCCB C: 2-pole fuses Travel Power generator Figure 11.
DOMETIC AB ENERGY SYSTEMS SE-171 54 SOLNA SWEDEN Ph: + 46 (0)8 501 025 00 Telefax: +46 (0)8 501 025 98/99 27
