400 70 69-00, Rev.2 DOMETIC AB
INSTRUCTION FOR INSTALLATION
TRAVEL POWER
®
230 V AC, 16 A (991 00 10-06)
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
- 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.
- Service on the Travel Power must
only be made by an authorised
workshop.
WARNING!
Only appliances marked 220 V or
230 V may be connected to Travel
Power.
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.
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
3
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. If external power from the
regular 230 V network is wanted a two phase, three positioned selector
must be installed between the Travel Power lines and the regular lines, see
further the Instruction for installation.
Extension cords for work outside the vehicle must be intended for outdoor
use, 2.5 mm
2
and max 100 m long.
Note if the on-off switch is in the on-position when the vehicle engine starts
the Travel Power will immediately generate 230 V to the outlet. Ensure that
appliances not intended for use are turned off or disconnected.
1.2 TRAVEL POWER PARTS
A Travel Power unit consist of the following three main parts:
A) Generator
B) Power box
C) Shielded cable between the generator and the Power box.
Consequently none of these parts may or can be used separately. These
three parts shall be installed and handled due to the instructions in this
manual.
1.3 PERFORMANCES
Travel Power delivers 230 V AC, 50 Hz sine wave.
Depending on vehicle engine rpm, Travel Power delivers up to 16 A
continuously.
The frequency is not dependent on the engine rpm. However the power
loading is.
Travel Power is working with self-magnetised generator that means no
connection to the battery is necessary.
4
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.
2.1 PACKAGE CONTENTS
The following items are included in the Travel Power 991 00 10-06
package:
- 1 Power box
- 1 Travel Power generator with PK 6 pulley
- 1 Warning label
2.2 MOUNTING KITS FOR GENERATOR AND POWER
TRANSMISSION
There are custom-made installation kits available for the generator and the
power transmission. Ask your dealer if a mounting kit is available for your
vehicle.
An authorized Travel Power installer must make the installation.
Installation includes work on the vehicle's engine and on other parts in the
engine compartment. Personal injury and/or mechanical damage may
occur if someone makes the installation not familiar with vehicle
installations.
5
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.
The following parts must be made or purchased:
- Crankshaft, at least PK 5pulley for the vehicle engine
- At least a PK 5 belt
- Mounting bracket for the Travel Power generator
- Various fasteners for the installation of brackets and pulleys
- (Tension pulley with bracket for tightening of the belt)
- (Idler/s pulley/s with bracket/s for rerouting of the belt)
- Locking glue for fasteners
It is of the greatest importance that the above mentioned parts must
be correctly dimensioned if Travel Power is to function without
problem.
The transmission belt and pulleys must be dimensioned to transmit at
least 5.5 kW from the engine to the generator. A PK 5-profile or larger
is recommended for this.
Brackets and other metal parts must be made of construction steel no
less than 8 mm thick.
There is normally a place on the engine block designed for an extra
alternator or compressor for an air conditioner that can be used for Travel
Power. Contact a service station authorized for the vehicle, to find out if
there is a bracket designed to hold an extra alternator or compressor that
can serve for Travel Power.
6
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.
To ensure good performance, the area of
contact between the belt and the pulley should be as large as possible.
To ensure sufficient clearance for the belt and to obtain a large contact area idlers
and/or tensions may be needed as shown in Figure 2.
Figure 1
Figure 2
7
8
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
It is of great importance that the large support washer is placed closest to
the backside of the fan to obtain necessary support to the fan.
Figure 3. Alignment of the generator pulley
T=0.5
T=3
T=0.5
(
2x
)
T=1
T=3
Shim sen kan byta
plats vid
upplinjering av
re m hju le n
Bricka /
Washer
Fläkt /
Fan
M om entdrages /
T o rq u e tig h th e n
50± 5 N m (5 .1 ± 0.5 kpm
/
36.9± 3.7 ft Ib
The washers for alignment are placed first on the
shaft. On the outside of the washers the large
support washer is placed and thereafter the fan.
Remaining washers not needed for alignment are
placed between the outside of the fan and the
throat nut.
Remaining washers are placed
here, between the outside of the
pulley and the throat nut.
Relative position between
washers is unimportant.
Washers to align
the pulley.
Relative position
between washers
is unimportant.
Large support
washer
Fan
Torque tighten:
50 ± 5 Nm / 5.1 ±0.5 kpm / 36.9 ± 3.7 ft lb
9
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.
MAXIMUM-ALLOWED RPM FOR THE TRAVEL POWER GENERATOR
18000 rpm Maximum rpm, intermittently, must not be
exceeded at any time when driving the vehicle
in any gear.
15000 rpm Maximum rpm which is the highest
continuously rpm for the generator.
Design the pulleys for a generator speed of 3000 rpm when the engine is
idling and a maximum speed less than 15000 rpm for cruising speed.
The vehicle's idling rpm may have to be adjusted to ensure that the
generator rpm is sufficient to allow Travel Power to produce enough
power when the vehicle is stationary.
10
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 (Max
cont
).
- Divide the diameter of the large pulley (D
lp
) with the diameter of the
small pulley (dsp). Multiply the result with the maximum rpm for the
engine (Max
rpm
). This result must not exceed 18 000 rpm. If it is larger a
smaller pulley should be chosen for the crankshaft.
Max
rpm
∗ D
lp
/ d
sp
< 18 000
- Divide the diameter of the large pulley (D
lp
) with the diameter of the
small pulley (d
sp
). Multiply the result with the engine's maximal
continuous rpm (Max
cont
). This result must not exceed 15 000 rpm. If it
is greater, a smaller pulley should be chosen for the crankshaft.
Max
cont
∗ D
lp
/ d
sp
< 15 000
Divide the diameter of the large pulley (D
lp
) with the diameter of the
small pulley (d
sp
). Multiply the result with the engine's idling rpm (I
dl
).
This result should be close to 3000 rpm to enable Travel Power to
deliver 1000 W when the engine is idling.
I
dl
∗ D
lp
/ d
sp
> 3 000
If the results of the above computations are not acceptable, pulleys with
different diameters must be selected.
11
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.
If no custom-made installation kit is used, please proceed according to the
following instructions:
1 Mount the large pulley securely on the engine crankshaft.
2 Install the mounting bracket securely on the engine. The mounting-
bracket parts must be installed without built-in tension to prevent
damage induced by vibrations. Use locking agents, for example
Loctite, to secure bolts and nuts.
3 Mount the generator in the bracket. Make sure that the generator
pulley is mounted parallel to and in line with the crankshaft pulley,
Figure 1 and Figure 3. The result could otherwise be extensive wear of
the belt. Stick the warning label on the generator and make sure that
the message is visible.
4 If necessary, mount idler- (and tensioner-) pulley brackets.
5 If necessary, mount idler- (and tensioner-) pulley/s and make sure that
they are parallel and aligned.
6 Mount the belt with care and without using tools or too much force.
Otherwise the belt may be damaged. Tighten the belt according to the
manufacturer's recommendations. A too tight or too loose belt can
reduce the life of both the belt and the generator and possibly impair
Travel Power's performance.
7 Make sure that the belt runs clear of obstructions. Please observe that
the belt can strike violently on the non-pulling side at large load
changes.
8 Check and, if necessary, adjust the tension of the belt after an initial
running period of approximately 30 minutes.
12
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.
- Do not install the Power box in the battery or engine compartment.
- The Power box can be installed both horizontal and in vertical position.
It shall be placed at least 200 mm from nearest wall, floor or roof (see
Figure 4). This lead to an air space of least 200 mm at the air inlet and
air outlet to obtain a good airflow throughout the Power box. Keep also
the Power box ventilation openings clear, as overheating may cause
malfunction.
Figure 4. Location of the Power box
Vertical
location
Horizontal
location
13
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.
14
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.
Determine the best route to install the shielded cable between the power
box and the generator. Prepare the installation of the cable by drilling holes
for necessary passages. Use rubber grommets to protect the cable from
damage caused by wear. Fasten the cable, avoid hot spots and sharp
edges. Don't stretch the cable too tight. Leave enough slack to enable it to
withstand vibrations without being damaged. Before the cable is mounted
to the sockets on the generator tension relieving turns should be made on
the cable between the generator and the mounting point on the chassis as
shown in Figure 6. It should consist of 2 to 3 turns held together by a strap.
This measure helps to reduce the cable tension between the generator and
the mounting point in the chassis.
PLEASE OBSERVE! Do not make an extension or alteration to the
shielded cable. Different lengths can be ordered from your dealer.
Figure 5. Shielded cable for connection between generator and Power box
Figure 6. Tension relieving on the shielded cable.
Generator
connectors
Power box
connectors
Generator
connectors
15
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.
Travel Power should never be used unless all parts in the shielded
cable are carefully connected in both ends.
The contact should be carefully secured over the shield at both ends.
Make sure that the shield is carefully grounded at both ends.
Figure 7. Shielded cable connection on the generator
16
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. Extension cable (ordered separated) suiting the on-off switch containing
following parts must have been ordered:
- Extension cable, 10 m. Special length can be ordered.
- Plastic cover
- Explaining label
2. Remove the on-off switch from the Power box cover. This is done by
pressing the flange under the cover together and at the same time
pushing it through the cover (see the backside of the on-off switch in
Figure 9).
3. Attach the plastic cover to the Power box cover where the on-off switch
was located.
4. Remove the short cable connecting the Power box with the on-off
switch from the inlet on the Power box.
5. Attach the on-off switch at an easily accessible place, for example at
the dashboard. Choose the position so the LED does not irritate while
driving at night. The enclosed label, shown in Figure 8; can be tagged
close to the on-off switch.
6. Find a proper way to install the extension cable between the Power box
and the on-off switch. Do not fix the extension cable too tight and also
avoid sharp corners and hot places.
7. Connect the adapter on the extension cable to the on-off switch and the
other end to the inlet plug on the Power box.
The built-in measurements for the on-off switch are 21.08 mm x 36.83 mm,
the panel thickness is 0.75 to 2.5 mm.
17
Figure 9. On-off switch
Figure 8
18
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.
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.
For safety reasons a RCCB and a two-pole fuse 16 A must be installed on
the 230 V AC circuit.
If an external power source is required a two-pole three position manual
switch with a 0-position must be used to separate the external power from
the power delivered by Travel Power.
If an automatic switching device is used the Travel Power must be
connected to the zero position and external power to the active side. The
switching device must have a terminal distance not less than 3 mm.
Power is never to be connected from an external source to the 230 V
outlet on Travel Power. This will cause damage to Travel Power.
Figure 10. Connection to the Power box
Socket for 230 V connection
From the generator
230 V cable
19
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. Please
note that the belt needs sufficient clearance in order not to damage
surrounding parts at large load changes.
- Make sure that all the wiring is done in a secure and correct way. Make
sure that all cables are undamaged, unloaded, securely attached, not
rubbed or pinched in any way.
- Check that the power box is mounted in a correct way on a plane
surface in a well-ventilated area protected against moisture and that the
openings of the power box are not covered.
4.2 Electrical control
- Check that all cables are mounted and fixed in a proper way. Check that
all connector and socket screws are securely fastened.
- Be sure that the earth connector (PE-strand) is properly connected to
the 230 V socket on the Power box.
20
5. TECHNICAL DATA
991 00 10-06 TRAVEL POWER 230 V AC, 16 A
Power box
Output voltage 230 V ±5 % (RMS)
Output power continuously 3500 W (Resistive load)
Phase 1
Voltage type AC
Wave from Sinus
Frequency 50 Hz ±0,5 %
Max current continuously 16 A (RMS)
Max start current during 5 s. 44 A (Peak value)
Efficiency 95 %
Automatic protection Overload, phase to phase short-circuit,
over temperature
Generator
Max rotor voltage 18 V (DC)
Max rotor current 5 A (RMS)
Rotor resistance 3.5 Ω±0.2 %
Stator phases 3
Max stator voltage 270 V (RMS)
Max stator current 12 A (RMS)
Stator resistance 5 Ω±0.2 % (Between phases)
Dimensions and weight
Height Width Deep Weight
[mm] [mm] [mm] [kg]
Power box 354 315 82.5 9,3
Hole distance, Power box 280 300
Generator 170 150 190 6,5
For detailed dimensions of the Power box see Figure 11.
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