Dometic GFA2303 User manual

Brand: Dometic

Model: GFA2303

Type: User manual

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

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

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.

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.

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.

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

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

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

(

)

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

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.

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

) 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

/ d

< 18 000

- Divide the diameter of the large pulley (D

) with the diameter of the

small pulley (d

). 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

/ d

< 15 000

Divide the diameter of the large pulley (D

) with the diameter of the

small pulley (d

). Multiply the result with the engine's idling rpm (I

This result should be close to 3000 rpm to enable Travel Power to

deliver 1000 W when the engine is idling.

∗ D

/ d

> 3 000

If the results of the above computations are not acceptable, pulleys with

different diameters must be selected.

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.

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

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.

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

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

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.

Figure 9. On-off switch

Figure 8

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

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.

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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Dometic GFA2303 User manual

Dometic GFA2303 User manual

Dometic GFA2303 User manual

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