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ENGLISH BATTERY-POWERED SYSTEMS FOR DOMETIC AUXILIARY AIR CONDITIONING SYSTEMS INSTALLATION GUIDELINES Dometic Corporation, Environmental Division Rev. 20091009 L-2597 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. No part of this publication may be reproduced, translated, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without prior written consent by Dometic Corporation, Environmental Division. Every precaution has been taken in the preparation of this manual to ensure its accuracy. However, Dometic Corporation, Environmental Division assumes no responsibility for errors and omission. Neither is any liability assumed for damages resulting from the use of this product and information contained herein. 2 ENGLISH 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 HVAC UNIT 12 WIRING THE 120VAC POWER TO THE HVAC UNIT 12 OPTIONAL: INSTALLING 120VAC OUTLETS INSIDE THE SLEEPER 13 OPTIONAL: INSTALLING SHOREPOWER CONNECTION 13 WIRING DIAGRAMS FOR BATTERY CONNECTION CONFIGURATIONS ENGLISH 14 – 21 3 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. The system includes: • Inverter (or optional inverter with built-in charger) • High-capacity alternator with external regulator • AGM Group 31 batteries • Shorepower connection (optional) • Inside AC power plugs (optional) • Dometic air conditioning units with digital controls Do not substitute any other components than those specified by Dometic. Using non-standard components may not provide the performance specified by Dometic and may void your warranty for the air conditioning system. BEFORE YOU START •Realize that all the manuals are written to inform an installer that is skilled in mechanical areas, such as alternators, batteries, and cabling, as well as skilled in HVAC and electrical areas. If you have any questions after reading this and all manuals that accompany the individual parts, please call 804-746-1313, and ask for the Dometic Truck Applications Department. •Open all boxes and check conditions of parts. If parts are damaged, please file the appropriate forms with the shipping company. If parts are missing, please contact Dometic. • Refer to Technology and Maintenance Council (TMC) RP160 for guidelines on inverter wiring. • Realize that all parts required may not necessarily be included, such as: • Battery cables • Cable secondary protection (wire loom) • Some fasteners (i.e., wire ties) •All tools (i.e., frame drill, bits, wrenches, drills, hole saws) (Note that it is highly recommended that the called-out tools be used when called for) • General shop supplies GETTING THE MATERIALS TOGETHER • Open all boxes and lay out materials in areas with parts that will be used for the same type of system. TOOLS THAT MAY BE REQUIRED • See each individual manual for a list of the tools required. UNDERSTANDING LOW VOLTAGE DISCONNECTS (LVD) There are two different LVDs we are going to discuss: the one that is integral to the truck, and the one that is integral to the Battery-Based HVAC System. The truck’s LVD shuts down at approximately 12.3 VAC. The HVAC’s LVD shuts down at approximately 10.5 VDC, which yields an open circuit volt (OCV) of approximately 11.5 VDC. This means that during the normal run process of the HVAC system, truck systems will shut down before the HVAC will. 4 ENGLISH 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. Available space will vary based on the truck specifications, such as frame length, fuel tank length and empty tool boxes already on the truck. Figure 1 – AGM batteries replace standard lead-acid batteries If additional boxes are included in your kit, you will need to mount them firmly to the frame of the truck. This may require that some slight adjustments be made to fuel tank placement. Be creative, however, always be cautious, as any changes you make could cause problems elsewhere. If you choose to use boxes already installed on the truck for additional batteries make sure they are rated for the weight of the batteries and inverter. Never disregard OEM suggestions relating to frame welding and drilling, as they are very important. Consider center-mount battery boxes (Fig. 2). Freightliner and Volvo offer center-mount boxes that offer four battery spaces. Figure 2 – Center-mount battery box Dometic offers a range of battery boxes that will mount on the side of the frame well and a center mount box, which mounts between the rails, just behind the cab. Refer to Dometic Publication L–2328 for more information. These boxes are typically offered pre-loaded with components. However, the boxes can also be purchased empty. ENGLISH 5 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. Depending on the mounting location, you may be able to utilize all four clamps, or you may have to use a combination of clamp-on vs. through bolting. The final strength of the bolting solution on the frame rests with the installer. Washers on both sides with a locking nut (ny-lock, tri-lobe or stover) are suggested. Lock washers are not recommended. Torque 5/8" bolts to 140-155 ft-lbs. Torque 3/4" bolts to 260-280 ft-lbs. Drill the frame for at least four bolts in the vertical section (web). Most OEMs do not allow drilling in the horizontal sections. Most OEMs also do not allow welding or torching frames. Please be sure that whatever you do meets OEM requirements, so as not to void any warranties. weight, complexity and number of batteries. Use the wiring diagrams at the back of the manual for different wiring configurations (Fig. 3).Conductors between each battery should be of the same size as conductors between each bank. We normally recommend at least 2/0 gauge. Conductors should be as short as possible and should be routed and clipped securely so as to prevent chafing and rubbing. Secondary chafe protection (wire loom) is recommended on AT LEAST the positive conductors between banks. It is also recommended that chafe protection be placed in chafe-prone areas on the negative wire. If you make your own cables, either crimp the end on the cable with the correct tool or solder it on. There are cable ends available with the solder already in the end. Either way, it is suggested that the connection be covered with heavy-duty heat shrink. This helps to prevent corrosives from being wicked up into the copper strands, where they can cause hidden corrosion. Before installing any batteries, load test each one. One bad battery can ruin the entire bank. And yes, sometimes brand new batteries can be bad. Before and during connection of battery terminals, apply a light coating of the supplied dielectric grease (in the small clear packet) to every connection. This will help keep corrosion and voltage drop to a minimum. Batteries can be wired in one of two methods: A dualbank system (house and starting), and a single-bank system. The dual-bank system provides redundancy, while the single-bank system provides for less total Replace the hex or wing nuts on the batteries with the supplied locking hex nuts. These will help keep the connections tight over the long haul. Tight connections will ensure less voltage drop. WIRING THE NEW BATTERIES Figure 3 – Batteries connected 6 ENGLISH 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. The inverter should be installed in the same box as the batteries, so as to keep the cable lengths short, reducing voltage drop to a minimum. Make sure that you attach the shunt with the polarity correct by following the labels marked “Load” and “Battery.” Attach the small red wires to the positive battery post. If the cables need to be extended, use conductors of the same size. Connections that are outside should be at least butt-connected and covered in outsiderated shrink tube. Waterproof plugs are also a good method. The battery fuel gauge display should be mounted in an easily accessible place, probably the same area in which you will mount the HVAC or inverter controls. 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. The fuel gauge requires a hole size of a standard round truck gauge. A hole saw of 2 1/8” gives the correct mounting hole. Mount the inverter directly to the metal of the box, with no material or spacer in between. Make sure to ground the chassis of the inverter to the chassis of the truck. Note that 12-gauge wire is acceptable for this requirement. Install the Dometic 200 amp circuit breaker or a properly-sized fuse in the positive cable between the last battery and the inverter. Note: If the inverter is to be installed anywhere other than in the battery box, consult Dometic Truck Engineering. OPTIONAL: INSTALLING THE INVERTER/ CHARGER The inverter/charger and controls will be installed in the same manner as the inverter (Fig. 4). However, the inverter/charger will be connected to the shorepower connection (to be discussed later in this manual). Figure 4 – Inverter/Charger installed ENGLISH 7 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. Inverter control If you are installing in a day cab, and the inverter controls consist of a switch that measures 3/4" x 1 1/2", then you can remove the switch from the panel and install it into an empty dash switch location. If the cables need to be extended, use conductors of the same size. Connections that are outside should be at least butt-connected and covered in outsiderated shrink tube. Waterproof plugs are also a good method. 8 Figure 5 – Inverter control installed ENGLISH 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. The alternator cabling will have to be upgraded to a 2/0 cable for a 270-amp alternator (typically a day cab) or a 3/0 cable for a 320-amp alternator (most sleepers). Run this cable from the positive alternator stud to the positive starter stud. (See page 20 for instructions on FTL Cascadia.) Figure 6 – Alternator installed Note: On Volvo trucks, you will have to add a 3/0 cable from the truck-side of the negative fuse (see Battery-Volvo diagram on page 21) to the chassis stud located just to the inside of the frame rail behind the driver's side from tire. Alternator power wiring may have to be upsized or paralleled with an additional cable if the OEM cable size is not able to conduct the required current. Refer to the alternator literature for guidance. The negative cable must be attached to the negative terminal on the alternator and the negative terminal on a battery. It must not go just to chassis ground. Secondary chafe protection (wire loom) is recommended on AT LEAST the positive conductor. It is also recommended that chafe protection be placed in chafe-prone areas on the negative wire. If you make your own cables, either crimp the end on the cable with the correct tool or solder it on. There are cable ends available with the solder already in the end. Either way, it is suggested that the connection be covered with heavy-duty heat shrink. This helps to prevent corrosives from being wicked up into the copper strands where they can cause hidden corrosion. Make sure that all connections are tight, as loose connections can cause the regulator not to work correctly. ENGLISH 9 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. This wire will later be used to connect to the charge light relay. See drawing “Charge Light Circuit for Alternators” below. The relay required is a small flange-mount 12VAC relay, like Song Chaun #792H, Tyco #V23234A0001X036, Bosch #0 332 209 150, Dometic P/N 4135000 or P/N 4135010. 10 ENGLISH 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. Volvo Charge Lite Relay Hook-up See also 4163717 Dometic Corporation PROPRIETARY NOTE: THE INFORMATION CONTAINED WITHIN THIS DOCUMENT IS THE PROPERTY OF DOMETIC CORPORATION. ANY ATTEMPT TO COPY OR DISTRIBUTE WITHOUT WRITTEN CONSENT FROM DOMETIC CORPORATION SHALL BE CONSIDERED UNLAWFUL AND CAN BE CONTESTED IN A COURT OF LAW. To Charge Lite Relay Wire Labeled "12VDC" Wire Labeled "Charge Lite Wire" To Charge Lite Wire (removed from old Alternator's "I" Terminal) DWG ENGLISH REV Stator Terminals Stator Terminals Stator Terminals Battery-Powered Systems Installation Guidelines CHARGE LIGHT CIRCUIT FOR ALTERNATORS WITH INTEGRAL (Built-In) REGULATORS 11 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. • Start engine, increase to high idle (1500 RPM): The volt meter should now indicate that the alternator output voltage has increased to a range from 13.8 volts to 14.2 volts. (Ensure that all electrical accessories of the vehicle are in the off position.) If voltage increases but is out of range, inspect to see if the alternator has an adjustable regulator. If so, reduce engine speed to idle and adjust voltage to a setting of 14.0 volts. If voltage is higher than 14.7 volts and cannot be adjusted below 14.25 volts, or if voltage is lower than 13.8 volts and cannot be adjusted into range, then replace the alternator. For more information, please reference LeeceNeville Technical Publication, TSB-1019. WIRING THE 120VAC POWER TO THE HVAC UNIT Follow the directions and wiring diagrams in your air conditioner installation manual. The connection of the 120VAC cable to the inverter should be done with either the extension cable or the Y-cable assembly. Dielectric grease should be applied to any connections outside of the cab structure. “Splicing” outside of the cab without taking precautions for waterproofing is not permissible and may void your warranty. Only as many extensions as required should be used. Cables should be routed and clipped securely so as to prevent chafing and rubbing. The connection at the HVAC unit should be done with the supplied plug. WIRING THE "IGNITION INTERLOCK" ON THE HVAC UNIT • If your HVAC is provided with an “Ignition Interlock” cable, then follow these steps to properly connect it. 1. C onnect the white wire from the “Ignition Interlock” cable to the “ON" position of the key switch. Here are some suggestions: 12 • Volvo - in the sleeper control panel cabling - wire F60A1-08 • FTL Cascadia - wire under passenger dash to connector X-6 of the SAM-Cab, pin #10 • International Prostar - pink wire labeled "A13EE" in the driver's side luggage box. 2. Connect the black wire from the “Ignition Interlock” cable to grounded, metal chassis connection. •S tart the HVAC unit. Turn the key to the “ACC” position. If the HVAC turns off when the ignition is in the “ACC” position, you need to revise your connection. Use a voltmeter to ensure that your connection point allows for power ONLY when the keyswitch is in the 'ON' position. ENGLISH 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). The outlets should be installed with the Y-cable connection to the main cable between the inverter and the HVAC unit. OPTIONAL: INSTALLING SHOREPOWER CONNECTION Figure 8 – Shorepower connection installed The shorepower connection is only available with the inverter/charger. The shorepower connection should be installed preferably on the driver’s side of the truck. If the driver’s side of the truck is not in reach of the battery box in which the inverter/charger is mounted, then the connection should be installed as close to the inverter/charger as possible (Fig. 8). This will probably be in the side of the battery box in which the inverter/ charger is mounted. ENGLISH 13 14 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. - APPLICATION NEXT ASSY Overcurrent Protector + PROPRIETARY AND CONFIDENTIAL Factory starter cable Inverter 120VAC Line USED ON DO NOT SCALE DRAWING FINISH MATERIAL INTERPRET GEOMETRIC TOLERANCING PER: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL COMMENTS: Q.A. MFG APPR. ENG APPR. CHECKED DRAWN UNLESS OTHERWISE SPECIFIED: DATE 9/29/08 NAME KEA SCALE: 1:1 WEIGHT: B Battery1 SIZE DWG. NO. SHEET 1 OF 1 B REV Day Cab system -HVAC System Powered by Inverter and Multiple Starting/ Deep Cycle Batteries TITLE: Dometic Environmental NOTES: 1) Batteries must be of the AGM dual purpose deep cycle/ startingtype 2) Alternator must 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 should be choosen based on voltage drop and load. HVAC Unit Battery-Powered Systems Installation Guidelines HVAC SYSTEM POWERED BY INVERTER AND MULTIPLE STARTING/DEEP CYCLE BATTERIES ENGLISH 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. 3) Inverter must be of approved type by Dometic in order to insure proper operation of system. 4) All added DC cables shall be of 2/0 size or larger, unless otherwise noted on drawing. 5) Either bank may have as many or few batteries in order to provide the desired run time. - Alternator AC Wiring DC Wiring PROPRIETARY AND CONFIDENTIAL 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 CORP IS PROHIBITED. + APPLICATION NEXT ASSY - House Battery 1 USED ON - Secondary Box - House Battery 3 DO NOT SCALE DRAWING FINISH MATERIAL INTERPRET GEOMETRIC TOLERANCING PER: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL COMMENTS: Q.A. MFG APPR. ENG APPR. CHECKED DRAWN UNLESS OTHERWISE SPECIFIED: + House Battery 2 HVAC Unit + DATE 9/29/08 NAME KEA - + Overcurrent Protection SCALE: 1:1 WEIGHT: B Battery2 SIZE DWG. NO. SHEET 1 OF 1 E REV HVAC System Powered by Inverter and Separate Battery Banks with Batt. Separator TITLE: Dometic Environmental House Battery 4 - Inverter + 120VAC Line Battery-Powered Systems Installation Guidelines HVAC SYSTEM POWERED BY INVERTER AND SEPARATE BATTERY BANKS WITH BATTERY SEPARATOR 15 16 - 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. 3) Inverter must be of approved type by Dometic in order to insure proper operation of system. 4) All added cables shall be of 2/0 or larger, unless otherwise specified on the drawing. 5) Either bank may have as many or few batteries in order to provide the desired run time. Alternator AC Wiring DC Wiring 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 CORP. IS PROHIBITED. PROPRIETARY AND CONFIDENTIAL Battery Separator HVAC Unit APPLICATION NEXT ASSY USED ON - House Battery 1 - + DO NOT SCALE DRAWING FINISH MATERIAL INTERPRET GEOMETRIC TOLERANCING PER: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL COMMENTS: Q.A. MFG APPR. ENG APPR. CHECKED DRAWN UNLESS OTHERWISE SPECIFIED: + House Battery 2 Inverter with Shorepower Pass-Thru Capability OR Inverter/charger Cab Power Outlets DATE 9/29/08 NAME KEA - House Battery 3 - + Overcurrent Protection House Battery 4 + 120VAC Line Dometic Environmental SCALE: 1:1 WEIGHT: E REV SHEET 1 OF 1 B Battery 3 SIZE DWG. NO. HVAC System Powered by Inverter and Separate Battery Banks with Separator. Shore power and cab power outlets TITLE: + - Y-Cord Splitter Shorepower Inlet Battery-Powered Systems Installation Guidelines HVAC SYSTEM POWERED BY INVERTER AND SEPARATE BATTERY BANKS WITH SEPARATOR SHOREPOWER AND CAB POWER OUTLETS ENGLISH 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. 3) Inverter must be of approved type by Dometic in order to insure proper operation of system. 4) All added DC cables shall be 2/0 or larger unless otherwise noted on the drawing. 5) Either bank may have as many or few batteries in order to provide the desired run time. Alternator AC Wiring DC Wiring 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. PROPRIETARY AND CONFIDENTIAL Battery Separator APPLICATION NEXT ASSY USED ON - House Battery 1 + DO NOT SCALE DRAWING FINISH MATERIAL INTERPRET GEOMETRIC TOLERANCING PER: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL COMMENTS: Q.A. MFG APPR. ENG APPR. CHECKED DRAWN UNLESS OTHERWISE SPECIFIED: + House Battery 2 + NAME KEA DATE 9/29/08 - + Overcurrent Protection House Battery 4 + SCALE: 1:1 WEIGHT: B REV SHEET 1 OF 1 B Battery 4 SIZE DWG. NO. HVAC System Powered by Inverter and Separate Battery Banks with Separator. Shorepower capability TITLE: Dometic Environmental - 120VAC Line Secondary Box - House Battery 3 Inverter with Shorepower Pass-Thru Capability OR Inverter/charger HVAC Unit Shorepower Inlet Battery-Powered Systems Installation Guidelines HVAC SYSTEM POWERED BY INVERTER AND SEPARATE BATTERY BANKS WITH SEPARATOR SHOREPOWER CAPABILITY 17 18 + - 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. PROPRIETARY AND CONFIDENTIAL + Battery 5 120VAC Line Battery 4 Cab Power Outlet Starter Add at least a 3/0 cable from the alternator positive to the starter posiive lug. 3/8" ring terminal at the alternator, 1/2" at the starter. NOTES: 1) ALLBatteries must be of the AGM deep cycle type 2) Alternator must 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) All added DC cables shall be of 2/0 size or larger, unless otherwise noted on drawing. 5) Battery bank size may have as many or few batteries in order to provide the desired run time. Alternator AC Wiring DC Wiring - APPLICATION NEXT ASSY + DO NOT SCALE DRAWING FINISH MATERIAL INTERPRET GEOMETRIC TOLERANCING PER: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL COMMENTS: Q.A. MFG APPR. ENG APPR. CHECKED DRAWN UNLESS OTHERWISE SPECIFIED: Overcurrent Protection USED ON Secondary Box + Battery 6 Y-Cord Splitter to GFCI Receptacle HVAC Unit + DATE 9/29/08 NAME KEA SCALE: 1:1 WEIGHT: B REV SHEET 1 OF 1 B Battery 5 SIZE DWG. NO. HVAC System Powered by Inverter. Single starting/house Battery Bank. Shore power with cab power outlets TITLE: Dometic Environmental Inverter with Shorepower Pass-Thru Capability OR Inverter/charger - Shorepower Inlet Battery-Powered Systems Installation Guidelines HVAC SYSTEM POWERED BY INVERTER - SINGLE STARTING/HOUSE BATTERY BANK SHOREPOWER WITH CAB POWER OUTLETS ENGLISH 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. - APPLICATION NEXT ASSY USED ON Secondary Box + Battery 6 120VAC Line Battery 5 PROPRIETARY AND CONFIDENTIAL Battery 4 Starter Factory Starter Cable Primary (OEM) Box Battery 2 + Add at least a 3/0 size cable from the alternator positive to the starter positive lug. 3/8" ring terminal at the alternator, 1/2" at the starter. NOTES: 1) ALLBatteries must be of the AGM deep cycle type 2) Alternator must 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) All added DC cables shall be of 2/0 size or larger, unless otherwise noted on the drawing. 5) Battery bank may be as many or few batteries in order to provide the desired run time. Alternator AC Wiring DC Wiring DO NOT SCALE DRAWING FINISH MATERIAL INTERPRET GEOMETRIC TOLERANCING PER: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL COMMENTS: Q.A. MFG APPR. ENG APPR. CHECKED DRAWN UNLESS OTHERWISE SPECIFIED: Overcurrent Protection + HVAC Unit + DATE 9/29/08 NAME KEA SCALE: 1:1 WEIGHT: B REV SHEET 1 OF 1 B Battery 6 SIZE DWG. NO. HVAC System Powered by Inverter. Single starting/house Battery Bank. Shore power capability. TITLE: Dometic Environmental Inverter with Shorpower passthrough OR inverter/cherger - Shorepower Inlet Battery-Powered Systems Installation Guidelines HVAC SYSTEM POWERED BY INVERTER - SINGLE STARTING/HOUSE BATTERY BANK SHOREPOWER CAPABILITY 19 20 - - - 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. - Battery 4 Primary (OEM) BOX Battery 2 + - AC Wiring DC Wiring Battery 1 + Alternator + - Battery 5 Starter . 2/0 Connector Cables Add at least a 3/0 positive cable fromthe alternator to the positive starter stud. 3/8" post at alterntor, 1/2" post at starter. Remove factory wires from alternator. Splice together, insulate, and tie up out of the way To intake grid heater PROPRIETARY AND CONFIDENTIAL + APPLICATION NEXT ASSY - Battery 8 SECONDARY BOX - THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF <INSERT COMPANY NAME HERE>. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF <INSERT COMPANY NAME HERE> IS PROHIBITED. - + Battery 7 + Battery 6 Y-Cord Splitter to GFCI Receptacle Cab Power Outlet 120VAC Line USED ON DO NOT SCALE DRAWING FINISH MATERIAL INTERPRET GEOMETRIC TOLERANCING PER: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL COMMENTS: Q.A. MFG APPR. ENG APPR. CHECKED DRAWN UNLESS OTHERWISE SPECIFIED: Overcurrent Protection HVAC Unit + DATE 9/29/08 NAME KEA SCALE: 1:1 WEIGHT: B REV SHEET 1 OF 1 B Battery 7 SIZE DWG. NO. Dometic HVAC System to FTL Cascadia. Inverter/charger, shorepower, and alternator. TITLE: Dometic Environmental Inverter with Shorepower Pass-Thru Capability OR Inverter/charger - Shorepower Inlet Battery-Powered Systems Installation Guidelines DOMETIC HVAC SYSTEM TO FTL CASCADIA – INVERTER/CHARGER, SHOREPOWER, AND ALTERNATOR REGULATOR ENGLISH 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.) 5) Drawing does NOT apply to Volvo trucks manufactured between 1996 and end of 2006. 6) 400 amp Fuse in Negative cable changed to fusible link in 2008, week 46. 7) Alternator and/or starter location may change depending on the type of engine installed. Factory Wiring Frame Ground Post Engine Ground Post Factory Negative Alternator Right Front Tire A A B B - 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. A - + APPLICATION NEXT ASSY - + Positive Fuse USED ON Negative Fuse (or fusible link) PROPRIETARY AND CONFIDENTIAL + - + Added 3/0 Negative cable Factory Negative Revisions DO NOT SCALE DRAWING FINISH MATERIAL INTERPRET GEOMETRIC TOLERANCING PER: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL COMMENTS: Q.A. MFG APPR. ENG APPR. CHECKED DRAWN UNLESS OTHERWISE SPECIFIED: DATE 10/2/08 NAME KEA KEA KEA APPROVED SCALE: 1:1 WEIGHT: REV B SHEET 1 OF 1 B Battery-Volvo SIZE DWG. NO. Field added DC cabling for Volvo Trucks YM post 2006: Change to upgraded alternator for Dometic Battery Powered HVAC System TITLE: Dometic Environmental 8/25/2009 Chg Alternator Cabling to 3/0. Add note about YM 2009 and later trucks. B DATE 4/21/2009 Change Title to include only Volvo Trucks built post2006. Add notes pertaining to this change. DESCRIPTION A REV. Battery Box Left Frame Rail NOTE: Volvo has several variations of this cabling. The most recent change is that the ground post on the frame is located behind the battery box. In this can, route a new negative cable from the ground on the alternator to this stud. See also Note 6 below. Right Frame Rail Battery-Powered Systems Installation Guidelines FIELD-ADDED DC CABLING FOR VOLVO: CHANGE TO UPGRADED ALTERNATOR FOR DOMETIC BATTERY-POWERED HVAC SYSTEM 21 NOTES: 22 ENGLISH NOTES: ENGLISH 23 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 [email protected] 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.