Tundra M1500 User manual

Quick Troubleshooting Guide
TUN-QTSG-0519-EN
For power inverter models M1500 – M2000 – M2500 – M3000
Tel.: [phone] Fax.: [phone]
TUNDRAINVERTERS.COM
TRUCK POWER INVERTERS
Quick Troubleshooting Guide
For power inverter models M1500 – M2000 – M2500 – M3000
INDEX
P.2 INTRODUCTION - SAFETY - LIMITATIONS
P.3 FRONT PANELS & MONITORS
P.4 ERROR CODES
PP.5-6 COMMON PROBLEMS & COMMON CAUSES
PP.7-21 PROCEDURES
P.22+ ANNEXES
© ALL RIGHTS RESERVED
No part of this publication may be reproduced or used without the prior written permission of Tundra
International. No liability can be accepted for any inaccuracies or omissions in this publication, although every
possible care has been taken to make it as complete and accurate as possible. The right is reserved to make
changes at any time without prior notice, and without incurring an obligation to make such changes applicable to
previously manufactured products. All information contained in this publication is based on the latest product
information available at the time of publication. Illustrations and photographs in this publication are intended for
reference use only.
TUNDRAINVERTERS.COM
May 2019
Part No. TUN-QTSG-0519-EN
First Edition
PRINTED IN CANADA
1

Quick Troubleshooting Guide
TUN-QTSG-0519-EN
For power inverter models M1500 – M2000 – M2500 – M3000
Tel.: [phone] Fax.: [phone]
TUNDRAINVERTERS.COM
INTRODUCTION
This step-by-step troubleshooting guide will help you identify the root cause of the most common problems on
power inverters installed in a commercial truck application. This guide is designed to be used primarily by
trained mechanics and in a properly equipped shop. A basic knowledge of mechanics and electricity, the proper
use of tools and common workshop procedures are required to adequately and safely perform all recommended
tasks. For a successful diagnostic, you must read all the instructions thoroughly to familiarize yourself with
procedures before starting the work.
SAFETY FIRST
A power inverter is an energy conversion device that must be taken seriously. Similar to that produced by a conventional
electrical network, its electric current is powerful enough to injure or kill. As such, the inverter should only be installed and
serviced by qualified technicians.
 A power inverter is an energy conversion device that MUST be taken seriously and MUST
be serviced with care.
 For your own safety and that of others, make sure you understand all the steps outlined in
this manual before servicing.
 Do not carry out the tasks of an electrician if you don’t have the knowledge and skills required.
 Always keep in mind that you can be badly injured working on or around a motor vehicle.
 Only do service work for which you have the proper knowledge. If you have any doubt
about your ability to perform a maintenance or a repair job, you should not undertake it.
LIMITATIONS
The procedures described in this guide are only suggestions and are not mandatory. Therefore, Tundra
International cannot be held liable for incidental or consequential damages or any other damage arising from the
use of this guide. This includes, without limitation, injuries, damage resulting from loss of use, installation or
uninstallation costs, and any other problems.
2

Quick Troubleshooting Guide
TUN-QTSG-0519-EN
For power inverter models M1500 – M2000 – M2500 – M3000
Tel.: [phone] Fax.: [phone]
TUNDRAINVERTERS.COM
FRONT PANELS & MONITORS
Models: M1500 – M2000
Models: M2500 – M3000
3

Quick Troubleshooting Guide
TUN-QTSG-0519-EN
For power inverter models M1500 – M2000 – M2500 – M3000
Tel.: [phone] Fax.: [phone]
TUNDRAINVERTERS.COM
ERROR CODES
M Series power inverters are equipped with an LCD
monitor that displays important information to better
understand the operational limitations of the inverter.
It will also display error codes to advise the user about the reason for the device to shutting down. Make sure
you understand each error code as it will help troubleshoot the root cause of most related problems.
NOTE: The monitor is a great diagnostic tool! If the inverter you are
evaluating is not equipped with an LCD monitor, you must
install one to get a more accurate and faster diagnosis.
CAUTION: Get the right monitor! Mixing the versions
could lead to false results.
4

Quick Troubleshooting Guide
TUN-QTSG-0519-EN
For power inverter models M1500 – M2000 – M2500 – M3000
Tel.: [phone] Fax.: [phone]
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COMMON PROBLEMS & COMMON CAUSES (Part 1)
This section explains common problems encountered in a commercial truck application and gives possible root
causes. Review each procedure to obtain the best results.
MONITOR FUNDAMENTALS
1. ERR LOW  Low voltage protection shut down
A. Improper installation P.7
B. Lack of maintenance P.8
C. Discharged/damaged batteries PP. 9-10
D. Vehicle electrical system issues P.11
2. OVR LOAD  Overload protection shut down
E. High-reaching power consumption P.12
F. Inadequate/damaged 120 V wiring P.13
3. OVR TEMP  High temperature shut down
H. Improper inverter location P.15
I. Damaged cooling fan P.16
4. ERR HIGH  High input voltage shut down
D. Vehicle electrical system issues P.11
5

Quick Troubleshooting Guide
TUN-QTSG-0519-EN
For power inverter models M1500 – M2000 – M2500 – M3000
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COMMON PROBLEMS & COMMON CAUSES (Part 2)
OTHER COMMON PROBLEM
5. The inverter does not turn on
A. Improper installation P.7
B. Lack of maintenance P.8
J. Reversed polarity P.17
K. Main DC fuse blown (on DC cables) P.18
L. Damaged monitor cable / monitor P.19
6. No output voltage
G. Defective 120V output receptacle P.14
7. Improper output voltage
M. Improper diagnostic tools P.19
8. Noise in audio/video equipment
N. Magnetic field side effects P.20
9. Certain loads are not properly working
O. Modified sine wave limitations P.20
10. Cable size & fuse rating
P. Cable & fuse chart P.21
ANNEXES
1. Dynacraft battery cables modification
2. Testing for parasitic loads
3. Installation workbook
6

Quick Troubleshooting Guide
TUN-QTSG-0519-EN
For power inverter models M1500 – M2000 – M2500 – M3000
Tel.: [phone] Fax.: [phone]
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A – IMPROPER INSTALLATION
Improper installation is the most common cause of power inverter malfunction, which often results from impaired
flow of current between the batteries and the power inverter. A power inverter operates between 11.0 and
13.6 volts. If the input voltage at the power inverter drops below 11.0 volts, the low voltage protection mode will
be activated, and the power inverter will shut OFF by itself.
INSTALLATION FUNDAMENTALS
1. Follow installation procedures carefully and use the proper techniques.
References: TDIW-0417-EN / Installation Workbook (ANNEX 3)
QIG1530-0119-EN_A2 / Quick Installation Guide (ANNEX 2)
PROCEDURE P / Cable Sizing & Fuse Rating (Page 21)
2. Make sure that all terminals are properly “crimped” and NOT soldered.
3. Make sure the connection at the batteries are clean and in full contact with the battery’s posts.
4. If equipped with Dynacraft battery links, make sure there is full contact between terminals.
Reference: TUN-NL_DYNA-1114-EN / Dynacraft battery cables modification. (ANNEX 1)
5. Perform routine maintenance on batteries and terminals. See PROCEDURE B (Page 8).
IF A SMALL LOAD (I.E. 100 W) CAN BE SUPPLIED PROPERLY BUT A GREATER ONE
(I.E. 1000 W) IS PUTTING THE INVERTER IN A LOW VOLTAGE PROTECTION MODE,
(ERR LOW) YOU SHOULD PERFORM A VOLTAGE LOAD TEST TO DETERMINE IF THE
INSTALLATION IS AT FAULT.
VOLTAGE DROP TEST PROCEDURE – BATTERIES MUST BE FULLY CHARGED
 Try to run the inverter with the greatest possible load.
 Measure the voltage difference between the batteries and the inverter DC inputs.
This procedure will give you the voltage drop (loss) in the DC cables. A tolerance of 0.5 V is acceptable at full
capacity of the power inverter. If you are not at full capacity, and if the voltage drop is greater than 0.5 V, the
installation requires attention.
BEST PRACTICE
Using one of our CM Series Installation Kits is strongly recommended as it will resolve most related issues. For
best results, it is important you follow recommended procedures.
 RECOMMENDED cable sizing & fuse rating available on page 21
7

Quick Troubleshooting Guide
TUN-QTSG-0519-EN
For power inverter models M1500 – M2000 – M2500 – M3000
Tel.: [phone] Fax.: [phone]
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B – LACK OF MAINTENANCE
Battery maintenance on a commercial vehicle is often overlooked. Over time, the various electrical connections
tend to loosen, corrode and lose their effectiveness. Battery maintenance should be part of a regular preventive
maintenance program to avoid the most common power inverter issues.
MAINTENANCE FUNDAMENTALS
Today’s battery terminals and connectors that are mostly tinned or zinc plated are therefore less prone to visible
corrosion like it used to be with bare copper. On the other hand, they are subject to a chemical reaction that
produces a “gum” which will prevent the free flow of electricity over time.
 BASIC TERMINAL CLEANING MUST BE PERFORMED EVERY 6 MONTHS.
1. Battery cleaning must be made regularly using a grease dissolvent agent.
2. All battery terminals and accessory cables must be disassembled and cleaned on BOTH faces.
3. All battery terminals must be re-installed DRY. If you intend to use a protective sealant, we
suggest using an aerosol type protectant that "dries” like paint. The protective sealant must
only be applied on top of properly tightened connectors.
BEST PRACTICE
Never use grease on battery terminals. Most
greases being dielectric, they can interfere with
the free flow of electricity and promote attraction
of road contaminants. The accumulation of
contaminants on the batteries can cause a faster
deterioration of terminals and cause unwanted
cycling and premature battery failure.
We recommend using PLASTIKOTE 278.
8

Quick Troubleshooting Guide
TUN-QTSG-0519-EN
For power inverter models M1500 – M2000 – M2500 – M3000
Tel.: [phone] Fax.: [phone]
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C – DISCHARGED / BAD BATTERIES (Part 1)
To supply a power inverter with the voltage and amperage it needs,
batteries must be in good condition and preferably fully charged. In the
event where the power inverter would go into ERR LOW, (Low Voltage
Protection Mode) a thorough assessment of the situation must be made.
BATTERY PROBLEM FUNDAMENTALS
1. IS CONSUMPTION TOO HIGH FOR THE BATTERIES?
Episodic and sudden battery discharge problems are frequent. The consumption through the power inverter could
be greater than expected by the user. The use of a 1500-watt toaster oven for example (150 A consumption at
the batteries) will quickly deplete the batteries, while a television set can operate for many hours without any
problem.
Typical load consumption VS. Consumption at the batteries
Load consumption in watts @ 120 V Consumption @ 12 V at the batteries
1500 W (toaster oven) → 150 A
700 W (microwave) → 120 A
150 W (television set) → 15 A
 IN A CASE OF AN ERR LOW SITUATION, RUNNING THE ENGINE IN FAST-IDLE MODE COULD
HELP REPLENISH THE BATTERIES AND RESUME OPERATION OF THE POWER INVERTER. A
FEW HOURS AT HIGHWAY SPEED COULD BE REQUIRED IN SOME CASES.
DID YOU KNOW?
Consuming 10 times more energy (i.e. 150 A vs. 15 A)
discharges the batteries about 30 times faster!
2. IS THE RIGHT GRADE OF BATTERY BEING USED?
Medium CCA batteries offer the best durability (800 CCA for example) and the best compromise between
autonomy, engine start capacity and durability. Ultra-high CCA batteries (950+ CCA) tend to wear out more
quickly than lower CCA versions. They contain less water and therefore, evaporate faster.
→ CONTINUES ON PAGE 10
9

Quick Troubleshooting Guide
TUN-QTSG-0519-EN
For power inverter models M1500 – M2000 – M2500 – M3000
Tel.: [phone] Fax.: [phone]
TUNDRAINVERTERS.COM
C – DISCHARGED / BAD BATTERIES (Part 2)
3. ARE THE BATTERIES IN GOOD CONDITION?
A battery bank that gets discharged faster than usual could be at the end of its useful life.
 Slowly recharge all 4 batteries and load-test them individually using a quality AVR designed for this
purpose. If one or more batteries are to be replaced, you should replace them all at once and keep the
good batteries for later temporary fixes.
4. ARE THE BATTERIES CLEAN?
Batteries should always be kept clean. The accumulation of dirt and wet contaminants tends to create a constant
discharge pattern (cycling) and favors premature wear. See PROCEDURE B (Page 8).
5. ARE THE BATTERIES RUNNING OUT OF POWER AFTER SEVERAL DAYS OF INACTIVITY?
Tundra power inverters consume about 150 mA (0.150 A) when turned ON and left unattended (no load is
supplied). At this level of consumption, it would take several weeks before completely discharging a truck
battery bank. If you have such discharg problems after of a few days of inactivity, it is most likely due to the
following two reasons:
A. The battery bank could be at the end of its useful life.
 Slowly recharge all 4 batteries and load-test them individually using a quality AVR
designed for this purpose.
 If one or more batteries are to be replaced, you should replace them all at once
and keep the good batteries for temporary fixes.
 At the same time, verify alternator capacity.
B. You are dealing with one or more parasitic loads that are unrelated to the power inverter and that
discharge the vehicle's batteries (e.g. CB radio, refrigerator, electric blanket, fan, lamp).
 If the batteries of the vehicle have been tested as functional, it is recommended you look for a parasitic
load before suspecting the inverter. See PROCEDURE D (Page 11).
BEST PRACTICE
A. Batteries should never be tested without being slowly recharged.
B. When evaluating batteries, alternator capacity should always be verified at the same time.
C. Never replace only one battery on a bank of 4 batteries. Combining new batteries with older ones will
promote a rapid deterioration of the most recent / better batteries.
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