March 1, 2011 APU Installation Manualwillisapu.com/WillisAPU/files/72/72d59b0c-5a79-443a-8… ·...

Cool Only March 1, 2011

APU Installation Manual

Willis Power Systems

2950 N Martin Suite B

Springfield, MO 65803

Office: 417-831-2330

[email protected]

www.willisapu.com

Willis Power Systems, LLC

mailto:[email protected]�

http://www.willisapu.com/�

CONTENTS

System Description and Benefits ................................................................ 7

Overview of Installation .......................................................................................... 7

Subsystems ...................................................................................................... 7

Required Tools ................................................................................................. 8

Preparing for Installation ........................................................................................ 8

Adapting the Installation to Specific Trucks ............................................... 9

Hoses, Harnesses, and Fuel Lines ............................................................... 9

APU Location ............................................................................................ 10

Mounting Holes for APU J-Brackets ......................................................... 11

Connecting the APU to the Truck Battery ............................................................. 15

INSTALLING THE FUEL SYSTEM ............................................................................. 15

Tools Needed............................................................................................ 16

Standard Fuel System ............................................................................... 16

Remote Condenser/radiator BAND ASSEMBLY .................................................... 19

Installing the Manex Evaporator ........................................................................... 21

Install Face Plates .................................................................................................. 24

Manex and Willis Control Harness Installation ..................................................... 25

The Main Power Harness for The Manex ................................................. 27

DSE Controller Harness ............................................................................ 28

Manex Power Harness Connections ......................................................... 28

Throttle Wire from DSE Harness to the Manex Relay Board .................... 29

Press Switch on Dryer ............................................................................... 30

Installing Control Harness for Manex/Willis ............................................. 30

View of Complete Pressure Switch........................................................... 30

View of power harness to the Manex ...................................................... 31

Power Harness to the Truck Battery ........................................................ 32

Lubricating the Air Conditioning System ............................................................... 32

Installing the DSE3000 Series Control Module ..................................................... 35

DIMENSIONS AND MOUNTING ...................................................................... 35

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Fixing clips ................................................................................................ 35

OPTIONAL SILICON SEALING GASKET ....................................................... 36

USER CONNECTIONS and TERMINAL DESCRIPTION................................ 36

DC SUPPLY, FUEL AND START OUTPUTS ................................................... 37

GENERATOR VOLTAGE SENSING AND DIGITAL INPUTS ............................ 39

MAGNETIC PICKUP AND DIGITAL INPUTS ................................................ 39

Can and digital inputs ............................................................................... 40

PC CONFIGURATION INTERFACE CONNECTOR ......................................... 40

Operational Instructions ....................................................................................... 41

QUICKSTART GUIDE .................................................................................. 42

STARTING THE ENGINE .................................................................................. 42

STOPPING THE ENGINE .................................................................................. 42

CONTROLS ............................................................................................................. 43

AUTOMATIC MODE OF OPERATION ......................................................... 44

WAITING IN AUTO MODE .............................................................................. 44

STARTING SEQUENCE .................................................................................... 45

ENGINE RUNNING .......................................................................................... 45

STOPPING SEQUENCE .................................................................................... 46

MANUAL OPERATION ............................................................................... 46

WAITING IN MANUAL MODE ......................................................................... 46

STARTING SEQUENCE .................................................................................... 47

ENGINE RUNNING .......................................................................................... 47

PROTECTIONS ....................................................................................................... 49

WARNINGS ............................................................................................................ 49

SHUTDOWNS ........................................................................................................ 49

8 MODULE DISPLAY ............................................................................................... 49

RUNNING ICON .............................................................................................. 50

USB ICON ....................................................................................................... 50

MEMORY CORRUPTION ................................................................................. 50

BACKLIGHT ..................................................................................................... 50

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FAULT ICONS .................................................................................................. 51

FAULT FINDING ..................................................................................................... 54

Operating Control Module .................................................................................... 57

Operational functions: 4410 Controller with or without thermostat ...... 57

Setting the controller to Auto Start the APU............................................ 58

Setting Time & Day ........................................................................................ 58

Setting the Auto Start .................................................................................... 58

Operating Thermostat .......................................................................................... 59

Fan Operating Mode ................................................................................ 59

Displaying the temperature ..................................................................... 59

Setting the Temperature .......................................................................... 60

Backlight ................................................................................................... 60

Thermostat Control Mode ........................................................................ 60

Manual/Permanent Hold Mode .................................................................... 60

Programmable Mode ..................................................................................... 60

Temporary Bypass .................................................................................... 60

Filter Replacement Indicator .................................................................... 60

Battery Replacement Indicator ................................................................ 61

Completing Installation ......................................................................................... 62

Initial Checkout and Troubleshooting ...................................................... 62

Appendix A – Diagrams ......................................................................................... 63

Motor Wiring Diagram ............................................................................. 64

Manex H/C Wiring Diagram...................................................................... 65

Thermostat Special Instructions Diagram ................................................ 66

Willis APU trouble shooting guide ........................................................................ 68

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WILLIS APU INSTALLATION lthough the procedures described in this manual will enable any skilled technician to install the unit, it is recommended that you contact a certified trained technician so as not to void the warranty. No specialized

tools or complex system tests are required once a unit is installed. Installing the APU involves mounting the APU on the truck chassis frame. The cooling is closed loop and does not integrate with the truck. The cab controller consists of a cab display with electronic components inside. The electronic control unit and associated components mount in the sleeper compartment area for ease of control.

SYSTEM DESCRIPTION AND BENEFITS

The Willis Power System (WPS) has several elements (or subsystems).

1. The main subsystem is the Auxiliary Power Unit (APU) an enclosure that attaches to the truck frame.

2. The electronic controller that mounts in the truck’s cab/sleeper.

Some of these capabilities include heating and air conditioning for the cab and sleeper and an alternator that replicates the trucks charging system. The APU for this specific manual has its own system separate from the truck’s engine to provide cold air for the sleeper compartment area.

OVERVIEW OF INSTALLATION

All trucks are different, to some degree, unless they are part of a fleet. The instructions in this manual can vary to the particular installation being performed.

SUBSYSTEMS

The subsystem installations in this manual are mostly independent of each other, which makes it possible and in some instances standard for two or more technicians to complete the installation in almost any order of the subsystems.

A

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For example, the installation of the fuel system is not affected by the installation of the air system.

REQUIRED TOOLS

Tools needed are those typically found in any well-equipped truck repair facility. Generally, these include, but are not limited to the following:

• Welding capabilities • Automobile transmission jack(s) • An air conditioner servicing and refrigerant recovery machine • Portable hoist(s) for automobile engines • Hose fitting crimping tools for A/C, oil, air and coolant fittings • Wire lug (4 gal.) crimping tool • An assortment of wire end crimping tools

Additional common parts may be required that were not packaged with the APS may include, but are not limited to the following:

• Bolts • Hoses • Fillings • Lubricants • Electrical Lugs • Clamps • R-134A Cleaning Solvents • Radiator Coolants (ethylene glycol or extended life coolant)

The need for each of these parts will be identified in the appropriate sections of this manual.

PREPARING FOR INSTALLATION

IMPORTANT

Make sure all of the truck’s systems and subsystems are in working condition. They must operate correctly and need no further maintenance before you begin installation of the APU.

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IT IS STRONGLY ADVISED THAT YOU COMPLETE THOROUGHLY, THE ‘PRE-INSTALLATION

INSPECTION’ CHECKLIST (APD FORM PART NO. 170-2002) AND CONFIRM OPERATION

OF EVERY SUBSYSTEM PRIOR TO INSTALLATION.

ADAPTING THE INSTALLATION TO SPECIFIC TRUCKS

The APS installation requirements can vary slightly from truck to truck. The major variances that may affect the APS installation include, but are not limited to the following:

1. The location of the APU on the truck’s frame-rail and the subsequent need to relocate the truck’s fuel tank and/or other frame-mounted components.

2. The air tank interface.

In most instances, adapting the systems installation is a matter of convenience for the installer and does not affect system operation. Exceptions to these conveniences are noted in the detailed instructions.

HOSES, HARNESSES, AND FUEL LINES

NOTE: THE MOST EFFICIENT WAY TO BUNDLE HOSES, WIRING HARNESSES, ETC, IS TO

LAY THEM IN POSITION, THEN TIE THEM TOGETHER. THIS WILL REDUCE THE CHANCE OR

ELIMINATE ERRORS SUCH AS DUPLICATION OF THE SAME WIRES AND/OR DAMAGED

WIRES.

It is important to properly manage the hoses, wiring harnesses, and the fuel lines during the install. This will prolong the life of the product as well as reduce errors during operation.

Prepare hoses to the following standards:

• Measured correctly.

• Clocked properly.

• Routed cleanly.

• Bundled neatly.

• Protected from chafing, and heat damage.

IMPORTANT

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ROUTE AND INSTALL ALL HOSES BEFORE WRAPPING THEM TOGETHER. USE LOOM

GUARD TO PROTECT ALL WIRES AND HOSES. WHEN CROSSING THE CROSS MEMBERS ON

THE CROSS FRAME, YOU MUST USE AN ADEQUATE SIZED CLAMP WHEN ROUTING FROM

ONE SIDE OF THE TRUCK TO THE OTHER.

DO NOT USE A ZIP TIE.

APU LOCATION

IMPORTANT

DISCONNECT THE BATTERY PER VEHICLE MANUFACTURE INSTRUCTIONS BEFORE PERFORMING ANY INSTALLATION PROCEDURES.

Check that the APU mounting surface or frame rail is straight and flat. The frame rail cannot be warped in a convex or concave manner. It is required that you mount to a strait and flat surface.

1. Carefully examine the truck chassis. Make sure you are mounting the APU in a healthy, non-damaged section of the frame. Establish all the possible locations the APU can attach to the truck’s frame rail (Passenger side). A minimum of 26 inches of frame rail space (in length) is required for the APU enclosure.

2. Keep note of what components or accessories you may relocate in order to install the APU to the frame rail. For example, it may be necessary to relocate a toolbox or air tank.

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3. The APU should be attached to the right (passenger) side of the truck to provide safety from passing vehicles if access to the unit is required while on the road.

4. The APU may be mounted behind of the fuel tank, or under the cab, where it will replace steps or a toolbox. The APU may also be mounted behind a fairing, if one is present on the truck.

5. If the APU is mounted under the cab, steps that attach to the APU enclosure and APU cover are available from WPS, LLC. Center the APU so that the steps to the cab are convenient for cab entry.

MOUNTING HOLES FOR APU J-BRACKETS

1. Remove the cover on the APU. Lift the APU using an engine hoist and a strap with hooked ends as follows: Attach hooks to the lifting eyes.

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2. Set the APU on an automobile transmission jack. Roll the APU up to the desired position on the frame to test how well it will fit. Set the cover (and fairings if equipped) back in place. Doing this will identify any potential clearance related issues. Remove the cover and guard again to prepare for installation.

CAUTION

TO PREVENT DAMAGE TO THE APU, SUPPORT THE ENTIRE BOTTOM OF THE BOX.

3. Use a square to measure the desired distance down from the top of the frame rail. Front and rear J-bracket mounting holes should be the same distance from the top of the rail to the center of the holes, so the APU

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will be installed horizontally, and square with the frame rail. See Figure 3.

4. All eight holes must be perfect for mounting the J-brackets to the truck at 27 and 7/8 inches from the out band holes. It is also recommended to use a paper pattern of the J-bracket to make your marks.

5. Drill 5/8” or 3/4” diameter holes in the rail. Use Grade 8.8, M16/2

bolts to secure the APU to the rail. Use washers on both sides and nylon insert nuts for reliable attachment of the APU. Tighten the bolt to the recommended torque specification of 158 ft-lbs.

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IMPORTANT

DO NOT ATTACH THE APU ENCLOSURE CLOSER THAN THREE INCHES AWAY FROM THE

TRUCK EXHAUST.

AFTER ATTACHING THE APU ENCLOSURE, THERE MUST BE ENOUGH DISTANCE BETWEEN

THE GROUND AND THE APU TO PREVENT ANY POTENTIAL CLEARANCE PROBLEMS.

IF THE APU IS CENTERED PROPERLY UNDER THE PASSENGER DOOR BEFORE DRILLING

THE MOUNTING HOLES, THE STEPS THAT ATTACH TO THE APU ENCLOSURE WILL

AUTOMATICALLY ALIGN WITH THE DOOR (UNDER THE CAB MOUNTING ONLY).

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CONNECTING THE APU TO THE TRUCK BATTERY

1. Install the 3/8” ring terminals on one end of the red and black 4AWG cable. Seal the ring terminals with the ½” shrink tube provided in the kit. Attach the two, 4 AWG battery cables to the APU, shown in Figure 4, below. Route the cables to the battery box (Positive cable is RED. Negative cable is BLACK.)

2. Cut the cable to length; crimp a 3/8” ring terminal onto the cable ends, and use ½” shrink tubing with sealant (supplied in the kit). Install both cable boots (red and black) on 4 AWG cable before installing cable on APU.

WARNING

DO NOT CONNECT THESE CABLES TO THE TRUCK’S BATTERY AT THIS TIME!

INSTALLING THE FUEL SYSTEM

WARNINGS:

DO NOT OVERTIGHTEN HARDWARE OR EXCEED THE RECOMMENDED

TORQUE FOR THE HARDWARE TO PREVENT DAMAGE.

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DO NOT TWIST TUBE DURING INSTALLATION, AS PERMANENT

DEFORMATION WILL OCCUR AND RESULT IN DAMAGED AND UNUSABLE

PARTS.

TOOLS NEEDED

You will require the following tools to install the fuel system:

1/2-inch street tee 3/8-inch street tee Number 4 strata flex 1/2-inch pipe to 3/8 bushing

3/8-male pipe to number 4 JIC Check valve APU fuel hose 24 inches of 1/4 inch tube Supply Side

STANDARD FUEL SYSTEM

Before installing the fuel tube, measure the diameter of the fuel tank. In the kit, you will get a 24 inch piece of 1/4-inch tubing: this is going to become the fuel supply to the Willie™ APU.

Do not cut the tube too short or leave it too long. Do not drop the tube into the tank.

1. If the diameter of the fuel tank is 24 inches, cut off 2 inches of the tube. If the tube is too long, the APU will be clogged from the residue that collects at the bottom of the tank. If the tube is too short, the APU will not draw enough fuel to power the engine.

2. To assemble the fuel block, use high-temp thread lock sealant on all threads except the compressing fitting where the pick-up tube is inserted. Insert all threads into their correct location (Image 34). There will be two other curved fittings that connect the hoses to the APU.

3. Complete the following to install the fuel assembly after assembling the fuel block:

Image 34: Use this picture to assemble the fuel block.

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4. Once it is tight, remove the lower end of the compression fitting with the tube; the boss should be tight on the tube (Image 35)

5. Remove the old fuel vent from the tank using a7/8-inch end wrench

6. Clean the area around the vent to prevent any debris from falling into the tank

7. Apply high-temperature thread lock sealant to the threading on the block

8. Ease the pick-up tube into the tank without any extreme bends; if you make slight bends while inserting the tube, make sure that you straighten it out (Image 36)

9. Twist the block into the tank, making sure it is secure (Image 37)

10. Attach the old vent into the fuel block

Note: The old fuel vent that is removed from the truck’s tank to install the WPS fuel block may not be the correct size. Some vents are too long and will not fit in the fuel block during the last step (7) of the installation. You will need to order a short vent. The Peterbilt part number is 2113-1.

Now it’s time to hook the pull and return lines to the block from the fuel block to the APU. Complete the following to attach the fuel lines:

11. Attach the return line to the upper 1/4-inch fitting

12. Attach the pull line to the lower fitting (Image 38)

13. Run the hoses along the truck’s frame to the APU

14. Zip tie the fuel hoses together

15. Secure the hoses to the truck’s frame

16. Connect the return line to the lower left port

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17. Connect the pull line to the lower right port

18. Pump the primer on the fuel filter housing until it is hard to push

REMOTE CONDENSER/RADIATOR BAND ASSEMBLY

Read this entire section before starting installation.

THE REMOTE CONDENSER/RADIATOR BAND ASSEMBLY KIT IS EQUIPPED WITH TWO

PRE-BUILT MOUNTING FRAMES.

1. The condenser is mounted on an angle iron bracket (provided with installation kit) on the truck frame.

2. Drill truck frame to match the condenser/radiator band assembly, and bolt the condenser/radiator band to the truck’s frame. Measure a minimum three inch fan space clearance on each side of the fan.

3. Mount the reservoir on the bracket (supplied by Willis) behind the cab.

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4. Attach the hoses from APU to the reservoir and the APU and the condenser/radiator band.

5. Install the proper clamps on all hose fittings.

6. Install coolant and check for leaks on all the hoses.

7. Check for proper rotation of the fan motor.

8. After installation is complete, you must bleed the motor to remove any air in the closed unit system and refill with coolant as necessary.

NOTE

SOME OF THE INSTRUCTIONS IN THIS MANUAL ARE FOR A SYSTEM THAT IS BEING

CONVERTED FROM DC MOTOR TO CONDENSER/RADIATOR CONFIGURATION. HOSES DO

NOT NEED TO BE REMOVED IF THIS IS AN INITIAL COND/RAD INSTALLATION.

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INSTALLING THE MANEX EVAPORATOR

1. Install the Manex under the bed of the truck’s cab with the template provided.

2. Prepare to move items to ensure ample space for the Manex.

3. The drains on the Manex will be exiting the bunk floor.

4. Use the template to mark the area for holes to be drilled into the floor.

5. After the drain hole is piloted, drill one inch holes into the floor.

6. Install the drain tubes provided with the Manex on the drain holes.

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7. Insert the drain tubes from the bottom of the Manex carefully through the drain holes of the floor.

8. Manex should look as follows:

9. Secure the Manex to the bunk floor using two self tapping screws.

10. Take the truck HVAC tube apart at the joint.

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11. Use a three inch hole saw and cut a hole into the HVAC tube. This is where you will attach the Manex vent tube.

12. Slip a vent adapter into the three inch hole into the HVAC tube then slip the Manex tube over the adapter and secure with a small screw.

13. Seal the vents with an epoxy.

14. Reinstall the truck’s HVAC tubes and attach the Manex vent tubes to the Manex.

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INSTALL FACE PLATES

1. For the Willis fan and AC control, find a good location in the bunk.

2. Draw and cut out a 3 inch by 3 inch square.

3. For the DSE Willis controller, draw and cut out a 2 and 5/8 inch by 3 and 1/8 inch rectangle.

4. After wiring is complete, you can install the Willis controllers to look like the following:

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5. Complete the instructions for wiring before completing installation of the face plates.

See Sections for Installing Control Modules.

MANEX AND WILLIS CONTROL HARNESS INSTALLATION

The relay switch board will be installed inside the storage space under the cab on the passenger side of the truck. This will protect the switchboard from corrosion. Access to the switch boxes can be made from the storage door outside of the cab.

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1. Use a two inch hole saw to cut holes in the bottom panel for the wire harness to fit through for the controllers.

2. Loom around the holes to keep the wires from rubbing a hole into one another.

3. Install the switch boxes to the inside wall using self tapping screws.

4. The wiring harness is extended from the APU unit to the cab from the floor.

5. Wiring harness is color coded by WPS. 6. Switch boxes are also labeled to direct the proper plug-ins to make it

easier for you to visually see where to connect the wiring harness to the relay switch board.

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7. Below is a view from above. Picture taken from inside the cab.

8. After the wiring harnesses are connected to the relay switch board, use an epoxy to seal the holes drilled for the wiring harness.

9. The epoxy will also help secure the harness and prevent loose wires from rubbing against each other.

10. The switches are connected to the battery box.

THE MAIN POWER HARNESS FOR THE MANEX

1. The black wire with the eye goes to the ground.

2. The white wire goes to the positive terminal on the Willis Power System.

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3. The orange wire trigger plugs into the Manex harness.

IMPORTANT

ALL TECHNICIANS MUST CONFIRM THAT BATTERY CABLES ARE UNHOOKED FROM THE WPS UNIT BEFORE ANY ELECTRICAL CONNECTIONS ARE MADE.

DSE CONTROLLER HARNESS

1. Two green plugs go to the DSE controller in the bunk.

2. The white wire is the WPS throttle wire which goes to the Manex control/relay board.

3. The pink and white wire plug goes to Manex wiring harness.

MANEX POWER HARNESS CONNECTIONS

1. Main power wire for Manex & trigger wire for manex relay board.

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2. The ground for the Manex power harness.

THROTTLE WIRE FROM DSE HARNESS TO THE MANEX RELAY BOARD

1. Connect the white wire from the DSE controller harness to the light blue wire coming out of the Manex relay board.

2. These wires have an attached plug, so you will not need a butt connector.

3. The following image shows where the Manex/Willis fan control switch is installed.

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4. Finished view of DSE controller:

PRESS SWITCH ON DRYER

1. The dryer is directional with the arrow on the top facing in the direction of the flow of Freon.

INSTALLING CONTROL HARNESS FOR MANEX/WILLIS

1. Freeze switch wires & blow fan switch

VIEW OF COMPLETE PRESSURE SWITCH

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VIEW OF POWER HARNESS TO THE MANEX

1. White wire will power 12 volts.

2. Black wire for ground.

NOTE: MANEX WILL ONLY WORK WHEN APU IS RUNNING.

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POWER HARNESS TO THE TRUCK BATTERY

1. White wire needs to go to the positive post of the truck battery.

2. Black wire goes to the ground of the truck battery.

3. This is so the 40 amp fuse is protected from the weather

LUBRICATING THE AIR CONDITIONING SYSTEM

These must be added to the air conditioning system.

1. During the initial A/C line routing, you are required to have 2 bottles of Polar Ice 32 and 2 ounces of PAG 46 A/C oil

DO NOT ADD THE TOTAL AMOUNT AT THE COMPRESSOR.

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2. Add equal amounts of both the ice 32 and PAG 46 oil at any of the A/C connections.

3. Once oil and ICE have been added to the A/C system and all connections have been made, it is required that a minimum 30 minute vacuum is pulled.

4. Add 2.95 lbs of Freon to start functional testing of A/C system.

5. Adjust as necessary to follow environmental requirements.

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INSTALLING THE DSE3000 SERIES CONTROL MODULE

DIMENSIONS AND MOUNTING

Dimension

99mm x 79 mm x 40mm (3.9“ x 3.1“ x 1.6”)

Panel Cut-out

80mm x 68mm (3.2“ x 2.7“)

Weight

89g (0.089kg)

FIXING CLIPS

The module is held into the panel fascia using the supplied fixing clips.

1. Withdraw the fixing clip screw (turn anticlockwise) until only the pointed end is protruding from the clip.

2. Insert the three ‘prongs’ of the fixing clip into the slots in the side of the 3000 series module case.

3. Pull the fixing clip backwards (towards the back of the module) ensuring all three prongs of the clip are inside their allotted slots.

4. Turn the fixing clip screws clockwise until they make contact with the panel fascia.

5. Turn the screws a little more to secure the module into the panel fascia. Care should be taken not to over tighten the fixing clip screws.

NOTE: USE ANTI-VIBRATION MOUNTING FOR PANEL IN CASE OF EXCESSIVE VIBRATION

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OPTIONAL SILICON SEALING GASKET

The optional silicon gasket provides improved sealing between the 3000 series module and the panel fascia.

The gasket is fitted to the module before installation into the panel fascia.

Take care to ensure the gasket is correctly fitted to the module to maintain the integrity of the seal.

NOTE: IN LINE WITH OUR POLICY OF CONTINUAL DEVELOPMENT, DEEP SEA ELECTRONICS, RESERVE THE RIGHT TO CHANGE SPECIFICATION WITHOUT NOTICE.

USER CONNECTIONS AND TERMINAL DESCRIPTION

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DC SUPPLY, FUEL AND START OUTPUTS

PIN DESCRIPTION CABLE NOTES

No SIZE

1

DC Plant Supply Input (Negative)

2.5mm² AWG 13

2

DC Plant Supply Input (Positive)

2.5 mm² AWG 13

(Recommended Maximum Fuse 15A anti-surge) Supplies the module (2A anti-surge requirement) and all output relays

3 Output A

(FUEL) 1.0mm² AWG 18

Plant Supply Positive from terminal 2. 3 Amp rated.

4 Output B (START)

1.0mm² AWG 18


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5 Output C 1.0mm² AWG 18


6 Output D 1.0mm² AWG 18


7 Charge fail

/ excite 2.5mm² AWG 13

Do not connect to ground (battery negative). If charge alternator is not fitted, leave this terminal disconnected.

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GENERATOR VOLTAGE SENSING AND DIGITAL INPUTS


No SIZE

8 Generator Neutral (N) input

1.0mm² AWG 18

Connect to generator Neutral terminal (AC)

9 Generator L1 (U) voltage monitoring

1.0mm² AWG 18

Connect to generator L1 (U) output (AC) (Recommend 2A fuse)

MAGNETIC PICKUP AND DIGITAL INPUTS

(MODEL 3110-XX-01) Model 3110-xx-01 (Magnetic pickup enabled module)

NOTE: CAN INTERFACE IS NOT FITTED TO THE 3110-XX-01 MODULE


No SIZE

10 Magnetic pickup Positive

0.5mm² AWG 20

Connect to Magnetic Pickup device

11 Magnetic pickup Negative

0.5mm² AWG 20

Connect to Magnetic Pickup device

12 Configurable digital input A

0.5mm² AWG 20 Switch to negative

13 Configurable digital input B


14 Configurable digital input C


15 Configurable digital input D


16 Configurable digital input E


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17 Configurable digital input F


NOTE: SCREENED CABLE MUST BE USED FOR CONNECTING THE MAGNETIC PICKUP, ENSURING THAT THE SCREEN IS EARTHED AT ONE END ONLY.

CAN AND DIGITAL INPUTS

(MODEL 3110-XX-02) Model 3110x-020 (Can enabled module) only.

NOTE: SCREENED 120 IMPEDANCE CABLE SPECIFIED FOR USE WITH CAN MUST BE USED FOR THE CAN LINK AND THE MULTI-SET COMMS LINK.

DSE STOCK AND SUPPLY BELDEN CABLE 9841 IS A HIGH QUALITY 120IMPEDANCE CABLE SUITABLE FOR CAN USE (DSE PART NUMBER 016-030).

PC CONFIGURATION INTERFACE CONNECTOR

This is a standard USB type A to type B cable.

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The USB connection cable between the PC and the 3000 series module must not be extended beyond 5m (5yds).

For distances over 5m, it is possible to use a third party USB extender.

Typically, they extend USB up to 50m (yds). The supply and support of this type of equipment is outside the scope of Deep Sea Electronics PLC.

CAUTION: DO NOT OVERLOAD THE PCS USB SYSTEM BY CONNECTING MORE THAN THE RECOMMENDED NUMBER OF USB DEVICES TO THE PC. CONSULT YOUR PC SUPPLIER FOR MORE INFORMATION

THE SOCKET MUST NOT BE USED FOR ANY OTHER PURPOSES.

OPERATIONAL INSTRUCTIONS

The following section details the function and meaning of the various controls on the module and the module’s operations.

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QUICKSTART GUIDE

This section provides a quick start guide to the module’s operation.

STARTING THE ENGINE

STOPPING THE ENGINE

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CONTROLS

Stop / Reset This button places the module into its Stop/Reset mode. This will clear any alarm conditions for which the triggering criteria have been removed.

If the engine is running and the module is in Stop mode, the module will automatically instruct the changeover device to unload the generator (‘Close Generator’ becomes inactive (if used)). The fuel supply de-energizes and the engine comes to a stand-still.

Should a remote start signal be present while operating in this mode, a remote start will not occur.

Auto This button places the module into its ‘Automatic’ mode. This mode allows the module to control the function of the generator automatically.

The module will monitor the remote start input and once a start request is made, the set will be automatically started and placed on load. Upon removal of the starting signal, the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary.

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The module will then await the next start event. For further details, please see the more detailed description of ‘Auto operation’ elsewhere in this manual.

Start Pressing this button in auto mode will start the engine and run off load. Pressing this button in STOP/RESET mode will turn on the CAN engine ECU (when correctly configured and fitted to a compatible engine ECU).

Page Pressing this button scrolls the display to show the various instruments.

AUTOMATIC MODE OF OPERATION

NOTE: IF A DIGITAL INPUT CONFIGURED TO PANEL LOCK IS ACTIVE, CHANGING MODULE MODES WILL NOT BE POSSIBLE. VIEWING THE INSTRUMENTS AND EVENT LOGS IS NOT AFFECTED BY PANEL LOCK.

Activate auto mode by pressing the push-button. The icon is displayed to indicate Auto Mode operation if no alarm is present.

Auto mode will allow the generator to operate fully automatically, starting and stopping as required with no user intervention.

WAITING IN AUTO MODE

If a starting request is made, the starting sequence will begin. Starting requests can be from the following sources:

• Activation of an auxiliary input that has been configured to remote start.

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STARTING SEQUENCE

1. To allow for ‘false’ start requests, the start delay timer begins.

2. Should all start requests be removed during the start delay timer, the unit will return to a stand-by state.

3. If a start request is still present at the end of the start delay timer, the fuel relay is energized and the engine will be cranked.

NOTE:-IF THE UNIT HAS BEEN CONFIGURED FOR CAN, COMPATIBLE ECU’S WILL RECEIVE THE START COMMAND VIA CAN.

4. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt is made. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and the display shows Fail to Start.

5. When the engine fires, the starter motor is disengaged. Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel (Selected by PC using the 3000 series configuration software).

6. Additionally, rising oil pressure can be used to disconnect the starter motor (but cannot detect under-speed or over-speed).

NOTE: IF THE UNIT HAS BEEN CONFIGURED FOR CAN, SPEED SENSING IS VIA CAN.

7. After the starter motor has disengaged, the Safety On timer activates, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilize without triggering the fault.

ENGINE RUNNING

Once the engine is running and all starting timers have expired, the animated icon is displayed. DSE3110 -The generator will be placed on load if configured to do so.

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NOTE:-THE LOAD TRANSFER SIGNAL REMAINS INACTIVE UNTIL THE OIL PRESSURE HAS RISEN. THIS PREVENTS EXCESSIVE WEAR ON THE ENGINE.

If all start requests are removed, the stopping sequence will begin.

STOPPING SEQUENCE

The return delay timer operates to ensure that the starting request has been permanently removed and isn’t just a short term removal. Should another start request be made during the cooling down period, the set will return on load.

If there are no starting requests at the end of the return delay timer, the load is removed from the generator to the mains supply and the cooling timer is initiated.

The cooling timer allows the set to run off load and cool sufficiently before being stopped. This is particularly important where turbo chargers are fitted to the engine.

After the cooling timer has expired, the set is stopped.

MANUAL OPERATION

NOTE: IF A DIGITAL INPUT CONFIGURED TO PANEL LOCK IS ACTIVE, CHANGING MODULE MODES WILL NOT BE POSSIBLE. VIEWING THE INSTRUMENTS AND EVENT LOGS IS NOT AFFECTED BY PANEL LOCK.

Manual mode allows the operator to start and stop the set manually, and if required change the state of the load switching devices. Module mode is active when the button is pressed.

WAITING IN MANUAL MODE

1. To begin the starting sequence, press the button.

2. If ‘protected start’ is disabled, the start sequence begins immediately.

3. If ‘Protected Start’ is enabled, the icon is displayed to indicate manual mode and the manual LED flashes.

4. The button must be pressed once more to begin the start sequence.

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STARTING SEQUENCE

NOTE:-THERE IS NO START DELAY IN THIS MODE OF OPERATION.

The fuel relay is energized and the engine is cranked.

NOTE:-IF THE UNIT HAS BEEN CONFIGURED FOR CAN, COMPATIBLE ECU’S WILL RECEIVE THE START COMMAND VIA CAN.

If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt is made.

Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and the display shows Fail to Start.

The starter motor is disengaged when the engine fires. Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel (Selected by PC using the 3000 series configuration software).

Additionally, rising oil pressure can be used disconnect the starter motor (but cannot detect under-speed or over-speed).

NOTE: IF THE UNIT HAS BEEN CONFIGURED FOR CAN, SPEED SENSING IS VIA CAN.

After the starter motor has disengaged, the Safety On timer activates, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilize without triggering the fault.

ENGINE RUNNING

In manual mode, the load is not transferred to the generator unless a ‘loading request’ is made. A loading request can come from a number of sources.

Activation of an auxiliary input that has been configured to remote start on load.

Activation of the inbuilt exercise scheduler if configured for ‘on load’ runs.

NOTE: THE LOAD TRANSFER SIGNAL REMAINS INACTIVE UNTIL THE OIL PRESSURE HAS RISEN. THIS PREVENTS EXCESSIVE WEAR ON THE ENGINE.

Once the load has been transferred to the generator, it will not be automatically removed. To manually transfer the load back to the mains either:

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1. Press the auto mode button to return to automatic mode. The set will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence.

2. Press the stop button

De-activation of an auxiliary input that has been configured to remote start on load.

STOPPING SEQUENCE

In manual mode the set will continue to run until either:

a) The stop button is pressed – The set will immediately stop

b) The auto button is pressed. The set will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence.

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PROTECTIONS

When an alarm is present, the common alarm LED if configured will illuminate. The LCD display will show an icon to indicate the failure.

WARNINGS

Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to draw the operators attention to an undesirable condition.

Warning alarms are self-resetting when the fault condition is removed. The icon will appear steady in the display.

SHUTDOWNS

1. Shutdowns are critical alarm conditions that stop the engine and draw the operator’s attention to an undesirable condition.

2. When shutdown alarms are latching, the fault must be removed and the button pressed to reset the module. The icon will appear flashing in

the display.

8 MODULE DISPLAY

TIMER ICON

When the module is controlling the engine (starting and stopping) an animated timer icon will be displayed in the icon area to indicate that a timer is active, for example cranking time, crank rest etc.

STOPPED ICON

When there are no alarms present, an icon will be displayed to indicate the engine is stopped and what mode the unit is in.

Stop Auto Manual

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The hand is only displayed when the ‘arming options’ is enabled; otherwise the engine starts when entering the manual mode.

RUNNING ICON

When there are no alarms present, an animated icon is displayed to indicate the engine is running.

USB ICON

When a USB connection is made to the module the USB icon is displayed.

MEMORY CORRUPTION

If either the configuration file or engine file becomes corrupted the unit will display the icon.

BACKLIGHT

The backlight will be on if the unit has sufficient voltage on the power connection while the unit is turned on, unless the unit is cranking for which the backlight will be turned off.

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FAULT ICONS

ICON DESCRIPTION

AUXILIARY INPUTS

Auxiliary inputs can be user configured and will display the message as written by the user.

FAIL TO START The engine has not fired after the preset number of start attempts

FAIL TO STOP The module has detected a condition that indicates that the engine is running when it has been instructed to stop.

NOTE: ‘Fail to Stop’ could indicate a faulty oil pressure sensor -If engine is at rest check oil sensor wiring and configuration.

LOW OIL PRESSURE

The module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm setting level after the Safety On timer has expired.

ENGINE HIGH TEMPERATURE

The module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm setting level after the Safety On timer has expired.

UNDERSPEED The engine speed has fallen below the under speed

pre alarm setting

OVERSPEED The engine speed has risen above the over speed

pre alarm setting

CHARGE FAILURE The auxiliary charge alternator voltage is low as

measured from the W/L terminal.

LOW FUEL LEVEL The level detected by the fuel level sensor is below

the low fuel level setting.

BATTERY UNDER/ OVER VOLTAGE

The DC supply has fallen below or risen above the low/high volts setting level.

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GENERATOR UNDER VOLTAGE

The generator output voltage has fallen below the pre-set pre-alarm setting after the Safety On timer has expired.

GENERATOR OVER VOLTAGE

The generator output voltage has risen above the pre-set pre-alarm setting.

GENERATOR UNDER FREQUENCY

The generator output frequency has fallen below the pre-set pre-alarm setting after the Safety On timer has expired.

GENERATOR OVER FREQUENCY

The generator output frequency has risen above the pre-set pre-alarm setting.

CAN ECU WARNING CAN ECU SHUTDOWN

The engine ECU has detected an alarm – CHECK ENGINE LIGHT Contact Engine Manufacturer for support.

CAN DATA FAIL The module is configured for CAN operation and does not detect data on the engine Can data link.

EMERGENCY STOP

The emergency stop button has been depressed. This is a fail-safe (normally closed to battery positive) input, and will immediately stop the set should the signal be removed. Removal of the battery positive supply from the emergency stop input will also remove DC supply from the Fuel and Start outputs of the controller.

NOTE: The Emergency Stop Positive signal must be present otherwise the unit will shutdown.

MAGNETIC PICKUP FAILURE

Pulses are no longer being detected from the magnetic pickup probe (3110-xxx-01 magnetic pickup version only)

INTERNAL MEMORY ERROR

Either the configuration file or engine file memory is corrupted. Contact your supplier for assistance.

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FAULT FINDING

SYMPTOM POSSIBLE REMEDY

Unit is inoperative Read/Write configuration does not operate

Check the battery and wiring to the unit. Check the DC supply. Check the DC fuse.

Unit shuts down Check DC supply voltage is not above 35 Volts or below 9 Volts Check the operating temperature is not above 70°C. Check the DC fuse.

Unit locks out on Emergency Stop

If no Emergency Stop Switch is fitted, ensure that a DC positive signal is connected to the Emergency Stop input. Check emergency stop switch is functioning correctly. Check Wiring is not open circuit.

Intermittent Magnetic Pick-up sensor fault

Ensure that Magnetic pick-up screen only connects to earth at one end, if connected at both ends, this enables the screen to act as an aerial and will pick up random voltages. Check pickup is correct distance from the flywheel teeth.

Low oil Pressure fault operates after engine has fired

Check engine oil pressure. Check oil pressure switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the 3310 Module and is correctly configured.

High engine temperature fault operates after engine has fired.

Check engine temperature. Check switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the 3000 series module.

Shutdown fault operates

Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input.

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Warning fault operates Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input.

Fail to Start is activated after preset number of attempts to start

Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply is present on the Fuel output of the module. Check the speed-sensing signal is present on the 3000 series module inputs. Refer to engine manual.

Continuous starting of generator when in AUTO

Check that there is no signal present on the “Remote Start” input. Check configured polarity is correct.

Generator fails to start on receipt of Remote Start signal.

Check Start Delay timer has timed out. Check signal is on “Remote Start” input. Confirm correct configuration of input is configured to be used as “Remote Start”. Check that the oil pressure switch or sensor is indicating low oil pressure to the controller. Depending upon configuration, the set will not start if oil pressure is not low.

Pre-heat inoperative Check wiring to engine heater plugs. Check battery supply. Check battery supply is present on the Pre-heat output of module. Check pre-heat configuration is correct.

Starter motor inoperative

Check wiring to starter solenoid. Check battery supply. Check battery supply is present on the Starter output of module. Ensure that the Emergency Stop input is at Positive. Ensure oil pressure switch or sensor is indicating the “low oil pressure” state to the 3000 series controller.

Engine runs but generator will not take load

Check Warm up timer has timed out. Ensure generator load inhibit signal is not present on the module inputs. Check connections to the switching device. Note that the set will not take load in manual mode unless there is an active remote start on load signal.

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Incorrect reading on Engine gauges Fail to stop alarm when engine is at rest

Check engine is operating correctly. Check sensor and wiring.

Module appears to ‘revert’ to an earlier configuration

When editing a configuration using the PC software it is vital that the configuration is first ‘read’ from the controller before editing it. This edited configuration must then be “written” back to the controller for the changes to take effect. When editing a configuration using the Front Panel Editor, be sure to press the Save button to save the change before moving to another item or exiting the Front Panel Editor.

Set will not take load Ensure the generator is available. Check that the output configuration is correct to drive the load switch device and that all connections are correct. Remember that the set will not take load in manual mode unless a remote start on load input is present.

Inaccurate generator measurements on controller display

The 3000 series controller is true RMS measuring so gives more accurate display when compared with an ‘average’ meter such as an analogue panel meter or some lower specified digital multimeters. Accuracy of the controller is better than 1% of full scale. IE Gen volts full scale is 333V ph-n so accuracy is ±3.33V (1% of 333V).

NOTE: THE ABOVE FAULT FINDING IS PROVIDED AS A GUIDE CHECK-LIST ONLY. AS THE MODULE CAN BE CONFIGURED TO PROVIDE A WIDE RANGE OF DIFFERENT FEATURES, ALWAYS REFER TO THE SOURCE OF YOUR MODULE CONFIGURATION IF IN DOUBT.

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OPERATING CONTROL MODULE

NOTE: YOU MUST HAVE A CLOSED LOOP (CIRCUIT) PROGRAM TO EFFECTIVELY USE THE THERMOSTAT CONTROLS. IF YOU HAVE A CLOSED LOOP AC SYSTEM ONLY, THEN ONLY THE AC CONTROLS ARE AFFECTED BY THE THERMOSTAT. IF YOU HAVE A CLOSED LOOP HEAT AND AC SYSTEM THEN BOTH HEAT AND AC CONTROLS ARE AFFECTED BY THE THERMOSTAT.

OPERATIONAL FUNCTIONS: 4410 CONTROLLER WITH OR WITHOUT THERMOSTAT

1. Press the green start button and allow the APU to power until low idle (90 second “glow plug” time is standard).

2. Set the Willis comfort panel switch to “cool”.

3. If applicable: with the thermostat in the auto position, set the thermostat to the same setting.

4. Adjust the thermostat to your desired temperature.

5. Adjust the blower fan to desired air flow.

6. The APU will cycle the LD air with the selected temperature on the thermostat automatically.

7. When you’re finished with the temperature controls, rerun the blower to the off position.

8. Disconnect power to the APU if you no longer need power.

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SETTING THE CONTROLLER TO AUTO START THE APU

SETTING TIME & DAY

1. Ensure the APU is at rest by pressing the stop/rest button on the front panel.

2. Press the stop/reset button and the “I” buttons simultaneously. A hammer and wrench icon will be displayed.

3. Press and index the “down” button to access the parameter page: GO TO PAGE 12 (1201).

4. Press the “start” button to select the following parameters:

a. 1201 code: to adjust time (military time).

b. 1202 code: to adjust date (0) Sunday, (1) Monday, (2) Tuesday, Wednesday, etc.

5. Press the “I” button and the parameter value will begin to flash.

6. Press “start” to index the value of the time.

7. Press “i” to stop the value from flashing to set.

8. Press and hold “I” to exit the 4410 editor and the “hammer/wrench” icon will no longer be on display.

SETTING THE AUTO START

1. Ensure the APU is at rest by pressing the stop/rest button on the front panel.

2. Press the stop/reset button and the “I” buttons simultaneously. A hammer and wrench icon will be displayed.

3. Press and index the “down” button to access the parameter page: GO TO PAGE 11 (1101).

4. Press “start” to select the following parameters:

5. Code 1101: Enable/Disable “Auto Start”

6. (1) On or (2) Off

7. 1103: Start time for “Auto start”

8. 1104: Day to run “Auto Start” (0) Sunday, (1) Monday, (2) Tuesday, etc.

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9. Press the “I” button and the parameter value will begin to flash.

10. Press “start” to index the value of the time.

11. Press “i” to stop the value from flashing to set.

12. Press and hold “I” to exit the 4410 editor and the “hammer/wrench” icon will no longer be on display.

OPERATING THERMOSTAT

For more information, view the instruction guide that accompanies your thermostat.

Use the selector switch to place the system in cooling mode or set mode to off.

NOTE: WHEN YOU PLACE THE THERMOSTAT IN COOLING MODE, YOU MIGHT NEED TO WAIT UP TO FIVE MINUTES BEFORE COOLING CAN START. THIS IS A SAFETY FEATURE FOR THE COMPRESSOR. THE SNOW ICON WILL FLASH ON THE SCREEN DURING THE DELAY.

FAN OPERATING MODE

Use the selector switch to set the fan to automatic mode or continuous mode.

NOTE: THIS SWITCH IS NOT USED IN A 2-WIRE INSTALLATION AS THE FAN IS NOT CONNECTED TO THE THERMOSTAT IN THIS TYPE OF INSTALLATION.

Auto The fan operates only when the cooling system is on (typical setting).

On The fan operates continuously. Use this setting to improve air circulation and air cleaning.

DISPLAYING THE TEMPERATURE

The actual temperature is normally displayed. To view the set point, press once on one of the buttons. The set point is displayed for 5 seconds along with the arrow icon.

NOTE: PRESSING EITHER OF THE BUTTONS MORE THAN ONCE WILL CHANGE THE SETPOINT.

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SETTING THE TEMPERATURE

Press one of the up or down buttons until the desired temperature is displayed.

BACKLIGHT

The display illuminates for 12 seconds when the backlight button or any of the buttons are pressed.

THERMOSTAT CONTROL MODE

MANUAL/PERMANENT HOLD MODE

This mode maintains the temperature at a fixed set point. To place the thermostat in this mode, press [Mode]. The house icon will disappear.

PROGRAMMABLE MODE This mode maintains the temperature according to the energy-saving schedule. To place the thermostat in this mode, press [Mode]. The current period will be displayed. The four possible periods are:

• Wake Up

• Leave for work

• Return Home

• Sleep

TEMPORARY BYPASS

If you modify the set point (using the buttons) when the thermostat is in Programmable mode, the thermostat will use the new set point for the next 2 hours. The house icon flashed during the bypass. Afterwards, the thermostat will return to the temperature setting of the period currently underway.

FILTER REPLACEMENT INDICATOR

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After 500 hours of operation, an icon appears to indicate that the filter needs replacement. Once the filter is replaced, press [Filter] for 3 seconds to remove the icon and reset the counter.

BATTERY REPLACEMENT INDICATOR

Install fresh batteries immediately when the icon starts flashing. The icon flashes for 120 days before the batteries are depleted. You should replace batteries once a year before leaving home for more than a month even if the icon has not appeared.

After replacing the batteries, set the time, day and date). However, the temperature and program settings are saved and do not need to be re-entered.

WARNING: BEFORE REMOVING THE BATTERIES, PLACE THE SYSTEM SWITCH ON THE THERMOSATE TO OFF. OTHERWISE, THE HEATING/COOLING UNIT MIGHT STILL BE RUNNING EVEN AFTER THE BATTERIES ARE REMOVED.

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COMPLETING INSTALLATION

Once all the subsystems are installed, the final step can be completed. This is to secure all hoses. Hoses should be bundled and secured with tie wraps or clamps as appropriate. There should not be any twists or sharp bends. No hose should be under tension that might contribute to failure of a fitting. Check for areas of possible chafing in the hose runs. Check one more time that hoses are connected correctly. Check all hoses for possible heat damage. If damage has occurred, move or protect these hoses.

If any hose is a little long, make sure it is looped up and does not sag. Secure any such upward curve to make sure it does not become a sag in the hose.

IMPORTANT

RECONNECT THE BATTERY! MAKE FINAL APU TO BATTERY CONNECTIONS!

INITIAL CHECKOUT AND TROUBLESHOOTING

Once the APS is completely installed, it needs to be inspected before the APU can be started. Remove the fairing from the APU. The following items need to be visually inspected before proceeding to the next steps:

Attachment of the APU (bolts tight, enclosure clearance OK and all connections to end plate are secured).

All hose tie wraps and other clamps are in place.

Coolant System (coolant is replaced and valves open). Check for leaks, and add coolant to top off system.

Fuel System (connected correctly to main fuel tank, line clearances).

Pneumatic Compressor (lines connected).

Air Conditioning.

Oil Pump (valve open).

Electrical System (wire wraps, connected to right terminals, no chafing). Electronic Control (wiring correct).

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VERIFY THE APU FOR THE FOLLOWING:

WARNING!!! DO NOT OVERFILL! THE CRANK-CASE HAS A CAPACITY OF 3 ½ U.S. QUARTS.

APU crank case is filled.

All valves open.

Fuel in lines… use primer pump: Check throttle for operation and settings.

Next, start the truck engine and run it (at 1200 RPM) for not less than twenty minutes.

NOTE: THIS WILL BLEED AIR FROM THE COOLANT SYSTEM. YOU WILL NEED TO ADD 1 TO 3 GALLONS OF COOLANT TO THE TRUCK.

Prime and start the APU, and while it is running with the cover off, check for leaks everywhere in the system. Check the low idle for 1500 RPM and the high idle at 2300 to 2400 RPM (with no load).

Recheck the hoses with the APU running to make sure there is no vibration that could result in hose chafing. No leaks, now is the time to reinstall the fairings and covers

APPENDIX A – DIAGRAMS

On Following Pages Are Diagrams

Motor Wiring Diagram

Manex H/C Wiring Diagram

Thermostat Special Instructions

A- Pin Out Diagram A-Cab Dash Control Comm Line Diagram A-Overall System Diagram

Willis APU Manual Aug, 28th 2009: B Collins

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MOTOR WIRING DIAGRAM

NOTE: ALL WIRES RUN INTO 12 PIN PLUG

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MANEX H/C WIRING DIAGRAM

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THERMOSTAT SPECIAL INSTRUCTIONS DIAGRAM

The thermostat must be set to HE (Heat Electric) instead of HG (Heat Gas).

If thermostat is not set to HE, you can remove the electronic tab or from the prongs and replace it on the proper setting.

1. Place the power input from the (DSE) controller harness to G.

2. The output power goes into the orange wire on the bottom of the relay board.

Note: Thermostat interrupts wire from controller harness to relay board.

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WILLIS APU TROUBLE SHOOTING GUIDE

Symptom Check #1 Additional Checks

Probable Cause Actions

APU does not start

Display does not have power

Check fuses and mega fuse block

Fuse / Relay link broken

Replace fuse and relay if necessary. Look for loose connections or corrosion in wire

Verify correct voltage at (+) post on APU

Bad battery or loose connection

12 volts minimum required

Are connections clean

Road dirt / tar Clean connections

Check supply power at ECU

This is pin(2) at the 12 pin male connector System voltage

If voltage checks OK Bad ECU Replace ECU

Before installing new ECU

Verify new ECU has new battery

Display has power

Check F1 fuse and R1 relay (Power at Starter)

Fuse / Relay link broken

Replace fuse and relay if necessary. Look for loose connections or corrosion in wire

If OK, check voltage at starter wire when activated

Potential Bad Starter

If voltage is system voltage then replace Starter

If voltage is not system voltage then

Potential Bad ECU

Check output voltage at ECU

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Pin #4 at the 12 pin male connector

If no voltage…replace ECU

Break in wiring harness or connection

Find and or replace wiring harness

APU cranks but will not start

Starter Check Fuse F-1, Relay R1

Replace fuse and relay if necessary. Look for loose

connections or corrosion in wire

Glow Plugs

Check Fuse F-7, Relay R4



Shut down Solenoid

Check Fuses F-3, F-5, Relay R2, R3



If OK then put in start mode and check voltage at glow plugs

If not system voltage; then broken wire. Find and

replace

Verify shut down solenoid is working Visual inspection

Check oil pressure switch

Bad Switch Replace Oil pressure switch

Check temp sender

Bad Temp Sender Replace Temp Sender

Check resistance

Bad RPM sensor

With no power 135 ohms resistance

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Check resistance and proper set of speed sensor

Dirt / Oil causing incorrect RPM reading

Remove RPM sensor and clean. Install to finger tight against the flywheel teeth

and back off 1/4 turn. Tighten secure nut.

Exhaust Check for blockage Visual

Lacks Fuel Check for fuel supply

Air blockage in line from fuel pump

Pull pump supply line and observe fuel flow

Check fuel filter supply

Bad or blocked filter Replace fuel filter

Lacks Air Check air filter

Blockage in air delivery Repair and or replace

Low engine power or bogs down

Check air filter for improper cleaning and replacement Replace air filter

Check fuel supply Find blockage and

remove

Check fuel filter Replace fuel filter

Engine starts but will not run to operating RPM

Review controller icon list for fault indication

Throttle Solenoid

Check fuse F-9 and relay R-5

Replace fuse and relay if necessary.

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Look for loose connections or

corrosion in wire

Check power at throttle solenoid and test solenoid with VOM System voltage

Check throttle solenoid travel by resistance ohms check

Open should be low ohms 2 or less Closed will be 18-

21 ohms

APU starts but major components are inoperable

Check drive belts visually Replace

AC inoperable Check in-line fuses



corrosion in wire

Check belt on AC compressor Replace

Check power at AC clutch connection System voltage

Check R134 level Add additional if

necessary

Check for evidence of R134 leakage at all AC fittings…this is the

Yellowish color at fitting crimp or

threads

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most common cause of AC failure

APU will not go to high idle

Throttle Solenoid

Check fuse F-9 and relay R-5



corrosion in wire

Check power at throttle solenoid and test solenoid with VOM System voltage

Check throttle solenoid travel by resistance ohms check

Open should be low ohms 2 or

less Closed will be 18- 21 ohms

WPS "Willie" APU

In Cab A/C switch connection

Fix connection or replace

switch

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APU alternator

not charging

Check drive

belt Broken belt Replace

alternator belt

Check alternator output to

system voltage 14

volts+ Bad

Alternator Replace

alternator

APU A/C compressor not working

Check drive

belt Broken belt Replace belt

Check for system

voltage at clutch wire A/C clutch

Replace A/C compressor and

clutch

Check for

freon leakage

Road vibration

causing leak at fitting or

hoses

Replace fittings / hoses and pull

vacuum to verify proper

seal.

APU A/C on not cooling

A/C charge Check for

leaks

Road vibration

causing leak at fitting or

hoses

Replace fittings / hoses and pull

vacuum to verify proper

seal.

A/C fan inoperable

Check in-line fuse / breaker

and relay Loose

connections



corrosion in wire

A/C high pressure

switch

Check for power going

through if over 300psi

Replace if no system voltage

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Oil pressure switch

Check for power going

through if truck engine

off Replace if no

system voltage

Solenoid

Check that solenoid is switching

Replace if not switching

Bunk Controller Unit shuts down

Check DC supply voltage is not above 35 Volts or below 9 Volts Check the operating temperature is not above 160°F. Check the DC fuse.

Replace fuse and relay if necessary. Look for loose connections or

corrosion in wire Intermittent Magnetic Pick-up sensor fault

Ensure that Magnetic pick-up screen only connects to earth at one end, if connected at both ends, this enables the screen to act as an aerial and will pick up random voltages. Check pickup is correct distance from the flywheel teeth.

Reset speed sensor to proper depth

Low oil Pressure fault operates after engine has fired

Check engine oil pressure. Check oil pressure switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed)

Replace oil sensor switch

High engine temperature fault operates after engine has fired.

Check engine temperature. Check switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed)

Replace temp sensor

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Fail to Start is activated after preset number of attempts to start

Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply is present on the Fuel output of the module.

System voltage: Replace wire to component or

component

Pre-heat inoperative

Check wiring to engine heater plugs. Check battery supply. Check battery supply is present on the Pre-heat output of module. Check pre-heat configuration is correct.


component

Starter motor inoperative

Check wiring to starter solenoid. Check battery supply. Check battery supply is present on the Starter output of module.


component

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