Trouble Shooting and Service Guide

Transcription

1 Trouble Shooting and Service Guide Page , Topic Component Locations Component Voltages Fuse Size & Fuse Location A/C Troubleshooting Heat Troubleshooting Inverter DC Power Converter Battery Separator Water Heater Cab Power Shore Power AGM Batteries Charge Circuit Amperage Draw Inverter Explained

2 Component Locations Exterior Unit The Exterior Unit contains: Top Level: Lower Level: Air Conditioner + Condenser fan Water Heater + fuel pump Battery Separator Battery Bank Fuse AGM Batteries Battery Quick Connectors Evaporator Assembly The evaporator assembly includes an evaporator, and a 120 Volt AC blower motor. There is a serviceable air filter located on the back side of the unit. Bunk Floor Module Bunk Floor Module includes: Inverter Buss Bars (positive & negative) Power Converter 120 VAC to 12 VDC Relays for Ignition, Compressor, Evaporator Blower fan Relay Wiring & Plumbing The wire harness uses industry standard connectors and is split to serve each component. The water heater is plumbed into the truck s coolant system by using the bunk s heater core supply (pressure side) hose as the intake (supply) for the Idle Free heater. The output hose on the Idle Free heater becomes the water supply hose for the truck s bunk heater core. The exterior unit contains 4 group 31 AGM batteries on the lower level The IF air conditioner is split into 2 parts The exterior portion of the IF air conditioner includes: o 120 VAC compressor o Accumulator o Dryer o Condenser o 12 VDC Cond. Fan o Capacitor o Hard Start Cap. All of the exterior Air conditioning components can be changed and/or serviced The IF air conditioner uses 134A refrigerant. This service manual contains chapters for all components The major components used in the Idle Free system are shipped with the manufactures manuals included 1

3 Components Electrical Power Type and Location Component Electrical Power Source Location Evaporator fan 120 VAC Closet Bunk Air Conditioning Compressor 120 VAC Exterior Frame Module Condenser Fan 12 VDC Exterior Frame Module IF Relay 120 VAC & 12VDC under bed Module 120 VAC (shorepower) under bed Module Battery Separator 12 VDC Exterior Frame Module AGM Batteries 12 VDC Exterior Frame Module Thermostat AA Batteries 12VDC Bunk Inverter 12 VDC under bed Module DC Power Connectors 12 VDC under bed Module Fan Control Relay 12 VDC under bed module 2

4 Fuse Use Fuse Size Fuse Location Truck Charge 250 Truck Battery box Inverter Master 250 APU (exterior) Water Heater 20 APU (exterior) Ignition Cut-out 5 Ignition source Truck Blower Fan 30 UBB Module (front) Fan control fuses 10 UBB module (front) Condenser Fan 15 APU (exterior) 1101 Industrial Drive Watertown, WI Phone Fax

5 Air Conditioning Check: Ignition switch is not in the ON position Thermostat set to air conditioning Trouble Shooting Air Conditioning Quick Guide Temperature set to a temperature below room temperature Thermostat s AA batteries are properly seated in the thermostat Thermostat s AA batteries are not dead Inverter is turned on Inverter remote switch (option) is plugged into inverter Inverter remote switch has a phone cord plugged into it Inverter Master switch is in the ON position Inverter is sending 120 VAC power from outlet GFI outlets on inverter are not tripped AGM battery voltage is above 11.0 volts Thermostat wires are properly seated inside the thermostat (Base of thermostat) Thermostat cord is plugged into the UBB Box Thermostat Fuse (5 AMP) is not blown APU power cord is plugged into the UBB The IF system will not operate if the ignition switch is turned on Hold the up or down arrows to move the temperature setting on the thermostat The Thermostat AA Battery holder is the small door on the bottom of the thermostat face The inverter master switch is located below the outlets on the inverter Turn the master switch to OFF center position and then back to REMOTE to reset the inverter The inverter master switch can be placed to ON to test the inverter Leaving the switch in the ON position will not allow the inverter to be turned on/off with the remote switch The face of the thermostat can be removed by pressing the tab IN located near the bottom of the thermostat Evaporator fan is plugged into the UBB 4

6 Issue: No heat (no blower fan) Check: Heat Trouble Shooting 1. The ignition switch is in the on position. a. Turn ignition key off 2. Thermostat not set to heat. a. Thermostat System switch must be set Heat 3. Batteries in thermostat are low or dead. a. Check and replace if necessary 2 AA batteries in thermostat 4. Thermostat cable disconnected or damaged between thermostat & UBB a. Replace bad cable 5. Thermostat not providing signal. a. Check 5 AMP Fuse Issue: No heat, but blower runs Check: 1. Key on, truck off. a. Turn ignition key to off position 2. Thermostat not set to heat. a. Turn thermostat to HEAT 3. Heater not receiving 12VDC power. a. Check for water heater for a blown fuse. 4. Heater not getting fuel. a. Check fuel delivery system from tank pick up to heater, including proper operation of dosing (fuel) pump in Exterior Battery Box. 5. Heater not able to receive or provide water due to blockage. This will cause the heater to go into an over heat condition, and shut down. a. Check for any kinks in hoses, shut water valves (on engine block), low coolant level, or other constriction of cooling system & hoses. Confirm Water pump on coolant heater is getting voltage, and is running. Check body of heater. If it is too hot to touch, it does not have coolant in the body of the heater. The cause of this must be corrected before continuing. 6. Heater has timed out due to safety value being exceeded. a. Check above issues to determine fault, and then reset heater by removing top two wire connector going into heater (Red & Brown wires). Wait 30 seconds, and then replace. The manual that comes with this heater has been included with the paper work included with this system. Please reference that manual if you need more detailed information. 5

7 Bunk Floor Module Inverter The inverter is located inside the Bunk Floor module. The inverter receives 12 volt DC power from the DC power connectors (next, to the. inverter) The inverter provides power for the AC compressor, and evaporator fan, as well as power to the bunk 120VAC outlets. Issue: Inverter does not work Check: 1. Inverter switch is not on. a. Press Inverter remote on button. 2. Inverter remote switch is disabled at the Inverter. a. Identify switch location and place in remote position. 3. Inverter remote cord damaged or disconnected. a. Reconnect, or repair/replace damaged cord. 4. DIP switches have been changed. a. Correct DIP switch configuration is DIP Switches 2 3 are off (0) to the right 1&4 (left) 5. Inverter fuse (In IFS Exterior Battery Box) is blown. a. Check fuse and replace with 250 Amp fuse if blown. 6. DC input leads loose at Inverter or DC Power connectors. a. Check and tighten as necessary. 7. Over or under DC input voltage. a. Confirm with meter at input terminals. b. Also check LED fault display on Inverter end with 120 VAC plugs. DC Power Converter 1. The AC to DC Power Converter will charge the AGM batteries as well as the truck s batteries. 2. The Converter is capable of maintaining both battery banks, and allows unlimited use of AC operation. 3. The Converter receives its 120 VAC power from a Shore Power connection, and works in conjunction with a battery separator to keep both battery banks at optimal charge when shore power is available. 4. The bunk s 120 VAC outlets are powered by the Inverter (Inverter is on). 5. The Power converter provides up to 55 DC Amps of power. 6. The power converterprovides DC power to the DC buss; located in the Bunk Floor Module. 7. The Power Converter's DC power is distributed throughout the Idle Free System. 6

8 Trouble Shooting Battery Separator The ground wire for the battery separator connects on the bottom terminal. The opposite end of the ground wire connects to a ground post located near the battery separator The voltage reading taken at the top of the battery separator will be the same if the truck s engine is running. The voltage reading taken at the top of the battery separator will be the same if the battery charger is plugged in. One terminal on the top of the battery separator is connected to the truck s battery bank One terminal on the top of the battery separator is connected to the Idle Free AGM battery bank. 7

9 Trouble Shooting Water Heater Check: The water heater will allow the user to attempt to start (the water heater) 5 times without success. After a 5 th try the water heater will not go through the start cycle The fusewillneed toberemoved for 5 seconds to reset the computer The water heater will not work properly (start) for 3 reasons: 1. No fuel 2. No water in the heater 3. No electrical power Fuel If the water heater has not been used for a period of time the fuel supply tube may need to be primed. This is the most common reason that the water heater does not start. To prime the water heater fuel system, turn on the water heater. If the water heater does not come on, remove the power plug (top of water heater) for 5 seconds or more. This resets the water heater s computer. Yellow fuse is under the black fuse cover (near the water heater) Remove the power supply connector on the top of the water heater to reset the water heater faults The water heater is located on the exterior of the truck inside the frame mounted IF system module Remove the APU cover and you will find the water heater on the upper level ( left side) The fuse for the water heater is to the left of the water heater in a black plastic fuse holder Typically the water heater will have water present The only time that the water heater does not have water present is when the truck s water valves have been closed or during the initial installation when air is introduced into the water heater The best way to purge the system of air is to ensure that the engine s water heater valves are open & that the engine is run until engine heat is felt on the side of the water heater body Fuel can be seen traveling through the plastic fuel line When the fuel reaches the water heater ignition can be heard Check the fuel pump connector to make sure that both wires are properly connected to the fuel pump 8

10 The water heater goes through a 3 4 minute start cycle: 1. Water pump begins to run 2. Fan runs at low speed 3. Internal glow plug heats up 4. After about 30 seconds the fuel pump begins to pump (click) 5. Fuel moves from the fuel pump to the heater body (you can see the fuel moving) 6. Fan begins to pick up speed 7. Fuel pump speed (clicks) increase 8. Heat begins to exit the heater body exhaust This start cycle will stop if fuel does not reach the water heater If water heater cycle stops because of lack of fuel, wait for the heater to stop and then restart the cycle by turning the water heater switch off and then on again Note; anytime that the water heater does not start a fault is recorded in the water heater s computer. After the Water heater s computer records 5 faults the water heater will not attempt to start without a computer reset. To reset the water heater s computer, remove the power plug (top of water heater) for 5 seconds or more. This clears the recorded faults and resets the water heater s computer The water heater can be reset by pulling the power plug located on the top (center) of the water heater Make sure that you let the water heater go through its start cycle before attempting to start the unit again If the water heater does not see fuel you may have to attempt to start a number of times If the fuel tank pickup tube has not been placed low enough in the fuel tank the water heater will run out of fuel and priming of the fuel system will need to take place anytime that the tanks fuel level drops below that of the fuel pick up If you can see the fuel pick up tube inside the tank, you can determine if the end of the tube is submerged in fuel If the fuel pick up tube is above the fuel line, use a clean rod to reposition the fuel pick up tube closer to the bottom of the tank 9

11 Cab Power Check Cab Power receives its 120 VAC power from the Idle Free inverter The inverter must be turned on in order for the Cab Power to have 120 VAC power Is the Cab Power switch on? Is the Cab Power circuit breaker tripped? Inverter is turned on Inverter remote switch is plugged into inverter Inverter remote switch has a phone cord plugged into it Inverter Master switch is in the REM position Inverter is sending 120 VAC power to the circuit board GFI outlets on inverter and Cab power are not tripped AGM battery voltage is above 11.0 volts Does the LED light bar show voltage? (LED s lit) Check 12 volt DC power fuse located under the aluminum cover on the exterior unit if the inverter does not have a DC voltage reading on the DC input terminals Reset switch on Cab Power Box 120 Volt Interior Outlets Cab Power Box is located in the driver s side box and is mounted on a side wall Cab Power switch is resettable OFF and then ON to reset If the truck is plugged into shore power (120 VAC) the inverter must be on to supply power to the bunk The inverter remote plugs into the inverter using a phone cord The phone cord plugs into the inverter on the rear side, near the DC cable inputs The inverter has a GFI reset button in between the VAC outlets The cab power box has a GFI outlet The GFI outlet is the same as you will find in your home The inverter remote is working when the RED LED is lit (inverter On) 10

12 Shore Power When the truck is plugged in to a 120 volt AC power source, Shore Power, the power is sent to the Power Converter. The power converter provides 12VDC power to the AGM Batteries The power to run the Idle Free Air conditioner or heater is supplied through the power converter. The 120 volt outlet strip is powered by the Inverter (inverter on). The DC Power fuse (250 AMP) is located above the batteries under a rubber covered fuse holder (exterior) The Idle Free System batteries are automatically charged when plugged into shore power The truck s batteries will receive 12VDC power from the power converter once the voltage of the AGM batteries reaches 13.2 VDC and above. Shore power s power cord starts on the driver s side of the truck, enters into the bunk floor and is plugged into the power cord attached to the battery charger Shore power does not power the 120 VAC power strip The Battery Charger charges the IF AGM batteries and the truck s batteries when the AGM batteries reach 13.2 volts DC power is transferred from the IF bunk floor module to the exterior battery box through the positive and negative buss bars A 250 AMP fuse is located under the aluminum cover in the exterior IF Power Module 11

13 AGM Battery Check Procedure 09/01/10 Overview The Idle Free system receives its DC battery charge power from the truck s alternator through the truck s battery bank. Defective starter battery(s), a weak alternator, or poor truck cables/connections prohibit the Idle Free AGM batteries from receiving an adequate charge from the truck s charge circuit. The Idle Free Battery Separator automatically closes (connects) when the truck s alternator s voltage output reaches 13.2 volts. When a problem exists in the truck s charge circuit the Idle Free Battery Separator does not close and the Idle Free battery bank does not charge. Since the Idle Free AGM batteries depend on the truck s charge circuit to receive their energy, the truck s charge system needs to be checked prior to testing the Idle Free AGM batteries. Truck Starter Batteries Alternator Idle Free AGM Batteries Idle Free Battery Separator 250 AMP Fuse Ground 12

14 How to Check the IFS Charge System 1. Start the truck 2. Remove the APU cover 3. Check the AGM battery voltage and the trucks battery voltage at battery separator a) Single cable = truck side b) Double cable = AGM side Battery Separator 4. With the truck running, the single cable (truck side) on the top of the battery separator should be 13.8 volts or greater. Record the actual voltage. 5. The closer of the two terminals on top of the separator is the AGM battery bank. Since the battery separator closes at any voltage above 13.2 volts, this connection point should read the same as the truck side cable. 6. Measure DC voltage at the trucks alternator truck running 7. Determine voltage differential (battery voltage drop) between the battery separator (single cable) and the truck s alternator. Record this voltage and compare it to the battery voltage taken at the truck s alternator. Acceptable DCV drop.3 VDC or less If greater than.3, check the all DC connection points, these connection points include the following: Alternator + - Truck Battery AMP Fuse (2 connectors) Green, Red and Black Marinco Connector Panel mount Marinco (3) Red, Green black (female) AGM Battery = 4 x 2 Battery SEP = 2 Fuse 2500 (2) APU UBB + - Check the connections to make sure they are: Clean Tight Note: Volvo protects their truck cab circuitry by use of a fusible link on the ground side of the DC alternator circuit. We had known that Volvo uses such a device but we did not know that the fusible link specified was based on the size of the alternator. Volvo downsizes their DC cable (2 sizes) for their fusible link. This issue relates to the voltage drop seen across this fusible link as it relates to adequate AGM battery charging. A voltage drop is clearly evident when a larger alternator is used on a truck that has a fusible link. If your customers have Volvo trucks, move the IFS ground cable be moved to the alternator side of the Volvo DC fusible link. Idle Free Systems Page 13

15 Volt to Amp Chart 2 hours in = 12.3 or 50% Time at and above 14.0 volts determine 100% charge AGM Batteries 90% charged when AGM batteries hit 14.0 VDC Using a clamp amp meter to check the truck charge (the clamp amp meter must be DC capable) Truck Engine Running: Use AMP to Volt chart to determine what AMPs and Volts to look for under current Volt and Amp conditions If Alternator voltage is >14.0 VDC: Expect to see <10 amps going into the AGM batteries To separate AGM batteries from truck battery, disconnect green Marinco connector and take amperage reading at alternator with and without Green Marinco connector connected Difference between amperages = AGM amperage High amperage (under shops conditions) signals a problem with the charge circuit. The quality of the DC connections is a contributing factor in the amperage and voltage output of the alternator. Check all DC connections to make sure that they are tight. Amperage Draw from the Truck s Battery Bank The procedure used to determine the amperage draw of the truck s starter batteries when the truck s engine is off is as follows: Set the clamp meter dial to DC 40A ZERO the meter (yellow button) Place the clamp meter around the Positive Cable that is coming from the alternator or starter. Record the amperage reading If the amperage is greater than 1.0 AMPS, something in the truck s electrical system is drawing down the truck s starter batteries Idle Free Systems Page 14

16 Determine what truck component is using energy when the truck is turned off. To see the effect on the Clamp meter,(amperage change) when you turn on an electrical device in the truck, turn on the headlights or open the door to turn on the cab ceiling lights Compare the amperage draw (read on the meter) with the amperage draw you found prior to turning on the headlights or cab lights. A constant amperage draw on the starter batteries will shorten their life A constant amperage draw on the starter batteries will not allow the Idle Free battery bank to receive a full charge Alternator Amperage and Voltage Check Voltage Output Amperage output Truck Engine Off Check the voltage of the Idle Free APU and the truck s batteries by removing the Marinco Red, Black, and Green DC connectors located on the side of the exterior Idle Free battery box. The Black connector is ground The Red connector is AGM battery positive The Green connector is truck voltage Use the (female) box mounted Red and Black connections to measure AGM battery voltage. Use the (male) cables Green and Black connections to measure truck battery voltage. The Red (and black) box connectors should read at least 12.6 volts (AGM) Idle Free Systems Page 15

17 The Green (and Black) cables should read at least 12.5 volts (Truck) If voltages are near their normal voltages start the truck. Set the truck s idle speed to about 1000 rpm s. Return to the IF exterior battery box DC connectors Use voltage meter probes placed between the Green (and Black) male cables to measure truck battery voltage (engine running) Voltage should read alternator output voltage (13.5 to 14.0) If voltage is less than 13.5 volts, take clamp AMP meter to the truck s alternator Read voltage output of alternator If alternator output voltage is less than 13.5 volts: Set the clamp meter dial to DC 400A ZERO the meter (yellow button) Clamp meter around positive post of alternator Read amperage output of alternator Amperage should be about 80% of rated alternator output Amperage rating of alternator is located on a tag on the alternator An alternator with a rating of 160 AMPS should be putting out at least 130 amps if the voltage is 13.5 volts or less. If amperage is below 100 AMPS voltage is rising or alternator circuit needs attention The alternator circuit includes: Alternator ground Alternator positive connection Starter DC connections Battery DC connections Frame Ground connection Engine Ground connection Once you determine that the alternator is putting out a voltage of 13.5 volts or higher return to the Idle Free exterior located battery box. 1. Plug in (only) the green and black cables into the correct connectors (green and black) on the side of the Idle Free battery box. 2. After the black and green DC cables are plugged into the Idle Free box, measure the voltage on the red female DC connector located on the side of the Idle Free battery box. 3. This voltage should be at least 13.2 volts (and rising). Idle Free Systems Page 16

18 Checking the Idle Free System Amperage Draw Idle Free system Amperage Draw To quickly determine if all of the Idle Free system components are properly working, use the clamp meter to measure the amperage being run through the red cable (Idle Free battery box) Idle Free System Amperage (A/C) The clamp meter can be used to determine if the Idle Free A/C unit is working properly: A/C Operation Turn on the idle Free inverter Turn on only the evaporator fan (right thermostat switch) Set the clamp meter dial to DC 40A Clamp meter around the Red DC cable (Idle Free battery box) Look at the below chart to see if DC amps are about 4.0 AMPS DC. Turn on Idle Free A/C unit Look at chart to see if DC AMPS are between 36.0 and 50.0 AMPS. Idle Free Amperage Chart Component DC Amperage Air Conditioner Condenser Fan 6 Evaporator Fan 3 Inverter <20 Water Heater 6,0 9.0 Heater Fan 6-20 Idle Free system Amperage (Heat) The clamp meter can be used to determine if the Idle Free heat system is working properly. Heater Operation Turn on the idle Free heater (thermostat, switch set to heat) Set the clamp meter dial to DC 40A Clamp meter around the Red DC cable (Idle Free battery box) Look at chart below to see if DC amps are about 6.0 to 9.0 AMPS DC. If bunk blower fan is on, the amperage will be between 12.0 and 20.0 AMPS Inverter Water Heater Heater Fan Idle Free Systems Page 17

19 Battery Charger Output Check 1. Plug extension cord into a 120 volt outlet (Shore Power) 2. Turn Clamp Meter pointer to 400DC 3. Clamp around the red Idle Free cable on the Idle Free battery box 4. DC Amperage should be as much as 55 ADC 5. Level of Amperage is based on: a. Voltage level of batteries b. A/C unit running If amperage is not present, ensure that extension cord is plugged in and supply 120VAC power to cord end. Voltage on the Red DC terminal is not above 13.2 volts If the voltage is not at least 13.2 volts, the Idle Free battery separator has not closed. Prior to removing the cover to expose the battery separator, verify that the voltage on the green cable is at least 13.2 volts. If the voltage on the green and black connectors was above 13.5 volts and the red connector does not read at least 12.9 volts, the battery separator has not closed and needs to be checked. Locate the battery separator and verify that the green (or brown)(14 gauge) ground wire is in place on the bottom push-on terminal. If the wire is on the terminal, check for continuity between this terminal and a truck ground. If continuity is not present, trace this green (or brown) 14 gauge wire to its grounding point. Verify that it is properly grounded. Voltage on the Red DC terminal is above 13.2 volts: The battery separator has closed and the charge system is working properly. Set the clamp meter to DC 400A Place Clamp meter over the green cable Meter will read amperage going into Idle Free battery bank Amperage seen on meter will based on the voltage level of the AGM batteries, voltage level of the truck s batteries, amperage rating of the truck s alternator. Connect the red cable connector to the Idle Free battery bank. Place Clamp meter over the Red cable No amperage should be present If the meter shows amperage on the red cable, something is turned on (the Idle Free system) Turn off the Idle Free inverter or Check the fuse on the Idle Free ignition cut-out circuit Replace the fuse if needed Idle Free Systems Page 18

20 Use the Clamp AMP meter to determine: Alternator output amperage Amperage traveling into the truck s battery box Amperage traveling to the Idle Free batteries Idle Free battery amperage + truck amperage = total alternator amperage output. The total alternator amperage output is based on: Voltage of truck s batteries Voltage of IF AGM batteries Amperage rating of the alternator Idle Free Systems Page 19

21 Inverter Master Switch Input Voltage Level Light Load Level Inverter Status Ground fault trip indicator light Idle Free Systems Page 20

22 Top Light: DC input voltage light Inverter Trouble shooting RED LIGHT Idle Free Systems Page 21

23 Center Light: Center Light: Inverter load level Inverter load level This center light will not be lit when the inverter is in stand-by mode or if the inverter is turned off or if the Power Saving Mode Normal GREEN LIGHT Plugged into shore Power or Reefer Running (OKAY) Out of Battery Power Overheated (ventilation) Inverter was over loaded RED LIGHT RED LIGHT Inverter shut down because: Bottom Light: Status Light This light is the key to what is happening to the inverter and knowing its status will help determine Idle Free Systems Page 22

24 Bottom Light: INVERTER STATUS GFCI Light: This light is the key to understanding if the Inverter is working BUT the GFCI is If the inverter has a: GREEN INPUT LEVEL LIGHT & GREEN or FLASHING GREEN STATUS LIGHT The GFCI (light) should have a GREEN or FLASHING GREEN LIGHT as well. IF the GFCI Light is not GREEN or FLASHING GREEN, it will need to be RESET. How to RESET the GFCI Outlet: The INVERTER Status Light MUST BE SOLID GREEN to RESET the GFCI Outlet. If the INVERTER STATUS LIGHT is FLASHING turn the inverter OFF and then back ON. You now have 5 seconds to RESET the GFCI because the inverter takes 5 seconds to go into Flashing (standby) mode. Idle Free Systems Page 23