Operation And Service Manual
Contents
1. DIAMONDPOWER s y s t e m amp DIAMONDPOWER s y s t e ms OPENING TROUBLESHOOTING Safety Measuring Procedures Safety Alerts c iii 3 8 1 Measuring AMP draw for components 3 13 Component Layout C V 3 8 2 Measuring Voltage and Hz readings 3 13 General Equipment Layout Additional Information APU Measurements c vi 3 9 1 Changing the 120 A C Voltage 3 14 CCU Measurements c vii 3 9 2 Capacitor Troubleshooting 3 14 Condenser Measurements c vil 3 9 3 Capacitor Theory 3 14 3 9 4 Potential Relay Theory 3 15 FUNCTIONALITY OF MULTI FUNCTION D C P 3 9 5 Alternator Diagnosis Troubleshooting 3 15 Setting Up The Apu Funtions 1 1 1 Multi Function D C P Components 1 1 APPENDICES 1 1 2 How The Diamond Power System Operates 1 2 CAPACITIES AND SPECIFICATIONS A 2 Manual Operations FUSE LOCATIONS A 4 1 2 1 Starting the APU 1 3 CIRCUIT BREAKER LOCATIONS A 5 1 2 2 Stopping the APU 1 3 APU CONTROL UNIT A 6 1 2 3 Turning the Heater ON OFF 1 4 CCU CONTROLLER A 7 1 2 4 Heating Setting the Temperature 1 4 FUEL SYSTEM PURGE PROCEDURE A 8 1 2 5 Turning the A C ON OFF 1 4 COOLANT PURGE PROCEDURE A 9 1 2 6 Setting the A C Temperature 1 4 DEFROST HEAT amp DCP SENSOR A 11 1 2 7 Fan Functionality 1 5 ENGINE INTERLOCK A 12 Automatic Operations APU WIRING A 13 1 3 1Password Protection 1 5 1 3 2 Entering Password 1 6 1 3 3 Setting the Clock 1 7 1 3 4 Comfort Monitor 1 7 1 3 5 Timer 1 8 1 3 6 Cold Temperature Monitoring 1 10 1 3 7 Maximum Run Time 1 11 1 3 8 Ba2. if you password is 432 press D 4 shows then press o Repeat each digit in the password Press again entering the last digit new password is displayed Repeat the above steps to enter the new password confirm is displayed Enter the new password again then press o to exit this function Protect Functions with a PASSWORD Press o i Press K3 or a until password protect is displayed then press If this menu item does not appear then you have not yet changed the factory password from 9999 Change the password and then try again Enter Password is displayed with three blank squares one for each digit in the password The first square flashes DIAMONDPOWER s y ste ms Press v or D until the first number in the password is displayed then press o Repeat for each digit in the password Press o again after entering the last digit The first feature that can be password protected is displayed with yes or no indication whether it is currently password protected Press iy or D to change the yes or no Press Oo to move to the next feature Or press v or a to skip to the next feature 1 3 2 Entering the Password When you try to set up a function you may be prompted to enter the password Press v or D until the first number in the password is displayed then press Repeat for each digit in the password Press o again after entering the last digit 1 3 3
3. Setting the Clock You can set the clock on the DCP This clock is used y the timer function If you use the timer function remember that as you move from one time zone to another you must adjust the clock Otherwise the timer will start the APU at the wrong time The clock settings remain even when the APU is turned off Press Press v or a until clock is displayed then press If enter password is displayed enter you password If you do not know the password then you cannot setup the function The clock function takes you through several settings 12 24 hour clock hour set minutes set am pm set for 12 hour clock only and day of the week Press B or a to change the setting DIAMONDPOWER s y s t e ms Press to move to the next setting Or press a to cancel any changes you have not yet accepted ESC RESET When done press o to exit 1 3 4 Temperature Monitor You can specify the temperature you want in the truck bunk When the truck bunk goes 2 degrees above or below this temperature the APU starts and the HVAC turns on until that temperature is reached or for fifteen 15 minutes whichever is longer Turning Temperature Monitor ON and OFF Press o Press v or D until temperature monitor is displayed then press If enter password is displayed enter your password If you do not know the password then you cannot set up this function Press v or D to display ON or OF
4. CP will also stop flashing DIAMONDPOWER s y s t e ms Automatic Operation and Minimum Time Off All these automatic functions work on a minimum time off the Diamond Power must be off for at least 10 minutes before the automatic function will turn it on again For example the Timer function may be set to turn on the Diamond Power at 10 00 a m You have been running the Diamond Power in manual mode You turn off the Diamond Power at 9 55 a m The Timer will only turn on the Diamond Power again 10 minutes later at 10 05 a m Clock In order to use the Timer correctly you must set the DCP clock Maximum Run Time You can set the maximum time that the APU is allowed to continuously run in manual mode MANUAL OPERATIONS 1 2 1 Starting the APU One Touch Start Press and hold then release the switch once The display shows APU starting When stops flashing then the APU has started successfully The APU startup sequence consists of 20 seconds of glowing and up to 10 seconds of cranking If the sequence fails restarting appears for six seconds Then the startup sequence automatically repeats up to five times Or until the APU starts If crank limit appears see troubleshooting section appears 1 2 2 Stopping the APU Press The APU will stop The display shows APU OFF 1 2 3 Turning the Heater ON OFF 1 2 5 Press EAA to activate the heater The display shows heat low wA The hea
5. F Press o to confirm this setting The current setting remains until you change it turning off the APU or manually starting the APU does not permanently cancel this setting Setting the TEMPERATURE Press o Press v or a until temperature monitor is displayed then press If enter password is displayed enter your password If you do not know the password then you cannot set up this function Press v or BD to display set Press o to confirm this setting The current temperature is displayed Press v or a to scroll to the desired temperature Press O confirm this setting Or press a to cancel and retain the current temperature Press to exit Page10 DIAMONDPOWER s y s t e ms 1 3 5 Timer You can set up Diamond Power so that the APU and HVAC run automatically for a specified time on specified days of the week There are two timers so you can set up two schedules For example one schedule may be to run every day at 6 00 p m for 5 hours and the other schedule may be to run every Monday at 6 00 a m for 5 hours You must set up the timer as follows Specify the day and time you want to run the APU specify the duration the length of the time you want the APU to run for and specify the temperature you want maintained in the truck bunk while the APU is running Turning Timer ON or OFF Press o Press v or a until timer 1 or timer 2 is displayed then press If enter passw
6. d then press If enter password is displayed enter you password If you do not know the password then you cannot set up this function Press v or BD to display Set Temp Press o to confirm this setting The current temperature is displayed Press v or a to scroll to the desired temperature Press to confirm this setting Or press g to cancel and retain the current temperature Press o to exit 1 3 6 Cold Temperature Operation You can set up the APU so that it automatically runs for a specified time whenever the ambient temperature goes below a specified value This feature ensures that the APU engine and truck engine do not get so cold that they will not start This feature is not intended to maintan a comfortable truck bunk temperature instead see temperature monitor Page12 DIAMONDPOWER s y s t e ms Turning Cold temperature operation On and Off Press Press v or a until temp start is displayed then press If enter password is displayed enter you password If you do not know the password then you cannot set up this function Press v or a to display set temp Press to confirm this setting The current start temperature is displayed Press v or a to scroll to the desired start temperature Press confirm this setting Or press a to cancel and retain the current start temperature Press o to exit Setting the START TEMPERATURE Press o Press v or D until te
7. displayed enter you password If you do not know the password then you cannot set up this function Press v or BD to display ON or OFF Press to confirm this setting Setting the DESIRED RUN TIME Press Press Lv or D until maximum run time is displayed then press If enter password is displayed enter you password If you do not know the password then you cannot set up this function Press v or B to display set Press o to confirm this setting The current frequency is displayed Press v or D to scroll to the desired number of hours Press to confirm this setting Or press to cancel and retain the current frequency Press o to exit Page14 DIAMONDPOWER s y s t e ms 1 3 8 Battery Monitoring You can set the APU so that it automatically runs for 90 minutes when the truck batteries are low When you set up this feature you must enter the current voltage of the batteries see set the initial voltage The Diamond Power can then calculate how much the voltage drops as the batteries are used Set the INITIAL VOLTAGE Press f Press v or D until calibrate voltage is displayed then press If enter password is displayed enter your password If you do not know the password then you cannot set up this function Press v or a to set the current voltage of the batteries Press Oo to confirm this setting Turning BATTERY MONITORING ON and OFF Press Press
8. el Heater Control Ee 18 C Temp Set Up rpm Engine RPM Fan Control Fan Speed Medium Menu Set Up Driver Control Panel DCP A C Control DIAMONDPOWER s y s t e ms HOW THE DIAMOND POWER OPERATES The Diamond Power has two adjustments for operation Manual and Automatic Manual Mode You start the APU from within the truck bunk using the APU button on the driver control oanel DCP Once the APU is running you can start and stop the fan heater air conditioning using the DCP Once the heater or A C is running It will cycle automatically turn on and off in order to keep the truck bunk at the temperature you specify The HVAC will continue to cycle until you turn it off While the HVAC is cycling the APU remains on and will only turn off when you manually turn it off using the button on the DCP Described Below The APU automatically turns OFF and ON as required When the APU is running power is supplied to the power outlet in the truck bunk except in high heat In manual mode the APU will turn off automatically if the Maximum Run Time is reached Automatic Mode The Diamond Power has several functions that will start It in automatic mode FEATURE amp DESCRIPTION Comfort Monitor The APU and HVAC automatically turn on to maintain a comfortable temperature in the truck bunk When the desired temperature is met the APU and HVAC automatically turn off When the temperature is again out of range they wi
9. g when the desired temperature has been reached as the air conditioning or heat cycles off Press MM to toggle between low high and off The speed of the fan may automatically change when the heat or A C comes on then automatically change back when the heat or A C goes off DIAMONDPOWER s y s t e ms AUTOMATIC OPERATIONS 1 3 1 Password Protection You can reset a password to the DCP the you can protect one or more functions so that only a person who knows the password can set the function On a newly installed DCP the password is always 9999 which means that no password protection is in place To password protect functions first change the factory password see Setting up for Password Protection All functions will now be password protected Then remove password protection from chosen functions as desired see Protect Functions with a Password If you know the password you can change it at any time if you need to Note that if you change the password to 9999 you will remove password protection from all functions If the password is ever lost contact your dealer to reset the password to 9999 Setting up for PASSWORD PROTECTION Press Press Y or D until Set Change Password is displayed then press Enter password is displayed with 4 blank squares one for each digit in the password The first digit flashes Press Y or PY until the first number in the password is displayed For Example
10. ll both turn on again and cycle heat air conditioning as needed Timer At the specified time the APU and HVAC automatically turn on During the specified timer duration the HVAC cycles on and off to maintain the desired temperature is again out of range they will both turn on again and cycle heat and air conditioning as needed Cold Temperature Operation The APU and heater on the HVAC automatically turn on in order to prevent the APU engine and truck engine from getting too cold Turning on the heater creates a load that makes the APU work harder and therefore warm up faster Both the APU and HVAC turn off automatically one the preset duration time expires Battery Monitor The APU automatically turns on for 90 minutes in order to recharge the batteries The HVAC does not turn on After the 90 minute run time the system will sense voltage for 10 minutes before restarting if needed There are indicators on the DCP that flash when the APU and HVAC are running If you enter the truck bunk and APU or HVAC is on but you did not start it you can assume it has started in one of the automatic modes as described above On the DCP one icon will be flashing steadily this is the icon for the mode that is currently operating Whenever the Diamond Power is running in automatic mode if you then press the heat A C or fan buttons on the DCP the Diamond Power will switch to manual mode The APU will not automatically turn off This icon on the D
11. mp start is displayed then press If enter password is displayed enter you password If you do not know the password then you cannot set up this function Press v or BD to display set temp Press to confirm this setting The current start temperature is displayed Press v or a to scroll to the desired start temperature Press o to confirm this setting Or press to cancel and retain the current start temperature Press to exit Setting the Frequency Press o Press v or a until temp start is displayed then press If enter password is displayed enter your password If you do not know the password then you cannot set up this function Page13 DIAMONDPOWER s y s t e ms Press v or a to display set frequency Press Q to confirm this setting The current frequency is displayed in hours Press v or D to scroll to the amount of time you want the APU to run before automatically shutting off Press o to confirm this setting Or press to cancel and retain the current start temperature Press o to exit 1 3 7 Maximum Run Time You can set the maximum time that the APU is allowed to run continuously If the APU runs for longer than the specified time it automatically shuts off You can then start it manually if desired the run time clock will start counting again Press Press v or D until maximum run time is displayed then press o If enter password is
12. ord is displayed enter you password If you do not know the password then you cannot set up this function Press v or BD to display ON or OFF Press Oo to confirm this setting The current setting remains until you change it turning off the APU or manually starting the APU does not cancel the timer function Setting the Start Time Day Press o Press v or D until timer 1 or timer 2 is displayed then press If enter password is displayed enter you password If you do not know the password then you cannot set up this function Press v or D to display set start Press Q to confirm this setting The current start time is displayed Press v or D to set the hours minutes and day Press o to confirm each setting Page11 DIAMONDPOWER s y s t e ms Setting the DURATION Press o Press v or D until timer 1 or timer 2 is displayed then press o i If enter password is displayed enter you password If you do not know the password then you cannot set up this function Press v or a to display set duration Press o to confirm this setting The current duration time is displayed Press v or a to scroll to the length of time to run the APU Press Oo to confirm this setting Or press a to cancel and retain the current duration to exit Press o to exit Setting the TEMPERATURE for the Timer Press o Press H a until Timer 1 or Timer 2 is displaye
13. se severe personal injury and or death Anyone suspected of suffering from CO inhalation should be removed from the hazardous area and be given medical assistance immediately WARNING California Proposition 65 Warning This product contains lead a chemical known to the state of California to cause cancer and birth defects and other reproductive harm FUEL BATTERIES Extreme caution is needed when working near fuel or fuel filled equipment Do not operate equipment during fueling operations Use eye protection when working near batteries which contain acid and can explode Do not smoke or use near open flames ELECTRICAL Electric Shock can cause severe personal injury burns and even death Before working on any unit disconnect the batteries Use only approved materials and methods when working on the electrical system and follow local electrical codes Never work on the APU or the electrical circuitry when the APU is running Never work with electricity in wet conditions or when you are tired INTOXICANTS Fuel oil coolant and refrigerant are toxic and in some cases carcinogenic Wear eye and hand protection at all times Remove contaminated clothing immediately and wash contaminated skin Do not breathe in vapors HOT OR MOVING PARTS Moving part can cause severe injury and or death Before working on any unit shut it off and disconnect the battery Do not start until protective covers have been replaced Also loose parts falling into rota
14. ter will turn on only if the temperature is too low to adjust the temperature see below When the heater is on 1 appears N DIAMONDPOWER s y s t e ms Press again to switch between high and low heat to heat the truck bunk more or less quickly In heat high mode the power outlet is disabled The heat or A C will turn off when the specified temperature is reached Press MSN to deactivate heating 1 2 4 Heating Setting the Temperature Press v or D when the heater is on heat low or heat high shows The notch on the temperature bar moves The heater will automatically turn on and off to maintain this temperature 1 2 6 Turning the A C ON and OFF Press MEN to activate the A C The dispay shows A C low The A C will turn on only if the temperature is too high Press again to switch between high and low A C to cool the truck bunk more or less quickly Press to deactivate the A C 1 2 6 A C Setting the Temperature Press v or D when the A C is on A C low or A C high shows The notch on the temperature bar moves The A C will automatically turn on and off to maintain this temperature 1 2 7 Fan Operation You can still have the fan working even when the temperature is not low or high enough for the heat or A C to come on The fan operation is independent of the air conditioning and heat modes When the fan speed is manually set to high or low the fan will return to that settin
15. ting machinery can cause severe accidents Always ensure bolts and clamps are correctly torque and secured Inspect mechanical components periodically for damage corrosion and proper torque MISUSE The APU is designed to provide electrical power for heating and cooling vehicles in normal on road conditions Never use the APU to power critical medical equipment or sensitive electronic equipment without the manufacturer s written approval DIAMONDPOWER s y s t e ms OPERATION OF MULTI FUNCTION DRIVER CONTROL PANEL 1 1 STATUS CODES AND SIGNS 1 1 1 Multi function Driver Control Panel Components e HEAT SUN 2 sign When heat is visible the heating system is heating on high power mode e HEAT SUN 1 sign When heat is visible the heating system is heating on low power mode e SNOW FLAKE sign When cool is visible the A C is cooling e FINGER TEMP sign Temperature set up indicator e THERMOMETER Indicates cab temperature e RPM sign Indicates running APU engine RPM s revolutions per minute e FanH sign Indicates the fan speed is on high speed mode e WIND sign Indicates the fan speed is on medium speed mode e FanL sign Indicates the fan speed is on low power mode e WT sign Indicates the water temperature LCD Screen APU On Off Switch Menu Select STATUS CODES AND SIGNS tis h aii HVAC Off Button a a ES E dl MENU ESC Reset Button ESC RESET Heat High WT alar T
16. ttery Monitoring 1 12 TEMPERATURE CONTROL UNIT Preparation 2 3 2 Charging the CCU 2 1 Service 2 3 3 Maintenance Frquency 2 2 2 3 4 CCU Spring Tune UP 2 3 TROUBLESHOOTING Manual Operations 3 1 APU 3 2 3 2 GENERATOR 3 6 3 3 DRIVER CONTROL PANEL 3 7 3 4 CCU AIR CONDITIONING 3 8 3 5 CCU Fan 3 11 3 6 CCU Heat 3 11 3 7 ELECTRICAL PANEL 3 12 DIAMONDPOWER s y s t e ms SAFETY ALERTS Throughout this manual you will see notes labeled Warnings or Cautions to alert you to special instructions or precautions concerning a particular procedure that would be hazardous if performed incorrectly or carelessly Observe them carefully These safety alerts alone cannot eliminate hazards that can occur Strict compliance with these special instructions when performing the installation and maintenance plus common sense are major accident prevention measures DANGER Immediate hazards that will result in severe personal injury or death A WARNING Hazards or unsafe practices that could result in severe personal injury or death A CAUTION Hazards or unsafe practices that could result in minor injury or product or property damage A NOTE Information that is important to proper installation or maintenance but is not hazard related For example DANGER A certified refrigeration technician must charge and test the HVAC DIAMONDPOWER s y s t e ms EXHAUST Inhalation of exhaust gas containing carbon monoxide may cau
17. v or D until battery monitor is displayed then press Q If enter password is displayed enter you password If you do not know the password then you cannot set up this function Press v or D to display ON or OFF Press to confirm this setting The current setting remains until you change it turning off the APU or manually starting the APU does not permanently cancel this setting The APU starts if the battery voltage goes below the level you specify here Setting the Voltage Level Press Press v or D until battery monitor is displayed then press If enter password is displayed enter your password If you do not know the password then you cannot set up this function Page15 DIAMONDPOWER s y s t e ms Press Lv or a to display set Press o to confirm this setting The current voltage level is displayed and flashes Press v or a to scroll to the desired voltage Press o to confirm this setting Or press to cancel and retain the current voltage Press Oo to exit
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