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RigMaster Service Manual-DC Electrical and

1. 7 White Drive Motor to Open Close Water Valve Max 2A 12V ON OV OFF Water Valve Connection Point NOT IN USE Power Module J2 Connection Point W41 J2PIN7 vi J2PINS NOT USED W4 JZPIN4 2 PINT TO GROUND Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 8841009 J3 Pin Cabin Control Power and Communication J2 J3 PIN TYPE COLOR R8485 TRANSCIEVER INPUT OUTPUT half duplex INPUT OUTPUT RS485 TRANSCIEVER half duplex POWER 7V LOGIC POWER 7V LOGIC GROUND ISOLATED GROUND GROUND ISOLATED GROUND SHEILD NON ISOLATED GROUND Contact Side Note The communication cable is a 28 AWG Category 5e cable which uses the RJ 45 modular connector The transceiver is half duplex and powered by 7Vdc logic voltage Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 8841009 J4 Pin Sensor Inputs TYPE COLOR Green Oil Pressure Sensor INPUT 12V Normal pressure OV Low oil pressure J4 Black Safety Cover Sensor INPUT 12V Cover OFF OV Cover ON Green Yellow Pickup Speed Sensor INPUT 6 10V AC Engine ON OV AC Engine OFF Red Main Engine Running Optional 12V Main
2. Press UP or DOWN key to find the Set Temperature mode Press SELECT key Press UP or DOWN keys to find desired temperature Press SELECT key to save setting Press MODE key to return to normal mode NOTE Temperature control ranges from 65 F to 85 F The system will remember the last set temperature when it is turned off Fan Speed Control Press MODE key Press UP or DOWN key to find the Set Fan Speed mode Press SELECT key Press UP or DOWN key to desired fan setting Press SELECT key to save setting Press MODE key to return to menu NOTE The system will remember the last fan setting after system is shutdown To stop climate control the fan speed MUST be set to the off setting During warmer months use the automatic on setting to improve air conditioner efficiency During the cooler months use the automatic off setting to improve heater efficiency Low Battery Alarm Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 5811009 When the truck battery voltage reaches 12 0 V 2 Volts the low battery alarm will sound AUTOSTART CONTROL OPTION This feature can be purchased at an additional cost AutoStart Date Time Allows you to program the AutoStart to the exact date and time you need your RigMaster to start automatically up to seven days in advance If you are setting this feature to heat or cool the bunk you MUST make sure your fan speed and temperature settings
3. Press LEFT or RIGHT scroll button to change Press SELECT button day of week stop flashing and Month will start flashing Press LEFT or RIGHT scroll button to change Press SELECT button Month stop flashing and Date will start flashing Set Alarm Clock Press ALARM button The display will read Set Alarm Press SELECT button to continue MODE to exit Alarm Clock hour will start flashing Press LEFT or RIGHT scroll button to adjust Alarm Clock hour Press SELECT button Alarm Clock hour will stop flashing and Alarm Clock minutes will start flashing Press LEFT or RIGHT scroll button to adjust Alarm Clock minutes Press SELECT button Alarm Clock minutes will stop flashing and am pm will start flashing Press LEFT or RIGHT scroll button to change Press SELECT button Press LEFT or RIGHT scroll button to turn Alarm clock on off Press SELECT button to save settings and return to menu or press MODE to return to menu without saving When enabled ALARM symbol is flashing Fan Speed Control Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S821009 Press FAN button to adjust fan speed Press the FAN button to cycle through fan settings AUTO OFF AUTO ON FAN LOW FAN MEDIUM FAN HIGH FAN OFF There is no need to press any other buttons to confirm AUTO OFF is for heating efficiency during winter operation AUTO ON is for air conditioning efficiency during summe
4. SELECT key and Set Time AutoStart appears Press UP or DOWN key to find the Set Auto Temperature mode Press SELECT key and on off will start flashing Press UP or DOWN key to turn on off Press SELECT key to save setting and return to menu mode Press MODE key to return to normal mode Note This is a onetime program and will default to OFF If you touch any keys once this program is activated it will default to OFF You MUST set this program each time you use it Set Auto Battery Control Press MODE key Press UP or DOWN key to find the Set AutoStart mode Press SELECT key and Set Time AutoStart appears Press UP or DOWN key to find the Set Auto Battery Press SELECT key and on will display Press SELECT key to exit and return to the menu mode Press MODE key to return to normal mode Note This setting can not be changed on cabin controller version 1 08 or higher it is always set to ON This setting can be changed on older cabin controller versions Notes Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S821009 S8 2 Operation of the Electronic Control System Version 2 To perform many of the procedures in this manual it is necessary to know how to use the electronic control system to start and stop the unit and confirm the operation of its systems after service and repair The Cabin Controller consists of two sections 1 LCD Liquid Crystal Display wit
5. are programmed This program has a run time of three hours and will override all other AutoStart features Once the program is completed it will shut off and the last time date will be stored You will need to turn on this feature each time you use it NOTE If your RigMaster is running on another AutoStart program e g Auto Temperature Control or Low Battery Start up program and surpasses the time and date set for AutoStart then the APU will not start on this program Automatic Temperature Control This control allows you to regulate the temperature in the bunk automatically providing additional fuel savings Fan and temperature settings MUST be set in order to activate this control The engine will NOT shut down if the fan setting is set to the off position If you are setting the Auto start Temp to heat the bunk the APU will start at 6 degrees below the set temperature and run until set temperature is reached then shut off If you are setting the Auto start Temp to cool the bunk the APU will start at 6 degrees above the set temperature and run until set temperature is reached then shut off NOTE Fan speed has to be set to low medium high automatic off or automatic on before the engine will shut down when using the AutoStart feature The engine will not shut down if the fan setting is set to off Low Battery Start Up This feature replaces the low battery alarm and automatically starts up the RigMaster to charge the truck batteries
6. if they get below 12 volts 2 volts The engine will shut down after 20 minutes of charging The engine will then restart after four minutes if the truck batteries are still below 12 volts 0 2 volts When the truck batteries fail to sustain voltage and the truck batteries drop below 11 5V the RigMaster will shut down and a system charging error message will display on the cabin controller Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 5811009 NOTE Once the RigMaster starts on low battery AutoStart it will not operate any system other than the engine charging system and the 110V generator regardless of fan speed and temperature settings Programming AutoStart Code When you purchase the AutoStart feature you will be provided with a 4 character digit code which must be first programmed in to the cabin controller Ensure the cabin controller is in low power mode Status light off Press and hold the MODE key and SELECT key at the same time for 5 seconds The display will show AutoStart code XXXX and the first character digit will be flashing Press UP or DOWN key to locate the first digit character in the code Press the SELECT key to accept the data and move to the next digit Continue entering the code in the above manner until all four characters have been selected Once all four digits have been entered the system will accept the code and a message will display C
7. 8 09 RigMaster Power Service and Repair Manual Document S831009 S8 3 Electronic Control Operation and Fault Codes The RigMaster APU s electronic control will display fault codes on the LCD display if the unit fails to start or shuts down The following table contains fault codes and information on the cause and or remedy These fault codes will display one time only if the code is cleared from the cabin controller failure will have to reoccur for the code to be displayed again fete 3 REMEDY CAUSE REMEDY COMMENT Engine cover of APU unit e Cover not seated Error Code 1 is open APU will not start e Damaged wiring Safety Cover Open or run until the cover is e Failed cover switch closed e Switch out of adjustment e Low oil level Error Code 2 Low oil pressure e Wiring damaged Low Oil Pressure e Faulty switch e Dirty Oil Filter e Damaged or broken battery Error Code 3 Low battery voltage cables 3 Battery Low Voltage Start system immediately Br cE KGS ONG Gad oN DENCKIES e Bad battery e Faulty charging system Error Code 4 Engine started but did not e Speed sensor adjustment a Engine Run Failure run properly Manual start e Damaged speed sensor wiring attempts can occur e Failed speed sensor Engine will not run until ae ocean Error Code 5 t e High Engine Temperature Low Coolant omperatura Decomes e Failed Tem t Coolant perature or Coolan Enaine Overheated normal or coolant level is Level Switch e
8. 9 Safety Cover Switch Figure 9 15 Low Coolant Sensor RP5 1005 The low coolant sensor has a 30 second delay so if coolant levels remain low for greater than 30 seconds the APU will shut down The low coolant sensor is connected to the same circuit as the high coolant temperature sensor If low coolant and or high temperatures are sensed the unit engine will shut down and display a fault code on the cabin controller 12 Volts normal volume OVolts Low Coolant volume Surge Tank Assembly Figure 9 16 NOTE The aluminum coolant overflow tank RP5 1002 AL replaces the plastic overflow tank RP5 1002 Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S8101009 8 10 Battery Fuse The following procedures present hazards which can result in injury or death Only persons qualified to carry out electrical and mechanical servicing should undertake this work A 100 Amp in line DC fuse must be installed on the RigMaster APU s positive battery cable The fuse assembly kit and individual part numbers are listed below Description Part Number Fuse Kit Includes fuse holder with fuse 18 Cable RPN Fuse Holder with Fuse RP7 071 100 Amp Fuse only RP7 073 18 positive battery cable RP7 042 NOTE The RigMaster APU positive battery cable should be located on a separate battery than the negative cable The RigMaster APU positive battery cab
9. C Error Code 13 Battery Discharge Alarm system will enter low power mode Auto and manual starts can not occur Bad batteries Error Code 14 Check External Temperature Sensor External temperature sensor disconnected from the power module External Temperature Sensor Disconnected Connection loose or damaged Error Code 15 External Temp Disable Limit Engine shut down since the external temperature is outside the programmed range Set default to OFF from factory The APU has been programmed not to start when the external temperature is outside a pre programmed range Error Code 16 Module Reset Set Clock Power to the cabin controller has been lost Reset clock Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S841009 8 4 General Electrical System Information and Power Module Connections To perform service maintenance and repairs you must disconnect the APU from its battery source In the recommended installation configuration the APU shares the battery bank with the vehicles main engine After disconnecting the battery cables check the battery posts inside the APU engine cabinet to confirm there is no voltage to the auxiliary power unit APU The RigMaster APU electrical system is a 12 Volt DC system in which vehicle and APU electrical accessories are powered by the vehicles battery and in turn charge
10. OV OFF Max current 2A Green A C Clutch Control 12V ON OV OFF Max current 4A Not In Use Black Ground 0V Red Black Stripe Positive Supply 12V Brown Glow Plug Relay 12V ON OV OFF Max current 200 mA White Block Heater Relay NOT USED DEDE Yellow Starter Relay 12V ON OV OFF Max 200mA Red Positive Supply 12V Red Positive Supply 12V Note Pin output 7 is an option for a block heater for the engine and has a short white wire with a bullet connector Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 J2 Pin RigMaster Power Service and Repair Manual Document 8841009 Electronic Coolant Control Blower Motor Control J2 3 J2 PIN TYPE COLOR White Feedback Signal from Water 1 INPUT Valve 12V Valve Open OV Valve Closed Black Fan Control Signal Max Current 9A 12V ON OV OFF output is 50 duty cycle for low speed White Drive Motor to Open Close Water Valve Max 2A 12V ON OV OFF White Water Valve Control Power 12V Max 7A 4 Black Fan Control Signal Max Current 9A 12V ON OV OFF output is 75 duty cycle for medium speed Black Fan Control Signal Max Current 9A 12V ON OV OFF output is 100 duty cycle for high speed 1 J2 TO WATER VALVE W
11. RigMaster Power Service and Repair Manual Document 5801009 8 0 Engine Electrical and Control System General Information The RigMaster APU electronic control system consists of two main components a Cabin Controller CC and a Power Module PM which are linked by an 8 wire category 5e communication cable with RJ 45 connectors at each end The Cabin Controller is the interface sending user commands to the Power Module The Power Module provides control intelligence to the unit by monitoring inputs and regulating outputs based on commands sent from the Cabin Controller and various engine sending units There are 2 versions of the RigMaster Power Module and Cabin Controller The RP7 901 controller uses the Yellow faced RP7 902 power module The RP50 201 controller uses the grey faced RP50 202 power module You cannot combine the old and new components as the software in each power module is written for the functionality of the cabin controller Foner I wooe Ca Cv Ie RP7 901 Version 1 Controller RP50 201 Version 2 Controller Green OK s Fuse 20Amps fee gs S RP50 202 Power Module Made in Canada RP7 902 Version 1 Power Module RP50 202 Version 2 Power Module The cabin controller displays a number of error messages intended to act as diagnostic aids These error messages do not indicate a specific problem but rather provide general guidelines to aid in the troubleshooting process See S8 2 for a list of troub
12. Sending Units Flywheel Speed Sensor RP7 103 e It sends an alternating current signal proportional to the engine RPM that indicates the engine is running at its proper speed above 800 RPM e The RigMaster APU will not operate if the speed sensor is disconnected faulty or disabled Figure 9 12 Note The speed sensors can become caked with belt dust and other debris causing the sensor to fail PEST SPEC Resistance 625 Q 75 Gap from Flywheel 0 015 Voltage Output 8 VAC 2V Speed Sensor E NOTE This resistance test can be done at the power module through pins 3 and 7 on the J4 connector to ensure continuity in the wiring from the power module to the speed sensor Oil Pressure Switch Perkins 185246060 Caterpillar 153 6617 The power module sends a signal to the oil pressure sensor from the J4 connector When low oil pressure is detected the oil pressure switch closes and grounds the signal to the engine Voltage at Switch Condition Battery Voltage Normal Oil Pressure 0 Volts Low Oil Pressure The oil pressure switch on the Perkins 400 Series engine screws into the engine block at the location shown in figure 9 13 On the Perkins 100 Series engine the oil pressure sensor screws in to the cylinder head near the injectors shown in figure 9 14 After reinstalling the switch it should be tightened to 13 3 ft lbs Ensure that thread sealant is used to prevent leaks High Temperature S
13. Solenoid Glow Plug Relay Glow plugs Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S851009 Air Conditioning and Cooling Fan Schematic MTS Model Note On all RMP RMC build RigMaster models the fan relay takes power from the AC compressor clutch connection at the binary switch This cycles the electric cooling fan with the AC clutch Cabin Controller RP50 201 Display Power Module RP50 202 J1 GRN AJC Clutch Control Evaporator Thermostatic Terminal Posts Switch Evaporator Core RP9 011 aj AIC Controlled Engine Temp Controlled RD Birary Pressure 7 5 Amp Switch 35 Amp Receiver Ai inni Fi ir Conditionin ws Engine Dryer Conguaxsor 9 Temp Senso RP9 027B RP9 132 GND GND Electric Cooling Fan RP7 230 Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S861009 S8 6Testing the Electric Coolant Control To test the coolant control valve there is two things that need to be checked first The male pins on the valve have to be straight The connector on the J2 harness has 6 double pins holes Make sure that the female connector pins on the J2 connector is plugged into the male pins on the valve Note Figure 8 7 shows the female connector Make sure that t
14. and or adjust those values 3 Understanding the Cabin Controller LCD Display The Cabin Controller LCD has a white backlight that turns on each time a user presses a button and will remain on for 2 minutes after the last button that has been pushed The backlight will turn red when there is an alarm condition A fault code will be displayed if the unit shuts down or fails to start The LCD displays 4 groups of information 1 System information 2 Temperature information 3 Clock day and alarm information 4 Alphanumeric display for additional information 1 System Information SYSTEM ALARM SYSTEM ALARM symbol will flash if an alarm condition has occurred The alphanumeric display along the bottom of the display screen will show more information about the alarm Red status LED will be on SYSTEM ON symbol will display if the unit is in ON mode Green status LED will be on ENGINE RUNNING symbol will display when the engine is running AUTOSTART symbol will display and flash if temperature AutoStart is enabled when engine is off If the engine has been started through AutoStart this symbol is constantly on while the engine is running HEATING symbol will display when the system is in heating mode COOLING symbol will display when the system is in cooling mode FAN AUTO FAN HIGH FAN MED or FAN LOW symbol will display depending on which setting has been selected Nothing will display in this area if the fan is se
15. current time and use the alarm clock function Fan button is used to change fan setting Pressing the button cycles between auto high med low and off settings Clear button will take you back to the main screen without saving any information Clock button is used to set the time date day menu features Alarm button is used to set the alarm menu features AutoStart button is used to access and set AutoStart menu features Mode button is used to activate the different operational modes Pressing the mode button will back you out of a menu mode but does not save the information just entered Ext Temp button will display the external temperature on the LCD when pressed Oprtg Hour s button will display the total hours of use Ore oe N Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S821009 The operating hours of the APU are recorded within the cabin controller Replacing the cabin controller will reset the operating hours to zero There is no means of transferring the operating hours from the old controller to the new controller 10 Select button enters the data and advances the program to the next menu step Pressing the select button will save the information when entering operational data 11 Left scroll button with lt symbol 12 Right scroll button with gt symbol The left and right arrow buttons are used to locate the desired data
16. d by the RigMaster APU alternator when the APU is running General Electrical Troubleshooting 1 Ensure proper grounding of the RigMaster APU unit and the vehicles electrical system Check the RigMaster APU s electrical connections including battery and vehicle connections look for damaged wires signs of corrosion and secure connections 3 Check Fuses and Relays Starter and Glow plugs 4 Verify that the correct voltage is present and continuity within the circuit Harness Markings 2 Figure 8 3 Figure 8 4 Power Module Connections The power module has several connection points that are individually labelled on the face of the module itself Please read the following section for detailed information on the function of these terminals The connection points are the same for both version 1 and version 2 power modules LED Green OK Fuse 20Amps J1 Main Power Input Relay Outputs Air J3 Pieper gen J1 Conditioning Control i J2 Electronic Coolant Control Blower Motor Control a sens J4 J3 Cabin Control Power and Communication te J4 Sensor Inputs Es PE kes J2 tome J5 J5 External Temperature Sensor RP50 202 Power Module Made in Canada Figure 8 5 Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 8841009 J1 Pins Main Power Input Relay Outputs Air Conditioning Control ar z TYPE COLOR White Engine Run Solenoid J 1 12V ON
17. e The Engine Running symbol will turn off Temperature Control Press UP or DOWN red blue buttons to adjust temperature set point on the display When editing the set point the LCD display will show the set point instead of internal cabin temperature The set point is stored without a need to press any other buttons NOTE The manual temperature control ranges from 59 F 90 F 15 C to 32 C The system will remember the last set temperature when the APU is turned on If the system is already running the change will take effect a few seconds after the last UP or DOWN key is pressed and the display will switch back from set point to internal cabin temperature Clock amp Date Set Up It is necessary to enter the time and date programming mode if the module has never been programmed or a different time zone is required SET symbol is flashing and CLOCK symbol is turned on during clock setup Press CLOCK button The display will read Set Clock Press SELECT button to continue MODE to exit Clock hour will start flashing Press LEFT or RIGHT scroll button to adjust Clock hour Press SELECT button Clock hour will stop flashing and Clock minutes will start flashing Press LEFT or RIGHT scroll button to adjust Clock minutes Press SELECT button Clock minutes will stop flashing and am pm will start flashing Press LEFT or RIGHT scroll button to change Press SELECT button am pm will stop flashing and day of week will start flashing
18. e and Repair Manual Document S821009 Glow Plug Duration NOTE The default time for all RigMaster units up to the MTS models is 16 seconds MTS models with the serial number T4 6 gt 5130 have their glow plug timing adjusted at the factory during testing The glow plug times reflect the settings programmed in by RigMaster during testing and should be used when adjusting glow plug times Extending glow plug times too long will prematurely burn out the glow plugs e lt 14 F 10 C 16 seconds e lt 50 F 10 C 16 seconds e 85 F 30 C 8 seconds e 285 F 30 C 4 seconds NOTE If the engine fails to start on the first try the controller is programmed to default to 16 seconds for the glow plugs on the second and third attempt at starting This is done to ensure that the pre combustion chamber has adequate heat to initiate combustion in colder temperatures Battery Voltage Range AutoStart NOTE The battery voltage range is set default to 12 volts On MTS units gt 5130 the battery setting is raised to 12 3 volts to reduce the work load on the alternator e 0 12 0V Default The voltage lower limit is 11 5V 5 the upper limit is 12 9V 9 By increasing the number by 1 you increase the voltage range by 1 volts Decreasing into the negative will set the range below 12 volts Keypad Backlight and Status LED Timeout e On Default or Off Copyright RigMaster Power by Mobile Thermo Systems Inc 09 2
19. e at full sate i r amaged Wiring Error Code 6 Power Module is not e Failed P Modul Module Failure responding AOG ideo Engine did not start e Bad glow plug relay Error Code 7 Automatic start is disabled e Bad starter relay Engine Start Failure until operator presses e Failed glow plug select button e Lack of fuel Communication between Error Code 8 comirol panel and PAWS e Communication Cable Damaged No C mm nication module is lost Engine will 4 Poor Connecti atth y at the Error nonnunsumt terminals communication is re established Truck engine is running e Optional engine wire is enan R AN APU will not run if the main connected to DC voltage supply engine is already running at the power module The APU has shut down Error Code 10 Be he maximum run tirne e Engine will only run 3 hours max Run Timeout pas Peet exceeded mie when set on AutoStart Time Day AutoStart Time Day Setting Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 8831009 Error Code 11 Check Power Module Fuse Very low battery voltage detected at the power module Check 20 Amp fuse at the power module Located under the bunk on the HVAC unit Error Code 12 Battery Charging Failure Battery voltage still low two minutes after cranking Auto and manual starts can occur Faulty charging system Bad batteries Engine harness ground wires disconnected at the HVA
20. ed Time AutoStart symbol will be flashing Automatic Temperature Control Start Up Shut Down will start and stop the APU to regulate the temperature giving you further fuel savings on extended absences from the cab Set Automatic Temperature Start Up Press AUTOSTART button twice Temp AutoStart will scroll across the screen Press SELECT button to continue MODE to exit Press LEFT or RIGHT scroll button to select mode of temperature control Mode options include OFF AUTO HEAT or COOL only Press SELECT button to continue MODE to exit Press LEFT or RIGHT scroll button to select AutoStart temperature set point if HEAT or COOL have been selected Press SELECT button to save settings or press MODE to return to menu without saving NOTE The Automatic Start temperature range is between 32 F and 95 F 0 C and 77 C Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S821009 When enabled the AutoStart symbol will flash AutoStart temperature start up will engage when the inside temperature is more than 5 F 3 C lower or more than 5 F 3 C higher than the temperature control setting in auto mode It also engages at least 1 minute after enabling AutoStart temperature Low Battery Start Up automatically starts up the APU to charge the truck battery if it gets low This option is always enabled in active mode The voltage sensitivity of the low battery Aut
21. en the fan speed is HIGH To test the fan circuit refer to section S8 7 Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S861009 Water Valve Schematic J2 C a 1 C Q vme 3 3 Power Module RP50 202 Oj 0 a J 5 5 O O 6 6 4 7 Blower Fan GND Back to Negative Terminal Post Pin Number 7 on the power module is an output This pin will tell you if there is power going to the valve When the air conditioning is needed the power module will send power to the valve to close it amp stop the coolant flow through the heater core The voltage will be present when the valve is closing When the valve is closed the voltage will disappear Pin Number 8 on the power module is not used Pin Number 6 on the water valve is the ground wire for the water valve The heater box is a good ground source Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S871009 S8 7 Blower Motor Wiring The blower motor has a single black power input wire and a single blue neutral wire See figure 8 8 Power is supplied to the blower motor via three black power wires from the J2 connector Each of the three power input wires will supply a different wattage to the blower motor which corresponds with one of three fan speed settings see connector output
22. engine ON OV Main engine OFF Orange Coolant Temperature Sensor dl 12V normal temperature OV high temperature Blue White DPF Optional OV Normal backpressure NEUT 12 V Pulse Level 1 Cleaning 12 V Constant Level 2 Cleaning INPUT Red Orange Pickup Speed Sensor Ground INPUT i K x A o e gt E Not in Use Plugged NOTE Main Engine Running is optional and is spliced to a truck ignition source near the HVAC box The source is usually from the truck s factory HVAC box When 12V ignition is applied to this input on pin number 4 it will NOT allow the RigMaster to start in any mode while the truck s main engine is running NOTE The Speed Sensor uses pin 7 as a loop back signal ground Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S841009 J5 Pin J 5 External Temperature Sensor J3 TYPE COLOR INPUT Red INPUT Black Black 3 GROUND heavier gage wire Temperature Sensor Note The sensor hangs through the cabin floor with the other electrical wiring Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 8851009 8 5 System Schematics Engine Sensor Schematic BLK 12V Batte 2 100A Inline Fuse gA O lf 1 Termi
23. flashing Press UP or DOWN key to adjust clock minutes Press SELECT key clock minutes will stop flashing and am pm will start flashing Press UP or DOWN key to change am pm Press SELECT key on or off will display Press UP or DOWN key to change setting Press SELECT key to save changes and return to menu mode Press MODE key to back out of the menu Note The Alarm symbol will appear on the screen to indicate that the alarm is on When the alarm is activated the SELECT button will cancel the alarm and remove the alarm symbol from the screen If the alarm is not turned off manually it will ring for one minute and then snooze for four minutes before sounding again Engine Start Press MODE key Start System will display Press SELECT key The control panel will display the status of the operation as it occurs e Starting System e Glow Plugs and a 15 second countdown e Cranking Engine Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 5811009 e Please Wait Engine Running will display for 5 seconds and then return to the normal mode The normal mode will display System On Engine Stop Press MODE key Stop System will display Press SELECT The control panel will display the status of the operation as it occurs e Engine Running e Engine Stopped The control panel after 5 seconds will return to normal mode Temperature Control Press MODE key
24. h basic control buttons 2 Advanced control buttons The LCD and basic control buttons are always visible to the user The advanced control buttons are concealed behind semi circular cover The controller also contains a LED indicator When the LED is green the system is active if it Figure 8 2 ii glows red then the system is detecting a problem and an error message will scroll across the bottom of the LCD screen The LED is turned off in low power mode 1 Basic Controls and Functions Basic controls contain the following buttons 1 Start system 2 Stop system 3 Up arrow Red triangular button 4 Down arrow Blue triangular button If the unit is in advanced mode pressing any of the basic control buttons will return the unit to basic mode Alternately the control panel will return to basic mode after two minutes of inactivity When the cabin controller displays the current temperature pressing either the up or down button will show the set point temperature without changing it Once the set point is indicated pressing up or down buttons will adjust the set point The new set point takes effect only when display is returned to show internal temperature 2 Advanced Controls and Functions The advanced controls are as follows 1 Power button controls whether the module is active In inactive mode all system functions including engine start climate control and AutoStart are disabled You can still see the temperature reading
25. he larger pin holes are facing to the outside of the water valve when making the connection Outside edge of water valve Water Valve Harness Female Pins Water Valve Male Pins Figure 8 7 Pin Number 1 on the power module is an input This pin will tell you if the valve is open or closed Put you red lead from you multi meter in pin number one on the power module connector and put your black lead from you multi meter to ground the heater box is a good ground If you have Ovolts then the valve is closed If you have 12 40volts then the valve is open CHECK TO MAKE SURE THE VALVE IS OPENING amp CLOSING Pin Number 2 on the power module is an output This pin will have power when fan speed is LOW To test the fan circuit refer to section S8 7 Pin Number 3 on the power module is an output This pin will tell you if there is power going to the valve When the heat is needed the power module will send power to the valve to open it and let the coolant flow through the heater core The voltage will be present when the valve is opening When the valve is open the voltage will disappear Pin Number 4 on the power module is a power wire This pin has to provide power to the valve at all times battery voltage Pin Number 5 on the power module is an output This pin will have power when the fan speed is MEDUIM To test the fan circuit refer to section S8 7 Pin Number 6 on the power module is an output This pin will have power wh
26. le shooting codes The cabin controller does not have any memory function to store codes Once a button has been pushed the code will be cleared Ensure you have the code written down prior to pressing a button as there is no way to retrieve the code once cleared Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 5811009 8 1 Operation of the Electronic Control System Version 1 Cc STATUS E R POWER Mone A IV ES 4 CONTROL PANEL FIGURE 8 1 5 1 The LCD MODULE DISPLAY is used to prompt the user through each operating mode The display will back light when the user touches any key and will turn off if not used for 30 seconds 2 The GREEN STATUS light indicates the cabin controller is active and functional The RED STATUS light indicates a system problem and an error message will appear on the display Refer to error message listing of this supplement NOTE No STATUS light indicates the system is inactive OFF 3 The POWER key controls whether the module is active Pushing the Power key will turn on the LCD backlight and activate the menu display or will turn the system off 4 The MODE key is used to activate the different operational modes and will back you out of the menu mode to the main display 5 The ARROW keys are used to locate the desired data and or adjust those values 6 The SELECT key enters the data and advances the program to the
27. le should also be on an independent post i e there should be no other line or load terminals connected to the same stud as the RigMaster APU s positive battery cable Installation of the Battery Fuse Battery Fuse Hardware Fuse Housing 2 Nuts 2 Lock Washers Fuse Base 100 Amp Fuse al 1 Install the battery cables on the RigMaster APU engine compartment battery studs and route them to the battery box ensuring that the cables are protected from any hazards that may damage them N iiaee dl Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S8101009 2 Once the cables reach the battery box find a suitable location to mount the in line fuse base The fuse assembly must be located in an area free of hazards and firmly secured mounting hardware not included NOTE Ensure that the 18 inch battery cable will reach the positive battery terminal and the fuse assembly prior to mounting the fuse assembly 3 Cut back any excess cable that connects the RigMaster APU to the fuse assembly and secure the 5 16 eye terminal The use of shrink tube and dielectric grease on all points of connection is highly recommended 4 Connect the fuse assembly to the positive battery terminal with the 18 inch positive battery cable prior to connecting the RigMaster APU s negative terminal 5 Check for battery voltage to the main unit terminal po
28. nal Posts issan Cabin Controller RP50 201 O O GND 12VDC Power wt i Module _ GND PWR DEF RP50 202 5 RDBLK PWR RD PWR Display on i Pressure O ian Sensor 1 GN Cover x Sensor 2 BLK HiTemp Low coolant Low Coolant 5 ore Sensor Sensor 1 f DPF SE Back Pressure O Sensor 6 BLWHT External Tier4 Option Temp Engine O Sensor Run 3 GNL Sensor P 17 RD ORG Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S851009 Starting and Charging Schematic 12V Battery E 100A Inline Fuse Terminal Posts GND 12VDC Chassis GND SLE GND Power Module Nea Engine j Engine iJ1 j RP50 202 Bi ia WHT Starter i Solenoid 1 Solenoid BLK 47 ONP 1 PWR o RD BLK Starter Block bess ______ 4 Heater By Relay WHT 7 Relay PWR RD 60 Amp Alternator optional 9 PwRO RD 10 GND aA ahah Starter YL A i A Relay Jig SS Lo Engine 2 8 RD lt 4 Running Glow Engine optional Plugs eT Run Relay i
29. next menu step NOTE Pressing the select button will save the information inputted when entering operational data Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 5811009 OPERATION OF THE CABIN CONTROLLER Power On When the RigMaster system is off the cabin controller enters the low power mode and becomes inactive shutting off all non critical functions In low power mode the display shows the day of the week and date on the top line and the time and total hours of operation on the bottom line Pressing the POWER key will activate the normal mode turning the system on The display will light and the status LED will become green The display will show the day of the week and time on the top line and the system status on off as well as the temperature setting on the bottom line Pressing the MODE key again will activate the menu mode The display will show SELECT on the top line and START SYSTEM on the bottom line Set Time Date NOTE It is necessary to enter and date programming mode if the module has never been programmed or a different time zone is required Press MODE key Press UP or DOWN key to find Set Time Date mode on the display Press SELECT key Press UP or DOWN key to find Set Time Press SELECT key clock hour will start flashing Press UP or DOWN key to adjust clock hour Press SELECT key clock hour will stop flashing and clock minutes will sta
30. oStart feature can be adjusted however this is a dealer programmable feature and must be performed at a RigMaster APU trained facility Automatic Low Battery Start Up Low Battery AutoStart does not require that it be set by the user in the same way as the time date and temperature based AutoStart All that is necessary to ensure that low battery AutoStart functions is to leave the APU engine OFF and the cabin controller powered on active mode However the battery voltage that the AutoStart engages at can be reset by the dealer technician The default voltage is 12 V 0 2 V Version Display Press MODE button Current version of the Power Module software will appear on the screen Press MODE or SELECT to return Programming Options for Version 2 Controllers The technician has the ability to access the Version 2 controller s programming and adjust the settings of various features To access the programming options of the controller perform the following procedure 1 Ensure the controller power is off 2 Press the Select and gt key together The controller will ask for a 4 digit code 3 Enter the code Z123 to access the programming options The programming options and defaults are as follows Language Selection e English Default no other options available at this time Display Temperature e Degrees F default or C Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Servic
31. ode Ok AutoStart Code Note The AutoStart code will ONLY function on provided controller kit Programming AutoStart Press MODE key Press UP or DOWN key to find the Set AutoStart mode Press SELECT key and Set Time AutoStart appears Press SELECT key and day of week starts flashing Press UP or DOWN key to adjust day of week Press SELECT key and day of week will stop flashing and clock hour will starts flashing Press UP or DOWN key to adjust clock hour Press SELECT key and clock hour will stop flashing and clock minutes will start flashing Press UP or DOWN key to adjust clock minutes Press SELECT key and clock minutes will stop flashing and am pm will start flashing Press UP or DOWN key to adjust am pm Press SELECT key and am pm will stop flashing and on off will start flashing Press UP or DOWN key to change on off Press SELECT key to save settings and return to menu mode Press MODE key to return to normal mode Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 5811009 Note Once you have set the program a symbol will appear on the normal mode screen If you touch any keys once this program is activated it will default to OFF This control will run a continuous 3 hour program and then will default to OFF You MUST set this program each time you use it Set Auto Temperature Control Press MODE key Press UP or DOWN key to find the Set AutoStart mode Press
32. oose 2 Inspect and or replace i i battery connection battery connections Batteries not Charging 3 Poor battery condition 3 Test batteries 4 Faulty alternator 4 Check voltage at alternator field coil wire and truck batteries 1 Faulty alternator 1 Check alternator output Batteries Overcharging 2 V above Battery voltage 1 Check drive belt tension ensure the alternator mounting bolts and adjusting belts are tight Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S881009 Belt Tension Chart Initial Belt Tension Used Belt Tension 90 to 110 Ibs 400 to489 N 60 to 80 Ibs 267 to 356 N 1 Initial belt tension refers to new belt 2 Used belt tension refers to a belt that has been in operation for 30 minutes or more 2 Check the positive and negative posts are in good condition and that all wiring connections are secure 3 Check the positive cable between the alternator and the starter for a loose or damaged cable 4 Before running the system ensure the regulator power supply yellow or white wire has approximately 12 VDC when system is on 5 With the unit running check the output at the battery The battery reading should be approximately 13 0 V DC to 14 0 V DC Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S891009 S8 9 Sensors Switches and
33. r operation NOTE The air conditioning heating system will only operate when the fan speed is in a setting other than OFF To stop the operation of the air conditioning heating system the fan speed must be set to OFF If the system was stopped by another method the air conditioning heating will start immediately when the system is restarted 4 AutoStart Features and Operation AutoStart Time Day Programming allows you to program a day and time for the APU for the start automatically up to 7 days in advance This feature will run for three hours and shut down At the end of the AutoStart program the cabin controller will display the error code 10 Run Timeout this is normal Set Automatic Start Timer The user can adjust the time and day for the next timed AutoStart event SET symbol is flashing and TIME AUTOSTART symbol is turned on during alarm setup Press AUTOSTART button Time AutoStart will scroll across the screen Press SELECT button to continue MODE to exit Press LEFT or RIGHT scroll button to adjust AutoStart hour as required Press SELECT button Continue to set the AutoStart Minutes and am pm as you would set the clock Press SELECT button after each entry Press LEFT or RIGHT scroll button to adjust AutoStart Day as required Press SELECT button Press LEFT or RIGHT scroll button to locate On Off Press SELECT button to save settings or press MODE button to return to menu without saving NOTE When enabl
34. rm The alarm symbol flashes when the alarm has been set TIME AUTOSTART symbol appears if the display shows time AutoStart setting It flashes if time AutoStart is set 4 Additional Information Message Area This line is used to show extra information in the basic mode error messages to provide interface when going through menus in advanced mode Longer text lines are scrolled to the left on the display WI AVL Aw Aw AL AL A AW ANY AN AN AS ANI 2M ZN IN IZN JN ANI Operation of the Cabin Controller Functions To Turn Power On Press the POWER button to activate the system When the power switch is activated the LCD display will light and SYSTEM ON symbol will turn on active mode Press POWER button again for 2 seconds to switch the unit back to low power mode Engine Start Press START button The control panel will display the status of the operation as it occurs Glow Plug and a countdown will display on the screen Once the countdown is complete the display will read Cranking as the APU starts up and the ENGINE RUNNING symbol will blink Once started the control will display Engine Running for 5 seconds and ENGINE RUNNING symbol will turn on Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S821009 Engine Stop Press STOP button The screen will initially display Stopping and then change to Stopped once the operation is complet
35. rt flashing Press UP or DOWN key to adjust clock minutes Press SELECT key clock minutes will stop flashing and am pm will start flashing Press UP or DOWN key to change am pm Press SELECT key to save settings and return to menu mode Press MODE key to back out of the menu To Set Date Press MODE key Press UP or DOWN key to find Set Time Date mode on the display Press SELECT key Press UP or DOWN key to find Set Date mode Press SELECT key Month will start flashing Press UP or DOWN key to find the correct month Press SELECT key Month will stop flashing and calendar date will start flashing Press UP or DOWN key until correct date appears Press SELECT key to save settings and return to menu mode Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document 5811009 Press MODE key to back out of the menu To Set Day Press MODE key Press UP or DOWN key to find Set Time Date mode on the display Press SELECT key Press UP or DOWN key to find Set Day mode Press SELECT key Press UP or DOWN key to find the correct day of the week Press SELECT key to save settings and return to menu Press MODE key to back out of the menu Set Alarm Clock Press MODE key Press UP or DOWN key to find Set Alarm Clock mode Press SELECT key clock hour will start flashing Press UP or DOWN key to adjust clock hour Press SELECT key clock hour will stop flashing and clock minutes will start
36. s for J2 S8 4 Only one of the three power input wires should be hot at any given time The neutral blower motor wire blue is connected to a source of ground Figure 8 8 an totutn Filler y Det Blower Ground Connecti n PEN N Biower Power Connection Remove and Replace the Blower Motor Assembly Disconnect the power and neutral wires from the HVAC and J2 wiring harness Remove the ducting from the blower motor Remove the lid of the HVAC unit four hex head screws The hex head screws that secure the blower assembly are accessed from within the HVAC unit Remove the fan assembly Reinstallation if the reverse of removal POND Do Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S881009 S8 8 Alternator Charging The RigMaster APU is equipped with an automotive style alternator that has a built in regulator NOTE Check the condition and charge of the truck batteries prior to testing the alternator s output Weak or discharged batteries will affect alternator output Ensure all the truck s batteries are fully charged and in good condition Replace any failed batteries first NOTE It is recommended that dielectric grease be used on electrical connections Figure 8 1 CHARGING SYSTEM DIAGNOSTIC PROCEDURE SYMPTOM PROBABLE CAUSE REMEDY COMMENT 1 Loose or broken belt 1 Tighten or replace belt 2 Damaged or l
37. sts and at the power module Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09
38. t to off systemon ENGINE RUNHIHG AUTOSTART HEATING COOLING MID FAH LOW 2 Temperature Information gjj This area indicates the internal or external temperature and can be programmed to display in either Celsius or Fahrenheit Internal temperature is shown if EXT TEMP and SET TEMP symbols are not illuminated Pressing the Ext Temp button will Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S821009 momentarily display the outside temperature After 5 seconds the display will default back to showing the internal temperature EXT TEMP symbol will flash when showing external temperature After a few seconds the display returns to show internal temperature SET TEMP symbol appears and the numeric temperature value will flash whenever adjusting temperature set point A few seconds after adjusting the temperature the display returns to show internal temperature 3 Clock and Alarm F w m mR sa S _ Il Il a lt II l ll I a This is a 12 00 hour clock system with AM PM symbols and 7 symbols indicating day of the week MO TU WE TH FR SA SU OCK ALARM TIME AUTOSTAR CLOCK symbol appears when the current time is showing ALARM symbol appears to indicate that the alarm setting is showing Pressing the alarm button allows you to set the ala
39. witch Perkins 385720101 Caterpillar 176 7705 The power module sends a signal to the high coolant temperature sensor from the J4 connector When high engine temperature is detected 230 F switch closes and grounds the signal to the engine Voltage at Switch Condition Battery Voltage Normal Temperature 0 Volts High Temperature Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S891009 The high engine temperature switch screws into the water pump at the location shown in figure 9 13 After reinstalling the switch it should be tightened to 20 ft lbs Ensure that thread sealant is used to prevent leaks Oil Pressure Switch Coolant High Temperature Switch f j 4 j Perkins 4bo Serie 4 Fuel Injectors Oil Pressure Switch NOTE Ensure that there is a rubber boot over the each switch to prevent corrosion and exposure to moisture which may cause the switches to malfunction The use of dielectric grease is highly recommended at these points of connection Safety Cover Switch RP7 021 When the engine cover is in place the safety cover switch is closed and the signal travels to ground 0 volts will be at the power module J4 pin 2 when the cover is closed Battery voltage will be at J4 pin 2 when the door is open Copyright RigMaster Power by Mobile Thermo Systems Inc 09 28 09 RigMaster Power Service and Repair Manual Document S89100

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