Willie APU Manual Operation & Maintenance DSE 4410 Controller
Willie Owner’s Manual Copyright © 2012 by Willis Power Systems All rights reserved. No part of this book may be reproduced in any form by any electronic or mechanical means including photocopying, recording, or information storage and retrieval without permission from the author. Willis Power Systems www.willisapu.com E-mail: service@willisapu.com Rev C 05/02/12 Printed in U.S.A.
Willis Power Systems Owner’s Manual Willie APU & DSE 4410 Rev C 05/02/2012
NOTE The Willie APU offers up to 50% more engine power than competitive products and its compact and lightweight design allows for easy installation. Willie™ provides the power and quality while priced competitively to meet the needs of the average driver and trucking company. Willie™ gives built-in redundancy to a big rig’s critical systems. It is designed to be serviceable and is backed by parts availability.
Contents Important APU Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OWNER/OPERATOR Safety . . . . . . . . . . . . . . . . . . . . . . . . . 7 Required Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 8 Every 50 Hours of APU Runtime . . . . . . . . . . . . . . . . . . . . . . . . 8 Every 500 Hours of Runtime . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Cont’d EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Module Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Graphical Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Mode Icon . . . . . . . . . . . . . .
OWNER/OPERATOR SAFETY Thank you for choosing an APU from Willis Power Systems. It is our goal to make sure you have the best unit on the market. Willis Power Systems is proud to provide options to our customers in order to best serve individual needs on the road. Because of the customized options, different APU systems will have their own operating instructions that must be followed to ensure that you get the maximum performance from your unit.
REQUIRED MAINTENANCE SCHEDULE Performing simple maintenance checks, and following the schedule will result in a long lasting engine that improves the performance of your APU, the life of your unit, and long term savings on the road. Ignoring the maintenance schedule can result in a void warranty, and/or preventable engine problems.
HOW TO START YOUR APU 1. Select Stop for the manual mode. 2. Then press the Start button to crank the engine. 3.
HOW TO STOP ENGINE SET FAN BLOWER 1. Set the fan blower to AC or Heat. 2. Select the blower settings to adjust the airflow. 3. The system automatically cycles to the thermostat settings. 4. When you are finished with the temperature controls, or are shutting down your APU, always return the blower to the OFF position.
THERMOSTAT SETTINGS 1. Set the Thermostat to A/C or Heat. 2. Use the selector switch to set the fan to automatic mode (AUTO) or continuous mode (ON). • AUTO-The fan regulates cabin temperature according to selected temperature on the thermostat. • ON-The fan operates continuously and does not regulate to the selected temperature. 3. Select your temperature setting. The cabin temperature is normally displayed. To view the set point, press a button once. The set point & icon is displayed for 5 sec.
SPECIAL INSTRUCTIONS FOR UNIT TYPE Closed Loop System for A/C only Coolant Flow Hose Fittings Direction of Coolant Flow Hoses pictured above do not show the proper installation, and is provided solely as an overview of connections. Refer to your installation manual for specific instructions or contact WPS. • The small fan only turns on when the AC is engaged to pull the heat out of the chassis that is produced by the engine and the AC compressor.
Standard Integrated System This system integrates the APU into the coolant flow of the truck engine, allowing the APU to heat the coolant as it circulates through your truck engine to prevent cold starts. The sleeper heater core of the truck engine accesses the heated coolant which keeps the sleeper heater core warm for a few hours. If you were to run your sleeper heater blowers on, you can take advantage of this heat for approximately 6 to 8 hours.
Extreme Cold Weather System The standard system is integrated into the truck engine’s coolant flow to keep the truck engine warm at all times. Included in the standard system is a valve assembly that uses the coolant flow to produce maximum heat in cold temperatures. Below are the instructions on how to use the valve system when you are running the A/C or the heat. Please follow these directions in order for your system to operate properly. For Heat 1.
For Air Conditioning A. Both parallel valves on the evaporator side must be closed. B. The cross valve between the two coolant lines must be open. This prevents the hot coolant from flowing into the heater core of the evaporator when you are running the AC.
DSE OPERATION GUIDE Stop / Reset and Manual 1. This button places the module into its Stop/Reset Manual mode. This will clear any alarm conditions for which the triggering criteria have been removed. 2. Once in Manual mode the module will respond to the start button or Auto button, start the engine, and run off load. 3. The return delay timer operates to ensure that the starting request has been permanently removed and isn’t just a short term removal. 4.
the starter motor is disengaged for the crank rest duration after which the next start attempt is made. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and the display shows Fail to Start when the engine fires, the starter motor is disengaged.
Metering Generator Voltage, 3-phase, L-L and L-N Engine hours Run/ Oil Pressure Gauge Generator Frequency Engine Temperature Gauge Mains Voltage, 3-phase, L-L and L-N Fuel Level Battery Voltage Fail to Start Indicators Fail to Stop Low Oil pressure High Engine Temp Under/Over-speed Failed to reach loading voltage Failed to reach loading frequency Charge Fail Over Current – Warning, Shutdown or Electrical Trip Under/Over voltage – Warning, Shutdown or Low DC Voltage; AMF indications Electrical Tri
Module Display Backlight The backlight will be on if the unit has sufficient voltage on the power connection while the unit is turned on, unless the unit is cranking for which the backlight will be turned off. Graphical Display A 48x132 pixel LCD is used for the display. The display is segmented into areas for instrumentation, units, alarm icons and various other icons. MODE ICON An icon is displayed in the mode icon area of the display indicates the current mode of the unit.
INSTRUMENTAL ICONS When displaying instrumentation a small icon appears in the screen to indicate what is currently displayed. This allows you to distinguish icons for oil pressure, voltage, and coolant temperature for consistency. Icon Image Details Generator Used for generator voltage and frequency Mains Used for mains voltages and frequency. The WPS compact APU has NO generator.
ALARM ICONS When current instrumentation is being displayed the icons area will be used to display currently active conditions. In instances where more than one alarm is present the icon area will transition between icons to display all active alarm conditions. When the event log is being displayed the alarm icon area will be used to indicate which alarm was logged.
THERMOSTAT GUIDE The following information reflects the standard instructions for operating a common thermostat. Making adjustments to the settings of your controller is not recommended without reviewing the provided information. For detailed information, view the instruction guide that accompanies your thermostat. Use the selector switch to place the system in heating mode or cooling mode or to set both modes to off.
Setting the Temperature Press one of the arrow buttons until the desired temperature is displayed. Backlight The display illuminates for 12 seconds when the backlight button or either of the arrow buttons is pressed. Manual/Permanent Hold Mode This mode maintains the temperature at a fixed set point. To place the thermostat in this mode, press [Mode]. The house icon will disappear. Programmable Mode This mode maintains the temperature according to the energy-saving schedule.
Setting the Time and Day 1. Press [Clk] once to set the hour, then press the up and down arrow buttons to appropriate time. 2. Press [Clk] again to set the minutes, and press the up and down arrow buttons to appropriate time. 3. Press the [Clk] button a third time to set the day (day will flash), and use the arrow buttons to set the day. 4. Press [Exit] to exit the controls. Setting the Date The date is needed for automatic daylight savings changeover. 1.
Modifying your Schedule You can program up to 4 periods per day, each period having its own temperature settings. You can have a different program for each day of the week. For each period, you can set the start time, the heating set point and the cooling set point. If you wish to use on 2 periods, set periods “1 and 4” or periods “2 and 3”. Early start will not work if you set periods “1 and 2” or 3 and 4”. 1. Press [Pgm] to display the period 1 settings. 2.
BASIC TROUBLESHOOT Battery Replacement Indicator • Immediately install new batteries when the icon starts flashing. • The icon flashes for 120 days before the batteries are depleted. • You should replace batteries once a year or before leaving your thermostat unattended for more than a month even if the icon has not appeared. WARNING: It is extremely important to keep the batteries charged in the thermostat. • After replacing the batteries, set the time, day, and date.
Recognizing a Blown Fuse A blown fuse is common, although it does not happen often it is usually the first place to look when diagnosing your system. To check a fuse, pull the fuse out of the fuse box, and look carefully at the filament inside the plastic shell. If there is a break in the filament, the fuse is blown as shown in image two below. Image 1 - Working Fuse Image 2 - Blown Fuse WARNING: Do not install the incorrect fuse size. A fuse will regulate the power to components of your APU system.
FUSE BOX OVERVIEW Your APU system has two main fuse boxes. The Engine Harness (EH) Fuse Box, and the A/C or A/C & Heat (AC/HT) fuse box depending on your system. The fuse box has two rows. • The right side row is labeled from R1 to R5. • The left row is labeled from F1 to F10. Your relays are large square blocks with metal prongs. The only way to check a relay is by replacing and testing it with a new, working relay. A fuse requires a visual check shown on the previous page.
EH Fuse Box & Cover The engine harness fuse box protects the auxiliary power unit’s engine components. When you replace a fuse, remember to make sure that you have installed the fuse in the proper slot as described in the information label inside the fuse box cover. Image 1 - AC/HT Fuse Box Image 2 - AC/HT Fuse Box Cover Condenser Fan Fuse The fuse for the condenser fan is located below the EH fuse box on a single fuse holder. To change, simply pull the fuse out and replace it.
A/C Compressor Fuse The A/C compressor has a 15 amp fuse located inside the APU chassis. If you need service assistance, please call Willis Power Systems. Office hours are Monday - Friday from 8 AM to 5 PM central time. Willis Power Systems, LLC 2950 N. Martin Springfield, MO 65803 Toll Free: (800) 825-4631 Phone: (417) 831-2520 Fax: (417) 831-0030 service@willisapu.com sales@willisapu.com www.willisapu.
COMMON PARTS & PART NUMBERS All APU parts are available for replacement. Orders can be submitted on our website, by e-mail, or over the phone with our parts department at Willis Power Systems. Most Kubota parts are available at WPS only. For your convenience, we have included outside options for parts. Willis Power Systems 2950 N Martin Ave, Springfield, MO 65804 Toll Free: 800-825-4631 | Fax: 417-831-0030 Web: http://www.willisapu.com parts@willisapu.com | service@willisapu.com | sales@willisapu.
SERVICE CENTERS Location of Sales, Installation, and Service centers for WPS auxiliary power units. Please call your nearest location to confirm your needs as some sites are sales, installation, service, or maintenance specific while other locations offer both installation and service. General maintenance is available at all Travel Centers of America locations nationwide. Visit our service locator on our website to find a location nearest you. www.willisapu.
Minnisota AllState Peterbilt N 21701 John Deere Ln Rogers 55374 763-428-4333 AllState Sales 558 E. Vilaume Ave S. St. Paul 55075 800-328-0104 AllState Peterbilt 27053 County Rd 12 Winona 55987 800-533-7384 AllState Peterbilt 2265 Howard Dr. W. N. Mankato 56003 507-388-9312 Peterbilt Mid America #1 North Central Dr. O’Fallon 63366 800-765-7383 Peterbilt of Springfield 3026 N. Mulroy Rd. Strafford 65757 800-666-7383 Peterbilt 4044 Coyote Dr.
Pensylvania Hunter Truck Sales 9981 Old Route 22 Breinigsville 18031 610-285-2244 Hunter Truck Sales 519 Pittsburgh Rd. Butler 16002 724-586-7744 Hunter Truck Sales 1503 Airstream Way Clearfield 16830 814-768-7679 Hunter Truck Sales 101 E. Main St Eau Claire 16030 724-791-2525 Hunter Truck Sales 6390 Clintonville Road Emlenton 16373 724 867 5290 Hunter Truck Sales 8125 Wattsburg Rd.
WARRANTY Upon warranty activation, Willis Power Systems, LLC (WPS), warrants to the original buyer that the Willis APU (less Major Components), configured with closed loop cooling, will be free from defects in material and workmanship for two years or 2000 hours of operation, whichever comes first, from the date of original truck installation by a WPS Authorized Service Center or Dealer.
including but not limited to filters, filter elements, oils, lubricants, coolant, belts and glow plugs. 3. Non-approved parts. 4. Parts that are returned for warranty credit and verified to be in good working order. 5. Used parts. 6. Any damage caused by overheating the Willis APU that is not a direct result of a defect in APU materials or workmanship. 7.
Warranty Activation Activation of the WPS APU warranty requires that the following be completed in full and returned within 30 days of install to WPS via website, mail or fax (417) 831-0030. The WPS APU warranty is void and non-valid until the information is returned. A letter of receipt will be sent to the purchaser’s address acknowledging the below information has been received and warranty is activated. 1. Warranty registration form (SER 001-001) 2. Installation Checklist (SER 001-013) 3.
