Paccar SmartAir eHVAC System Manuale utente
SERVICE
MANUAL
Section HVAC
Title SmartAir eHVAC System Service Manual
Number PM820010
Date Rev. 10 © 6/2019
Model All w/ SmartAir eHVAC System
Page 1 of 40
SmartAir eHVAC System
Technical Information and Diagnostic Guide
HVAC
PM820010 Rev. 10 © 6/2019
This guide will assist you in becoming more familiar with the working components
of the Peterbilt SmartAir eHVAC System and the proper steps and procedures to
completely diagnose the Peterbilt SmartAir eHVAC System unit.
©2019 PACCAR Corporation
Confidentiality Notice: This document and the information contained herein is proprietary. It shall not be reproduced, copied or disclosed,
in whole or in part, or used for manufacture without the written permission of PACCAR. You are hereby notified that any dissemination of
this information is strictly prohibited.
Page 2 of 40
Number PM820010
HVAC: SmartAir eHVAC System
Contents
GENERAL SAFEY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Precautions for Working with HFC134a (R134a) Refrigerant and Polyvinyl Ether
(PVE) Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
• Important Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXTERNAL COMPONENT IDENTIFICATION AND LOCATION . . . . . . . . . . . . . . . 8
A. Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
C. Fan and Temperature Control Display LED Display . . . . . . . . . . . . . . . . . 9
D. System and Compressor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
E. Linear Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F. Discharge Temperature Sensor – Freeze Switch . . . . . . . . . . . . . . . . . . 10
G. Evaporator Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
H. Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
I. Battery Management System (BMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
J. Battery Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INTERNAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A. High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
C. Thermal Limit Switch on Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
D. Evaporator Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A/C System Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ESPAR Heating System Diagnostic Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A. Battery Condition and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B. Fan and Temperature Control Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
C. Relay Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
D. Pressure Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
E. Check Continuity Across Fuse Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F. Discharge Temperature Sensor/Freeze Switch Testing . . . . . . . . . . . . . 19
G. Compressor Thermal Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Number PM820010
HVAC: SmartAir eHVAC System
H. Main Controller/Compressor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
I. Condenser Fan Motor Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
J. Evaporator Blower Motor and Linear Power Module Testing . . . . . . . . . .20
K. Compressor Rubber Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
L. Testing the Battery Management System (BMS) . . . . . . . . . . . . . . . . . . . 21
M. Can Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
N. Testing the Espar Heater Connected to the EHVAC Digital Controller . . . 22
O. Connecting the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
P. Evacuating the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Q. Charging the EHVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Service Instructions for Ring Terminal / Controller and Compressor . . . . . . . . . . . . 33
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Number PM820010
HVAC: SmartAir eHVAC System
List of Figures
Figure 1. Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 2. Fuses and Relays (Units built 8/1/2016 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 3. Fan and Temperature Control Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 4. System and Compressor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 5. Linear Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 6. Discharge Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 7. Evaporator Blower and Condenser Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 8. Battery Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 9. Battery Separator Solenoid, located in the battery box.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 10. High Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 11. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 12. Thermal Limit Switch on Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 13. Evaporator Inlet Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 14. Relay Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 15. Service Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 16. Service Recovery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 17. Internal Wiring Diagram (Before 8/1/2016) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 18. External Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 19. Wiring Diagram (8/1/2016 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 20. On/Off Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 21. Changing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 22. Changing Blower Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 23. Changing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 24. View System Runtime/Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 25. Change from °F to °C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 26. Enter Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 27. Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 28. EHVAC Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Page 5 of 40
Number PM820010
HVAC: SmartAir eHVAC System
GENERAL SAFEY INSTRUCTIONS
A number of alerting messages are in this manual.
Please read and follow them. They are there for your pro-
tection and information. These messages can help you
avoid injury to yourself or others and help prevent costly
damage to the vehicle.
Warnings, Cautions, and Notes
Key symbols and “signal words” are used to indicate
what kind of message is going to follow. Pay special
attention to instructions prefaced by symbols and signal
words “WARNING”, “CAUTION”, or “NOTE”. Please do
not ignore any of these alerts.
WARNING!
When you see this symbol and word, the message that
follows is especially vital. This signals something that
can cause injury or even death. This message will tell
you what the hazard is, what can happen if you don’t
heed the warning, and/or how to avoid it.
CAUTION
This symbol and word signals something that could
damage your vehicle.
NOTE
This symbol gives you information we believe to be
helpful. The information can be a service hint or some-
thing to assist with the repairing of the vehicle.
Precautions for Working with HFC134a
(R134a) Refrigerant and Polyvinyl Ether
(PVE) Refrigerant Oil
WARNING!
• DO NOT breathe A/C refrigerant and oil vapor or
mist. Exposure may irritate eyes, nose and throat.
• Additional health and safety information may be
obtained from refrigerant and oil manufacturers.
• If accidental system discharge occurs, ventilate
work area before resuming service.
CAUTION
• The air conditioning system uses HFC134a
(R134a) refrigerant and polyvinyl ether (PVE)
refrigerant oil, which are not compatible with
CFC-12 (R12) refrigerant, mineral oil, or PAG
oil. If the refrigerants or oils are mixed the com-
pressor may fail.
• Do not attempt to use R-12 servicing equipment;
damage to the air condition system or your servic-
ing equipment will result.
• Use only service equipment that is U.L. listed and
is certified to meet the requirements of SAE J2210
to remove HFC134a (R134a) from the air condi-
tioning system.
• Verify the HFC134a (R134a) refrigerant in the vehi-
cle system and the recycling equipment/recovery
tank are contaminant free by using a refrigerant
identifier.
NOTE
THIS SYSTEM MUST BE SERVICED BY QUALIFIED
PERSONNEL ONLY.
R134a service equipment or vehicle air conditioning
systems should not be pressure tested or leak tested
with compressed air.
• This air conditioning system may contain R134a
fluorescent dye for leak detection. Inspect with a
high intensity ultraviolet light system.
• A label on the unit will identify systems with fluores-
cent dye.
NOTE
The Air Conditioning system is designed for use only
with the specified polyvinyl ether (PVE) refrigerant oil
for HFC134a (R134a) A/C systems and HFC134a
(R134a) components. Idemitsu FVC68D PVE oil is the
ONLY recommended oil. The PVE oil is very Hygro-
scopic. Hygroscopic means that it absorbs water. With-
out proper sealing, oil will become moisture saturated
and should not be used.
NOTE
Take care to follow the handling procedures below:
• Only use the specified FVC68D PVE oil from a
sealed container.
• Immediately reseal containers of oil.
• To avoid contamination, do not return oil to original
container once it is dispensed, and never mix it
with other refrigerant oils.
• Do not allow PVE oil to come in contact with Styro-
foam parts. Damage may occur.
• Do not allow PVE oil to come in contact with vehi-
cle paint. Damage may occur.
• If any connection in the refrigerant loop is opened it
should be closed as soon as possible in order to
minimize the amount of moisture that enters the
system.
• Any components that are replaced should have
dust caps left in place until the component is ready
to be installed in the refrigerant loop.
• Any component removed from the refrigerant loop
should have dust caps in place as soon as possible
in order to minimize moisture intrusion.
Page 6 of 40
Number PM820010
HVAC: SmartAir eHVAC System
Important Safety Notices
WARNING!
Improper practices, carelessness, or ignoring any
warnings may cause death, personal injury, equipment
or property damage.
Read and understand all of the safety precautions and
warnings before performing any repair. This list contains
the general safety precautions that must be followed to
provide personal safety. Special safety precautions are
included in the procedures when they apply.
Work areas should be dry, well lit, ventilated, and be free
from clutter, loose tools, parts, ignition sources and haz-
ardous substances. Be aware of hazardous conditions
that can exist.
• Wear protective glasses and protective shoes when
working.
• Rotating parts can cause cuts, mutilation or strangu-
lation.
• Do not wear loose-fitting or torn clothing. Remove all
jewelry before working.
• Before beginning any repair, disconnect the battery
(negative [-] cable) from both battery boxes and dis-
charge any capacitors.
• Disconnect the air starting motor, if equipped, to pre-
vent accidental engine starting.
• Put a “DO NOT OPERATE” tag in the operator's
compartment or on the controls.
• Allow the engine to cool before beginning any repair.
• Always use blocks or proper stands to support the
vehicle or vehicle components before performing any
service work. Do not work on anything that is sup-
ported only by lifting jacks or a hoist.
• To reduce the possibility of personal injury, use a
hoist or get assistance when lifting components that
weigh 23 kg [50 lb] or more. Ensure all lifting devices
such as chains, hooks, or slings are in good condi-
tion and are of the correct load capacity. Make sure
any lifting devices are positioned correctly. Always
use a spreader bar when necessary. The lifting
hooks must not be side-loaded.
• Corrosion inhibitors and lubricating oils may contain
alkali. Do not get the substance in eyes and avoid
prolonged or repeated contact with skin. Do not swal-
low. In case of contact, immediately wash skin with
soap and water. In case of harmful contact, immedi-
ately contact a physician. Always keep any chemi-
cals OUT OF REACH OF CHILDREN.
• Naptha and Methyl Ethyl Ketone (MEK) are flamma-
ble materials and must be used with caution. Follow
the manufacturer's instructions to ensure safety
when using these materials. Always keep any
chemicals OUT OF REACH OF CHILDREN.
• When working on the vehicle, be alert for hot parts on
systems that have just been turned off, exhaust gas
flow, and hot fluids in lines, tubes, and compart-
ments. Contact with any hot surface may cause
burns.
• Always use tools that are in good condition. Make
sure you have the proper understanding of how to
use the tools before performing any service work.
Use ONLY genuine replacement parts from PAC-
CAR.
• Always use the same fastener part number (or equiv-
alent) when replacing items. Do not use a fastener of
lesser quality if replacements are necessary.
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Number PM820010
HVAC: SmartAir eHVAC System
• Do not perform any repair when impaired, tired,
fatigued or after consuming alcohol or drugs that can
impair your functioning.
• Some state and federal agencies in the United States
of America have determined that used engine oil can
be carcinogenic and can cause reproductive toxicity.
Avoid inhalation of vapors, ingestion, and prolonged
contact with used engine oil.
• Liquefied petroleum gas is heavier than air and can
accumulate near the floor, in sumps, and low-lying
areas.
• Close the manual fuel valves prior to performing
maintenance and repairs, and when storing the vehi-
cle inside.
• California Proposition 65 Warning – Diesel engine
exhaust and some of its constituents are known to
the State of California to cause cancer, birth defects,
and other reproductive harm.
•DO NOT breathe A/C refrigerant and oil vapor or
mist. Exposure may irritate eyes, nose and throat.
• Additional health and safety information may be
obtained from refrigerant and oil manufacturers.
• If accidental system discharge occurs, ventilate work
area before resuming service.
Page 8 of 40
Number PM820010
HVAC: SmartAir eHVAC System
EXTERNAL COMPONENT
IDENTIFICATION AND LOCATION
A. Fuses
Figure 1. Fuses and Relays
Figure 2. Fuses and Relays (Units built 8/1/2016 to
Present)
F1 Fuse 10 Amp (Mini)
This fuse provides short circuit protection for the System
control.
NOTE
Removing fuse F1 for 10-15 seconds will reset the sys-
tem controller to factory default settings.
Location: on the control center.
F2 Fuse 10 Amp (Mini)
This fuse provides short circuit protection for the con-
denser fan.
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Number PM820010
HVAC: SmartAir eHVAC System
Location: on the control center.
F3 Fuse 20 Amp (Mini)
This fuse provides short circuit protection for the evapo-
rator blower.
Location: on the control center.
F4 Fuse 60 Amp (Maxi)
This fuse provides short circuit protection for the com-
pressor.
Location: on the control center.
B. Relays
Location: on the control center.
R1. This relay controls the voltage to the condenser fan.
R2. This relay controls the voltage to the linear power
module and evaporator blower.
R3. This relay controls the voltage to the compressor
controller.
C. Fan and Temperature Control Display
LED Display
Allows for temperature and Blower speed adjustment of
the EHVAC (Electrical Heating and Ventilation Air Condi-
tioning) unit when operating in Auto, cool or heat mode.
A/C Unit – stops when unit is shut off or batteries are
depleted.
Figure 3. Fan and Temperature Control Display
Auxiliary heater will shut down when batteries are
depleted but will continue to run through the cool down
cycle. Also displays hours of service, battery health and
service items.
D. System and Compressor Controller
This device controls the unit and the output voltage to the
variable speed compressor. It is located under the large
access cover.
Figure 4. System and Compressor Controller
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HVAC: SmartAir eHVAC System
E. Linear Power Module
This module controls the amount of voltage delivered to
the evaporator blower creating variable blower speeds. It
is located in the return air in front of the evaporator coil.
Figure 5. Linear Power Module
F. Discharge Temperature Sensor – Freeze
Switch
This sensor monitors the evaporator outlet temperature
as it enters the vehicle duct system.
Figure 6. Discharge Temperature Sensor
G. Evaporator Blower
This blower pulls air through the evaporator coil and
blows conditioned air into the interior of the sleeper.
H. Condenser Fan
This blower draws air through the condenser coil to cool
the refrigerant flowing through the system.
Figure 7. Evaporator Blower and Condenser Fan
I. Battery Management System (BMS)
This device monitors the auxiliary batteries for state of
charge, communicates with the EHVAC system and con-
trols the battery separator solenoid. LED light on this
device indicates power to the device and does not pro-
vide diagnostics. Power inputs to this device are fuse
protected.
If one of the BMS fuses blows, the solenoid will disen-
gage.
Figure 8. Battery Management System
J. Battery Separator
This device connects the truck batteries to the EHVAC
batteries. When the starting batteries are at or above
13.2 volts, the battery management device will engage
the solenoid to allow the alternator to charge the auxiliary
batteries. When the voltage drops to or below 12.5 volts
the battery management system will disengage the sole-
noid to prevent the truck starting batteries from being dis-
charged below the engine start level.
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