Carrier TRANSICOLD Aspen 200INT Installation Manual

Auxiliary power unit (apu)

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Installation Manual

Aspen 200INT, AspenSTA,

AspenPWR, AspenSKY

Auxiliary Power Unit (APU)

62-12173

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Summary of Contents for Carrier TRANSICOLD Aspen 200INT

Page 1 Installation Manual Aspen 200INT, AspenSTA, AspenPWR, AspenSKY Auxiliary Power Unit (APU) 62-12173...
Page 2 Installation Manual Aspen 200INT, AspenSTA, AspenPWR, AspenSKY Auxiliary Power Unit (APU) © Carrier Corporation, 2023 Printed in U. S. A. June 2023...
Page 3 Manual Revision History 62-12173 Rev. Date Reason for Release 6/20/2023 New product, new manual release...
Page 4 TABLE OF CONTENTS PARAGRAPH NUMBER Page Safety ..............................1–1 Warnings, Cautions and Notice Statements ................1–1 Safety Considerations ........................1–1 Components ............................2-1 Power Unit ............................3-1 Power Unit Dimensions ........................ 3-2 Cover Removal ............................3-4 Power Unit Installation ..........................3-5 Exhaust ...............................
Page 5 PARAGRAPH NUMBER Page 11.4 2 VDC/CAN Harness ........................11-6 11.5 Condenser Fan/AAT ........................11-7 11.6 Aspen Interface .......................... 11-7 11.7 Heater Option ..........................11-8 11.8 Power Outlet ..........................11-9 11.9 Block Heater (Option) ......................... 11-9 11.10 Low voltage sensor/thermistor harness..................11-10 11.11 High voltage output harness .....................
Page 6 Safety 1.1 Warnings, Cautions and Notice Statements Read these instructions carefully before operating the system. Safety alerts labeled DANGER, WARNING, and CAUTION alert to special instructions or precautions concerning procedures that would be hazardous if performed incorrectly or carelessly. The safety alerts alone cannot eliminate all hazards. Strict compliance with these special instructions and common sense are major accident prevention measures.
Page 7 Diesel Fuel. Refer to Table 1 Exercise safety precautions when working near flammable fuel. The seal or foam gasket must be replaced each time the heater is removed and re-installed Under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the direction of travel.
Page 8 Vehicles with longer wheelbases should have the APU mounted closer to the sleeper unit to avoid obstacles such as railway crossings, speed bumps, curbs, etc. Before beginning installation of the Aspen APU system, disconnect the vehicle's batteries. INTEGRATED APU ONLY-If truck is equipped with a coolant valve, valve must be fully opened before starting the APU.
Page 9 Read before starting installation. Each truck is unique and will require a different approach. Plan the placement of ALL components before beginning the installation. The APU requires periodic maintenance. Ensure there is access to internal components (i.e., oil filter, air filter, fuel filter and the oil filler). The APU does NOT come filled with coolant.
Page 10 through either the Aspen or the OEM system. Make sure supply air is not directed at the CAT sensor. Return air to CCU is essential. DO NOT remove caps until ready to make connections DO NOT over tighten connections DO NOT twist or stress tubes when tightening hoses. DO NOT bend tubes to adjust alignment/fit Use backing wrench P-clamps must capture the hose to eliminate any pre-loading of the hose assembly on the fitting...
Page 11 Hazard Cautions Preventative Actions • Use personal protective equipment. • Ensure adequate ventilation. Diesel • Combustible liquid. • Material can create slippery conditions. Fuel • May cause cancer. • Avoid contact with skin, eyes, and clothing. • Irritating to eyes and skin. •...
Page 12 Lockout-Tagout Equipment The following equipment is required to perform lockout-tagout (LOTO) on the Aspen APU • Battery cable lockout is used on the APU battery cables and disables the 12 VDC power source for the APU. • In some applications there may be potential ground path through the APU and truck frames so BOTH the B+ and B- cables must be disconnected and locked out.
Page 13 Lockout/Tagout locations for Aspen APU • Disconnect the APU B+ and B- battery cables from the truck batteries. • Apply battery cable lockout to each of the battery cable ends • Refer to truck OEM and local regulations for additional battery cable lockout requirements •...
Page 14 2. Components The Aspen is a fully featured diesel-powered Auxiliary Power Unit (APU) that provides air conditioning, heating, cab power, truck engine warming, battery charging, and the ability to connect to shore power. The Aspen consists of four main components: power unit, condenser, Climate Control Unit (CCU), and Aspen Interface (AI).
Page 15 Auxiliary Power Unit (APU) Climate Control Unit (CCU) Climate Control Module (CCM) 62-12173...
Page 16 Aspen Interface (AI) Condenser (APU) Power Outlet Coolant Surge Tank (Stand-alone) Component Weight (lbs) Weight (kg) Power Unit Integrated Power Unit Stand-Alone Condenser Assembly CCU Assembly Add for Aspen SKY 62-12173...
Page 17 Required Tools Part Number Description 07-00176-11 Pump, Vacuum 07-00294-00 Gauges, Refrigerant R-134a 07-00295-00 Detector, Leak 07-00315-00 Charging/Recovery Meter (Scale) 07-00414-00 Gauge, Micron 07-00447-00 Rivnut installation tool 07-00487-00 Heat Gun TK9002 Flow Meter, Coolant Additional Required Tools Tool Description Cable jacket stripper Lifting sling, 3 point Center punch Marker, Permanent...
Page 18 Installation Kit Parts The following tables are representative of the parts that are included in the installation kits. Parts and quantities included will vary by model and are subject to change. The parts contained within each kit are packaged so that the parts required for each section contained within the same bag/box.
Page 19 NAME PART QUALIFIER PACKAGING KIT AUXILLARY HEATER OPTION KIT HEATER ASSY SD AT2000STC D 12V HARNESS ASSY EXT 2M DP 42 AT EVO TUBE,FLEXIBLE 22MM X 1M W CAP TUBE,FLEXIBLE PAK 60MM X 1M TUBE,FLEXIBLE AA 22MM X 0.5M PIPE 4.76X828MM 0.25 IN MANUAL INSTALL AIR TOP 2000 STC MOUNTING PLATE...
Page 20 NAME PART QUALIFIER TUBE,PICKUP FUEL TANK CLAMP,HOSE 0.28-0.60 ID, PACKAGING KIT BATTERY FUSE FUSE 200A FUSE HOLDER MEGA FUSE/COVER LUG, TERMINAL 4AWG, 5/16 HOLE LOG, TERMINAL 4AWG, 3/8 HOLE HEAT SHRINK 0.50 ID (BLK) HEAT SHRINK 0.50 ID RED X 2.0 L STA-STRAP 0-4.00 DIA CABLE STA-STRAP...
Page 21 NAME PART QUALIFIER ASPEN INTERFACE MOUNT ASPEN INTERFACE BRACKET ASPEN INTERFACE WIRE HARNESS ASPEN INTERFACE BATTERY CHARGER 10 AMP HARNESS SHORE POWER GND SELECTOR SWITCH SHORE POWER CABLE SHORE POWER HARNESS SHORE POWER Y HARNESS SHORE POWER DC HARNESS SHORE POWER AC CABLE 10 AWG 2C, TECK 90 BUSHING...
Page 22 3. Power Unit The location and how the APU is mounted is critical to a successful installation. Before selecting a mounting location review the mounting requirements listed in Table 3. Consider how the coolant and fuel lines as well as electrical wiring will be routed and secured prior to beginning the installation.
Page 23 3.1 Power Unit Dimensions 62-12173...
Page 24 62-12173...
Page 25 3.2 Cover Removal Removing the covers from the power unit will aid in installation. Unscrew the knob located on the top of the APU Pull the latch handles down and out to release Grab both sides of the cover and pull out to clear posts Once the cover holes are clear of the posts, slide the cover out until it is past the flange bracket...
Page 26 3.3 Power Unit Installation Do not bottom mount APU. APU must be connected to side of truck frame. Consult truck OEM for frame drilling requirements Determine the location on the truck frame where the APU will be mounted. Refer to Figure 2 for mounting clearance requirements.
Page 27 Lift the APU off the shipping pallet using one of the following methods 3a Bottom Lift – APU lower legs supported and lifted with jack/forklift 3b Overhead Lift – Lifting sling attached to APU lift points and lifted with overhead lifting device When supported, the APU must be positioned so that: The back of the APU frame will be flush with the side of the tractor frame •...
Page 28 Remove the two bolts securing the step plate Install lifting eyes into step plate frame inserts (1) Using 3-point lifting sling, secure hooks to lifting eyes and the engine lifting eye (2) closest to the DO NOT us the lifting eye on the air cleaner bracket (3) for lifting the APU.
Page 29 Position the frame grippers on the truck frame rail. Insert the mounting bolts/washers into the frame grippers and then into the back of the APU frame through the mounting holes. Upper hole: Install washers and nuts on the mounting bolts from the inside of the APU frame. Lower slot: Install spacers, washers, and nuts on the mounting bolts from the inside of the APU frame...
Page 30 3.4 Exhaust Exhaust from the engine exits the APU through the tailpipe mounted to the left side of the lower frame. The tailpipe and mounting hardware are shipped loose and must be installed. Depending on the model, the tail pipe will connect to the DPF or muffler outlet.
Page 31 11 ft-lb Secure the exhaust pipe to the exhaust support with exhaust clamp. Adjust exhaust support and tighten bolts 4 ft-lb 19 ft-lb 3-10 62-12173...
Page 32 3.5 APU Wiring The 12VDC/CAN and interlock harnesses must be connected to the APU. The 12 VDC/CAN harness provides 12 volt power to the CCM as well as the CAN communication circuit that connects the CCM and APU module. The interlock prevents the tractor engine and APU from running at the same time. Installation of the interlock harness is required for the automatic operation of the APU.
Page 33 Insert the non-fused end of the interlock harness through the grommeted opening in the APU frame Locate the interlock wire (yellow) in the APU engine harness Trim interlock harness length as required Position heat shrink tubing over the end of the interlock wire Crimp butt splice to the interlock wire Strip end of interlock harness to 0.25”...
Page 34 Route the 12 VDC/CAN harness from the APU to the opening in the cab floor (Section 9) for the wiring harnesses. Secure harness every 12.0” (300mm) 3.6 Cover Installation Inspect that the air cleaner and fan foam rings are in place and not damaged Inspect the side cover and verify that the bumpers, grommets, and compression limiters are present and in good condition.
Page 35 Verify the lower cover grommets and compression limiters are in place. Note: The compression limiters for the lower cover are attached to the front of the APU frame Hold the lower cover flat and fit the cover slots over the skid plate tabs (1). Rotate the cover up the to front the frame.
Page 36 Insert the knob through the hole in the flange bracket and cover. Tighten by hand until secure. Pull latch handles down and over the keeper. Grab cover and pull out to verify it is secure Covers must be secure, and knob installed while vehicle is moving 3-15 62-12173...
Page 37 4. Condenser The function of the condenser is to remove heat from the refrigerant before returning to the CCU. A filter/drier is also included to keep the refrigeration system clean and free of moisture. The condenser assembly and filter drier mount to the rear of the truck cab. Before selecting the condenser mounting location review the mounting requirements listed in Table 3.
Page 38 4.1 Condenser Dimensions 62-12173...
Page 39 4.2 Condenser Installation Determine the location on the truck frame where the APU will be mounted. Refer to Figure 2 for mounting clearance requirements. Hold the condenser at mounting location and mark the location of the mounting holes. Condenser assembly weights 26 lbs. (11.8 kg) Drill 17/32”...
Page 40 Position condenser and filter/drier assembly over mounting holes. Secure with bolts, lock washers, and flat washers. The receiver drier bracket attaches to the condenser assembly using the top two condenser mounting bolts. Tighten bolts 11 ft-lb Keep condenser and filter drier capped until refrigerant lines are installed 62-12173...
Page 41 5. Cooling System Prior to installing the cooling system components, carefully plan how the coolant lines will be routed and connected. The preferred installation method has the APU draw coolant from the truck engine below the thermostat and coolant returns near the truck water pump. Locate these connections as far apart as possible on the engine.
Page 42 Install adapter fittings/valves in the main truck engine. If using Y-fittings, ensure they are oriented correctly Consult truck OEM for appropriate pressure and suction connection locations. Apply self-closing wrap or equivalent on coolant hoses. Route and secure coolant hoses from truck engine to APU. Avoid sharp bends and kinking the heater hose.
Page 43 Install coolant flow meter in-line with the coolant hoses between the APU and tractor engine. Connect coolant hose to APU coolant outlet, and the other end to suction fitting on truck engine. Connect coolant hose to APU coolant inlet, and the other end to pressure fitting on truck engine.
Page 44 5.2 Cooling System Installation (Stand-alone) Surge Tank Installation 2.875 Hold the surge tank at mounting location and mark (73.0) the location of the mounting holes. Drill 17/32” holes at mounting hole locations 9.625 (245) Tap Rivnuts into the hole Use 07-00447-00 to install Rivnuts into holes 07-00447-00 62-12173...
Page 45 Secure tank with supplied bolts, lock washers, and flat washers. Tighten bolts 11 ft-lb 5.3 Coolant Connections (Stand-alone) Apply self-closing wrap or equivalent to coolant hoses Route and secure coolant hoses from surge tank to APU. Avoid sharp bends and kinking the heater hose.
Page 46 Connect coolant hose to APU coolant outlet to top barb on the surge tank. Connect coolant hose to APU coolant inlet to bottom barb on surge tank. Install coolant hose strain relief at APU and surge tank connections. Slowly fill the surge tank until coolant is visible in the sight glass.
Page 47 6. Air Heater Option When installed, the air heater option is used as the heating source in place of the electric heater in the CCU. The air heater is powered by diesel fuel that is drawn from the truck fuel tank. Fuel for the heater is supplied through a pickup tube that is independent of the APU fuel pick-up.
Page 48 Fuel Pump Install according to section 6.5 and secured with supplied clamp Enter from top of tank Allow for connection of fuel lines Not subject to physical damage Does not interfere with any truck fuel connection, baffles, or fuel level sensor Fuel pickup Drilling debris not allowed to enter tank Minimum 1.0"...
Page 49 Figure 6.0 Heater Dimensions 62-12173...
Page 50 6.1 Control Unit (Heater) Mounting The heater can be mounted using one of two methods Direct mount – Heater mounted directly to cab floor • Plate mount – Heater attached to mounting plate and plate attached to floor • Determine the location for heater installation The heater must be installed with the minimum space requirements shown in Figure 6 Drill the cab floor according to the template as shown...
Page 51 Install the hot air inlet grille Align the tabs on the air inlet with the openings in the grille Install the (1) mounting gasket on the bottom of the heater Install the heater to the cab floor. Tigthen the mounting nuts Ensure all moving parts can move freely When using the optional mounting plate and closed cell foam gasket, do not over tighten the...
Page 52 6.2 Hot Air Ducting The heater must not be integrated into the vehicle or CCU air system. Determine the location for the hot air vent and duct routing Drill hole for hot air vent 2.375” (60mm) Install clamps on the hot air duct Connect hot air duct to the heater and outlet Tighten clamps 62-12173...
Page 53 6.3 Fuel System Components and Locations The air heater fuel system components must be installed in the configuration shown in Figure 6.1 and be located within the height/length requirements given in Table 6.1. Additional installation requirment are provided in Table 6.0 Maximum suction height 3’-3”...
Page 54 6.4 Fuel Pickup Installation The fuel pickup can be installed using one of two methods Fuel tank plug (Preferred Method) – Existing ¼” NPT plug in tank removed and fuel pickup installed • Drill fuel tank – 1.00 (25.4) hole drilled in top of fuel tank •...
Page 55 6.4.2 Drill Fuel Tank (Alternate Method) Care must be taken to prevent debris from entering the fuel tank during the drilling process. The following best practices will reduce the likelihood of debris entering the tank. Remove any dirt/debris from exterior of tank before drilling •...
Page 56 6.5 Fuel Metering Pump Installation The metering pump must be installed in a cool place as close as possible to the tank (see Figure 8). The metering pump and fuel lines must not be installed within range of the radiated heat from hot vehicle parts. A heat shield must be used if necessary.
Page 57 6.6 Fuel Line/Filter Install fuel line coupler on the fuel pickup tube Insert fuel line into the fuel line coupler and secure both ends of the coupler with clamps Note: Tighten fuel clamps until the two tabs are touching each other. Failure to do so will result in air leaking into the fuel system and poor performance of the heater, or a no-start condition.
Page 58 Attach fuel line coupler to the inlet and outlet of the fuel filter Connect the fuel line from the tank to the fuel filter inlet coupler. Secure with clamp Note: Tighten fuel clamps until the two tabs are touching each other. Failure to do so will result in air leaking into the fuel system and poor performance of the heater, or a no-start condition.
Page 59 6.7 Fuel Pump Harness Install the connector on the terminals that come out of the heater Note: Wires are not polarity sensitive Push the wires into the connector until an audible click is heard Pull on the connector/wire to verify installation Connect the fuel pump harness to the fuel pump connector on the heater Route harness from the heater to the metering...
Page 60 6.8 Combustion Air/Exhaust An intake silencer must be fitted if the intake hose length is shorter than 0.6 m. The combustion air must be extracted using a combustion air line from a position that is as cool as possible and protected from splashing water. Do not use an exhaust line as the combustion air line, as is may result in damage to the fuel pump harness.
Page 61 Route the combustion air line from the heater to the intake point. Cut line to length as required Secure line every 12.00” (305mm) Install clamp on the exhaust line in the orientation shown Install exhaust line on the exhaust outlet tube on the bottom of the heater (metal) Tigthen the clamp Route the exhaust line from the heater to the intake...
Page 62 6.9 Electrical Connections Remove the control unit cover on the heater. and connect the wiring harness plug to the control unit. Note: Before using the heater for the first time install the control unit cover to prevent the escape of hot air (heater overheating). Adjust the cable grommet position on the wiring harness to ensure that it seals properly against the control unit and cover.
Page 63 Install heat shrink tubing on the end of the B+ (red) and ground (brown) wires Strip the ends of the wires to 0.25”(6.35) Crimp ring terminal on the end of the wires Position heat shrink over the barrel portion of the teminal.
Page 64 Clean area near hot air outlet Apply hot air outlet caution label near hot air outlet 6-18 62-12173...
Page 65 7. Fuel System The APU uses the same fuel tank as the truck. Fuel is drawn from the tank using the fuel pick-up tube supplied in the kit. Fuel lines from the APU engine connect to the pick-up tube. The location of the fuel pick-up and routing of the fuel lines should be made according to the installation requirements in Table 7 Component Requirement...
Page 66 7.1 Fuel Tank Preparation 7.1.1 Fuel Tank Plate (Preferred Method) Remove block-off plate from fuel tank Mark center of plate with punch. Drill hole 1.00 (25) with hole saw. Deburr hole 62-12173...
Page 67 7.1.2 Drill Fuel Tank (Alternate Method) Care must be taken to prevent debris from entering the fuel tank during the drilling process. The following best practices will reduce the likelihood of debris entering the tank. • Remove any dirt/debris from exterior of tank before drilling •...
Page 68 7.2 Fuel Pick-up Installation Measure the depth of the fuel tank Cut the fuel pickup tubes to requirement in table 7 Separate supply and return tubes Squeeze fuel tube together and insert into tank Install the gasket, washer, and nut on the outside of the tank.
Page 69 Fuel Lines Route and secure fuel lines from APU to the fuel pickup. 12.0 (305) Route fuel lines away from sharp edges, pinch points, and moving parts. Fuel lines must be protected from abrasion 2.5 MIN Keep fuel lines away from exhaust pipes or (64) other heat sources Cut fuel lines to length...
Page 70 8. CCU Installation The CCU assembly is typically installed under the bunk in the sleeper. Before selecting the mounting location, consideration needs to be made for how the supply air ducts will be routed, and return air provided. There are several wiring harnesses that must be connected to the CCU, plan how these harnesses will be routed and secured prior to installation.
Page 71 8.1 CCU Dimensions Figure 8.1 CCU Top Dimensions Figure 8.2 CCU Duct Side Dimensions 62-12173...
Page 72 Figure 8.3 CCU Air Intake Side Dimensions Figure 8.4 CCU Alternate Duct Side Dimensions 62-12173...
Page 73 8.2 CCU Installation Do not cut, drill, or modify any structural member of the truck cab or chassis The CCU is heavy (78 lbs. kg). Do not drop. Use lifting device or team lift when lifting the CCU. The CCU may temporarily be positioned with the CCU air filter facing up to allow it fit in the truck cab. The CCU must be mounted flat on the cab floor using the supplied brackets.
Page 74 Install clamp and kazoo on evaporator drain hose Insert evaporator drain hose on evaporator drain tube on the bottom of CCU Secure clamp Pass the evaporator drain hose through the hole in the floor and position the CCU on the floor. Install the mounting brackets (4) to CCU leaving bolts loose.
Page 75 8.3 CCM Installation The standard mounting location for the CCM is on the top of the CCU. The CCM can also be remotely mounted for applications with reduced bunk height. When remotely mounting the installer is responsible for selecting a location that meets the requirements listed in table 9.1. Consider how the module will be attached and harnesses routed/secured when selecting the location.
Page 76 4 ft-lb 62-12173...
Page 77 9. Ducting The way the supply and return air components are installed affects cooling and heating performance. Before installing any of the ducts or vents consideration must be given to where they will be located and routed. Refer to Table 9 for supply and return air installation requirements. The preferred method for supply air installation is to use the ducts and diffusers supplied in the kit.
Page 78 Component Requirement Two return air vents required Return Air Minimum opening size behind vents 11.25x 5.00 (286x127) Three CCU outlet ports/vents must be used Cap unused outlets on the CCU Outlets not pointed directly at the AI Supply Air Low – Locate vent near the floor Mid - Locate vent 30.00-36.00 (762-914) above floor High - Locate vent as close as possible to bunk roof Minimum duct bend radius 7.00 (178)
Page 79 Attach return air vents using supplied self-tapping screws (black) Supply Air Determine location for supply air vents Cut 3.00” holes at vent locations using hole saw Debur hole. (76) (76) Attach supply air collar with self-tapping screws (silver). Insert diffuser into collar and snap in place. 62-12173...
Page 80 Route the ducts from CCU to the supply air vents Support ducts as required Install band clamps on ends of supply air ducts Connect the supply air ducts to the outlets at the CCU and supply air collars Tighten band clamps 35 in-lbs 62-12173...
Page 81 10. Refrigerant Hose Refrigerant hoses connect the condenser assembly on the outside of the truck to the CCU under the bunk. The hoses are pre-formed for ease of installation. Install of the hoses should be made according to requirements in Table 10.0.
Page 82 Remove the plastic cap for the line being installed DO NOT remove caps until ready to make connections DO NOT over tighten connections DO NOT twist or stress tubes when tightening hoses. DO NOT bend tubes to adjust alignment/fit Use backing wrench Lubricate the O-ring with oil Install hose fitting on connection at the CCU/Condenser Tighten fittings...
Page 83 Ambient Air Temperature (AAT) Sensor Bracket/Harness Attach the AAT bracket to the bottom of the condenser frame. The longer leg of the bracket faces outward Secure the AAT to the AAT bracket with push-on connector. Orient the sensor as shown. Secure the AAT wires to the bracket with edge clip and cable tie Connect CDM connector to the condenser fan motor...
Page 84 11. Climate Control Module Wiring Routing Generator Cable High Voltage Climate Control Module, power outlet, and block heater must be installed by qualified personnel Always perform these steps before connecting the APU to the battery Route the Generator cable from the power unit and through the hole in the floor. If shore power option is being installed, refer to Section 13 for Generator cable routing and installation.
Page 85 Mark inner cable 3.00 (75) from end of metal jacket Trim inner cable cover Do not cut inner wire insulation Insert Anti-Short Bushing (ASB) Install heat shrink and apply heat to shrink 11-2 62-12173...
Page 86 11.2 Generator Cable Connection Insert wires through 90° connector Insert wires through strain relief Strip black and white wire ends to 0.56 (14) Crimps ferrules on wire ends. Refer to section x Pull on ferrule to verify crimp Insert wires through CCM opening Position nut over wires Insert ferrule into TB1 connector Tighten set screws...
Page 87 3.5x0.6mm 10.6 – 13.3 in-lb (1.2-1.5 Nm) Position Wire Bare White Black Tighten jam nut Tighten 90 degree strain so that inner cable is secure and routes toward floor opening when locked. Lock angle connector Note: When locked the end of heat shrink should be flush with connector 11-4 62-12173...
Page 88 11.3 CCM Board Connections The procedure for connecting the high and low voltage harnesses is the same for each connector. Pinch the cone portion of the grommet and insert into the slot in the CCM housing Align the harness connector with the board connector Grab the harness behind the grommet and push the harness to seat harness to the board...
Page 89 11.4 2 VDC/CAN Harness Route 12VDC harness from the APU to the hole in the cab floor for the Generator cable Route harness along generator cable and to the left side of the CCM Connect the 12 VDC connector to J6 Connect the CAN connector to J10 11-6 62-12173...
Page 90 11.5 Condenser Fan/AAT Route condenser fan/AAT harness from the condenser to hole in the cab floor for the Generator cable Route harness along generator cable and to the left side of the CCM If the condenser and the CCU are not mounted to the same part of the truck (i.e.
Page 91 Connect the AI connector to J11 11.7 Heater Option Route the heater harness from the heater to (Section?) to the CCU Harness can be routed along generator cable or front face of CCU Route harness along generator cable and to the left side of the CCM Connect the heater connector to J9 11-8...
Page 92 11.8 Power Outlet Connect the power outlet harness to the J12 connector on the left side of the CCM. Harness can be routed along generator cable or front face of CCU Route harness from left side of CCM to oper outlet location 11.9 Block Heater (Option) Connect the block heater harness to the J13...
Page 93 Harness can be routed along generator cable or front face of CCU Route harness from left side of CCM to AFCI/GFCI device. 11.10 Low voltage sensor/thermistor harness Connect the sensor harness connector to J1 Connect the thermistor connector to J2 11-10 62-12173...
Page 94 Coil the excess low voltage harness 11.11 High voltage output harness Install HV harness support bracket 4 ft-lb Connect evaporator fan connector to J3 Connect compressor connector to J4 Connect heater connector to J5 Install cushion clamp on HV cables above grommet Secure cushion clamp to stud with nut Secure HV cables to support bracket with wire ties 11-11...
Page 95 4 ft-lb Install CCM cover Secure cover with hardware (screw, lock washer, washer) Install ground wire, screw, and lock washer 12 in-lb 11-12 62-12173...
Page 96 Install HV harness cover over studs 11.12 Securing cables Secure cables on left side of CCM as shown Secure cushion clamps with CCU cover bolts 1. Cushion clamp 2. Cable tie Secure Generator cable bundle to front of CCU with mounting bracket and cable tie Mounting bracket is secured with cover bolt Secure bundle to side of CCU with cushion clamp Clamp secured using HV cover stud/nut...
Page 97 Secure low voltage harness to the high voltage cover using cushion clamps Tighten high voltage cover nuts 1. Cushion clamp 4 ft-lb 11.13 High Voltage Ground Validation The CCU compressor, evaporator fan, and heater as well as the CCM contain high voltage components.
Page 98 Connect test leads to multimeter Validate low resistance in test leads. Connect one end to unpainted part of generator ground ring terminal at the ground/neutral stud (1) Connect second lead to HV harness cover stud (2) Measure resistance between generator ground and HV harness cover stud If resistance is less than 5.0Ω...
Page 99 12. Aspen Interface The Aspen Interface (AI) is the user control for the system. The AI turns the unit on/off and allows the user to select the mode of operation. The AI should be installed in an easily accessible location in the bunk area of the truck.
Page 100 12.1 Mounting Preparation and Harness Routing Determine the AI location and mounting method: • Flush – Rectangular hole cut in OEM panel. Has “factory installed” appearance and requires greatest care/precision during installation • Panel – AI attaches to flat bracket. Allows mounting to variety of surfaces and can cover existing openings.
Page 101 12.2 Flush Mount Apply masking tape to the surface where the AI will be installed Using the panel mount plate as a template, mark the opening for the AI with a permanent marker Drill a 0.25 (6.5) hole in one corner of the opening and at the CAT slot.
Page 102 12.3 Panel Mount Position the panel mount plate at the desired location Mark the opening with a permanent marker Center punch the hole locations Drill a 0.25 (6.5) hole in one corner of the opening and at the CAT slot. Cut the opening (cut just outside of the marked line) using a compact reciprocating or jig saw Note: Accuracy of this cut is not as important as...
Page 103 12.4 Surface Mounting Verify there is minimum 2.0 (50) behind the mounting surface and the mounting hole will not interfere with wiring harnesses, supports, etc. Mark the location for the AI harness passthrough Drill hole at marked location ᴓ 2.25 (38.1) Deburr hole 2.25...
Page 104 Insert DM connector into the back of the AI Engage the connector locking tabs by pulling away from connector. Audible click will be heard when locked Install self-tapping screws to secure the AI 12-6 62-12173...
Page 105 13. Shore Power The shore power option allows HVAC functions to operate off an external 120 VAC power source instead of running the diesel engine. When operating in shore power mode, the 120 VAC power source is automatically switched between the APU and shore power connection. The default power source is the APU. The APU engine does not run in shore power mode.
Page 106 13-2 62-12173...
Page 107 13.1 Shore Power Components Install the Shore Power Manager and battery charger under-bunk in one of the side jockey boxes and the AC receptacle on the driver's side of the vehicle. Install the Shore Power Manager so that the existing AC Teck cable connected from the APU to the CCU can be disconnected from the CCU and re-connected to the Shore Power Manager.
Page 108 Locate mounting position for plug housing. Mount to a metal panel or use the supplied bracket for under-cab mounting. Drill 1-11/16” diameter hole. Drill four 3/16” mounting holes. Install housing into panel and bolt into place using 8-32 bolts and nuts. Install molded male plug into the rear of the housing.
Page 109 13.3 Teck Cable Preparation (SPM) Route SPM cable in front SPM cable opening Mark cable 4.5 (114) past the right edge of cable opening/strain relief 4.5 (114) Cut cable to length at mark Mark outer covering 4.5 (114) from end of cable Score outer covering circumference at mark Bend cable at score line to separate metal jacket Metal jacket edge is sharp.
Page 110 13.4 Connecting SPM (HVAC) to CCM Route the Teck cable included in the shore power kit from the Shore Power Manager to the CCM. Secure cable as required. Terminate and connect the CCM end of the cable according to section ? Cut the Teck cable to length.
Page 111 Crimp the large barrel non-insulated ring terminal provided to the green ground wire. Use Panduit crimping tool #CT-1570 or equivalent. Connect the wires to the shore power terminals 13.7 Connecting SPM to Battery Charger Insert pre-crimped end of the AC battery charge cable through the shore power strain relief and connect wires as shown in Figure 58.
Page 112 13.8 Connecting Battery Charger to 12 VDC Harness Route the battery charger 12 VDC cable from the SPM to the CCM Remove the cap from the SPM connector located on the 12VDC harness near the CCM Connect the battery charger cable to the SPM Secure harness as required 13.9 Ground Harness Connect the ground wire from the SPM ground stud to vehicle chassis.
Page 113 14. Power Outlet and AFCI/GFCI Device Power outlet(s) are included with all models and provide 120VAC power to operate various loads. All outlets are protected by combination Arc Fault/Ground Fault Circuit Interrupter (AFCI/GFCI). The configuration and functionality varies by model. •...
Page 114 Power Outlet Remove the knockout for the location where the harness will enter the box Note: For applications where the box will be mounted to the bunk wall, using the rear knockout is preferred. This eliminates the need to route the outlet cable outside the bunk and reduces the chance that it will be damaged in use.
Page 115 Drill holes for cable Install grommet(s) if required If using rear knockout 1.00 (25) If outlet cable is externally routed 7/16 (11) Attach outlet box with self-tapping screws Insert threaded strain relief into box Do not tighten compression nut at this time 14-3 62-12173...
Page 116 14.2 Cable preparation Route the power cable(s) from the CCM to the outlet location Route the block heater cable from the block heater location to the AFCI/GFCI device Mark outer braiding where cable will enter outlet box and 12.0 (300) past the first mark Cut braiding/cable to length at the second mark Insert utility scissors in braid and cut along length of braid to the mark...
Page 117 Install cable tie 0.5 (13) from the end of the braid Insert cable through strain relief and into box Cut cable jacket 5.00” (125) past where it enters the box Mark cable 0.25” (6) past where it enters the box 5.00”...
Page 118 14.3 Ferrule Installation Strip the end of the wires to 0.50 (13) Position the insulated ferrules on the black and white wires Position the bare ferrule on the green wire (Power outlet only) Ferrule should bottom out on wire insulation and conductors flush with end of ferrule.
Page 119 14.4 Outlet Wiring Insert the ferrules under the line terminal clamps according to the table Tighten screw terminals Black Gold line White Silver line Green Device ground 14.5 AFCI/GFCI Device Wiring (Engine Block Heater) Twist the ends of the two green wires and the pigtail together Install the crimp sleeve over the wire ends Crimp sleeve using tool...
Page 120 Insert the ferrules under the terminal clamps according to table AFCI/GFCI device must be installed so that the ground screw is at the top of the box Tighten the terminal screws Black from CCM Gold line White from CCM Silver line Green from CCM Ground splice Black to heater...
Page 121 14.7 AFCI/GFCI Status Indicator Outlet Status Indicator Light Status/Action Reset Button Status Power SET – Button in Device is working normally Tripped – Button out Line and Load wires are reversed; reinstall with corrected line and load connections Solid Green Tripped –...
Page 122 15. Battery Cable The APU battery cables connect to the truck battery pack. The truck batteries provide 12 VDC power to start the APU engine. When the APU is running, the batteries are charged by the APU alternator. Determine the location and routing of the battery cables and fuse/fuse holder according to the installation requirements in Table 15.0 Component Requirement...
Page 123 15.1.1 Fuse Cable 1. Measure the length from the positive battery terminal to the desired fuse holder location. Maximum 12.00 (300) 2. Cut a piece of cable off the end of the positive (red) battery cable. The length should be the same as measured in the previous step.
Page 124 Do not attach battery connections until installation is complete and unit is ready for commissioning 1. Cut positive battery cable to length 2. Strip end of cable to 3/8” 3. Position one piece of red heat shrink tubing over the stripped end 4.
Page 125 15.1.4 Fuse Holder Do not attach battery connections until installation is complete and unit is ready for commissioning Fuse/fuse holder must be installed 1. Secure fuse holder in the battery box using M6 bolts or wire ties using the wire tie mount slots 2.
Page 126 16. Commissioning 16.1 Battery Cable Connections Separate the Starter Solenoid Disconnect (SSD) located at the front of the APU engine. Connect positive (A) and negative (B) battery cables Apply corrosion protection to battery cable connections Reconnect the SSD after completing the configuration steps in section 16.2 16.2 Configuration The model number, software, and configurations must be set for the Aspen APU to function properly.
Page 127 Connect harness (D) to CAN BUS Interface (C) Connect CAN BUS Interface (C) to USB A port on PC (A) Connect harness (D) to CAN SERVICE connector located on 12 VDC/CAN harness near the CCM Launch Cabin Tech program Select System Setup Menu 16-2 62-12173...
Page 128 Set the following controller data Unit Model Number – Select from drop down A-INT Integrated with CCU A-STA Standalone with CCU A-PWR Integrated without CCU A-SKY Intergrated with CCU and DPF APU Module Serial Number – Auto populated CCU Module Serial Number – Auto populated Unit Serial Number –...
Page 129 Select System Configuration menu Set system configuration and functional settings using one of the following methods a. Configuration file – Customer specific configuration parameters are loaded from file b. Manual entry – Individual configuration paramaters are selected and sent to contoller To open existing configuration files, click the open (2) button at the top right part of the system configuration screen.
Page 130 16.3 System Configuration (Table 16) Alarm Settings Parameter Default Description Coolant Sensor Alarm Shutdown APU engine shutdown if coolant temp sensor is detected open/short Engine Oil Pressure Shutdown APU engine shutdown if low oil pressure is detected High Engine Temp Shutdown APU engine shutdown if coolant temperature is high Compressor Alarm Shutdown APU/CCU shutdown if compressor alarm is detected.
Page 131 Parameter Options Default Description Pretrip type Short or Long Short Length of pretrip test Alarm Description YES or NO Alarm descripton displayed in service menu APU Mode OFF, Cool, Sets APU run mode Heat, Fan, Comfort Monitor Control Probe Cabin, Return, Cabin Sets temperature sensor input that system will Supply...
Page 132 Auto Temp Start ON or OFF Enables temp start configuration Temp Start Temp 41 to -4 14F (-10C) Temperature where temp start is activated 5C to -20C Temp Start Duration 1 to 4 Hours in 1 2 Hours Duration that APU will run when temp start is hour increments activated Auto Battery...
Page 133 Stand-Alone Fill the stand-alone surge tank Open the APU engine bleeder valve ½ turn, allow coolant to gravity feed into the APU. Before starting the engine verify the coolant level is still full. Start the APU engine. Run the engine until all air is purged from the bleed line and coolant begins to flow.
Page 134 Note: If system did not fully charge with unit OFF proceed with following steps. Start the APU and set to Run Mode Cool, fan speed Adjust the setpoint below cabin temperature. 16.6 Seal Cab Holes Apply appropriate sealant or expanding foam to the following holes in the cab floor: •...
Page 135 16.7 Engine Break-in/ Heat Verification Start the APU and set to Run Mode Heat With APU running check AC Voltage and Generator Frequency. Is voltage is greater than 107? And frequency greater 60 hz If Yes proceed to next step. If No refer to (62-12174 Aspen Operation and Service Manual - Low/No Voltage Diagnostics) Adjust setpoint to 85F Open tractor doors and other vents to allow air to exit the cab.
Page 136 16.10 Engine Interlock Start APU Start tractor engine and verify that the APU shuts down. Start APU (truck engine running). APU should not start 16.11 Air Heater Option Connect heater diagnostic tool 1320920A to the heater diagnostic connector Connect the USB adapter cable to the diagnostic tool and the other end of the cable to a computer with the heater diagnostic test software installed Prime the heater fuel metering pump using the diagnostic tool Adjust set point to 85F...
Page 137 16.13 Final Steps Check APU and truck for leaks Check engine oil level and adjust if needed Check coolant level and adjust if needed Reinstall fairings, panels, or interior panels removed during installation Clean interior of cab Complete PDI for and warranty registration forms Place Operator’s Manual/AI operation card in cab of truck 16-12 62-12173...
Page 138 17. Appendix 17.1 Self-closing Wrap Installation (58-60992) The purpose of this technical instruction is to provide the installer guidelines for installing the 58-60992 self- closing wrap. The wrap is intended to be used in place of convoluted wire loom where protection from chaffing is required.
Page 139 Applying Self-closing Wrap Position the end of wrap a few inches from the end of the cable Open the end of the wrap and begin covering the cable. Keep the wrap open ahead of the area being covered by inserting finger into opening in the wrap. Continue inserting the cable into the wrap the length of the cable Cut the wrap to length using sharp utility scissors T1.
Page 140 Wrap the cable with harness tape (A) at the end of the wrap. Make a minimum of two tape turns on the exposed cable. Tape should be wrapped in the same direction as the exposed edge of the wrap. Cut the tape at a 20-45° angle. Leave enough length to make another two turns.
Page 141 Taping Cable Length The self-closing wrap needs to have additional tape wraps placed along the length of the wrap to prevent the wrap from opening. Use the following best practices when adding tape and positing the wrap. • Apply tape wraps every 150 mm (6.0) along the length of the wrap. •...
Page 142 Harness Diameter Diameter Black Wrap Orange Wrap mm (a) min-max mm (in) 58-60992-00 58-60992-30 1 - 5 (0.04 - 0.20) 58-60992-01 58-60992-31 6 - 8 (0.24 - 0.32) 58-60992-02 58-60992-32 9 - 10 (0.35 - 0.40) 58-60992-03 58-60992-33 11 - 13 (0.43 - 0.50) 58-60992-04 58-60992-34 14 - 16 (0.55 -0.63)
Page 143 Central America and Mexico Carrier Transicold Carrier Transicold Ejercito Nacional 253-A Piso 5 700 Olympic Drive Colonia Anahuac 11320 Mexico Athens, GA 30601 D.F. ©2023 Carrier Corporation. Printed in USA 6/23. Carrier, Carrier Transicold is a registered trademark of Carrier Corporation.

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