TKT-20ES DC POWERED AIR CONDITIONINGSYSTEM INSTALLATION MANUAL

Contents• AC unit and accessories .........................................................................................3

• Preparation for installation. ..... ......... ..... ....... ......... ..... .... ...........................4

• Auxiliary box installation.... .... ...................... ......................... ................ .... ....... 5 -8

• Condenser installation.... ..... ............... ..... .................. ..... ............... ..... .......... 9 - 11

• Evaporator installation...................................................................................................12 - 13

• Hosing,Pluming& Wiring installation........................................................................ 14- 27

• Testing for leaks and evacuation................... ...................... ......................... ........... 28 - 29

• Charging the system........................................................................................................ 30-31

• Connecting auxiliary battery box to power source for charging............................... 32

• Testing and starting unit.................................................................................................. 33 - 34

• Warranty and contact information................................................................................. 35

AC Unit & AccessoriesPARTS INCLUDED:

Evaporator unit with remote control and installation

hardware Condenser/Compressor box unit with

hardware and wiringharness ElectricalCables and all

connections

Refrigerant hoses with fittings and charging ports

Installation bolts and Insulating tape

Wiring included in the unit as shipped

OPTIONAL PARTS:

In frame battery box

Auxiliary battery separator

Charging cable's and connections from main to auxiliary battery box

Optional evaporators are available

The estimated installation time is, 3.0 Hours if hooked up to original batteries or you can install some auxiliary batteries asneeded

Preparation For Installation• The mounting surfaces must be clean and free of debris.

• The location of the evaporator and condenser is at the installer's discretion.

• Mounting hardware is not supplied as the specific size and quantity of hardware is determined by the installer,dependent upon the type and modelof vehicle.

• The installer should determine:

• Whether the rear cab wall should be reinforced. NOTE: Caution should be exercised when working on the cab.Damage could occur when extra weight is applied. If necessary,the rear wall should be reinforced with plywoodor other suitable material.

• Twelve 5/16" bolts will be sufficient to mount the evaporator and condenser securely. Extra bolt holes areprovided in the frames to allow for additional mounting points. All mounting hardware must be able to safelysupport the weight of the evaporator or the condenser.

• The No idle ACUnit is supplied with an adequate length of refrigerant hose complete with couplings for theaverage installation. The installer should calculate the length of hose required for the installation and reduce oradd hose as required using similar fittings. Electrical power cables from the condenser to the power source aresupplied.

• The length of 5/16" bolts should be determined prior to the installation and drilling of holes in the cab as each cabmay vary depending on model and various configurations.

Auxiliary Battery Box Installation

• Be sure to have sufficient space between frame rail to fit batterybox.If not then an alternative spot will need tobe used.

• Place Box between frame rails

• Mark holes for drilling

• Drill hole size5/16".

• Mountbox with hardware provided.

Auxiliary Box Batteries

Install the batterybox,between theframes andtighten it withsuppliedhardware.

Place the selectedbatteries in thebox and securethem with thesupplied brackets.

Battery and Boxholding brackets.

Holders Separator

Batteryholdingbrackets.

Separator todisconnect theauxiliary batterybox from main.

Battery wiring start

Tighten holdersto securebatteries inplace.

Battery box wiring Locks of battery box

Completedbattery box

Easy lockingmechanism thatholds battery boxlid.

Finished surface

Exterior of thefinished box

Condenser InstallationAdditional reinforcement or support may be required to support the weight of the condenser on the outside of the rear cabwall. All mounting hardware must be able to safely support the weight of the condenser.

• Remove the screws that attach the cover to the frame. Set the screws and cover aside

• Using the mounting holes on the backing frame asa guide,mark eight (8) or more holes for drilling for the 5/16" bolts. Aminimum of eight (8) holes must be used in order to properly support the condenser weight. Select holes that will line upwith any reinforcement or with added reinforcement. Mark additional holes if necessary.

• Drill the mountingholes.

• Position the condenser and install the 5/16" bolts with the appropriate size washers and lock nuts.

• Seal the holes with silicone sealant to prevent moisture and air leaking into the cab through the wall.

• Tighten the bolts.

• DO NOT reinstall the cover at this point.

Condenser unit Drilling

distancebetween thetop bolt holes.

Drilling the holesaccordingto the

Installation of bolts

Install the boltsfrom insidetowards outside,using properwashers.

Installation of bolts Condenser installation

Bolts fromoutside.

Hang thecondenser tothe boltsand secure itwith the

Tightening the bolts

bottom holders,drill them andbolt thecondenser tothe wall from allfour corners

Evaporator Installation• The evaporator is mounted in a horizontal fashion inside the vehicle cabin in an area to be determined by the

installer given necessity of cooling and the location where cooling is most important. This is usually at the rearof the cabin. Additional reinforcement or support may be required and all mounting hardware must be able tosafely support the weight of the evaporator.

• Using the mounting holes on the back plate as a guide, drill 3 or more self tapping screws to secure themounting bracket.

• Position the evaporator on the bracket and secure the 3 -10mm bolts.

• Tighten the bolts using an appropriate torque to secure without over tightening.

Finding back wall supports Install evaporator bracket to the support

Evaporator box installed

Hosing, Plumbing &Wiring Installation1. INSTALLING THE REFRIGERANT HOSES

• Depending on the desired routingof the hoses from the condenser to the evaporator you will have tocut one or twoholes to accommodate the two refrigerant hoses.

• When routing the hoses,ensure that they do not touch sharp metal or any rotatingcomponents. A rubber grommet orsimilar protector to the hole(s) would best be installed to protect the integrity of the hose. Always allow sufficient slack to

avoid tight bends.

• Connect the two refrigerant hoses from the condenser to the fittingsat the bottom of the evaporator,as shown in thephotograph below.

• Ensure the supplied 0-rings are in place at each end of the refrigerant hoses.

• Oil the Q-rings with refrigerant oil.

• Using a wrench, tighten the refrigerant hose fittings; tighteneach fittingas follows:

a) For #6 size hose -10- 13ft-lb b) For #10 size hose -15- 18 ft-lb

2.DRAIN HOLES

The No idle ACUnit has an equipped drain hose located on the side of the evaporator unit which should have a connection madeusing a hose(supplied) to an area where water can escape or is confined without damage.Make sure the Evaporator is installed level for the proper condensation drainage.

3.ELECTRICAL CONNECTION FROM CONDENSER TO EVAPORATOR

The No idle ACUnit comes with electricaI connectors to connect the evaporator with the condenser using Andersonconnectors which will make the connection easy and without error. Refer to the photo below and review the location ofyour installation. Fix the connectors as shown.

Back wall hole drilling Drilling

Make sure toinstall rubbergrommet toprotect hoses andwiring from sharpedge

Line installation Line installation

Attach lines tofind requiredlength.

Hose installation Hose installation

Pass the hosesthrough cab wall.Measure, and cut tothe requiredlength.

Hose installation

Hose installation Hose insta

Pass thelines throughhole(s).

\ ..

Line installation Evaporator line covers

Insulate the lowpressure line toavoid themoistureabsorption.

Install theevaporator coverto protect lines.

Back wall holecoverr

Condenserdrain hole

2.For extra drain

Back wall insulation Cover installation

Insulate hole from

outside.Install back wallcover.

Drain hole installation

lines and runevaporatordrain

Lines Lines

• Using C-clampssecure the aclines to rear wall,and zap strapwires to thehoses

Wiring preparation Wiring preparation

Crimp the rightconnections to thecable.

Use flux paste orliquid to havebetterconnection aftersoldering.

Wiring preparation

Solder everyconnection.

Wiring Wiring

Attach the main

auxiliary batteries.

Make sure you takeout main fuse toauxiliary box.

Secure and run thecables around safeareas and use thezap straps to holdthem in place andaway from sharpedges.

Wiring Wiring

Use breaker orfuse

(80amp)

Negativeattachment for

separator.

Wiring

Negative wireto separator.

Connecting wires Connecting wires

Connect positiveand negativewire to main

battery box.

Wire protection Wire protection

Use rubbersleeves toprotect the wiresfrom sharpedges ifnecessary.

Completed aux. battery box

Installwiringseparator andbreakeraccording to thisimage.

RE Y-

l

Wiring Diagram

00

( )0::0

AUX.BATTERY BOX

BATTERY 11=---- ._+_ t++--...,SEPARATOR L BRAKER

:VOL-,,. WAKEUP I

EVAPORATOR i!:jc::"'0

----------r1$--+--J[MAINCONTROLLER 80

ftlr-;:I+ TI

-I--::!_ . .__ - r---NEGATIVE---....1

HIVOLTAGElCOMPRESSOR

)

I _JLIMAIN BATTERY BOX

Testing For leaks &Evacuation

• The No idle AC Unit is a two part air conditioning systemthat requires the unit to be installed and then charged usingR134a refrigerant. Please review the following points with your air conditioning technician to ensure a trouble freeinstallation and operation:

• Perform a leak check at each fitting and overall throughout both the evaporator and condenser coils.

• Evacuate the entire unit to meet local refrigerant handling standards. We recommend at least thirty (30) minutes

vacuum before charge.

• Oncethe above hasbeen completed the systemcan be charged withR134a refrigerant according to the guidelines following below.

Charging The System

• The system should be charged by a qualifiedair conditioning technician using the followingas a

guideline:

• The charge points are located on each of the refrigerant hoses as shown in picture below.

• If using the full length of supplied refrigerant hose you will require2.2 lbs of R134a refrigerant. For each complete foot of hose either added or subtracted from the suppliedlength the amount of refrigerant charge should be added or reducedat a rate of O.llbs. (i.e. cut hose off by 2feet would reduce the amount of refrigerant by 0.21bs)

• The compressor is pre-charged so no additional oil is required.

Charge the unit

2.2 lbs of R134a refrigerant for full length hose.

..

Connecting System To Charge AuxiliaryPower Source

CAUTION: IF THE MAIN POWER IS LIVE WHEN INSTALLING THE CABLES TO CONNECT THE BATTER SOURCE TO THECONDENSER, THE ON/OFF SWITCH ON THE EVAPORATOR MUST BE IN THE OFF POSITION.

Check the polarity before installing the cables.

Power cable gauge guide;recommended sizing for minimum voltage drop and inrush current:

length Wire Gauge Current Rating Separator

Rating

5' -10' 4 180 amps 200 amps

Wire gauge is based on 135C insulation; for lower temperature rated insulation and/or applications insideengine spaces use next larger gauge. The following is a guide to wiring to the main power:

Cut the appropriate hole(s) based on the routing to the power supplyConnect the battery cables to the positive and negative terminals on the batteries. First connect the positivecable, and then the negative cable. Ensure the cables do not touch sharp metal or any rotating components.Allow sufficient slack to avoid tight bends.Tighten the battery terminal connectors.

Coat the battery connections with dielectric grease for corrosion protection.

Testing & Starting Unit• Ensure that the refrigerant hoses are securely attached, not rubbing against any sharp objects or moving parts,

and are not close to any extreme heat (>200F) source such as the exhaust system.

• Check the drains in the evaporator unit for any possible obstructions

• Check all parts of the system for refrigerant leaks

• Install both the condenser cover ensuring that all electrical connections are tight and using the screws/boltspreviously removed.

• Turn system on using the controls on the evaporator unit-see picture below

• Ensure all components are tight and secure and the system operates without excessive noise or vibration.

Final test and running the unit.

Test blower speed and compressor functions

in different desiredtemperature.