IS-20932A

IS-20932A
Instruction Sheet
H3 SERIES ENVIROCARE - IONS AIR SANITIZER
Effective vehicles: 2009+ (9-1409 and up)
Revision A
Parts info added
06-29-2021
MATERIAL
Kit #0610448 includes the following parts:
Part No.
Description
Qty
0610449
PLASMA CLUSTER
10
564288
DC/DC (24/12V) CONVERTER
1
0610510
SUPPORT CONVERTER DC-DC (1)
1
0610511
SUPPORT CONVERTER DC-DC ASSY. (2)
1
454472
SUPPORT
ASSY
1
454471
CLOSING,CONDENSER DUCT
1
5002071
NUT SPR U #8 .110-.187
18
506268
TAPE AD1 URE OP GY 3/8"X1/2"X25'
454469
SUPPORT ASSY. LEFT
1
454466
SUPPORT ASSY. RIGHT
1
370377
PLASMA CLUSTER BRACKET, DEFROST UNIT
2
314937
PLASMA CLUSTER BRACKET, PARCEL RACK
4
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PLASMA
CLUSTER,EVAP.DUCT
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0610501
WIRING, PLASMA CLUSTER CONDENSER
1
0610502
WIRING, PLASMA CLUSTER DC/DC
1
0610503
WIRING, PLASMA CLUSTER DRIVER
1
0610504
WIRING, PLASMA CLUSTER EVAPORATOR
1
0610505
WIRING, PLASMA CLUSTER PARCEL RACK
1
952624
CLAMP P STL ZP RUB 7.9 ID
1
500539
NUT HEX NYRT NX500 M4-0.7
2
500591
WSH FL Z050 4.3X9X.8 (M4,#8)
1
864368
SCREW 3/8 PLASTIC
12
502799
SCR CAP HEX N500 M4-0.7X16 G8.8
24
500855
WSH FL N500 .188X.438X.049 (M4,#10)
24
5001996
SCR MA PAN PH N500 M4-0.7X12
5
500957
SCR TP BDG PH N500 #10X3/4
35
500443
SCR TP PAN PH N500 #8X1/2
10
504637
CABLE TIE, NYLON BLK (STD)
40
504273
CABLE TIE, NYLON BLK (SMALL)
20
562679
4 WAY ADH. SQUARE BACKED MOUNTS
20
504335
RVT POP DOME AL CLE 3/16 (0.063_0.125)
6
564108
SELF-MOUNTING STUD
509815
FIR TREE MOUNTING (FT7 TYPE)
7
504534
GROMMET .875 X 1.250
1
0611019
DECAL (EN)
1
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1

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0610528
DECAL (EN/FR)
1
454769
SUPPORT
PLASMA
ASSY- TEMPLATE
454479
CLOSING,CONDENSER DUCT - TEMPLATE
1
0610547
DC/DC CONVERTER DECAL
1
IS-20932
INSTRUCTION SHEET (EN)
1
FI-20932
INSTRUCTION SHEET (FR)
1
CLUSTER,EVAP.DUCT
1
Other parts that may be required:
Part No.
Description
7771197
AIR ION COUNTER (TESTER)
Qty
1
NOTE
Material can be obtained through regular channels & Wiring diagram provided on page 30.
PROCEDURE
DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button.
Lock out & Tag out (LOTO) must be performed during set-up, maintenance or repair activities. Refer to
your local procedure for detailed information regarding the control of hazardous energy.
1. Install the # 564288 DC/DC converter in the vehicle last street side baggage compartment.
•
Using 2 of the supplied # 500597 screws, secure the # 0610510 part of the support to the vehicle
celing just next to the vehicle inverters (see picture for actual location). There should be a min 1/2
inch gap between the support and the vehicle structure.
•
Apply the # 0610547 decal to the front face of the DC/DC converter (inputs & polarity).
•
Pre-install the DC/DC converter # 564288 to the other half of the support (# 0610511). Use 4 #
502799 screws and 4 # 500855 washers.
•
Secure that assembly to the previously installed support half in the vehicle, use 2 loosely screwed
# 5001996 screws.
•
Secure the top of the assembly to the ceiling using 2 other # 500597 screws.
•
Tighten the support #5001996 screws to secure both parts of the support together.
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2. Pass the # 0610502 harness R12 connector (ring terminal with black fuse holder), the
ground terminal & the C582 connector in the evaporator compartment through the
compartment harness opening (grommet).
•
Pass a fish tape or a flexible rod through the baggage/evaporator wall grommet (some cable ties
may need to be removed around the rubber boot).
•
First pass the C582 connector through the grommet.
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NOTE
−
Pass all wires behind the HVAC duct
−
Do not connect the R12 connector (POWER+) and the GRND terminal yet.
−
Keep wires loose, secure only after final connection.
3. Connect the DC/DC converter to the # 061502 wiring harness.
•
Connect the DC/DC converter outputs and input wires as shown in the picture below. Wires are
numbered, make sure the order is correct.
NOTE: Make sure that the converter outputs & inputs are identified using the supplied # 0610547 decal.
•
Connect the DC/DC converter ground wire to the converter body.
•
Secure the clear fuse holder to the side of the DC/DC converter support using a # 5001996 screw
as shown (make sure that there is a good 5-amp fuse in the fuse holder).
•
Secure the fuse holder harness to the support using the supplied # 952624 clamp, # 500539
nylon lock nut and # 500591 washer. Use the free length of the previously installed converter to
support screw as shown.
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4. Connect the # 0610504 harness inside the vehicle (LH evaporator side).
•
Inside the vehicle, locate the HVAC diffuser cover located between the seats at foot height (just
above the HVAC duct in the evaporator compartment).
•
Loosen the seat bases from the floor and slide them back or forth to gain access to the cover.
•
Remove the cover to access the “gull wings” shaped deflector.
NOTE
In some vehicles, the REI Seat Audio system wiring
harness (or other optional systems) may be routed
through the middle of the cover. In those cases, the
corresponding system will need to be unplugged to
remove the cover and complete seat removal may
be necessary.
•
From the evaporator compartment, drill a 1-inch hole through the ceiling that will exit in front of
the diffuser area inside the vehicle as shown (hole must be close to the edge and be hidden by
the cover after reinstallation).
•
Pass the C582 connector of the # 0610502 harness inside the vehicle through the 1-inch hole.
•
Protect the connector harness from the hole sharp edge using a piece of rubber material (hose).
•
Connect the # 0610504 to the # 0610502 harness (C582 connector on both harnesses).
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5. Install two plasma cluster modules in the HVAC duct on the evaporator side.
•
Position the supplied # 454769 template on the top part of the duct (template must contact the
upper metal edge).
•
Using a light-colored paint marker, draw the position of the two modules opening.
•
Also mark the position of the 8 support plate screws.
•
Cut both marked openings in the duct.
•
Drill all screw marks using a 1/4 inch drill bit.
•
Install 8 of the supplied # 5002071 spring nuts over the screws openings.
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•
Apply a length of supplied # 506268 foam tape around the edges of the # 454472 evaporator duct
support.
•
Install 2 of the supplied # 0610449 plasma cluster modules on the support using only 2 loosely
mounted # 502799 screws and # 500855 washers.
IMPORTANT: The modules sensors must be mounted toward the slanted edge of the support as
shown.
•
Inside the vehicle, pass the connectors Plasma 5 and Plasma 6 of the previously connected
harness # 0610504 inside the duct so they can be reached from the 2 cut openings.
IMPORTANT: Make sure the connectors wires are passing over the deflector wings and away
from any sharp edge.
•
From outside of the vehicle, connect the Plasma 5 & 6 connectors at the back of the plasma
cluster modules (order is not important).
•
Install the missing # 502799 screws and # 500855 washers and secure the modules to the
support (do not overtight).
•
Secure the support to the duct using 8 supplied # 500957 screws.
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6. Route the C581, the Plasma 3 & the Plasma 4 connectors inside the left (evaporator side)
parcel rack frame.
•
Remove the lower HVAC deflector cover, the window pillar cover and the parcel rack HVAC
cover.
•
Remove the wall upper and lower rails fasteners in the pillar area
•
Fish connectors Plasma 3 Plasma 4 and C581 from the deflector area up to the base of the
window (pass behind the carpeted lateral panel).
•
Pass the connectors wiring along the window pillar up to the underside of the parcel rack.
•
Pull out the connectors from the upper grommet in the parcel rack floor (next to the HVAC unit).
NOTE
In some vehicles not equipped with parcel rack doors,
the hole & grommet may not be present.
In this case, the hole must be drilled using a suitable
hole saw and the provided # 504534 grommet.
•
Pass the connectors in the lower floor grommet (HVAC harness grommet).
•
Remove the over head light/register console to access the connector from under the parcel rack
HVAC unit.
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7. Install 2 plasma cluster modules # 0610449 in the area below the left parcel rack HVAC unit.
•
With a sharpie, mark the location of the # 314937 supports (2X) on the inner parcel rack rail. Both
supports must contact the extrusion edges, one on both sides (the support back shape must fit
the ribbed extrusion profile horizontally as shown).
•
Drill the 4 mounting points for a # 8 screw (1/8 or 9/64th inch drill bit).
•
Install 2 of the supplied # 0610449 plasma cluster modules on the supports using supplied #
502799 screws and # 500855 washers.
•
Connect the Plasma 3 and the Plasma 4 connectors (previously routed to the underside of the
parcel rack) to the two modules. Leave +/- 6 inches of wire behind the module to ease future
removal / installation during maintenance.
•
Secure the supports (and modules) to the extrusion using the supplied # 500443 screws.
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8. Route the # 0610505 harness from the HVAC unit to the front defrost unit area.
•
Remove the driver window pillar cover. Also remove the dash cover and the 2 defrost unit covers.
•
Connect the C581 connector of the # 0610504 harness (previously routed under the HVAC unit
with Plasma 3 & 4 connectors) to the C581 connector of the long # 0610505 extension harness.
•
Using a fish tape or a long flexible rod, pass the # 0610505 harness inside the parcel rack frame
up to the driver’s pillar area.
•
Follow the pillar down (use cable ties) and using a flex rod, fish the harness inside the front
electrical junction box.
•
Secure the harness inside the front junction box (in the upper area from rear to the front)
•
Still using the flex rod, route back the harness C580 connector inside the vehicle up to the
dashboard area.
•
Pass the harness over the dash cluster (secure with supplied cable ties) and make it exit the
C580 connector near the front defrost unit cover.
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9. Install two # 0610449 plasma cluster modules in the front defrost unit.
•
Remove the top bolt of the metal support preventing the removal of the defrost unit cover.
•
Remove the defrost unit cover screws and slide the cover out.
•
From inside the cover, mark the required new holes center point with a sharpie and drill the holes
using the appropriate step drill bit (see image below for hole size and positioning). Use # 370377
bracket as a template to mark and drill the remaining holes as shown.
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•
Using the supplied # 504335 rivets, fasten the two # 370377 supports to the inside of the cover.
•
Insert the # 0610503 harness through the larger 21.5mm hole making sure that the C580
connector is positioned outside the cover and that the Plasma 1 and Plasma 2 connectors are
inside.
•
Insert the harness grommet in the 21.5mm hole.
•
Clip the # 564108 self-mounting support on the outside of the cover (5mm & 6.5 mm holes) and
secure the C580 connector to it (connector pointing upward).
•
Connect 2 # 0610449 plasma cluster modules to the Plasma 1 and Plasma 2 connectors.
•
Install the plasma cluster modules to the brackets using supplied # 502799 screws and # 500855
washers.
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•
Install the supplied # 509815 cable tie mounting clips and secure the harness (use supplied cable
ties).
•
Reinstall the defrost unit cover.
•
Connect the # 0610503 harness C580 connector to the C580 connector previously routed under
the dashboard cover (# 0610505 harness).
•
Secure the wiring on top of the defrost unit, reinstall the metal support and all covers previously
removed in the driver’s area.
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10. Route the remaining C583 connector (# 0610502 harness) through the last baggage
compartment up to the condenser compartment.
•
Pass the wires of the C583 harness along the vehicle harness (left to right of the baggage
compartment) and secure with some supplied cable ties.
•
Using a flex rod, fish the C583 connector through the right side grommet (baggage compartment
to condenser compartment) of the vehicle.
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11. Route & connect the # 0610501 harness (RH condenser side of the vehicle).
•
Inside the vehicle, locate the HVAC diffuser cover located between the seats at foot height (just
above the HVAC duct in the condenser compartment).
•
Loosen the seat bases from the floor and slide them back or forth to gain access to the cover.
NOTE
As for the LH evaporator side, the Seat Audio system wiring harness (or other optional systems) may
be routed through the middle of the cover. In those cases, the corresponding system will need to be
unplugged to remove the cover and complete seat removal may be necessary.
•
Remove the cover to access the “gull wings” shaped deflector.
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•
From the condenser compartment, drill a 1-inch hole through the ceiling that will exit at the rear of
the diffuser area inside the vehicle as shown (hole must be close to the edge and be hidden by
the cover after reinstallation).
•
Pass the C583 connector of the # 0610501 harness inside the vehicle through the 1-inch hole.
•
Protect the connector harness from the hole sharp edge using a piece of rubber material (hose).
•
Connect the # 0610501 to the # 0610502 harness (C583 connector on both harnesses).
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12. Install two plasma cluster modules in the HVAC duct on the condenser side of the vehicle.
•
Position the supplied # 454479 template on the top part of the duct (template must contact the
upper metal edge).
•
Using a sharpie, draw the perimeter of the template on the insulating material.
•
Also draw the position of the two inside opening & the position of the 10 support plate screws.
•
Cut both marked openings in the duct (cut through the insulating material and the plastic duct).
•
Drill all screw marks using a 1/4 inch drill bit.
•
Cut the insulating material around the two openings following the previously scribed perimeter
mark (do not cut through the plastic duct).
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•
Inside the vehicle, install the # 454469 and the # 454466 supports on each side of the duct
opening. Use 4 supplied # 500957 screws for each support, two on the top and two on the side of
the duct.
IMPORTANT: Before the installation of the support remove any sealant accumulation or insulating
material that could prevent the straight and square installation of the support.
•
Install a # 0610449 plasma cluster module to each support using only one loose screw so it can
rotate freely (# 502779 & # 500855 screw & washer).
•
Pass the connectors Plasma 7 and Plasma 8 of the # 061501 harness inside the duct(pass over
the diffuser) so they can be reached from the 2 cut openings.
IMPORTANT: Make sure the connectors wires are passing away from any sharp edge.
•
Connect the Plasma 7 & 8 connectors at the back of the plasma cluster modules (order is not
important).
•
Install the missing # 502799 screws and # 500855 washers and secure the modules to the
support (do not overtight).
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•
Apply a length of supplied # 506268 foam tape around the edges of the # 454471 condenser duct
cover.
•
Install a # 5002071 spring nut at each screw position around the duct openings.
•
Close the duct opening with the # 454471 cover and 10 # 500957 screws.
•
Optional, stick some insulating material back to the cover using spray contact cement or
aluminum conduit tape.
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13. Route the Plasma 9 & the Plasma 10 connectors inside the right (condenser side) parcel
rack frame.
•
Remove the window pillar cover and the parcel rack HVAC cover.
•
Remove the wall upper and lower rails fasteners in the pillar area
•
Fish connectors Plasma 9 Plasma 10 from the deflector area up to the base of the window
(pass behind the carpeted lateral panel).
•
Pass the connectors wiring along the window pillar up to the underside of the parcel rack.
•
Pull out the connectors from the upper grommet in the parcel rack floor (next to the HVAC unit).
NOTE
In some vehicles not equipped with parcel rack doors,
the hole & grommet may not be present.
In this case, the hole must be drilled using a suitable
hole saw and the provided # 504534 grommet.
On vehicles equipped with a wheelchair lift (WCL) the
front WCL door pillar and lower cover must be
removed.
•
Pass the connectors in the lower floor grommet (HVAC harness grommet).
•
Remove the over head light/register console to access the connector from under the parcel rack
HVAC unit.
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14. Install 2 plasma cluster modules # 0610449 in the area below the right parcel rack HVAC
unit.
•
With a sharpie, mark the location of the # 314937 supports (2X) on the inner parcel rack rail. Both
supports must contact the extrusion edges, one on both sides (the support back shape must fit
the ribbed extrusion profile horizontally as shown).
•
Drill the 4 mounting points for a # 8 screw (1/8 or 9/64th inch drill bit).
•
Install 2 of the supplied # 0610449 plasma cluster modules on the supports using supplied #
502799 screws and # 500855 washers.
•
Connect the Plasma 9 and the Plasma 10 connectors (previously routed to the underside of the
parcel rack) to the two modules. Leave +/- 6 inches of wire behind the module to ease future
removal / installation during maintenance.
•
Secure the supports (and modules) to the extrusion using the supplied # 500443 screws.
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15. Connect the plasma cluster system to the vehicle power source.
•
In the evaporator compartment, locate the R12 relay and the ground stud on the firewall.
•
Connect the power terminal of the plasma cluster system to the middle terminal of the R12 relay.
•
Connect the ground terminal of the system to the ground stud.
•
Make sure both 5 amp fuses in the system are good before powering the vehicle.
•
Reinstall all trim parts and seats in the vehicle and proceed with the test procedure at the end of
this document to ensure proper function.
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16. Apply the Prevost EnviroCare decal on the vehicle body.
•
Clean the area just behind the H345 crest near the entrance door. Use isopropyl alcohol or anti
silicone (Some other decals may also be present in the area).
•
In Canada, carefully apply the bilingual decal # 0610528 just above any already installed factory
decals (leave around 10mm gap between decals).
•
In the United States, carefully apply the english decal # 0611019 just above any already installed
factory decals .Leave around 10mm gap (3/8in) between decals.
IMPORTANT: Make sure the surface is clean and dry. Do not apply in cold temperature, heat the area as
necessary to ensure proper adhesion.
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PLASMA CLUSTER INSTALLATION - IN VEHICLE TESTS
TESTER CALIBRATION
1. To operate the meter, flip the POLARITY switch to its center position, halfway between "+"
and "-", and the MEASURE switch to the STANDBY position.
2. Turn the RANGE knob to the 199.9 position.
3. Wait until the display becomes stable to within +/-2 counts. This will take about 10 seconds
after the meter is turned on.
4. Adjust the OFFSET knob so that the display reads zero +/- 2 counts (+/- 0.02). After this
step, the OFFSET might not need to be readjusted again, ever. However, it should be
checked at the beginning of each measurement session or if the temperature changes
significantly.
NOTE
If you change the knob to another range like "19.99", you will not need to readjust the
OFFSET.
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TEST POINTS & EXPECTED RESULTS:
AT LOWER WINDOW EXITS
1. At the lower window height, the removable
air shroud must be removed for accurate
measurements.
2. Ground the tester to the Audio/Video
mounting plate in the first parcel rack or the
AC unit bodies in the parcel racks.
3. Flip the POLARITY switch to whichever
polarity ("+" or "-") you want to measure (the
MEASURE switch set at the STANDBY
position). Wait for the display to become
stable.
4. Wait at least 10 seconds after flipping the
POLARITY switch then flip to the
MEASURE position (switch upward). This
will turn on the fan.
5. Place the tester opening in the middle of the
airflow exiting from the grille.
•
•
•
•
Take a reading in the center of the
steering wheel.
Take a second measurement in the
middle of the entrance handrail.
On the curb side of the vehicle, take a
reading in the middle of the 2nd and
the 5th windows.
On the curb side of the vehicle, take a
reading in the middle of the 3rd and
the 5th windows.
6. At the 199.9 scale, the readings should top
off and read –I (INFINITE).
On vehicles equipped with a Wheel Chair
Lift, a slightly lower reading of 150+ is
acceptable at the 5th window (behind the
WCL).
Writer: mg
WARNING !
Make sure that the tester airflow (rear fan
area) is not blocked by either your hand,
body, vehicle component (Ex: steering
wheel) or other solid object.

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AT PARCEL RACKS OVERHEAD AIR REGISTERS
1. At the overhead registers, the removable air
shroud must be removed for accurate
measurements.
2. Ground the tester to the AC unit body in the
parcel racks.
3. Flip the POLARITY switch to whichever
polarity ("+" or "-") you want to measure (the
MEASURE switch set at the STANDBY
position). Wait for the display to become
stable.
4. Wait at least 10 seconds after flipping the
POLARITY switch then flip to the
MEASURE position (switch upward). This
will turn on the fan.
WARNING !
Make sure that the tester airflow (rear fan
area) is not blocked by either your hand,
body, vehicle component (Ex: steering
wheel) or other solid object.
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5. Place the tester opening in the airflow
stream exiting from the register grille.
•
Take a reading at the register right in
front of the AC unit.
•
Take a reading at the register located
just after the AC unit.
•
Do both sides of the vehicle (4
readings total).
6. At the 199.9 scale, the reading should top
off and read –I (INFINITE).
Writer: mg