ZeroRPM IMS2 User manual

4806-00017 Revision F
IMS2, IMS3, IMS4, IMS5
Operator Manual
This operators manual is applicable to vehicles equipped with IMS soware version:
PLC: V4.95 and later
HMI: V4.95 and later

IMS 2-5 Operator Manual
4806-00017 Revision F
Section 1: Introduction..............................................................................................................................................
Section 1.1: Scope...................................................................................................................................................................................
Section 1.2: Definitions of Informational Headings..............................................................................................................................
Section 1.3: Safety...................................................................................................................................................................................
Section 2: Overview of the IMS Display........................................................................................................................
Section 3: Basic Operation.........................................................................................................................................
Section 3.1: Hood Sensor.......................................................................................................................................................................
Section 3.2: Brake Override....................................................................................................................................................................
Section 3.3: Brake Start...........................................................................................................................................................................
Section 3.4: IMS Bypass Mode (if Equipped)..........................................................................................................................................
Section 3.5: Rescue Switch.....................................................................................................................................................................
Section 3.6: Hybrid Disconnect Switch..................................................................................................................................................
Section 3.7: Forced IMS Controller Shutdown.......................................................................................................................................
Section 4: Climate Control..........................................................................................................................................
Section 4.1: Air Conditioning (if Equipped)............................................................................................................................................
Section 4.2: Heating (if Equipped)..........................................................................................................................................................
Section 4.3: Defrost Mode (if Equipped).................................................................................................................................................
Section 5: Battery Management..................................................................................................................................
Section 5.1: Engine Starting for Low Battery..........................................................................................................................................
Section 5.2: Engine Running for Battery.................................................................................................................................................
Section 5.3: ZeroRPM System Faults.......................................................................................................................................................
Section 5.4: Battery Management System Screens.................................................................................................................................
Section 6: Broadcasting to Intellimetrics.....................................................................................................................
Section 7: ZeroKEY Mode (if Equipped)........................................................................................................................
Section 8: ZeroIDLE Mode (if Equipped).......................................................................................................................
Section 9: ZeroDRAW Mode (if Equipped).....................................................................................................................
Section 10: Boost Mode (if Equipped)..........................................................................................................................
Section 11: Further System Information......................................................................................................................
Section 11.1: Communication Error.......................................................................................................................................................
Section 11.2: A/C Error Codes.................................................................................................................................................................
Section 11.3: Shore Power Charging......................................................................................................................................................
Section 12: Information Screens.................................................................................................................................
Section 12.1: Primary Information Screen.............................................................................................................................................
Section 12.1.1: B0........................................................................................................................................................................................
Section 12.1.2: B0 Current..........................................................................................................................................................................
Section 12.1.3: B1 and B2...........................................................................................................................................................................
Section 12.1.4: B2 Current and State of Charge........................................................................................................................................
Section 12.2: Information Screen 1........................................................................................................................................................
Section 12.3: Information Screen 2........................................................................................................................................................
Section 12.4: Information Screen 3........................................................................................................................................................
Section 12.5: Information Screen 4........................................................................................................................................................
Section 13: Input/Output Screens...............................................................................................................................
Section 13.1: Signal Glossary..................................................................................................................................................................
Section 13.1.1: Inputs..................................................................................................................................................................................
Section 13.1.2: Outputs...............................................................................................................................................................................
Section 13.1.3: Communication Connections............................................................................................................................................
Section 13.2: Screen/Controller Signal Locations.................................................................................................................................
Table of Contents
1
1
1
1
2
3
5
6
6
7
7
8
8
9
9
12
15
16
16
17
18
19
20
21
22
23
24
24
24
25
26
27
27
28
28
29
30
31
32
33
34
35
36
36
37
38
39

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F1
© 2021 ZeroRPM, Inc. All Rights Reserved
This document may be reproduced and/or distributed
only with the express consent of ZeroRPM, Inc.
Section 1.2: Definitions of Informational Headings
DANGER: This heading indicates noncompliance with the stated information will lead to serious injury or
death.
WARNING: This heading indicates noncompliance with the stated information may lead to serious injury or
death.
CAUTION: This heading indicates noncompliance with the stated information may lead to minor or moderate
injury.
NOTICE: This heading draws attention to specific information.
Section 1.1: Scope
Section 1: Introduction
This manual describes the operation of the ZeroRPM® IMS). It provides basic information about the system and
describes both the general theory of operation and the theory of operation of specific aspects of the system.
The IMS is designed to control the vehicle’s chassis engine to reduce idling while maintaining a comfortable work
environment in the cab. It maintains electrical power required for computers, lighting, and vehicle accessories.
The IMS provides an interface between the equipment and the vehicle while providing the operator with necessary
information.
The operation and simulated screens presented in this manual are based on soware stated on the title page of this
document. The information covered in this manual is subject to change without notice.
Section 1.3: Safety
All general safety regulations for the prevention of accidents and the relevant operational safety instructions must be
followed. Safety must be the top priority at all times.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F2
Section 2: Overview of the IMS Display
The IMS is controlled through the display’s sokey
integration.
CAUTION: The display is not a touchscreen.
• To select an option, press the relevant sokey(s).
• For example, if you wish to view the primary information
screen, press and hold the OK sokey for two seconds.
• The primary information screen will be displayed (see
Section 12.1 for more information).
The sokeys are identified as follows:
• F1 - far le
• F2 - second from le
• F3 - second from right
• F4 - far right
• D-pad - directional arrows (Up, Down, Le, and Right)
• OK - labeled “ok”; below F3 and F4 F1 F2
D-pad
F3 F4
OK

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F3
Section 3: Basic Operation
The Idle Mitigation System can be started as follows:
• When the ignition switch has been turned on, the IMS
will power on and the ZeroRPM initialization screen will
appear.
Aer initialization, the display will indicate the current
system status. The Start Engine message will be displayed
on the screen, verifying the engine has not been started
and is not running.
• The green State of Charge icon displays the current
percentage of charge in the lithium-iron battery pack.
• If the red battery icon is displayed at this time, the lead-
acid battery voltage has fallen below the set point. Either
start the engine to begin charging or turn o the ignition
switch.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F4
Once the vehicle has started, the system will continue
to charge the lead-acid batteries (B0) until the set point
conditions are met.
NOTICE: Idle Mitigation Mode will not be engaged until these
conditions are met.
• To begin system operation, start the chassis engine.
• The display will show the green Engine Running icon,
verifying the engine is running.
NOTICE: The lead-acid charging logic may prevent the engine
from shutting down until the charging criteria are satisfied.
• Once the chassis has reached the base idle condition
and the lead-acid battery/batteries have reached the set
point, the countdown timer will appear. The default is
five seconds, but it may be set to a greater value upon
customer request.
NOTICE: The countdown can be overridden by pressing the
vehicle’s brake pedal to engage the Brake Override feature
(if equipped; see Section 3.2 for details).
• When the countdown reaches 0, the engine will turn o
and the ZeroRPM logo will be displayed. The IMS will now
power the entire vehicle and will be ready to heat or cool.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F5
Section 3.1: Hood Sensor
If the engine is running while the vehicle is in Park, the
IMS can be engaged by holding F1. To force the engine
o during idle (in Park only), press and hold F1. This will
also engage ZeroIDLE Mode if applicable (see Section 8 for
details).
• A “Hold” message will be displayed for three seconds,
then the chassis engine will shut down and the IMS will
engage.
• If ZeroIDLE is equipped (see Section 8 for details), the
operator can simply press F1 without holding it. Doing so
will shut the engine down and engage ZeroIDLE Mode.
If the Hood Open icon appears on the display, either the
engine compartment hood is open or the controller has lost
communication with the screen.
• This is a safety feature to prevent the engine from being
started by the IMS controller when the hood is open. If the
Hood Open icon is present, the engine can be started and
stopped only by using the ignition switch.
• The Hood Open icon will disappear when the hood is
closed.
NOTICE: When this condition occurs in Idle Mitigation Mode, it
is required to cycle the ignition switch.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F6
Section 3.2: Brake Override
Section 3.3: Brake Start
When the chassis engine is started, the base idle RPM
is reached, and lead-acid charge set point is reached,
the five-second countdown will appear. During the five-
second countdown, the engine shutdown sequence can
be overridden by pressing and holding the vehicle’s brake
pedal, thus engaging Brake Override (if applicable). When
in brake override the engine running icon will have a yellow
flashing background.
• The engine will remain at idle as long as the override is
active.
• To disengage Brake Override and initiate the engine
shutdown sequence again, perform one of the following
actions (depending on your system settings):
1. Release the brake pedal.
2. Press and hold F1.
When the chassis engine is o and the IMS is active, the
chassis engine can be started quickly by pressing the brake
pedal.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F7
Section 3.4: IMS Bypass Mode (If Equipped)
IMS Bypass Mode prevents the engine from shutting down
as long as the mode is active.
• Engaging the customer designated trigger (i.e. winches,
emergency lights, li gates, etc.) while the system is in Idle
Mitigation Mode will start the chassis engine. The message
“IMS BYPASS” will appear on the operator screen.
• Activating IMS Bypass Mode while the system is not in Idle
Mitigation Mode will prevent the system from entering Idle
Mitigation Mode. The message “IMS BYPASS” will appear
on the operator screen.
• The “Emergency Light” switch must be disengaged before
Idle Mitigation Mode can be re-entered.
If the IMS does not wake up from a chassis start due to low
battery voltage, the operator can use the rescue switch
(a momentary pushbutton typically mounted near the
ZeroRPM operator screen) to reactivate the IMS.
The rescue switch should be used under the following
circumstances:
• Local or remote programming
• Diagnostics
• Secondary system wake-up due to the following:
1. Low-voltage brown-out during engine start
2. Non-ignition switch system reboot
NOTICE: The rescue switch is not intended for everyday use.
Section 3.5: Rescue Switch

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F8
The hybrid disconnect switch (a plunger mounted near
the driver-side chassis battery) opens the connection
between the lithium-iron batteries and the chassis. When
the disconnect is active, the lithium-iron batteries cannot
provide electrical power to the chassis, nor can they be
charged.
• To engage the hybrid disconnect switch, push the plunger
down. It will lock into the open position.
• To disengage the hybrid disconnect switch, twist the
plunger clockwise. It will unlock and return to the closed
position.
• The hybrid disconnect switch may be used under the
following circumstances:
1. Maintenance
2. Troubleshooting
3. Emergency situations
NOTICE: The hybrid disconnect switch is not intended for
everyday use.
NOTICE: The hybrid disconnect will not bypass the Idle
Mitigation System but will continue to allow the vehicle to shut
down. All loads will stay connected to the lead acid battery, the
truck will remain in IMS mode, but IMS climate control will be
disabled, and the engine will continue start stop depending on
the condition of lead acid battery.
Section 3.6: Hybrid Disconnect Switch
Section 3.7: Forced IMS Controller Shutdown
The green System Shutdown icon will be displayed when
the vehicle’s engine is turned o and the ignition switch is
o and the key is removed (if applicable).
• Hold F1 for three seconds. The display will power o and
the IMS PLC will enter a hibernation state. The PLC will
remain in this state until the ignition is turned on again.
NOTICE: Taking no action within 30 seconds will also cause the
display to power o and the PLC to enter a hibernation state.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F9
Section 4: Climate Control
Section 4.1: Air Conditioning (If Equipped)
Air conditioning is activated by setting the chassis HVAC
controls to the cool side and turning the blower fan on.
• The climate control field on the operator screen will
change to read “COOL”, the arrow below the field will turn
blue, and cool air will begin to blow from the vents within
a few seconds.
• The snowflake icon will appear on the le side of the
screen almost immediately.
NOTICE: If the engine starts due to an A/C fault/error, the
snowflake icon will flash (see Section 11.2 for details). If the
engine starts for any other condition, the snowflake icon will
disappear.
• Cool air will continue to blow from the vents until the
operator turns the blower fan o, turns the HVAC controls
to heat, or disables air conditioning using the operator
screen (see Page 10 for more information), or if the
minimum temperature set point (default 60°F) is reached.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F10
The air conditioning feature can be disabled through the
following process:
• Press the Down arrow sokey and the OK sokey
simultaneously.
• The display will show the Disable Air Conditioning icon to
verify the selection.
NOTICE: The operator has 10 seconds to disable air
conditioning. If no action is taken within 10 seconds, the
Disable Air Conditioning icon will disappear.
• Press the OK sokey again to disable air conditioning.
• The blue arrow below the climate control field will turn
grayish blue, indicating that the air conditioning feature
has been disabled.
NOTICE: If the ignition switch is turned o while the air
conditioning feature is disabled, the IMS will reset and the air
conditioning will start as normal the next time the system is
powered on.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F11
If the air conditioning feature has been disabled, it can be
re-enabled through the following process:
• Press the Down arrow sokey and the OK sokey
simultaneously.
• The display will show the Enable Air Conditioning icon to
verify the selection.
NOTICE: The operator has 10 seconds to re-enable air
conditioning. If no action is taken within 10 seconds, the
Enable Air Conditioning icon will disappear.
• Press the OK sokey again to enable air conditioning.
• The grayish blue arrow below the climate control field will
return to solid blue, indicating that the air conditioning
feature has been re-enabled. The snowflake icon will
reappear (if applicable) and the system will resume
cooling.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F12
Section 4.2: Heating (If Equipped)
NOTICE: If a fuel-fired heater is equipped, it will operate
identically to the ZeroRPM heating mode.
Heating is activated by setting the HVAC controls to the
heat side and turning the blower fan on.
• The climate control field on the operator screen will
change to read “HEAT”, the arrow above the field will turn
red, and warm air will begin to blow from the vents.
• The flame icon will appear on the le side of the screen
within five seconds.
• Warm air will continue to blow from the vents until the
operator turns the blower fan o, turns the HVAC controls
to cool, or disables heat using the operator screen
(see Page 13 for more information), or if the maximum
temperature set point (default 100°F) is reached.
Otherwise, the heat will continue to run until the engine
coolant temperature reaches its predetermined minimum
of 104°F (40°C). When the engine coolant reaches 104°F,
the chassis engine will start and will remain on until the
engine coolant reaches 150°F (75°C). When the engine
coolant reaches 150°F, the chassis engine will turn o and
the IMS will re-engage for heat.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F13
The heating feature can be disabled through the following
process:
• Press the Up arrow sokey and the OK sokey
simultaneously.
• The display will show the Disable Heat icon to verify the
selection.
NOTICE: The operator has 10 seconds to disable heating. If no
action is taken within 10 seconds, the Disable Heat icon will
disappear.
• Press the OK sokey again to disable heat.
• The red arrow above the climate control field will turn
grayish red, indicating that the heating feature has been
disabled.
NOTICE: If the ignition switch is turned o while the heating
feature is disabled, the IMS will reset and heating will start as
normal the next time the system is powered on.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F14
If the heating feature has been disabled, it can be
re-enabled through the following process:
• Press the Up arrow sokey and the OK sokey
simultaneously.
• The display will show the Enable Heat icon to verify the
selection.
NOTICE: The operator has 10 seconds to re-enable heating. If
no action is taken within 10 seconds, the Enable Heat icon will
disappear.
• Press the OK sokey again to enable heat.
• The grayish red arrow above the climate control field will
return to solid red, verifying that the heating feature has
been enabled. The flame icon will reappear (if applicable)
and the system will resume heating.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F15
Defrost Mode engages the auxiliary A/C compressor and the
coolant pump simultaneously to defrost the vehicle.
• To engage Defrost Mode, set the blend door to heat and
press the factory defrost button.
• The Engage Defrost Mode icon will appear above F3.
• Press F3 to engage Defrost Mode. The icon will turn green;
the Defrost Mode Engaged icon will appear on the le side
of the screen and the temperature will be replaced with
“DEF”; both climate control arrows will be displayed.
• Press F3 again to disengage Defrost Mode.
NOTICE: Defrost Mode runs in cycles of 10 minutes. During the
first four minutes, the IMS runs both the heat pump and the
A/C compressor. For the remaining six minutes, the IMS runs
only the heat pump. This cycle will continue until Defrost Mode
is disengaged.
Section 4.3: Defrost Mode (If Equipped)

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F16
Section 5: Battery Management
• If the state of charge (SOC) of the IMS batteries (or the
chassis batteries) becomes lower than the predetermined
low battery set points at any time during operation, the
Engine Starting for Low Battery icon will be displayed and
the five-second counter will begin counting down.
• The chassis engine will turn on to replenish the batteries’
energy.
NOTICE: The engine may start for any of the conditions listed
in Section 5.2.
Section 5.1: Engine Starting for Low Battery

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F17
Section 5.2: Engine Running for Battery
The battery icons listed on this page are commonly
displayed on the operator screen. The corresponding
character will appear to the le of the voltage on the
Primary Information Screen (see Section 12.1 for details).
• 0: This icon indicates the engine is running to charge
Battery 0 (the chassis lead-acid battery).
• 1: This icon indicates the engine is running to charge
Battery 1 (the 12V lithium-iron battery pack).
• 2: This icon indicates the engine is running to charge
Battery 2 (the hybrid lithium-iron battery packs).
• I: This icon indicates the engine is running because the
hybrid battery pack voltage is ≤ 10V. The engine will run for
a period of time determined by the system settings.
• F: This icon indicates the engine is running because an
individual battery cell is low during ePTO mode (if a hybrid
electric motor is equipped). The engine will run for a
period of time determined by the system settings.
• V: This icon indicates the engine is running because an
individual battery cell is low. The engine will run for a
period of time determined by the system settings.
• S: This icon indicates the engine is running because the
IMS battery packs have reached a state of charge (SOC)
below the SOC charge set point. The engine will run for a
period of time determined by the system settings.
• P: This icon indicates the engine is running because the
hybrid battery pack voltage is < 11.2V in parallel or <
22.4V in series. The engine will run for a period of time
determined by the system settings.
• X: This icon indicates an issue that does not correspond to
one of the aforementioned scenarios has occurred. If this
icon appears, it can be removed only by restarting the IMS
(see Section 3.7 for more information). If the problem
persists, contact your service department.

IMS2, IMS3, IMS4, IMS5 Operator Manual
4806-00017 Revision F18
NOTICE: The letter “E” inside the yellow triangle icon
represents an energy error. This may result from the
temperature or voltage of a low/unbalanced cell in the lithium-
iron pack(s). If the error occurs, the lithium-iron batteries
will no longer be allowed to connect to the vehicle. If you
encounter this error and do not believe it to be temperature- or
voltage-related, have the vehicle serviced as soon as possible.
IMS functionality varies at certain temperature ranges.
• If the ZeroRPM energy is between 135°F (57°C) and 32°F
(0°C), normal system functions are permitted.
• If the ZeroRPM energy is below 32°F (0°C) and above -4°F
(-20°C), the system will allow discharging but will prohibit
charging.
• If the ZeroRPM energy is below -4°F (-20°C) or above 135°F,
(57°C) the system will prohibit both charging and
discharging.
IMS functionality varies at certain voltage ranges.
• If the ZeroRPM energy is between 2.7V - 3.5V per cell,
normal system functions are permitted. (If any cell is at
2.7V for 30sec the SOC will reset to 0%.)
• The ZeroRPM energy will allow charging, but will prohibit
discharging if any cell voltage reaches 2.6V. If the voltage
drops below 2.6V for any cell, neither charging or
discharging will be permitted.
• The ZeroRPM energy will allow discharging, but will
prohibit charging if any cell voltage reaches 3.6V. If the
voltage exceeds 3.7V for any cell, neither charging or
discharging will be permitted.
NOTICE: The letter “W” inside the yellow triangle icon
represents a wiring related issue for battery #2.
NOTICE: The letter “G” inside the yellow triangle icon
represents an ignition error. This error results could result from
issues with ignition wiring or the ZeroKEY module is faulty or
not properly programmed, preventing the truck from starting
while in ZeroKEY.
NOTICE: The need for the engine to run varies among the
aforementioned conditions. Various icons may be displayed on
the ZeroRPM operator screen.
Section 5.3: ZeroRPM System Faults
The “!” will alternate blinking
with the fault code “W”, “G”,
“E”, etc.