Summary of Contents for Carrier ComfortPro PC6000
- Page 1 Auxiliary Power Unit Operation & Service Manual ™ ComfortPro Auxiliary Power Unit Models PC6000, PC6002, PC6003 & PC6006 62--11175 Rev --...
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Page 2: Table Of Contents
CONTENTS INTRODUCTION SAFETY Safety Alerts ................. c-iii Component Layout................c-v GENERAL ARRANGEMENT APU Dimensions ................c-vi CCU Dimensions................c-vii Condenser Dimensions ..............c-vii 1.0 OPERATION OF MULTI–FUNCTION D.C.P 1.1 PREPARATION 1.1.1 Multi–Function D.C.P Components........1-1 1.1.2 How the ComfortPro Operates ..........1-2 1.2 MANUAL OPERATIONS 1.2.1 Starting the APU .............. - Page 3 3.0 TROUBLESHOOTING (Cont.) 3.8 TESTING PROCEDURES 3.8.1 Testing AMP draw for components ........3-13 3.8.2 Testing Voltage and Hz readings .......... 3-13 3.9 ADDITIONAL INFORMATION 3.9.1 Adjusting the 120 A/C Voltage..........3-14 3.9.2 Capacitor Troubleshooting ........... 3-14 3.9.3 Capacitor Theory..............3-14 3.9.4 Potential Relay Theory............
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Page 4: Safety
SAFETY Safety Alerts Throughout this manual, you will see notes labeled "Warnings" or "Cautions" to alert you to special instructions or precautions concerning a particular procedure that would be hazardous if performed incorrectly or carelessly. Observe them carefully! These safety alerts alone cannot eliminate hazards that can occur. Strict compliance with these special instructions when performing the installation and maintenance, plus common sense, are major accident prevention measures. -
Page 5: Safety Considerations
Safety Considerations Exhaust Inhalation of exhaust gas (containing carbon monoxide) may cause severe personal injury and/or death. Anyone suspected of suffering from CO inhalation should be removed from the hazardous area and given medical assistance immediately. WARNING California Proposition 65 Warning: This product contains lead, a chemical known to the State of California to cause cancer and birth defects and other reproductive harm. -
Page 6: Component Layout
COMPONENT LAYOUT 62-11175 COMFORTPRO SERVICE MANUAL... -
Page 7: General Arrangement
GENERAL ARRANGEMENT APU Dimensions (Measurements in inches) 2.75 3.875 18.5 24.9 16.0 10.5 28.5 REAR LEFT SIDE FRONT VIEW RIGHT SIDE TOP VIEW c-vi 62-11175 COMFORTPRO SERVICE MANUAL... -
Page 8: Ccu Dimensions
CCU Dimensions (Measurements in inches) FRONT VIEW 12.9" 12.6" 12" 7.9" .125" 23.4" 24.4" BOTTOM VIEW 3.0" 16.2" 15.2" 6.9" 3.0" 3.0" 3.3" 3.1" 6.9" 3.0" 3.4" 1.3" Condenser Dimensions (Measurements in inches) 26.5" 8" 3.5" 24.25" 2.0" 5.62" 5.62" DOWN FRONT RIGHT SIDE... - Page 9 c-viii 62-11175 COMFORTPRO SERVICE MANUAL...
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Page 10: Operation Of Multi-Function D.c.p
1.0 OPERATION OF MULTI-FUNCTION DRIVER CONTROL PANEL HOURS 00000 HVAC ON/OFF ESC/ MENU RESET HEAT Figure 1-0: Multi-Function Driver Control Panel PREPARATION 1.1.1 Multi-Function Driver Control Panel Components When visible, the heating system is heating. NOTICE When visible, the A/C is cooling. The DCP (driver control panel), which 3 Indicates the number of operating hours on the APU. -
Page 11: How The Comfortpro Operates
1.1.2 How the ComfortPro Operates The ComfortPro has two modes of operation: manual and automatic. Manual Mode You start the APU from within the truck bunk using the On/Off button on the driver control panel (DCP). Once the APU is running, you can start and stop the fan, heater and air conditioning using the DCP. -
Page 12: Manual Operations
Automatic Mode and Minimum Time Off All these automatic functions work on a "minimum time off": the ComfortPro must be off for at least 10 minutes before the automatic function will turn it on again. For example, the Timer function may be set to turn on the ComfortPro at 10:00 a.m. -
Page 13: Turning The Heater On/Off
1.2.3 Turning the Heater ON/OFF 1 Press to activate the heater. NOTICE HOURS 00000 The display shows "HEAT LOW". The heat mode will not function if the temperature is higher than 85°F. The heater will turn on only if the HEAT LOW temperature is too low (to adjust the temperature, see below). -
Page 14: Fan Operation
1.2.7 Fan Operation You can still have the fan working even when the temperature is not low or high enough for the heat or A/C to come on. The fan operation is independent of the air conditioning and heat modes. When the fan speed is manually set to high or low, the fan will return to that setting when the desired temperature has been reached as the air conditioning or heat cycles off. -
Page 15: Entering Password
3 Press until the first number in the password is displayed. For example, if your password is "432" press until "4" shows, then press 4 Repeat for each digit in the password. 5 Press again after entering the last digit. "NEW PASSWORD" is displayed. -
Page 16: Setting The Clock
1.3.3 Setting the Clock You can set the clock on the DCP. This clock is used by the Timer function (page 1-8). If you use the Timer function, remember that as you move from one time zone to another, you must adjust the clock. Otherwise the Timer will start the APU at the wrong time. -
Page 17: Timer
Setting the TEMPERATURE 1 Press NOTICE HOURS 00000 Factory Default Temperature Setting is 2 Press until 21°C / 70°F. Range is 18°C / 64°F to COMFORT MONITOR "COMFORT MONITOR" is displayed, 30°C / 86°F. then press If "ENTER PASSWORD" is displayed, enter your password. If you do not know the password, then you cannot set up this function (see page 1-5). - Page 18 Setting the Start Time/Day 1 Press HOURS 00000 2 Press until TIMER 1 "TIMER 1" or "TIMER 2" is displayed, SET START then press If "ENTER PASSWORD" is displayed, enter your password. If you do not know the password, then you cannot set up this function (see page 1-5). 3 Press to display "SET START".
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Page 19: Cold Weather Watch
1.3.6 Cold Weather Watch You can set up the APU so that it automatically runs for a specified time whenever the ambient temperature goes below a specified value. This feature ensures that the APU engine and truck engine do not get so cold that they will not start. -
Page 20: Maximum Run Time
Setting the DURATION HOURS 1 Press 00000 NOTICE 2 Press until TEMP START Factory Default Duration Setting is 2 "TEMP START" is displayed, then SET DURATION hours. Range is 1 hr to 4 hrs. press If "ENTER PASSWORD" is displayed, enter your password. If you do not know the password, then you cannot set up this function (see page 1-5). -
Page 21: Battery Monitoring
1.3.8 Battery Monitoring You can set up the APU so that it automatically runs for 90 minutes when the truck batteries are low. When you set up this feature, you must enter the current voltage of the batteries (see “Set the Initial Voltage”). The ComfortPro can then calculate how much the voltage drops, as the batteries are used. -
Page 22: Climate Control Unit (Ccu)
CLIMATE CONTROL UNIT (CCU) PREPARATION 2.1.1 Charging the CCU WARNING Pressure test the system for leaks with nitrogen. This procedure must be performed by a certified air conditioning technician Vacuum all the nitrogen for a minimum of 30 minutes to 500 microns. who has experience with hermetic With the high and the low side valves open, charge the system with systems and Refrigerant R-134A. -
Page 23: Service
2.2 SERVICE 2.2.1 Maintenance Schedule First Every Interval between checks (in hours of operation) 1000 2000 Change oil and oil filter Check fuel hoses, fuel pipes, and clamps Check fasteners, muffler clamps and frame grippers Check battery cable connections Check coolant hoses and clamps Check alternator fan belt tension Check generator belt tension Check APU air filter, clean or replace as necessary... -
Page 24: Ccu Spring Tune-Up
2.2.2 CCU Spring Tune-Up Purpose: Recommended service and maintenance: • Condenser. • Air ducting and outlets. • Evaporator and temperature sensor. • Refrigerant lines connections and routing. • Harness Connections and wiring. • A/C operating efficiency - charge level. Frequency: Annually –... - Page 25 6. Check the refrigerant charge level: • Install the A/C gauges as shown in the ComfortPro Installation Manual. Operate the A/C on high. • Refer to chart below for high and low reference pressure. COMFORTPRO AIR CONDITIONING OUTDOOR AMBIENT TEMPERATURE AND PRESSURE CHART OUTDOOR TEMPERATURE 70°F...
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Page 26: Troubleshooting
3.0 TROUBLESHOOTING 3.1 APU (AUXILIARY POWER UNIT) .............3-2 WARNING 3.2 GENERATOR................3-6 Before undertaking ANY repair to 3.3 DRIVER CONTROL PANEL ............3-7 the APU, CCU or component of the ComfortPro system disconnect 3.4 CCU AIR CONDITIONING ..............3-8 the batteries from the APU. 3.5 CCU FAN ..................3-11 3.6 CCU HEAT ................3-11 3.7 RECEPTACLE PANEL ..............3-12... -
Page 27: Apu (Auxiliary Power Unit)
3.1 APU (AUXILIARY POWER UNIT) WARNING Disconnect the batteries from the APU before performing any repairs. Each symptom is followed by a probable cause and suggested solution. To isolate the possible cause, proceed in a systematic manner to determine the faulty component. This guide does not cover all possible situations that may occur under all conditions of operation. - Page 28 SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE Engine does not start • Low battery voltage to the APU • Check battery cables/charge battery • A-13 (starter does not work) • Starter/solenoid defective • Repair/replace • Kubota Manual* • Poor positive cable connection •...
- Page 29 SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE Oil level increases • Diesel fuel getting to oil pan • Replace O-ring in lower portion • Kubota Manual* through governor lever of governor lever • Fuel lift pump diaphragm defective • Replace • Kubota Manual* Low oil pressure •...
- Page 30 SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE APU suddenly stops • No fuel • Check fuel stand pipe length/fuel level in tank • A-8 (no message on Driver • Air in the fuel system • Bleed air • A-8 Control Panel display) •...
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Page 31: Generator
3.2 GENERATOR WARNING Disconnect the batteries from the APU before performing any repairs. Each symptom is followed by a probable cause and suggested solution. To isolate the possible cause, proceed in a systematic manner to determine the faulty component. This guide does not cover all possible situations that may occur under all conditions of operation. -
Page 32: Driver Control Panel
3.3 DRIVER CONTROL PANEL WARNING Disconnect the batteries from the APU before performing any repairs. Each symptom is followed by a probable cause and suggested solution. To isolate the possible cause, proceed in a systematic manner to determine the faulty component. This guide does not cover all possible situations that may occur under all conditions of operation. -
Page 33: Ccu Air Conditioning
3.4 CCU AIR CONDITIONING WARNING Disconnect the batteries from the APU before performing any repairs. Each symptom is followed by a probable cause and suggested solution. To isolate the possible cause, proceed in a systematic manner to determine the faulty component. This guide does not cover all possible situations that may occur under all conditions of operation. - Page 34 SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE Condenser fan not • A/C is not on • Set temperature to lower setting • 1- 4, 1- 8 working • DC power fuse blown • Determine reason and replace fuse • A-4 • Wiring damaged •...
- Page 35 SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE Air conditioner runs • Driver Control Panel temp sensor • Replace Driver Control Panel OK, but short cycles defective (cont.) • High pressure cut out due to: • Check: a) Insufficient air flow a) Air flow through condenser (fan) b) Overcharge b) Reduce charge to 64–68 oz.
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Page 36: Ccu Fan
3.5 CCU FAN WARNING Disconnect the batteries from the APU before performing any repairs. SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE CCU fan not working • Fuse on CCU Board • Check/replace • A-4 • Wiring defective • Repair/replace • Capacitor defective •... -
Page 37: Receptacle Panel
3.7 RECEPTACLE PANEL WARNING Disconnect the batteries from the APU before performing any repairs. Each symptom is followed by a probable cause and suggested solution. To isolate the possible cause, proceed in a systematic manner to determine the faulty component. This guide does not cover all possible situations that may occur under all conditions of operation. -
Page 38: Testing Procedures
3.8 TESTING PROCEDURES 3.8.1 Testing AMP draw for components When checking functions of individual components, place amp clamp over black (power) wire coming in from the generator to the CCU board. (As shown in below.) When cross-referenced with the “AMP DRAW AND VOLTAGE CHART”, the components should show the same amp readings. -
Page 39: Additional Information
3.9 ADDITIONAL INFORMATION 3.9.1 Adjusting the 120 AC Voltage This does not need to be adjusted under normal operation. If you find low AC voltage, check the generator belt, air filter, fuel filters and exhaust system before adjusting. With the APU running turn all 120-volt components off. Measuring the voltage at the outlet panel adjust the engine speed until 120 (+/- 10) volts AC and 60 Hz +/- 2 Hz is read. -
Page 40: Potential Relay Theory
3.9.4 Potential Relay Theory In a Capacitor Start, Capacitor Run compressor the start capacitor is only designed for momentary use. The Potential Relay (NC) is used to connect and disconnect the start capacitor from the compressors start windings. Induced Voltage is generated in the start winding when of the compressor when it is running. - Page 41 3-16 62-11175 COMFORTPRO SERVICE MANUAL...
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Page 42: Appendices
APPENDICES CAPACITIES AND SPECIFICATIONS ............ A-2 FUSE LOCATIONS ................A-4 CIRCUIT BREAKER LOCATIONS............A-5 APU CONTROL UNIT ................. A-6 CCU CONTROLLER ................A-7 FUEL SYSTEM PURGE PROCEDURE ........... A-8 COOLANT PURGE PROCEDURE............A-9 DEFROST/HEAT AND DCP SENSOR CHARTS ........A-11 ENGINE INTERLOCK DIAGRAMS ............ -
Page 43: Capacities And Specifications
CAPACITIES AND SPECIFICATIONS Engine ....13.9 hp Kubota, 2 cyl, 479cc (model Z482-B) Engine Oil ... . 3.5 US Qts (3.3L) with filter. You can use any API Service CF, CF-4, CG-4 or CH-4 oil and any ASE Viscosity (or weight) of Oil according to the chart. - Page 44 Maintenance Parts Crossover List FUEL FILTER INLINE FUEL OIL FILTER AIR FILTER GENERATOR ALTERNATOR FILTER BELT BELT CARRIER 96-101-24K 30-186-01K 96-101-23K 30-724-10K 40-304-01K 96-969-03K OIL FILTER INLINE FUEL FILTER OIL DIPSTICK FUEL FILTER AIR FILTER AIR INLET FILTER Figure A-1: Maintenance Components...
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Page 45: Fuse Locations
FUSE LOCATIONS DC POWER FUSE 12V, 20 AMP CCU FAN FUSE 250V, 3 AMP THERMAL FUSE x2 Figure A-2: Fuse Locations 62-11175 COMFORTPRO SERVICE MANUAL... -
Page 46: Circuit Breaker Locations
CIRCUIT BREAKER LOCATIONS GENERATOR 35 AMP BREAKER (MANUAL RESET) CCU BREAKER OUTLET BREAKER (AUTO RESET) (AUTO RESET) Figure A-3: Circuit Breaker Locations 62-11175 COMFORTPRO SERVICE MANUAL... -
Page 47: Apu Control Unit
APU CONTROL UNIT Output Indicators STARTER – This is the output (+) to the Starter solenoid. CONTROL UNIT GLOW PLUGS – This is the output (+) to the Glow Plugs. SOL PULL – This is the output (+) to the Fuel Solenoid Pull windings STARTER (Only on during cranking for the first .5 seconds). -
Page 48: Ccu Controller
CCU CONTROLLER Inputs AC – This is the input from the Driver Control Panel only when it is calling for Air conditioning. (Low or High A/C.) HEAT – This is the input from the Driver Control Panel only when it is calling for Heat. -
Page 49: Fuel System Purge Procedure
FUEL SYSTEM PURGE PROCEDURE 1. Start the APU with the APU Test Switch Module. If APU fails to start, crank in 15 second bursts until fuel system is purged of air and APU starts and runs smoothly. OPEN TO BLEED THE FUEL SYSTEM FUEL FILTER Figure A-6: Fuel Filter... -
Page 50: Coolant Purge Procedure
COOLANT PURGE PROCEDURE Ensure that the coolant supply valve to the APU (located at the truck engine) and the coolant return valve to the APU (also located at the truck engine) are open. Release pressure from coolant system. Remove the truck engine radiator cap. Top up the coolant if necessary in the expansion tank. - Page 51 Start the APU by following the instructions on page 1- 3 (Multi-Function Driver Control Panel). With the APU and truck engines running, open the thermostat bleed valve and let any trapped air escape until a steady stream of coolant flows from the valve. Shut the truck engine off.
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Page 52: Defrost/Heat & Dcp Sensor
DEFROST/HEAT & DCP SENSOR Temperature vs. RESISTANCE Ω T(°C) T(°F) Resistance Chart (kΩ) 157.6 150.4 (kΩ) 143.5 (kΩ) (kΩ) 137.1 130.9 (kΩ) (kΩ) 125.1 119.6 (kΩ) 114.3 (kΩ) (kΩ) 109.3 104.5 (kΩ) 100.0 (kΩ) 95.7 (kΩ) 91.6 (kΩ) (kΩ) 87.7 84.0 (kΩ) 80.5... -
Page 53: Engine Interlock
ENGINE INTERLOCK (PG1011) High Side Switching APU Controller Pin 9 Wired to engage when truck ignition on RELAY SPDT Low Side Switching APU Controller Pin 9 Wired to engage when truck ignition on RELAY SPDT NOTE: 1 Relay is supplied by end user. 2 Ground connections MUST be common with APU controller. -
Page 54: Apu Wiring Diagram
62-11175 COMFORTPRO SERVICE MANUAL A-13... - Page 55 Fax: 1- -706- -546- -5207 P.O. Box 4805 Tel: (5255) 9126.0300 Syracuse, N.Y. 13221 U.S A Fax: (5255) 9126.0373 www.carrier.transicold.com A member of the United Technologies Corporation family. Stock symbol UTX ©2006 Carrier Corporation • Printed in U. S. A. 0706...