Carrier ComfortPro PC6000, ComfortPro PC6002, ComfortPro PC6006, ComfortPro PC6003 Operation & Service Manual

R

62--11175 Rev --

Operation & Service Manual

for

ComfortPro

™

Auxiliary

Power Unit

Auxiliary Power Unit

Models PC6000, PC6002, PC6003 & PC6006

62-11175 COMFORTPRO SERVICE MANUAL

c-i

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 ................................................................ 1-3

1.2.2 Stopping the APU ............................................................... 1-3

1.2.3 Turning the Heater ON/OFF ................................................. 1-4

1.2.4 Heating: Setting the Temperature ........................................ 1-4

1.2.5 Turning the A/C ON/OFF ..................................................... 1-4

1.2.6 Setting the A/C Temperature .............................................. 1-4

1.2.7 Fan Operation .................................................................... 1-5

1.3 AUTOMATIC OPERATIONS

1.3.1 Password Protection........................................................... 1-5

1.3.2 Entering Password ............................................................. 1-6

1.3.3 Setting the Clock ............................................................... 1-7

1.3.4 Comfort Monitor................................................................. 1-7

1.3.5 Timer ................................................................................ 1-8

1.3.6 Cold Weather Watch ......................................................... 1-10

1.3.7 Maximum Run Time.......................................................... 1-11

1.3.8 Battery Monitoring............................................................ 1-12

2.0 CLIMATE CONTROL UNIT (CCU)

2.1 PREPARATION

2.1.1 Charging the CCU............................................................... 2-1

2.2 SERVICE

2.1.2 Maintenance Schedule ....................................................... 2-2

2.1.2 CCU Spring Tune–Up .......................................................... 2-3

3.0 TROUBLESHOOTING

3.0 MANUAL OPERATIONS

3.1 APU (Auxiliary Power Unit)............................................................... 3-2

3.2 GENERATOR .................................................................................. 3-6

3.3 DRIVER CONTROL PANEL ............................................................... 3-7

3.4 CCU AIR CONDITIONING ................................................................. 3-8

3.5 CCU Fan ..................................................................................... 3-11

3.6 CCU Heat.................................................................................... 3-11

3.7 RECEPTACLE PANEL..................................................................... 3-12

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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......................................................... 3-15

3.9.5 Alternator Troubleshooting................................................... 3-15

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 & DCP SENSOR............................................................ A-11

ENGINE INTERLOCK.............................................................................. A-12

APU WIRING (Serial# KZX98002290 to Date) ......................................... A-13

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SAFETY

DANGER

Immediate hazards that will result
in severe personal injury or death.

WARNING

Hazards or unsafe practices that
could result in severe personal
injury or death.

CAUTION

Hazards or unsafe practices that
could result in minor injury or
product or property damage.

NOTICE

Information that is important to
proper installation or maintenance,
but is not hazard-related.

DANGER

A certified refrigeration technician
must charge and test the CCU.

For example:

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.

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Safety Considerations

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.

Exercise extreme caution when working near fuel or fuel-filled equipment.
Do not operate equipment during fueling operations. Use eye protection
when working near batteries, which contain acid and can explode. Do not
smoke or use open flames near batteries.

Electric shock can cause severe personal injury, burns, and death. Before
working on any unit, disconnect the batteries. Use only approved materials
and methods when working on the electrical system, and follow local
electrical codes. Never work on the APU or the electrical circuitry when the
APU is running. Never work with electricity in wet conditions or when you
are tired.

Fuel, oil, coolant, and refrigerant are toxic and in some cases, carcinogenic.
Wear eye and hand protection at all times. Remove contaminated clothing
immediately and wash contaminated skin. Do not breathe in vapors.

Moving parts can cause severe injury and/or death. Before working on any
unit, shut it off and disconnect the battery. Do not start until protective
covers have been replaced. Also, loose parts falling into rotating machinery
can cause severe accidents. Always ensure bolts and clamps are correctly
torqued and secured. Inspect mechanical components periodically for
damage, corrosion, and proper torque.

The APU is designed to provide electrical power for heating and cooling
vehicles in normal on-road conditions. Never use the APU to power critical
medical equipment or sensitive electronic equipment without the
manufacturer's express written approval.

Exhaust

Fuel/Batteries

Electrical

Intoxicants

Hot or Moving Parts

Misuse

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.

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COMPONENT LAYOUT

Figure C1: Main Components of the Carrier ComfortPro system and Where They Should Best be Installed on the Truck

COOLANT SUPPLY

AND RETURN

PANEL (DCP)

DRIVER CONTROL

CONDENSER

120 VAC

RECEPTACLE PANEL

UNIT (CCU)

CLIMATE CONTROL

BATTERY

VEHICLE FUEL TANK

AND RETURN

FUEL SUPPLY

AUXILIARY POWER UNIT (APU)

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c-vi

GENERAL ARRANGEMENT

TOP VIEW

REAR

LEFT SIDE

APU Dimensions (Measurements in inches)

FRONT VIEW

RIGHT SIDE

3.0

2.75 3.875

18.5

16.0

10.5

2.6

24.9

28.5

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FRONT VIEW

BOTTOM VIEW

CCU Dimensions (Measurements in inches)

FRONT RIGHT SIDE

DOWN

Condenser Dimensions (Measurements in inches)

12"

7.9"

23.4"

24.4"

16.2"

15.2"

3.3"

3.1"

3.0"

6.9"

3.0"

6.9"

3.0"

3.4"

3.0"

12.6"

.125"

1.3"

12.9"

5.62"

13.93"

16.25"

16.90"

5.62"

26.5"

24.25"

8"

3.5"

2.0"

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62-11175 COMFORTPRO SERVICE MANUAL

1-1

1.0

OPERATION OF MULTI-FUNCTION
DRIVER CONTROL PANEL

Figure 1-0: Multi-Function Driver Control Panel

1.1.1 Multi-Function Driver Control Panel Components

1 When visible, the heating system is heating.

2 When visible, the A/C is cooling.

3 Indicates the number of operating hours on the APU.

4 Indicates the state of the APU.

The APU engine is running.

The APU engine is off.

The APU engine is in the starting process (flashing).

5 Indicates that Battery Monitor mode is enabled.

6 Indicates that maximum run time is enabled.

7 Indicates that Cold Weather Watch mode is enabled.

8 Indicates that Comfort Monitor mode is enabled.

9 Indicates that Timer 1 or Timer 2 mode is enabled.

10 Indicates that the ComfortPro is connected to shore power.

The APU cannot be started in Shore Power mode.

11 Indicates the state of the 115V outlet and CCU auto-reset breakers.

115 VAC power is being supplied to the outlet.

No power is being supplied to the outlet.

CCU breaker has tripped.
High Heat/Outlet breaker has tripped.

The breaker that tripped has reset automatically and the DCP needs
to be reset.

NOTICE

The DCP (driver control panel), which
is mounted inside the truck bunk,
controls the APU and the CCU. The
central panel on the DCP provides
status information using words
and icons:

PREPARATION 1.1

4 5

3

APU

ON/OFF

2

MENU

HOURS
00000

6 7 8 9

APU

A/ C FAN HEAT

1

10 11

SP

T2T

1

HVAC

OFF

ESC/

RESET

APU

APU

APU

T2T

1

OFF

TRIP

TRIP

RE­SET

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1-2

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. See page 1-3.

Once the heater or A/C is running, it will cycle (automatically turn on and
off) in order to keep the truck bunk at the temperature you specify. The
HVAC will continue to cycle until you turn it off. While the HVAC is cycling,
the APU remains on and will only turn off when you manually turn it off
using the button on the DCP.

Note that in manual mode, the APU remains on until you turn it off. But in
Comfort Monitor mode (described below), the APU automatically turns off
and on as required.

When the APU is running, power is supplied to the power outlet in the
truck bunk (except in high heat).

In manual mode, the APU will turn off automatically if the Maximum Run
Time is reached.

Automatic Mode

The ComfortPro has several functions that will start it in automatic mode.

Comfort Monitor

(page 1-7)

FEATURE DESCRIPTION

The APU and HVAC automatically turn on to
maintain a comfortable temperature in the truck
bunk. When the desired temperature is met, the
APU and HVAC automatically turn off. When the
temperature is again out of range, they will both
turn on again, and cycle heat and air conditioning
as needed.

Timer

(page 1-8)

At the specified time, the APU and HVAC
automatically turn on. During the specified
timer duration, the HVAC cycles on and off to
maintain the desired temperature. When the
timer duration expires, both the APU and HVAC
turn off automatically and remain off.

Cold Weather Watch

(page 1-10)

The APU and heater on the HVAC automatically
turn on in order to prevent the APU engine and
truck engine from getting too cold. (Turning on
the heater creates a “load” that makes the APU
work harder and therefore warm up faster).
Both the APU and HVAC turn off automatically
once the preset duration time expires.

The APU automatically turns on for 90 minutes
in order to recharge the batteries. The HVAC
does not turn on. After the 90 minute run time,
the system will sense voltage for 10 minutes,
before restarting if needed.

Battery Monitor

(page 1-12)

There are icons on the DCP that flash when the APU and HVAC are running.
See page 1-1. If you enter the truck bunk and APU or HVAC is on but you
did not start it, you can assume it has started in one of the automatic
modes, as described above. On the DCP, one icon will be flashing steadily:
this is the icon for the mode that is currently operating.

Whenever the ComfortPro is running in automatic mode, if you then press
the heat, A/C or fan buttons on the DCP, the ComfortPro will switch to
manual mode. The APU will not automatically turn off! This icon on the
DCP will also stop flashing.

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1-3

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. You have been running the ComfortPro in manual
mode. You turn off the ComfortPro at 9:55 a.m. The timer will only turn on
the ComfortPro again 10 minutes later, at 10:05 a.m.

Clock

In order to use the Timer correctly, you must set the DCP clock. See page 1-7.

Maximum Run Time

You can set the maximum time that the APU is allowed to continuously run
in manual mode. See page 1-11.

Password Protection

You can add a password to the DCP, then you can protect one or more
functions so that only a person who knows the password can set the
function. See page 1-5.

WARNING

Do not start the APU when the enclosure
cover is removed. Operating with the
cover off may result in injury and/or death.

Press and release once.

The display shows "PLEASE WAIT – APU
STARTING" and flashes.

When stops flashing, then the APU
has started successfully.

The APU startup sequence consists of
20 seconds of glowing (30 seconds when
the ambient temperature is below -5°C or
23°F) and up to 10 seconds of cranking.

If the sequence fails, "RESTARTING"
appears for six seconds. Then the
startup sequence automatically repeats
up to five times or until the APU starts.

If "CRANK LIMIT" appears, see
Troubleshooting section.

APU

APU

WARNING

When the APU is about to start, a buzzer
sounds. Make sure no one is standing
near the APU or touching it.

1.2.1 Starting the APU "One Touch Start"

Press

.

The APU will stop. The display
shows .

APU

1.2.2 Stopping the APU

1.2 MANUAL OPERATIONS

HOURS
00000

APU

PLEASE WAIT

APU STARTING

HOURS
00000

APU

RESTARTING

HOURS
00000

APU

CRANK LIMIT

HOURS
00000

APU

OFF

OFF

OFF

OFF

OFF

OFF

OFF

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1 Press to activate the heater.

The display shows "HEAT LOW".

The heater will turn on only if the
temperature is too low (to adjust the
temperature, see below). When the
heater is on, appears.

2 Press again to switch between

high and low heat to heat the truck
bunk more or less quickly. In "HEAT
HIGH" mode, the power outlet is
disabled and the display indicates .

The heat or A/C will turn off when the
desired temperature is reached.

3 Press to deactivate heating.

NOTICE

The heat mode will not function if the
temperature is higher than 85°F.

1.2.3 Turning the Heater ON/OFF

1.2.4 Heating: Setting the Temperature

1.2.5 Turning the A/C ON or OFF

1.2.6 A/C Setting the Temperature

Press or when the heater is on ("HEAT LOW"or "HEAT
HIGH" shows).

The notch on the temperature bar moves. The heater will automatically
turn on and off to maintain this temperature.

1 Press to activate the A/C.

The display shows "A/C LOW".

The A/C will turn on only if the
temperature is too high (to adjust the
temperature, see below). When the
A/C is on, appears.

2 Press again to switch between

high and low A/C to cool the truck
bunk more or less quickly.

3 Press to deactivate the A/C.

NOTICE

The air conditioning function will not
operate if the temperature is lower
than 65°F.

Press or when the A/C is on ("A/C LOW" or "A/C HIGH" shows).

The notch on the temperature bar moves. The A/C will automatically turn
on and off to maintain this temperature.

HOURS
00000

APU

HEAT LOW

CH

HOURS
00000

APU

HEAT HIGH

OFF

CH

OFF

HOURS
00000

APU

A/C LOW

CH

HOURS
00000

APU

A/C HIGH

CH

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Press to toggle between low,
high and off.

The speed of the fan may automatically
change when the heat or A/C comes on,
then automatically change back when
the heat or A/C goes off.

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.

1.2.7 Fan Operation

1.3.1 Password Protection

1.3 AUTOMATIC OPERATIONS

You can add a password to the DCP, then you can protect one or more
functions so that only a person who knows the password can set the function.

On a newly installed DCP, the password is always 000, which means that
no password protection is in place.

To password-protect functions, first change the factory password; see
'Setting up for Password Protection'. All functions will now be password
protected. Then remove password protection from chosen functions, as
desired; see 'Protect Functions with a Password'.

If you know the password, you can change it at any time, if you need to.
Note that if you change the password to 000, you will remove password
protection from all functions.

If the password is ever lost, contact your dealer to have the password
reset to 000.

Setting up for PASSWORD PROTECTION

1 Press .

2 Press or until "SET/CHANGE PASSWORD" is displayed,

then press .

"ENTER PASSWORD" is displayed
with three blank squares, one for
each digit in the password. The
first digit flashes.

HOURS
00000

APU

CH

HOURS
00000

APU

CH

FAN

LOW

FAN

HIGH

HOURS
00000

ENTER PASSWORD

APU

000

OFF

OFF

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When you try to set up a function, you may be prompted to enter the password.

1 Press or until the first number in the password

is displayed, then press .

2 Repeat for each digit in the password.

3 Press again after entering the last digit.

1.3.2 Entering the Password

3

Press or 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.

6 Repeat the above steps to enter the new password. "CONFIRM"

is displayed.

7 Enter the new password again, then press to exit this function.

PROTECT FUNCTIONS with a PASSWORD

1 Press .

2 Press or until

"PASSWORD PROTECT"
is displayed, then press .

If this menu item does not appear,
then you have not yet changed the
factory password from 000. Change
the password and then try again.
"ENTER PASSWORD" is displayed with three blank squares, one for
each digit in the password. The first square flashes.

3 Press or until the first number in the password is

displayed, then press .

4 Repeat for each digit in the password.

5 Press again after entering the last digit.

The first feature that can be password protected is displayed with
"YES" or "NO" (indicating whether it is currently password protected).

6 Press or to change the "YES" or "NO".

7 Press to move to the next feature.

Or press or to skip to the next feature.

HOURS
00000

APU

PASSWORD

PROTECT

OFF

OFF

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1.3.3 Setting the Clock

1 Press

.

2 Press or until "CLOCK"

is displayed, 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).

The clock function takes you through
several settings: 12/24-hour-clock,
hour set, minutes set, am/pm-set (for
12-hour clock only), and day of the week.

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.

The clock settings remain even when the APU is turned off.

3 Press or to change the setting.

4 Press to move to the next setting. Or press to cancel any

changes you have not yet accepted.

5 When done, press to exit.

1.3.4 Comfort Monitor

You can specify the temperature you want in the truck bunk. Whenever the
truck bunk temperature goes 2° above or below this temperature, the APU
starts and the HVAC turns on until that temperature is reached or for
fifteen minutes, whichever is longer.

Turning COMFORT Monitor ON and OFF

1 Press .

2 Press or until

"COMFORT MONITOR" is displayed,

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 or to display "ON" or "OFF".

4 Press to confirm this setting.

The current setting remains until you change it; turning off the APU or
manually starting the APU does not permanently cancel this setting.

NOTICE

The clock does not automatically
adjust for time zone changes; you
must adjust it.

HOURS
00000

APU

CLOCK

HOURS
00000

CLOCK: SET MODE

APU

12 HOUR

OFF

OFF

HOURS
00000

COMFORT MONITOR:

APU

ON

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1-8

You can set up the ComfortPro so that the

APU and CCU run automatically for

a specified

time on specified days of the week. There are two timers, so you

can set up two schedules.

For example, one schedule may be to run every day at 6:00 p.m. for .5 hours
and the other schedule may be to run every Monday at 6.00 a.m. for .5 hours.

You must set up the timer as follows: Specify the day and time you want
the APU to run, specify the duration (the length of time you want the APU to
run for) and specify the temperature you want maintained in the truck bunk
while the APU is running.

Turning TIMER On or Off

1 Press .

2 Press or until

"TIMER 1" or "TIMER 2" is displayed,

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 or to display "ON" or "OFF".

4 Press to confirm this setting.

The current setting remains until you change it; turning off the APU or
manually starting the APU does not cancel the timer function.

1.3.5 Timer

Setting the TEMPERATURE

1 Press .

NOTICE

Factory Default Temperature Setting is
21°C / 70°F. Range is 18°C / 64°F to
30°C / 86°F.

2 Press or until

"COMFORT MONITOR" is displayed,
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 or to display "SET".

4

Press to confirm this setting. The current temperature is displayed.

5 Press or to scroll to the desired temperature.

6 Press to confirm this setting. Or press to cancel and

retain the current temperature.

7 Press to exit.

HOURS
00000

COMFORT MONITOR

APU

SET

HOURS
00000

TIMER 1

APU

ON

OFF

OFF

T

1