Escolar Documentos
Profissional Documentos
Cultura Documentos
Conditioning
Equipment
Model
CAPRI-280
Septa
T-283
Downloaded from www.Manualslib.com manuals search engine
OPERATION AND
SERVICE MANUAL
BUS
AIR CONDITIONING
UNIT
Model CAPRI-280
Septa
Carrier Transicold Division, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221
Carrier Corporation 1997 D Printed in U. S. A. 1097
TABLE OF CONTENTS
Section
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
2
2.1
2.2
2.3
2.4
Page
SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.1
Condenser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.2
Evaporator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.3
Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration System Component Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Specifications ECDC Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Specifications --- Controller Input Sensors and Transducers . . . . . . . . . . . . .
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning Refrigerant Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Flow Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Board --- Electronically Commutated DC Motors with 2-speed Input Signal . . .
Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel (Diagnostic Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting, Stopping and Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1
HVAC Power to Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.3
Self-Test and Diagnostics (Check for Errors and/or Alarms) . . . . . . . . . . . . .
2.1.4
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Trip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1.1
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1.2
Cooling/Reheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1.3
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2
Boost Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3
Compressor Unloader Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.4
Evaporator Fan Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.5
Condenser Fan Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.6
Compressor Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.7
Alarm Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.8
Hour Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Microprocessor Diagnostic Service Tool (MDST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1
Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3
Setpoint Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.4
Mode Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.4.1
Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.4.2
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.4.3
Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.5
Fan Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-1
1-1
1-2
1-2
1-3
1-4
1-4
1-4
1-4
1-4
1-5
1-6
1-7
1-8
1-9
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-4
3
3.1
3.2
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
2.4.6
Temperature Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.7
Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.8
System Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction And Discharge Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Manifold Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pumping The System Down Or Removing The Refrigerant Charge . . . . . . . . . . . . . . .
4.4.1
System Pumpdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2
Removing the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evacuation And Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding Refrigerant To System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.1
Checking Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2
Adding Full Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.3
Adding Partial Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking For Noncondensibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking And Replacing High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.1
Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.2
Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter-drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 05G Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12.1
Removing the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12.2
Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12.2.1 Checking the Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . .
4.12.2.2 Adding Oil with Compressor in System . . . . . . . . . . . . . . . . . . . . .
4.12.2.3 Adding Oil to Service Replacement Compressor . . . . . . . . . . . .
4.12.2.4 Removing Oil from the Compressor . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Sensor Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction And Discharge Pressure Transducer Checkout . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Sensors and Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
2-4
2-4
2-5
3-1
3-1
3-1
4-1
4-1
4-1
4-1
4-2
4-2
4-2
4-2
4-3
4-3
4-3
4-3
4-4
4-4
4-4
4-4
4-4
4-5
4-5
4-6
4-6
4-7
4-7
4-7
4-8
4-8
4-8
4-8
4-9
4-19
5
5.1
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
LIST OF ILLUSTRATIONS
Figure
Page
1-1.
1-1
1-2.
Condenser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-3.
Evaporator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1-4.
1-6
1-5.
Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7
1-6.
Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8
1-7.
Diagnostic Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-9
2-1.
2-2
4-1.
4-1
4-2.
4-2
4-3.
4-4
4-4.
4-5
4-5.
4-5
4-6.
4-7
4-7.
4-7
5-1.
5-2
LIST OF TABLES
Table
2-1.
2-2.
3-1.
3-2
3-3.
4-1.
4-2.
4-3.
4-4.
Page
Main Evaporator Fan Speed Relay Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General System Trouble Shooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Sensor (AT, TSC, TSD and TSR) Resistance . . . . . . . . . . . . . . . . . . . . . . .
Suction and Discharge Pressure Transducer (SPT and DPT) Voltage . . . . . . . . . . . . .
Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R-134a Temperature - Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
2-3
2-5
3-1
3-2
3-4
4-8
4-9
4-10
4-11
SAFETY SUMMARY
GENERAL SAFETY NOTICES
The following general safety notices supplement the specific warnings and cautions appearing elsewhere in
this manual. They are recommended precautions that must be understood and applied during operation
and maintenance of the equipment covered herein. The general safety notices are presented in the
following three sections labeled: First Aid, Operating Precautions and Maintenance Precautions. A listing
of the specific warnings and cautions appearing elsewhere in the manual follows the general safety notices.
FIRST AID
An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention
immediately.
OPERATING PRECAUTIONS
Always wear safety glasses.
Keep hands, clothing and tools clear of the evaporator and condenser fans.
No work should be performed on the unit until all circuit breakers and start-stop switches are turned off, and
power supply is disconnected.
Always work in pairs. Never work on the equipment alone.
In case of severe vibration or unusual noise, stop the unit and investigate.
MAINTENANCE PRECAUTIONS
Beware of unannounced starting of the evaporator and condenser fans. Do not open the condenser fan
grille or evaporator access panels before turning power off, and disconnecting and securing the power plug.
Be sure power is turned off before working on motors, controllers, solenoid valves and electrical control
switches. Tag circuit breaker and power supply to prevent accidental energizing of circuit.
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires.
Problems with the system should be diagnosed, and any necessary repairs performed, by qualified service
personnel.
When performing any arc welding on the unit, disconnect all wire harness connectors from the modules in
the control box. Do not remove wire harness from the modules unless you are grounded to the unit frame
with a static-safe wrist strap.
In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).
SECTION 1
DESCRIPTION
1.1 INTRODUCTION
2
9
Compressor
Pressure Switches
Electrical Control and Relay Board
Evaporator Section
Evaporator Blowers and Motors
Condenser Axial Fan/Motor Assemblies.
7.
8.
9.
10.
11.
1-1
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Condenser Section
Main Harness
Power Harness
Alternator
Power Relay
T-283
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Condenser Coil
Condenser Fan Motor Assembly
Receiver Tank
Service Valve
Filter Drier
Liquid Hose
Gas Hose
Condenser Motor Harness
Condenser Motor Plate
Lid Screw Nut
Locking Screw Gasket
Lid Bolt Support
T-283
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1.
1a.
2.
3.
3a.
4.
5.
6.
7.
8.
1-3
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Suction Line
Discharge Line
Heating Line
Evaporator Motor Harness
Lid Screw --- Stopper
Locking Screw Gasket
Lid Bolt Support
Square Nut
Lid Locking Screw
T-283
b. Temperature Sensors
Input Range: ---52.6 to 158_F (---47 to 70_C)
Output: NTC 10K ohms at 77_F (25_C)
(See Table 4-1 for calculations.)
b. Compressor
Model: 05G
No. of Cylinder: 6
Weight (Dry): 165 lb (75 kg)
Oil Charge:
New Compressor: 6.75 pints (3.2 liters)
Replacement Compressor: 5.5 pints (2.6 liters)
Oil Level:
Level in sight glass between Min.---Max marks on
compressor crankcase (curbside)
Approved Compressor Oils - R-134a:
Castrol: Icematic SW68C
Mobil: EAL Arctic 68
ICI: Emkarate RL68H
T-283
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1-4
b. Pressure Switches
High Pressure Switch (HPS)
During the A/C mode, HVAC system operation will
automatically stop if the HPS switch contacts open due to
an unsafe operating condition. Opening HPS contacts
de-energizes, through the controller, the A/C compressor
clutch and condenser fan motor relays shutting down the
system.
d. Ambient Lockout
The ambient temperature sensor located in the
condenser section measures the condenser air
temperature. When the temperature is less than 45F, the
compressor is locked out until the temperature increases
above 50F to prevent compressor damage.
1-5
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T-283
T-283
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1-6
1.9 Relay Board -- Electronically Commutated DC Motors with 2-speed Input Signal
13
1
K1
K3
K2
D2
D6
K4
EF2 EF1
EF3 EF4
D14
D17
11
K7
2
3
K6
D81
EF HIGH
SIGNAL
EF6 EF5
D26
K10
10
D37
12
D85
CF2 CF1
K8
K9
D41
CF
HIGH
SIGNAL
K14
K15
K16
K17
K18
K20
K19
K13
CF6 CF5
JP6
D57
D54
D63
JP5
D60
D72
D66
JP4
D51
D69
JP3
JP2
JP1
c. Connectors
EF1-EF6
Evaporator Fans.
CF1-CF4
Condenser Fans.
JP1
External evaporator & condenser fan
thermal overload connections.
JP2
Logic board connector.
JP3
Booster pump.
JP4
A/C Clutch, Pressure fault output,
Compressor High Pressure Switch.
JP5
High pressure fail, motor fail output,
heat valve.
JP6
Unloaders 1 & 2.
EF-HIGH SIGNAL
Output to the evaporator
fans to operate on high
speed.
CF-HIGH SIGNAL
Output to condenser fans to
operate on high speed.
(Not used)
d. LEDS
D 2 Evaporator fans 1 & 2 are energized.
D 6 Evaporator fans 3 & 4 are energized.
D14 Evaporator fan 5 is energized.
D17 Evaporator fan 6 is energized.
D26 Condenser fans 1 & 2 energized.
D30 Condenser fans 3 & 4 energized.
D38 Condenser fans 5 & 6 energized. (Not used).
D51 A/C clutch output active.
D54 Unloader 1 output active.
D57 Unloader 2 output active.
D60 High low pressure failure.
D63 Heat valve output active.
D66 Alarm output active.
D69
D72 Motor fail light.
D81 Evaporator fans on high.
D85 Condenser fans on high. (Not used).
T-283
J1
J2
J3
J4
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1-8
11
1.
2.
3.
4.
5.
6.
10
Display
Down --- decrease selection
Up --- increase selection
Ventilation
Auto Control Selection
Air Conditioning
1-9
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T-283
SECTION 2
OPERATION
2.1 STARTING, STOPPING AND OPERATING
INSTRUCTIONS
2.1.1 HVAC Power to Controller
Before starting the system, electrical power must be
available from the bus power supply. The HVAC
controller receives power from two sources:
a.
b.
2.1.2
a.
Starting
2.1.3
b.
c.
d.
2.3
2-1
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SYSTEM OPERATION
Cool
High Speed
Loaded
Cool
High Speed
4 Cylinders
Cool
High Speed
2 Cylinders
Reheat
High Speed
2 Cylinders
Heat
Low Speed
Heat
High Speed
2.3.1.2 Cooling/Reheat
Cooling and reheat require various combinations of
compressor unloading. Cooling is accomplished by
energizing the compressor and condenser fans,
opening the liquid solenoid valve and closing the
heating valve. Reheat opens the heat valve while
cooling. This allows for reduced capacity around
setpoint and de-humidification.
2.3.1.3 Heating
During heating, the liquid solenoid is closed to stop
cooling and the compressor and condenser fans will
shut down. The fan speed will vary based on the
temperature difference from setpoint. Heating will
not start until the engine coolant switch (ECS) closes.
The ECS is located on the block of the vehicle and is
provided by the OEM. It senses the engine coolant
temperature. The switch closes at 105F on
temperature rise. The switch prevents the circulation
of cooler air throughout the vehicle during initial
start-up.
2.3.2 Boost Pump
When the unit is in heat the boost pump relay is
energized. This signal is read by the bus multiplex
system to activate the boost pump.
2.3.3 Compressor Unloader Control
The unloader outputs control the capacity of the
compressor by energizing or de-energizing unloader
solenoid valves. Energizing a valve solenoid
de-activates a pair of compressor cylinders. The
Model 05G compressor has six cylinders. Four
cylinders are equipped with two sets of unloader
valves (UV1 and UV2), each controlling two
cylinders; this allows the compressor to be operated
with two, four or six cylinders. When the compressor is
off, the unloaders are de-energized immediately.
Whenever the compressor is changed from off to on,
the unloaders are forced energized for fifteen
seconds. After fifteen seconds, one unloader may be
de-energized, if required. Any subsequent changes
between energizing and de-energizing the unloaders
must be staged with a two second delay. Only one
unloader may change state at a time when staging is
required.
a. Suction Pressure
In addition to temperature control, the electric
unloaders will be used to prevent coil frosting:
1.
2.
2.
T-283
EVAP FAN
RELAYS
Off
On
On
HIGH
SPEED
RELAY
Off
Off
On
b.
c.
d.
e.
NOTE
Be sure to reconnect J3 when testing is
completed or the system will fail to operate
when the MDST is disconnected.
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CODE NAME
DESCRIPTION
P1
This value is the temperature measured by the return air sensor. If the sensor
is shorted it will display CL. If it is open circuited it will display OP.
P2
Coil Temperature
P3
Ambient Temperature
P4
Not used.
P5
Suction Pressure
This value is the suction pressure measured by the suction pressure transducer. If the sensor is shorted it will display CL If it is open circuited it will display
OP. If the auto key is pressed and held for five seconds the suction pressure
will be calibrated to zero and the offset will be stored in no-volatile memory.
This calibration will be locked out if the offset is greater than 20 or less than
6.7 or if the clutch output is energized.
P6
Discharge Pressure
P7
Not used.
P8
Not used.
P9
This is the number of degrees F above setpoint at which the unloaders will be
both energized. This value can be modified between 0 and 10 degrees F. The
default value is 1 degree F.
P10
This is the number of degrees F above AC control window one at which the
first unloader will be energized. This value can be modified between 0 and 10
degrees F. The default value is 1 degree F.
P11
This is the number of degrees F above AC control window two at which the
evaporator fan speed will be set to low. This value can be modified between
0 and 10 degrees F. The default value is 1 degree F.
P12
This is the number of degrees F below setpoint before the heat valve is energized. This value can be modified between 0 and 10 degrees F. The default
value is 2 degree F for heat and 4 degrees F for reheat.
P13
This number is the minimum time in minutes that the compressor must be off
after a high or low pressure alarm before it can be restarted. This value can be
modified between one and five minutes. The default value is 1.
P14
Fan Delay
This is the minimum time (in seconds) that the fans must run at a particular
speed before changing to another speed. This value can be modified between one and 60 seconds. The default value is two seconds.
2-5
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Code Name
Description
P15
Unloader/Heat Valve
Delay
This is the minimum time (in seconds) that the unloaders and heat valve must
be in a particular state (open /closed) before changing to another state. This
value can be modified between 1 and 60 seconds. The default value is 2 seconds.
P16
This is the current state of the compressor head pressure switch input. CL
will be displayed if it is closed and OP will be displayed if it is open.
P17
Not used.
P18
Maximum Setpoint
This is the maximum value that the operator will be allowed to set the setpoint
temperature. The value can be modified in degrees with the up and down keys
to a value between 60F and 80F.
P19
Minimum Setpoint
This is the minimum value that the operator will be allowed to set the setpoint
temperature. The value can be modified in degrees with the up and down keys
to a value between 60F and 80F.
P20
This is the number of hours of operation that the compressor has run with the
clutch energized in thousands
P21
This is the number of hours of operation that the compressor has run with the
clutch energized in hundreds, tens and ones.
P22
This is the number (in thousands) of hours of operation with the evaporator
fans energized.
P23
This is the number (in hundreds, tens and ones) of hours of operation with the
evaporator fans energized.
P24
Maintenance 1 Hour
High
This is the value of compressor hours high (P20) at which maintenance alarm
#1 will be activated. This value can be modified by the up and down arrow
keys. If both high and low values are zero the alarm is disabled.
P25
Maintenance 1 Hour
Low
This is the value of compressor hours low (P21) at which maintenance alarm
#1 will be activated. This value can be modified by the up and down arrow
keys. If both high and low values are zero the alarm is disabled.
P26
Maintenance 2 Hours
High
This is the value of evaporator fan hours high (P22) at which maintenance
alarm #2 will be activated. This value can be modified by the up and down
arrow keys. If both high and low values are zero the alarm is disabled.
P27
Maintenance 2 Hours
Low
This is the value of evaporator fan hours low (P23) at which maintenance
alarm #2 will be activated. This value can be modified by the up and down
arrow keys. If both high and low values are zero the alarm is disabled.
P28
This is the value at which the freeze alarm will be activated. The default value
is 32F. This value can be modified between 20F and 40F in one degree increments by using the arrow keys
P29
P30
P31
P32
Ki
Not used.
P33
Kp
Not used.
2-6
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SECTION 3
TROUBLESHOOTING
!
CAUTION
NAME
DESCRIPTION
ER 1
Data Memory
ER 2
Program Memory
ER 3
A/D
ER 4
Communication Failure
ER 5
Program Memory
a. Alarm codes
Alarms will be displayed by AXX, or IXX where A
indicates that the alarm is active and I indicates that the
alarm is inactive. If the auto key is pressed the display will
scroll through the three digit hour meter readings. If
multiple alarms are present the user can scroll through
each alarm by pressing the auto key. When the end of the
alarm list is reached the display will show --- --- ---. If the
auto key is held down for five seconds while --- --- --- is
displayed all inactive alarms are cleared.
c. Alarm queue
The alarm queue consist of 10 alarm locations. When the
alarm queue is full an alarm will be generated but not
stored to indicated this. When alarms are viewed this will
be the first alarm to be shown.
d. Alarm clear
b. Activation
When an alarm becomes active they will be placed in an
alarm queue in the order at which they initiate unless the
T-283
3-1
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TITLE
CAUSE
REMEDY
CONTROLLER
RESPONSE
11
Coil Freeze
12
High Voltage
13
Low Voltage
14
15
Suction Pressure
Transducer Failure
16
Discharge Pressure
Transducer Failure
Discharge pressure
transducer failure or wiring defective.
17
21
22
23
Ensure connector is
plugged in or repair
wiring.
24
Ensure connector is
plugged in or repair
wiring.
T-283
3-2
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TITLE
25
Motor Failure
26
Not used
31
CAUSE
REMEDY
CONTROLLER
RESPONSE
Maintenance Alarm 1
32
Maintenance Alarm 2
99
T-283
3-3
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POSSIBLE CAUSES
REFERENCE
SECTION
3.2
Check
Check/Replace
Check/Replace
See Note
Check/Repair
Check/Reset
Check
See Note.
see below
3.5.6
p. 3-5 and 4.11
p. 3-5 and 4.11
4.5 and 4.7
Open
1.6
Check
p. 3-5
p. 3-5
Replace
4.4
Check
Check
Clean
See Note.
4.5 & 4.7
See Note.
Open
Check/ Open
4.10
4.5 and 4.7
p. 3-5
p. 3-5
Replace
See Note.
Check/Tighten
See Note.
See Note.
p. 3-5
4.12.2
Check
Check/Adjust
Clean
T-283
3-4
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T-283
3-5
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REFERENCE
SECTION
Check/Tighten
Replace
Check
Check/Replace
4.14 or 4.15
Check
Check
Defrost coil
Clean
Clean/Replace
Repair/Replace
Replace
Repair/Replace
Repair/Replace
Clean/Replace
Clean/Defrost
Check/Replace
1.6
Check
4.5 and 4.7
Check
4.6
Replace
Replace
4.11
4.11
4.6
Check
4.6
Replace
Replace
4.11
Clean
Check/Replace
Check
Clean
Open
Repair/Replace
Repair/Replace
Check/Replace
Replace
Repair/Replace
1.6
Replace
SECTION 4
SERVICE
WARNING
REFERENCE
SECTION
OPERATION
OFF
a. Daily Maintenance
X
2.2
None
b. Weekly Inspection
X
X
X
4.1.a
None
4.5
4.10
4.2
To Discharge or
from Suction Line
Port to
Compressor
Service Valve
Frontseated
(clockwise)
Valve Cap
Gauge
Connection
Valve
Stem
Service Valve
Backseated
(counterclockwise)
4-1
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4.1.b
None
Replace/Tighten
None
None
None
T-283
4.3
l.
4.4
High Pressure
Gauge
4.4.1
Hand Valve
(Open)
A. Connection to
Low Side of System
B. Connection to
High Side of System
Hand Valve
(Frontseated)
a.
c.
b.
c.
e.
f.
4.4.2
f.
g.
C. Connection to Either:
Vacuum Pump
Refrigerant Cylinder
Oil Container
Evacuation Line
b.
System Pumpdown
a.
counterclockwise
b.
NOTES
Before opening up any part of the system, a
slight positive pressure should be indicated on
the gauge.
When opening up the refrigerant system,
certain parts may frost. Allow the part to
warm to ambient temperature before
dismantling; this avoids internal
condensation, which puts moisture in the
system.
4.5
i.
j.
k.
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NOTE
It must be emphasized that only the correct
refrigerant drum should be connected to
pressurize the system. Any other gas or
vapor will contaminate the system, which
will require additional evacuation and
evacuation of the high (discharge) side of
the system.
1.
2.
3.
b.
4.
c.
5.
6.
7.
8.
9.
a.
f.
g.
a. General
b. Preparation
4.7
4.7.1
4.6
NOTE
2.
3.
a.
b.
c.
4.7.2
4-3
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a.
b.
c.
4.9
4.9.1
WARNING
4.7.3
a.
a.
b.
b.
c.
c.
1
4
1. Cylinder Valve
and Gauge
2. Pressure Regulator
3. Nitrogen Cylinder
4. Pressure Gauge
(0 to 400 psig =
0 to 2.8 mPa)
5. Bleed-Off Valve
6. 1/4 inch Connection
a.
b.
e.
c.
f.
g.
f.
g.
4.9.2
a.
b.
c.
4.10 FILTER-DRIER
2.
3.
4.
8
9
8
10
11
1.
2.
3.
4.
5.
6.
2.
3.
4.
5.
6.
8.
9.
1.
2.
3.
4.
5.
NOTE
7.
T-283
3.
4.
5.
6.
7.
Start bus and run on fast idle until unit has stabilized,
about 20 to 30 minutes.
4.
NOTE
When conducting this test, the suction pressure
must be at least 6 psig (41 kPa) below the
expansion valve maximum operating pressure
(MOP). Refer to section 1.3 for MOP.
8.
9.
NOTES
1. The service replacement 05G compressors
are sold without shutoff valves. Valve pads
are installed in their place. The optional
unloaders are not supplied, as the cylinder
heads are shipped with plugs. Customer
should retain the original unloader valves
for use on the replacement compressor.
2.
3.
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4-6
GASKET
12
11
2
3
4
10
9
SPRING
8
COMPRESSOR
HEAD
6
BYPASS
PISTON
PLUG
FLANGE
COVER
capscrews
(NOT INTERCHANGEABLE
WITH CONTROL VALVE
SCREWS)
1. Electric Unloader
Valve
2. Suction Service
Valve Charging Port
3. Suction Service
Valve
4. Clutch
5. Oil Fill Plug
k.
l.
4-7
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Bottom Plate
Oil Drain Plug
Oil Level Sight Glass
Oil Pump
O-ring
Discharge Service
Valve
12. Service Port
j.
6.
7.
8.
9.
10.
11.
T-283
2.
3.
NOTE
If oil drain plug is not accessible, it will be
necessary to extract oil through the oil fill plug
with a siphon tube.
c. Remove the oil drain plug on the bottom plate of the
compressor and drain the proper amount of oil from
the compressor. Replace the plug securely back into
the compressor.
d. Repeat step a. to ensure proper oil level.
CAUTION
3.
4.
b.
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4-8
b.
4-9
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T-283
Description
Jumper
A.
High Reheat --- When this configuration is removed the unit will default
to high speed in reheat mode and in the low speed cool band. If not
removed heat reheat will default to low speed.
REMOVED
B.
High Vent --- When this configuration is removed the unit will default to
high speed in vent mode. If not removed vent mode will default to
low speed.
REMOVED
C.
NA
D.
REMOVED
E.
Transducers --- When the transducer configuration is removed transducers will assumed to be present.
REMOVED
F.
NA
IN
G.
IN
H.
REMOVED
I.
NA
NA
J.
NA
IN
K.
REMOVED
L.
NA
REMOVED
M.
NA
IN
N.
C/F --- When this configuration is removed the display will show
temperatures in F. When not removed the display will show temperature in C.
O.
NA
IN
P.
NA
IN
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IN
4-10
REMOVED
Pressure
Psig
kPa
Kg/cm@
Temperature
Bar
kPa
Kg/cm@
Bar
_C
---40
---40
14.6
49.4
37.08
0.49
30
---1
26.1
180.0
1.84
1.80
---35
---37
12.3
41.6
31.25
0.42
32
27.8
191.7
1.95
1.92
---30
---34
9.7
32.8
24.64
0.33
34
29.6
204.1
2.08
2.04
---25
---32
6.7
22.7
17.00
0.23
36
31.3
215.8
2.20
2.16
---20
---29
3.5
11.9
8.89
0.12
38
33.2
228.9
2.33
2.29
---18
---28
2.1
7.1
5.33
0.07
40
35.1
242.0
2.47
2.42
---16
---27
0.6
2.0
1.52
0.02
45
40.1
276.5
2.82
2.76
---14
---26
0.4
1.1
0.03
0.03
50
10
45.5
313.7
3.20
3.14
---12
---24
1.2
8.3
0.08
0.08
55
13
51.2
353.0
3.60
3.53
---10
---23
2.0
13.8
0.14
0.14
60
16
57.4
395.8
4.04
3.96
---8
---22
2.9
20.0
0.20
0.20
65
18
64.1
441.0
4.51
4.42
---6
---21
3.7
25.5
0.26
0.26
70
21
71.1
490.2
5.00
4.90
---4
---20
4.6
31.7
0.32
0.32
75
24
78.7
542.6
5.53
5.43
---2
---19
5.6
36.6
0.39
0.39
80
27
86.7
597.8
6.10
5.98
---18
6.5
44.8
0.46
0.45
85
29
95.3
657.1
6.70
6.57
---17
7.6
52.4
0.53
0.52
90
32
104.3
719.1
7.33
7.19
---16
8.6
59.3
0.60
0.59
95
35
114.0
786.0
8.01
7.86
---14
9.7
66.9
0.68
0.67
100
38
124.2
856.4
8.73
8.56
---13
10.8
74.5
0.76
0.74
105
41
135.0
930.8
9.49
9.31
10
---12
12.0
82.7
0.84
0.83
110
43
146.4
1009
10.29
10.09
12
---11
13.2
91.0
0.93
0.91
115
46
158.4
1092
11.14
10.92
14
---10
14.5
100.0
1.02
1.00
120
49
171.2
1180
12.04
11.80
16
---9
15.8
108.9
1.11
1.09
125
52
184.6
1273
12.98
12.73
18
---8
17.1
117.9
1.20
1.18
130
54
198.7
1370
13.97
13.70
20
---7
18.5
127.6
1.30
1.28
135
57
213.6
1473
15.02
14.73
22
---6
19.9
137.2
1.40
1.37
140
60
229.2
1580
16.11
15.80
24
---4
21.4
147.6
1.50
1.48
145
63
245.6
1693
17.27
16.93
26
---3
22.9
157.9
1.61
1.58
150
66
262.9
1813
18.48
18.13
28
---2
24.5
168.9
1.72
1.69
155
68
281.1
1938
19.76
19.37
_C
Psig
_F
4-11
_F
Pressure
T-283
SECTION 5
ELECTRICAL
Figure 5-1 INTRODUCTION
This section includes electrical wiring schematics. The schematic shown in this section is for R-134a refrigerant systems.
5-1
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INDEX
A
A/D, 3-1
Abnormal Noise or Vibrations, 3-5
Activation, 3-1
Adding Full Charge, 4-3
Adding Oil, 4-7
Closed system method, 4-8
Condenser, 1-1
coils, 1-2
Fans, 1-2
Alarm Description, 4
Alternator, 1-1
Connectors, 1-7
controller, 1
Controller Configuration, 4-9
Boost Pump, 3
Breakers, 1-5
cooling, 1-3
Cooling/Reheat, 3
Capacity control, 1
DEHYDRATION , 4-3
Diagnostics, 1
clutch, 1-4
clutch , 1-4
Discharge Pressure, 3
T-283
INDEX
E
Electrical, 5-1
Heating, 3
heating coils, coils, 1-3
Heating Line, 1-3
Heating Malfunction, 3-5
Heating system, 3-4
High Pressure Cutout Switch , 4-4
High Discharge Pressure, 3-2
High discharge pressure, 3-4
High Pressure Switch, HPS, 1-5
high pressure switch, 1-4
High Pressure Switch (HPS), 1-4
High Reheat, 4-10
High suction pressure, 3-4
High Vent, 4-10
High Voltage, 3-2
Hour Meters, 4
Humidity Sight Glass, 1-3
F
Filter-drier, 1-2, 1-5, 4-5
Filter-drier, 4-5
Fuses, 1-5
LEDS, 1-7
Left Front Grille, 1-2
Lid Bolt Support, 1-2, 1-3
Lid Locking Screw, 1-3
Lid Screw --- Stopper, 1-3
Lid Screw Nut, 1-2
Liquid Hose, 1-2
T-283
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Index-2
INDEX
R
M
Main Harness, 1-1
Maintenance Alarm 1, 3-3
Maintenance Alarm 2, 3-3
N
No Evaporator Air Flow Or Restricted Air Flow, 3-5
O
Oil Pump Method, 4-7
Self-Test , 1
Service, 4-1
Service Valve, 1-2
Square Nut, 1-2, 1-3
Starting, 1
Stopping, 1
Parameter Codes
P2, Coil Temperature, 5
P20, Compressor Hours High, 5
P33, Kp, 6
Superheat, 5
pre---trip inspection, 1
Superheat, 4-5
System Parameters, 5
system operation, 1
Index-3
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T-283
INDEX
T
Troubleshooting, 3-1
UV1 Relay, 3
UV2 Relay, 3
T-283
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Index-4