Auxiliary Power Unit R Operation & Service Manual for ComfortPro™ Auxiliary Power Unit Models PC6011, PC6012, PC6013, PC6014, PC6015, PC6018, PC6019 PC6111, PC6112 62--11175 Rev E
Models covered by this publication 6000 SERIES Model # PC6011 PC6012 PC6013 PC6014 PC6015 PC6018 PC6019 Description Carrier 12K BTU Integrated APU ComfortPro 12K BTU Integrated APU ComfortPro 12K BTU Integrated APU with DPF ComfortPro GENX APU Only ComfortPro GENX 12K CCU with SHORE POWER Carrier GENX APU ONLY Carrier GENX 12K CCU with SHORE POWER 6100 SERIES Model # PC6111 PC6112 Description Carrier 12K BTU Stand Alone APU ComfortPro 12K BTU Standalone APU
CONTENTS INTRODUCTION SAFETY Safety Alerts ................................................................................. c-iii Component Layout.......................................................................... c-v GENERAL ARRANGEMENT APU Dimensions ............................................................................ c-vi CCU Dimensions........................................................................... c-vii Condenser Dimensions ...................................................
3.0 TROUBLESHOOTING (Cont.) 3.8 3.9 TESTING PROCEDURES 3.8.1 Testing AMP draw for components ....................................... 3-13 3.8.2 Testing Voltage and Hz readings .......................................... 3-13 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.................................................................
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.
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.
COMPONENT LAYOUT The main components of the ComfortPro are the Auxiliary Power Unit (APU), the Climate Control Unit (CCU) and the Driver Control Panel (DCP). BATTERY CHARGER DRIVER CONTROL PANEL (DCP) Note: In this manual, the term DCP refers generically to all models of Driver Control Panel, including DCP, DCP2, etc.
GENERAL ARRANGEMENT APU Dimensions (Measurements in inches) 3.875 2.75 18.5 2.6 24.9 16.0 10.5 X = 1.9 STAND-ALONE APU X = 3.0 INTEGRATED APU X 28.5 REAR LEFT SIDE 13.4 24.9 RIGHT SIDE (INTEGRATED APU) 24.9 2.6 FRONT VIEW 11.
CCU Dimensions (Measurements in inches) FRONT VIEW 12.6" 12" 7.9" 12.9" .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" 13.93" 16.25" 16.90" 5.62" 5.
c-viii 62-11175 COMFORTPRO SERVICE MANUAL
1.0 OPERATION OF MULTI-FUNCTION DRIVER CONTROL PANEL 4 5 6 7 8 10 9 11 3 APU ON/OFF HOURS 00000 T1 T2 SP APU HVAC OFF 2 ESC/ RESET MENU A/C FAN HEAT 1 Figure 1-0: Multi-Function Driver Control Panel 1.1 PREPARATION 1.1.1 Multi-Function Driver Control Panel Components 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.
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 APU 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 1-5. 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.
FEATURE DESCRIPTION Comfort Monitor Cont. (page 1-9) SET TEMP: Allows the user to set the desired ambient temperature in the range from 18°C (64°F) to 30°C (86°F). COMFORT MONITOR OPERATION APU ON/OFF key With Comfort Monitor enabled and its duration timer set to a non-zero value in the menu, the APU ON/OFF key may be used to activate / de-activate Comfort Monitor mode.
Temp Start (page 1-11) 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. Battery Monitor (page 1-13) The APU automatically turns on for 90 minutes in order to recharge the batteries. The HVAC does not turn on.
1.2 MANUAL OPERATIONS 1.2.1 Starting the APU "One Touch Start" WARNING Do not start the APU when the enclosure cover is removed. Operating with the cover off may result in injury and/or death. WARNING When the APU is about to start, a buzzer sounds. Make sure no one is standing near the APU or touching it. Press and release once. HOURS 00000 The display shows "PLEASE WAIT – APU STARTING" and APU flashes. When APU stops flashing, then the APU has started successfully.
1.2.4 Heating: Setting the Temperature Press or HIGH" shows). when the heater is on ("HEAT LOW"or "HEAT The notch on the temperature bar moves. The heater will automatically turn on and off to maintain this temperature. 1.2.5 Turning the A/C ON or OFF NOTICE The air conditioning function will not operate if the temperature is lower than 18.5°C (65°F). 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).
1.3 AUTOMATIC OPERATIONS 1.3.1 Password Protection WARNING Once Automatic functions are set the system could start at anytime. Before servicing the unit be sure to disconnect the unit from the batteries to prevent injury should the unit attempt to start while servicing. All presets will remain once battery cable is reconnected. 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.
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 7 Press to move to the next feature. Or press to change the "YES" or "NO". or to skip to the next feature. 1.3.
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. Enabling COMFORT MONITOR 1 Press . 2 Press or until "COMFORT MONITOR" is displayed, then press . HOURS 00000 APU COMFORT MONITOR: ON If "ENTER PASSWORD" is displayed, enter your password.
1.3.5 Timer 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.
Setting the TEMPERATURE for the Timer NOTICE Factory Default Temperature Setting is 21°C (70°F). Range is 18°C (64°F) to 30°C (86°F). 1 Press . HOURS 00000 2 Press or until "TIMER 1 or TIMER 2" is displayed, then press . APU T1 OFF TIMER 1 SET TEMP If "ENTER PASSWORD" is displayed, enter your password. If you do not know the password, then you cannot set up this function (see page 1-7). 3 Press or to display "SET TEMP". 4 Press to confirm this setting. The current temperature is displayed.
3 Press or to display "SET TEMP". 4 Press to confirm this setting. The current start temperature is displayed. 5 Press or to scroll to the desired start temperature. to confirm this setting. Or press 6 Press retain the current start temperature. 7 Press to cancel and to exit. Setting the DURATION NOTICE Factory Default Duration Setting is 2 hours. Range is 1 hr to 4 hrs. 1 Press HOURS 00000 . 2 Press or until "TEMP START" is displayed, then press .
Setting the DESIRED RUN TIME 1 Press HOURS 00000 . 2 Press or until "MAXIMUM RUN TIME" is displayed, . then press APU MAXIMUM RUN TIME SET If "ENTER PASSWORD" is displayed, enter your password. If you do not know the password, then you cannot set up this function (see page 1-7). 3 Press or to display "SET". 4 Press to confirm this setting.The current duration is displayed. 5 Press or to scroll to the desired number of hours. 6 Press to confirm this setting.
The APU starts if the battery voltage goes below the level you specify here. Setting the Voltage Level NOTICE Factory Default Voltage Setting is 11.8V. Range is 11.0V to 13.5V. 1 Press HOURS 00000 . APU OFF BATTERY MONITOR : SET or until 2 Press "BATTERY MONITOR" is displayed, then press . 11.8 V If "ENTER PASSWORD" is displayed, enter your password. If you do not know the password, then you cannot set up this function (see page 1-7).
2.0 CLIMATE CONTROL UNIT (CCU) 2.1 PREPARATION WARNING This procedure must be performed by a certified air conditioning technician who has experience with hermetic systems and Refrigerant R-134A. 2.1.1 Charging the CCU 1 Pressure test the system for leaks with nitrogen. 2 Vacuum all the nitrogen for a minimum of 30 minutes to 500 microns. 3 With the high and the low side valves open, charge the system with R-134A vapor to break the vacuum.
2.2 SERVICE 2.2.
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 – preferably in the spring for the coming A/C season. Recommended Service Actions: 1 Check the condenser for: Damage, leakage and/or contaminated fins that may restrict air flow.
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.
3.0 TROUBLESHOOTING WARNING Before undertaking ANY repair to the APU, CCU or component of the ComfortPro system disconnect the batteries from the APU. 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 .............................................................
3.1 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. Before using this guide verify correct voltage and ground to components.
SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE Engine does not start (starter does not work) • • • • • • • • • A-13 • Kubota Manual* Engine will not stop • Starter solenoid jammed • Replace start solenoid or starter • Kubota Manual* Engine runs rough • Fuel filters clogged or dirty • Air filter plugged or dirty • Fuel leak due to loose injection pipe retaining nut • Injection nozzle clogged/defective • Injection pump defective • Uneven cylinder compression • Incorrect valve clearance • Fuel return l
SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE Oil level increases • Diesel fuel getting to oil pan through governor lever • Fuel lift pump diaphragm defective • Replace O-ring in lower portion of governor lever • Replace • Kubota Manual* • • • • • • • • • • • A-2 • Kubota Manual* • Kubota Manual* Low oil pressure • • • • • Engine oil insufficient Oil strainer clogged Oil filter clogged Relief valve stuck with dirt Relief valve spring weakened or broken Excessive oil clearance of crankshaft bearings
SYMPTOM PROBABLE CAUSE SOLUTION APU suddenly stops • No fuel (no message on Driver Control Panel display) • Air in the fuel system • Water in fuel system • Check fuel stand pipe length/fuel level in tank • Bleed air • Drain fuel tank(s) and replace fuel filters • Check APU control cable, and Driver Control Panel cable for shorts or opens/replace • Replace • Tighten/replace • Repair/replace • Check battery cables/charge battery • Faulty communication between the APU Control Unit, CCU Control Board an
3.2 GENERATOR WARNING Disconnect the batteries from the APU before performing any repairs. Stand-Alone APU Generator Integrated APU Generator 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.
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.
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. NOTE: The five minute timer is activated any time the compressor is turned off (by the thermostat, EVAP temp sensor or high pressure switch.
SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE Condenser fan not working • • • • • • • • • 1- 6, 1- 9 • A-4 Compressor will not start (no hum) • High pressure switch open • Evaporator frozen A/C is not on DC power fuse blown Wiring damaged Fan defective (seized) • Five minute timer active • Overload protector tripped • Driver Control Panel not calling for A/C • Compressor seized Compressor will not start (hums) • Low A/C Voltage to CCU • Starting capacitor defective • Potential relay is open • Compre
SYMPTOM PROBABLE CAUSE SOLUTION Air conditioner runs OK, but short cycles (cont.
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 • Wiring defective • Capacitor defective • Check/replace • Repair/replace • Test/replace • A-4 CCU fan only works on high speed • Low speed resistor defective • Resistor wiring defective • CCU Board defective • Check/replace heating element • Repair/replace • Test/replace • A-2 • A-2 3.
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.
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. 3.8.2 Testing Voltage and Hz readings: When checking for 120 VAC at the CCU board, the probes are placed at the black wire terminal and the white wire terminal.
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. 1 With the APU running turn all 120-volt components off. 2 Measuring the voltage at the outlet panel adjust the engine speed until 120 (+/- 10) volts AC and 60 Hz +/- 2 Hz is read. 3.9.2 Capacitor Troubleshooting 1 Disconnect generator output from breaker.
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. The voltage induced in to the start winding is a function of the speed of the rotor and the magnetic field that is generated.
3.9.6 Fuel Solenoid Troubleshooting If a faulty fuel solenoid is suspected (per diagnostic flow chart 62-11409) then use instructions below for troubleshooting. Unplug the solenoid connector and check the resistance between the following terminals with a DVOM. • White to Black = 0.3 – 0.7 Ohm • Red to Black = 13 – 25 Ohm • White to Red = Open (OL) If the resistance is out of range then replace the fuel solenoid.
APPENDICES CAPACITIES AND SPECIFICATIONS .................................................... A-1 FUSE LOCATIONS ............................................................................ A-4 CIRCUIT BREAKER LOCATIONS.......................................................... A-5 APU CONTROL UNIT ......................................................................... A-6 CCU CONTROLLER ........................................................................... A-7 FUEL SYSTEM PURGE PROCEDURE ............
Engine compression . . . . Engine Speed . . . . . . . . . Valve Clearance (Cold) . . . Engine Drain Plug . . . . . . Intake & Exhaust Valves . Fast Burn Glow Plugs . . . . Starter . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . Generator . . . . . . . . . . . . Fuel Solenoid . . . . . . . . . 327 PSI min. (2.26 MPa min). Approx. 2400 RPM. 0.145 to 0.185 mm (0.0057 to 0.0073 in). Torque 25 ± 2 ft/lb. 0.0057-0.0073" (0.145 – 0.185 mm) Cold. 0.9 Ohms each, 22 Amps then ramps down to 12 Amps.
Maintenance Parts OIL FILTER INLINE FUEL FILTER OIL DIPSTICK FUEL FILTER AIR FILTER AIR INLET FILTER Figure A-1: Maintenance Components, CCU and Integrated APU.
FUSE LOCATIONS APU DC POWER FUSE 12V, 20 AMP CCU FAN FUSE 250V, 3 AMP THERMAL FUSE x2 CCU Figure A-3: Fuse Locations A-4 62-11175 COMFORTPRO SERVICE MANUAL
CIRCUIT BREAKER LOCATIONS GENERATOR 35 AMP BREAKER (MANUAL RESET) CCU BREAKER OUTLET BREAKER (AUTO RESET) (AUTO RESET) CCU Figure A-4: Circuit Breaker Locations 62-11175 COMFORTPRO SERVICE MANUAL A-5
APU CONTROL UNIT Output Indicators APU CONTROL UNIT STARTER – This is the output (+) to the Starter solenoid. GLOW PLUGS – This is the output (+) to the Glow Plugs. STARTER SOL PULL – This is the output (+) to the Fuel Solenoid Pull windings (Only on during cranking for the first .5 seconds). GLOW PLUGS SOL PULL SOL HOLD – This is the output (+) to the Fuel Solenoid Hold windings. SOL HOLD ALT POWER ALT POWER – This is the output (+) to the Alternator field windings.
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. (Low or High Heat.) FAN LOW – This is the input from the Driver Control Panel only when it is calling for CCU Low Fan. (Used in Fan, A/C, and Heat modes.) FAN HIGH – This is the input from the Driver Control Panel only when it is calling for CCU High Fan.
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.
COOLANT PURGE PROCEDURE FOR INTEGRATED APU 1. 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. 2. Release pressure from coolant system. 3. Remove the truck engine radiator cap. 4. Top up the coolant if necessary in the expansion tank. 5. Run the truck engine at fast idle until 85°C (185°F) is reached on truck temperature gauge. This should purge most of the air out of the APU. 6.
7. Start the APU by following the instructions on page 1-7 (Multi-Function Driver Control Panel). 8. 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. 9. Shut the truck engine off. 10. Check the truck engine; ensure it is getting hot coolant from the APU. If it is not, the APU is not purged of all its air. Stop APU by following the instructions on page 1-7 (Multi-Function Driver Control Panel).
DEFROST/HEAT & DCP SENSOR Temperature vs. Resistance Chart 62-11175 COMFORTPRO SERVICE MANUAL RESISTANCE Ω T(°C) T(°F) 15 59 157.6 (kΩ) 16 61 150.4 (kΩ) 17 63 143.5 (kΩ) 18 64 137.1 (kΩ) 19 66 130.9 (kΩ) 20 68 125.1 (kΩ) 21 70 119.6 (kΩ) 22 72 114.3 (kΩ) 23 73 109.3 (kΩ) 24 75 104.5 (kΩ) 25 77 100.0 (kΩ) 26 79 95.7 (kΩ) 27 81 91.6 (kΩ) 28 82 87.7 (kΩ) 29 84 84.0 (kΩ) 30 86 80.5 (kΩ) 31 88 77.1 (kΩ) 32 90 73.9 (kΩ) 33 91 70.
APU CONTROL RED GRN WHT WHT RED PUR BRN ORG BLU RED BLK RED RED GRN WHT BLK (-) BLK GLOW PLUG #1 GLOW PLUG #2 P IG L A B A B DRIVER CONTROL PANEL (DCP) POWER (120 VAC) GROUND A B A A A S R B C (+12 VDC) 134a A/C COMPRESSOR AC PRESSURE B SWITCH (NC) OPEN@P<28 PSI & >325 PSI GROUND(-) COMM TO APU: GLOWRUN 2.5V / CRANKING 3.5V COMM FROM CCU COMM TO CCU COMM TO CCU COMM FROM APU: GLOW RUN 5V / FAULT 1.
APU CONTROL RED GRN WHT WHT RED PUR BRN ORG BLU RED BLK RED RED GRN WHT BLK (-) BLK GLOW PLUG #1 GLOW PLUG #2 B A B A DRIVER CONTROL PANEL (DCP) B A B A C (+12 VDC) 134a A/C COMPRESSOR S R AC PRESSURE B SWITCH (NC) OPEN@P<28 PSI & >325 PSI GROUND(-) COMM TO APU: GLOWRUN 2.5V / CRANKING 3.5V COMM FROM CCU COMM TO CCU COMM TO CCU COMM FROM APU: GLOW RUN 5V / FAULT 1.
STARTER GLOW PLUGS SOL PULL SOL HOLD RED GRN WHT WHT RED PUR BRN ORG BLU RED BLK RED GLOW PLUG #1 CAPACITOR P IG L A B B DRIVER CONTROL PANEL (DCP) B CONDENSOR POWER (120 VAC) A A OUTLET (120 VAC) B A A S R B C (+12 VDC) 134a A/C COMPRESSOR AC PRESSURE B SWITCH (NC) OPEN@P<28 PSI & >325 PSI GROUND(-) COMM TO APU: GLOWRUN 2.5V / CRANKING 3.5V COMM FROM CCU COMM TO CCU COMM TO CCU COMM FROM APU: GLOW RUN 5V / FAULT 1.
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