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2-3

T-312

5. To open or close the fresh air damper, press the

FRESH AIR button.

6. To read interior or exterior temperature, press the

TEMPERATURE button to illuminate the indicator

light and bring the display to the desired temperature

reading. After a short delay, the display will return to

the default set point or return air temperature read-

ing.

7. Setpoint may be changed by pressing the UP or

DOWN arrow button. The UP button will increase the

setpoint temperature and the DOWN button will de-

crease the setpoint temperature.

2.1.4 Activating Defrost

Windshield defrost is initiated and controlled with the

Defrost switch and the Heat switch (Figure 2-1). Moving

the switches to the high setting on both will deliver the

highest volume of warm air on the windshield.

Correspondingly, moving either or both of the two

switches to the low setting will decrease the volume of

air and the temperature of air delivered across the

windshield.

2.1.5 Active Alarm

During normal operation, the controller monitors system

operating parameters for out of tolerance conditions.

The display gets the controller alarm queue information

every 30 seconds. Alarms will be shown as an alarm

code. If an alarm is activated and the display is reading

temperature, the display will show the temperature and

the alarm code alternately in 1 second intervals.

2.1.6 Diagnostics (Check for Alarms)

If an alarm condition exists, diagnostics can be manually

initiated to isolate system fault(s) by simultaneously

pressing the Up and Down Selection keys continuously

for five seconds. Diagnostics should be accessed only

when the coach is not moving. When entering the

diagnostic mode, all LEDs for the key pad will be turned

off. All keys except the On/Off, Up (increase) Selection

and Auto keys will stop functioning. To scroll through

the diagnostic information press the UP key. Pressing

the O/I key at any time will exit this mode. To clear the

alarm message, scroll thru the alarms until ’------’

appears, then press the Auto Key for 5 seconds or until

’------’ disappears. Refer to section 3 for description of

diagnostics. Refer to Table 3-3 for definition of alarm

messages.

2.1.7 Diagnostics (Parameters)

To access the system parameters press the Up and

Down Selection keys continuously for five seconds. The

display will now be in the Diagnostics mode and may be

displaying alarms. Scroll thru the alarms(if present) until

’------’ appears. With ’------’ displayed on the read--out,

press the Up Selection key. The first parameter code

will be displayed. To scroll thru the parameters press the

Up Selection key. When showing parameters, the

display will first flash out the parameter identifier Pxx for

one second and then show the parameter value. To

return to normal operation press the On/Off key (see

Figure 2-1). Refer to Section 3 for for definitions of the

parameter codes.

2.1.8 Stopping

With the system operating, pressing the ON/OFF key

will stop the HVAC system operation and the display will

be blank.

2.2 PRE-TRIP INSPECTION

After starting system operation, allow system to

stabilize for ten to fifteen minutes and check for the

following:
a. Listen for abnormal noises in compressor or fan mo-

tors.

b. Check compressor oil level. (Refer to paragraph

4.12.4)

c. Check refrigerant level. (Refer to paragraph 4.7.1)
d. Ensure that self-test has been successfully per-

formed and that there are no errors or alarms indi-

cated. (Refer to paragraph 2.1.5 or 2.1.6)

2.3 SYSTEM DESCRIPTION

Refer to Section 5 for sample schematic diagrams of the

power and control circuits.

2.3.1 Pull Up and Pull Down Modes

At power up, the system will enter a pull up or pull down

mode to rapidly obtain desired temperatures within the

coach. During this mode, the system will run at

maximum heating or cooling capacity until the set point

(in the passenger zone) is reached for the first time. For

the driver zone, temperature control is controlled by the

two slide switches next to the controller (See

Figure 2-1).
1. Pullup/pulldown main evaporator fan speed is limit-

ed to a maximum of thirty minutes and can be put in

pullup/pulldown speed only once. When the control-

ler switches out of pullup/pulldown speed, pullup/

pulldown speed is prevented again by the controller

unless the controller is shut off and restarted. The

display cannot override the fan speed to pullup/pull-

down.

2. The minimum run time in pullup or pulldown for the

main evaporator fans is three minutes for automatic

control.

a. Capacity State Selection

The main controller automatically compares system

temperature with the controller set point and changes

system operating modes at certain temperature

deviations. Figure 2-4 shows various changes in

operating modes and controller actions at various

temperature deviations from controller set point. Upon

rising temperature, mode changes occur at values in

Figure 2-4 above controller set points, On a falling

temperature, mode changes occur when temperatures

are equal to those given in Figure 2-4 The system will

operate in these modes unless pressure overrides the

controller settings. If the controller detects that the

temperature setting is not being reached during a period

of time, it will slowly adjust the temperature at which

these modes are entered; this will allow the system to

always attempt to reach the controller temperature

setting.

Summary of Contents for MCI J4500 COACH

Page 1: ...T 312 Rev Carrier Transicold Transport Air Conditioning Operation Service 68G5 105 SERIES MCI J4500 COACH...

Page 2: ...PMENT Carrier Transport Refrigeration and Air Conditioning A member of the United Technologies Corporation family Stock symbol UTX Carrier Transicold Carrier Corporation P O Box 4805 Syracuse N Y 1322...

Page 3: ...f 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 u...

Page 4: ...THE COMPRESSOR CRANKCASE OR THE RESULTANT PRESSURE WILL FORCIBLY DISCHARGE COMPRESSOR OIL WARNING WHEN MOVING THE COIL CARE MUST BE TAKEN TO AVOID PERSONAL INJURY BE CAUSE OF THE WEIGHT OF THE COIL C...

Page 5: ...OMATIC CONTROL DATA FLOW 1 14 OPERATION 2 1 2 1 STARTING STOPPING AND OPERATING INSTRUCTIONS 2 1 2 1 1 Operating Controls 2 1 2 1 2 HVAC Power to Controller 2 2 2 1 3 Starting 2 2 2 1 4 Activating Def...

Page 6: ...2 4 4 1 System Pumpdown 4 2 4 4 2 Removing the Refrigerant Charge 4 3 4 4 3 Refrigerant Removal From An Inoperative Compressor 4 3 4 4 4 Pump Down An Operable Compressor For Repair 4 3 4 5 REFRIGERAN...

Page 7: ...21 REMOVING THE CONDENSER ASSEMBLY 4 13 4 22 SERVICING THE CONDENSER COIL 4 13 4 23 SERVICING THE CONDENSER MOTOR 4 13 4 24 SERVICING THE DRIVER CONTROL BOX 4 13 4 25 SERVICING THE DRIVER EVAPORATOR...

Page 8: ...iver Control Box 4 13 5 1 Electrical Schematic Diagram Legend and Symbols 5 2 5 2 Electrical Schematic Diagram 5 3 5 3 Electrical Schematic Diagram 5 4 5 4 Electrical Schematic Diagram 5 5 LIST OF TAB...

Page 9: ...al cabling a parcel rack evaporator thermostat kit refrigerant piping engine coolant piping ductwork and other components furnished by the coach manufacturer to complete the system Table 1 1 Part Mode...

Page 10: ...o 2 CM1 and CM2 The control box also includes condenser speed relay no 1 CSR1 which controls the speed of both condenser fan motors CM1 and CM2 The main evaporator liquid line solenoid valve and the p...

Page 11: ...lve Charging Port 8 O Ring 9 Oil Drain Plug 10 Solenoid Unloader Electric Connectors 11 High Pressure Switch 12 Discharge Pressure Transducer 13 Capscrew 14 Lockwasher 15 Special Washer 16 Lock Nut 17...

Page 12: ...aporator heat valve EHV two fan and motor assemblies an air filter and two condensate drain connections The evaporator heat valve EHV for the driver evaporator is installed in the piping outside the e...

Page 13: ...ain Connections 14 Air Filter 15 Evaporator Coil Assembly 16 Heater Coil Assembly 2 11 14 9 13 4 16 15 12 10 8 7 6 5 3 1 13 Figure 1 4 Driver Evaporator Assembly 1 Suction Outlet Connection 2 Liquid I...

Page 14: ...ator Fan Relay High Speed EFRH 10 Evaporator Fan Relay Low Speed EFRL 11 Elastomeric Motor Mounts 12 2 Speed Motor 13 Blower Wheel Left 14 Blower Housing Left 15 Service Port 16 Coolant Drain valve 17...

Page 15: ...ecks of the program memory data memory and analog It has a self test feature which is executed when the system is first powered up The expansion board drives six discrete outputs in addition to the st...

Page 16: ...l In the vent mode the evaporator fans are operated to circulate air in the bus interior In the heat mode the heat valve and the OEM supplied floor blower and or boost pump are energized The evaporato...

Page 17: ...vaporator and Parcel Rack Evaporator Superheat Setting Nonadjustable 5 to 12_F 6 7 to 10 1_C MOP Setting None d High Pressure Switch HPS Opens at 385 10 psig 26 2 68 BAR Closes at 285 10 psig 19 39 68...

Page 18: ...1 3 d 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 main controll...

Page 19: ...uired temperatures inside the coach Engine coolant glycol solution is circulated through the heating circuit by the engine and auxiliary water pumps When the evaporator heat valve solenoid is de energ...

Page 20: ...liquid line solenoid valve to the main evaporator and thermal expansion valve and to the parcel rack evaporator solenoid valve if this option is active the parcel rack thermal expansion valve and thr...

Page 21: ...ER EVAPORATOR ASSEMBLY DRIVER SOLENOID VALVE MAIN LIQUID LINE SOLENOID VALVE DISCHARGE LINE SERVICE VALVE DISCHARGE LINE SUCTION LINE CONDENSER SUBCOOLER SIGHT GLASS FUSIBLE PLUG SERVICE PORT SERVICE...

Page 22: ...main controller and the rest of the system The following block diagram Figure 1 13 indicates data flow through the system Refer to section 2 for more detailed information on the theory of operation of...

Page 23: ...the passenger area and cooling to the driver area The panel has 10 keys whose functions are described as follows 1 On Off Pressing this key will change the display state from inactive to active If the...

Page 24: ...aporators will function only after the main evaporator is operating Figure 2 3 Driver A C e The Driver A C Switch Figure 2 3 allows the driver to control cooling with the driver s evaporator When the...

Page 25: ...ey When showing parameters the display will first flash out the parameter identifier Pxx for one second and then show the parameter value To return to normal operation press the On Off key see Figure...

Page 26: ...he Driver s A C switch on the left side console is turned on when cooling is desired in the driver area The driver area conditions are controlled by manually adjusting the Defrost and Heat slide switc...

Page 27: ...when staging is required a Suction Pressure In addition to temperature control the electric unloaders will be used to prevent coil frosting Staging is ignored for energizing the unloader solenoid due...

Page 28: ...a 2 3 11 RAM Air Control The RAM air control regulates admission of outside air into the system a Display Override The RAM air can be automatically controlled or set to open or closed by the display b...

Page 29: ...f the display does not receive data from the microprocessor Er5 Data Memory If memory on the display is not verified on power up Er6 Program Memory If program memory on the display is not verified on...

Page 30: ...ransducer Failure Sensor is unplugged wiring defective or humidity transducer failure Ensure sensor is plugged in Check transducer voltage or wiring Replace sen sor or repair wiring Refer to section 4...

Page 31: ...been activated three times in 30 minutes it de en ergizes the clutch for the minimum off time and until the alarm is de ac tivated Energizes the second con denser fan at high speed De ener gizes the r...

Page 32: ...will display CL If it is open circuited it will display OP NOTE This value is not updated it is the value at the time that the code is accessed P6 Discharge Pressure This value is the discharge pressu...

Page 33: ...erant overcharge Noncondensable in system Condenser fan rotation incorrect Condenser coil dirty 4 4 4 8 Check Clean Low discharge pressure Compressor valve s worn or broken Low refrigerant charge See...

Page 34: ...Valve Malfunction Low suction pressure with high superheat Low refrigerant charge Wax oil or dirt plugging valve orifice Ice formation at valve seat Power assembly failure Loss of bulb charge Broken...

Page 35: ...D DISCHARGE SERVICE VALVES The suction and discharge service valves See Figure 4 1 used on the compressor are equipped with mating flanges for connection to flanges on the compressor These valves are...

Page 36: ...t To connect the manifold gauge hose set for reading pressures do the following 1 Remove service valve stem cap and check to make sure it is backseated Remove access valve cap 2 Connect the field serv...

Page 37: ...ible it will be necessary to recover refrigerant through the suction service valve port only c Service or replace components as required and leak check the compressor d Using refrigerant hoses designe...

Page 38: ...paragraph 4 5 b Essential tools to properly evacuate and dehydrate any system include a good vacuum pump with a minimum of 6 cfm 10 2 m3 hr volume displacement CTD P N 07 00176 11 and a good digital...

Page 39: ...E LINE SERVICE VALVE PARCEL RACK LIQUID LINE SOLENOID VALVE DISCHARGE LINE SUCTION LINE CONDENSER SUBCOOLER SIGHT GLASS FUSIBLE PLUG SERVICE PORT SERVICE PORT SERVICE PORT D S 1 Reclaimer 2 Manifold G...

Page 40: ...ge the system may be under charged 3 If the actual discharge pressure is in the discharge pressure range the system charge is adequate NOTE Many system related problems will effect system pressures Us...

Page 41: ...e Slowly open the regulator valve to increase the pressure until it reaches cutout point The switch should open which is indicated by an infinity reading on an ohmmeter no continuity f Close cylinder...

Page 42: ...ed clamp making sure both bulbs are firmly secured to suction line See Figure 4 7 Reinstall insulation around the bulb e Connect an accurate low pressure gauge or install a manifold gauge set to the s...

Page 43: ...n c Install compressor in unit by performing steps c through g in reverse sequence It is recommended that new locknuts be used when replacing compressor Install new gaskets on service valves and tight...

Page 44: ...hose at the oil pump Add oil as necessary NOTE Allow time at least 60 seconds for the oil to flow thru to the crankcase and show on the sightglass 4 12 5 2 Closed System Method a Install manifold gaug...

Page 45: ...inside the coach the third sensor is located in the condenser section The two inside sensors are wired in parallel and together send an averaged signal to the controller If one of these sensors fails...

Page 46: ...orator motor mounting plate motor and blower housing assembly to the bottom panel f Remove motor and blower wheel assembly by sliding out of evaporator housing g Repair or replace any defective compon...

Page 47: ...t refrigerant lines to the module f Remove the door latch stud to the right side of the condenser compartment g Remove the front panel and the eight screws fastening the condenser to the coach h Remov...

Page 48: ...center and turn right corner past edge b Slide left hand side filter to the right and repeat as above c Clean replace filter and re install 4 25 4 Removal of Evaporator Heater Coil Assembly a Clamp o...

Page 49: ...1 1 20 1 18 20 7 18 5 1 30 1 28 22 6 19 9 1 40 1 37 24 4 21 4 1 50 1 48 26 3 22 9 1 61 1 58 Temperature Pressure F C Psig Kg cm Bar 28 2 24 5 1 72 1 69 30 1 26 1 1 84 1 80 32 0 27 8 1 95 1 92 34 1 29...

Page 50: ...TRODUCTION This section contains Electrical Schematic Diagrams covering the Models listed in Table 1 1 Contact your Carrier Transicold service representative or call the technical hot line at 800 450...

Page 51: ...T 312 5 2 COACH INTERFACE CONNECTOR A THRU K 1 2 3 L THRU Y PACKARD CONNECTOR Figure 5 1 Electrical Schematic Diagram Legend and Symbols Based On Drawing No 62 10907 Rev...

Page 52: ...IVER EVAPORATOR CONDENSER NOTE In 2003 early production units were retrofitted with diodes If servicing a unit that is not wired as shown above the unit should be retrofitted Contact Carrier Service E...

Page 53: ...T 312 5 4 Figure 5 3 Electrical Schematic Diagram Sheet 2 of 2 Drawing No 62 10907 Rev...

Page 54: ...T 312 5 5 Figure 5 4 Electrical Schematic Diagram Contact vehicle manufacturer for a specific diagram...

Page 55: ...Flow 1 14 Evacuation And Dehydration 4 4 Evaporator Assemblies 1 4 Evaporator Coils 1 12 F Filter Drier 4 7 H Heating Flow Cycle 1 11 Humidity Control 2 5 Humidity Sensor 4 11 4 12 I Installing Manif...

Page 56: ...5 4 5 5 Servicing Motor Brushes 4 12 Suction and Discharge Service Valves 4 1 Superheat Check Measure 4 8 System Pumpdown 4 2 System Service 4 1 T Temperature Pressure Chart 4 15 Temperature Sensor 4...

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