Storage Cooler Service Manual - Webasto Technical Support Website

Storage Cooler Service Manual - Webasto Technical Support Website
®
A DIVISION OF
KENWORTH CLEAN POWER™ SYSTEM
Storage Cooler
Service Manual
–
Improper installation or repair of auxiliary heating and cooling systems can cause fire
or the leakage of deadly carbon monoxide leading to serious injury or death.
–
Installation and repair of auxiliary heating and cooling systems requires special
training, technical information, special tools and special equipment.
–
NEVER attempt to install or repair an auxiliary heating or cooling system unless you
have successfully completed the factory training course and have the technical skills,
technical information, tools and equipment required to properly complete the
necessary procedures.
–
ALWAYS carefully follow the installation and repair instructions and heed all
WARNINGS.
–
The manufacture rejects any liability for problems and damage caused by auxiliary
systems being installed or serviced by untrained personnel.
Table of Contents
Contents
Page
1. Introduction
1.1
1.2
1.3
1.4
1.5
1.6
1.7
3
The Kenworth Clean Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Tests - Prior to Troubleshooting and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Tests - After Servicing or Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. General Description
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
5
Charging (Refrigeration) Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Storage Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air-handler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cold Transfer System (Coolant Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Storage Cooler Control Unit (SCCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Temperature Control Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ambient Temperature Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
High Refrigerant Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Low Refrigerant Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
External Thermal Protector – Hermetic Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Sleeper Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Charge Enable Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Main Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. Functional Description
3.1
3.2
3.3
3.4
13
Charging Under Inverter Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging Under Shore Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Troubleshooting
13
13
13
14
19
4.1
4.2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage Cooler Control Unit – SCCU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Preparation for Functional Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 SCCU Troubleshooting – Electrical Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Charge Unit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Charge Unit Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Discharging Mode Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Preparation for Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 Discharge Mode Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Troubleshooting – Refrigerant Compressor
5.1
5.2
3
3
4
4
4
4
4
19
20
20
22
23
23
24
24
24
25
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Service and Safety Precautions Concerning Refrigerant Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Trained Personnel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Terminal Venting and Electrocution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4 Fire Hazard from Terminal Venting with Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.5 Terminal Venting and Electrocution Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6 Refrigerants and Other Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.7 Compressor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.8 System Flushing, Purging, and Pressure Testing for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
25
25
25
25
25
25
25
26
26
27
Table of Contents
5.3
5.4
5.5
5.6
5.2.9 System Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.10 Capacitor Overheating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.11 System Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.12 Follow the Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Table – Refrigerant Compressor and Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identifying Compressor Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 Checking for a Ground Fault (a Short to Ground). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.2 Checking for Continuity and Proper Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3 Checking for Other Electrical Problems in Single Phase Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking for Adequate Compressor Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Is Your Compressor Eligible for Return Under Warranty? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Compressor Replacement and System Service
6.1
36
System Cleanup and Compressor Replacement After Compressor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7. Component Replacement - Refrigeration Unit
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
39
General Information and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Panel Removal for Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low or High Pressure Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Temperature Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Bypass Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Component Replacement - Large Pallet Assembly
8.1
8.2
8.3
39
39
41
42
42
43
44
44
44
45
46
Thermal Expansion Valve (TXV) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Storage Cooler Control Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Coolant Circulation Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9. Component Replacement - Small Pallet Assembly
9.1
28
28
28
28
29
31
31
32
33
35
35
48
Air Handler Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.Technical Data
50
10.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.1 Technical Data of the Storage Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.2 Technical Data of the Air Handler Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.3 Technical Data of the Charging Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Torque Values Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.Circuit Diagrams
50
50
50
50
51
53
11.1 Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.1 Control Schematic Part A (Continued on Next Page) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.2 Control Schematic Part B (Continued on Previous Page) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.3 Charging Unit Wiring Harness - 12 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.4 Charging Unit Wiring Harness - 120 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.5 120 Volt AC Connections and System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.Appendices
53
54
55
56
57
58
59
12.1 5700 Series One-Shot™ Brass Couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12.1.1 Reconnecting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2
Introduction
1. Introduction
1.1
The Kenworth Clean Power System
Kenworth Clean Power System features include:
The Kenworth Clean Power System is a battery-powered
sleeper climate control system with the capability to
provide engine-off heating and cooling, plus 120-Volt AC
accessory power to drivers for up to 10 hours. To
recharge the cooling and electrical capacity, the truck
must be driven or connected to shore power.
The Kenworth Clean Power System sleeper heating and
air conditioning system is an independent system from
the cab heating and air conditioning system. Both the
controls and the heating and cooling sources are
different.
1.2
•
Compliance with all state and federal anti-idling
regulations.
•
Engine-off sleeper heating, cooling, and 120-Volt
AC power.
•
No engine noise or vibration.
•
Improved fuel economy.
All information contained in this manual is based on the
latest production information available at the time of
publication. Kenworth Truck Company reserves the right
to make changes at any time without notice.
Location of Components
Fuel-Fired Heater
(in passenger’s
side tool box)
Enhanced Insulation
LED Lighting
Air Conditioning
Charge Unit
High Output Alternator
Starter Batteries Disconnect
Switch (cab floor)
Main Battery
Disconnect Switch
Shore Power
Connector
(120-Volt AC)
Main Battery Box
Starter Batteries
Main Batteries
Storage Cooler
(under lower bunk)
Circuit Breaker Box
(in driver’s side tool box)
Figure 1. Location of components
3
Introduction
1.3
Safety Signals
1.4
A number of alerting messages are in this manual.
Please read and follow them. They are there for your
protection and information. These messages can help
you avoid injury to yourself and your passengers, and
help prevent costly damage to the vehicle.
Key symbols and “signal words” are used to indicate
what kind of message is going to follow. Pay special
attention to instructions prefaced by symbols and signal
words “WARNING,” “CAUTION,” or “NOTE.” Please do
not ignore any of these alerts.
Recommended Service Tools
•
AC Recovery / Charging Machine - Must be R134a
compliant.
•
R134a Leak Detector - Must be R134a compliant.
•
Dry Nitrogen Gas (Bottled) with Regulator and
Safety Relief Device - for Pressure Tests
•
Digital Multi-Meter - Should be a good quality
VAO meter.
•
Temperature Probe or Thermometer
•
Basic Mechanic’s Tools
WARNING
1.5
When you see this symbol and word, the
message that follows is especially vital. This
signals something that can cause injury or even
death. This message will tell you what the
hazard is, what can happen if you don’t heed
the warning, and how to avoid it.
Electrical Tests - Prior to
Troubleshooting and Servicing
Proper troubleshooting cannot be performed on an
electrically weak system. As a minimum, inspect or
perform the following:
Example:
WARNING. Risk of asphyxiation. The auxiliary
heater must not be operated in enclosed areas
such as garages and workshops without an
emissions extraction system.
CAUTION
This symbol and word signals something that
could damage the vehicle or equipment.
•
Cleaning of battery connections
•
Cleaning of jumpers (bottom of connector typical
weak connection point)
•
Cleaning of cable connections at starter and DC
generator (alternator)
•
Cleaning ground connections at frame rails and
other points of contact
•
Load testing of batteries
1.6
Example:
Electrical Tests - After Servicing or
Repairs
Ensure batteries are fully charged prior to operating the
Kenworth Clean Power System. Batteries may have
become significantly discharged due to interior lights on
while working in the bunk or due to parasitic loss from
live accessories.
CAUTION: A temperature of 85°C must not be
exceeded in the vicinity of the auxiliary heater
in any circumstances (for example when
completing painting work on the vehicle).
NOTE
1.7
Servicing the Refrigerant Circuit
NOTE: Please read before opening the refrigerant
circuit for repairs or service.
Gives you information we feel you would like to have. It
could have to do with procedures and tips that will help
you work more efficiently.
It is recommended that the cold storage core be
completely discharged (brought up to room temperature)
before recovering the refrigerant. Otherwise, the system
will have to be evacuated for a period not less than 2
hours to ensure any liquid refrigerant lingering in the
storage core is boiled off.
Example:
NOTE: The connector housing can be locked (selflocking action) by simply pulling on the wiring
harness.
Servicing a charged (frozen) or partially charged (cold) system
will give you inaccurate or false pressure readings.
4
General Description
2. General Description
–
a cold “Storage Cooler” assembly
The storage cooler portion of the Kenworth Clean
Power™ System is based on the principles of
refrigeration and the simple storage of cold energy.
–
an air-handler assembly
–
a cold transfer system (automotive anti-freeze
mixture and R134a refrigerant)
–
a 120 VAC power source to drive the compressor
–
a 12 VDC power source
The storage cooler essentially consists of the following:
–
a refrigeration “Charging unit” assembly
2
1
3
9
4
8
5
7
6
1. High refrigerant pressure switch
6. Condenser outlet connection
2. Low refrigerant pressure switch
7. 12 Volt wiring harness and connector
3. Service port - High pressure liquid side
8. Service port - low pressure gas side
4. Run capacitor
9. Magnetic equalization (bypass) valve
5. Condenser
Figure 2. Charging Unit - Overview 1 (Sheet metal removed for purpose of illustration)
5
General Description
1
2
3
4
11
5
10
9
8
7
6
1. Condenser inlet connection
7. Refrigerant supply line to TXV and evaporator
2. Condenser fan - Radial
8. Refrigerant return line from TXV and evaporator
3. Positive Temperature Coefficient Resistor (PTCR)compressor hard-starting aid
9. Hermetic compressor for R134a refrigerant system
4. Refrigerant filter/dryer
10. Cover for electrical connections and thermal/
overload protector
5. Accumulator
11. Ambient temperature limiter
6. 120 VAC power connection
Figure 3. Charging Unit - Overview 2 (Sheet metal removed for purpose of illustration)
6
General Description
1
2
3
4
5
13
6
12
11
10
9
8
1. Storage cooler assembly
8. Coolant return line from air handler
2. Storage Cooler Control Unit (SCCU)
9. Coolant supply line to air handler
7
3. Lifting bolt - 3 total
10. Coolant circulating pump (AC Pump)
4. Refrigerant supply line from charging unit
11. Coolant reservoir with filler cap
5. Refrigerant return line to charging unit
12. Large pallet (Base)
6. Temperature control thermostat
13. Control and power harness with connectors SCCU-1
and SCCU-2
7. Thermal expansion valve (TXV)
Figure 4. Storage Cooler Assembly
7
General Description
1
2
3
12
11
4
5
10
9
8
7
6
1. Cover - Air filter housing and filter
7. Coolant outlet to storage cooler assembly
2. Port - Access to heat-exchanger bleeder valve
8. Connection Socket - Mode door actuator
3. Conditioned air outlet
9. Motor - Mode door actuator (Fresh/Recirculated)
4. Fan and scroll housing
10. Fresh air inlet
5. Small pallet (Base)
11. Cabin temperature sensor (Recirculated air mode)
6. Coolant inlet from storage cooler assembly
12. Recirculated air inlet (Interior return)
Figure 5. Air Handler Assembly
8
General Description
2.1
Charging (Refrigeration) Unit
2.4
Cold Transfer System (Coolant Circuit)
The charging unit is comprised of an electric refrigeration
compressor, a condenser core with an electric automotive
type radial fan, a pressure equalization valve, refrigerant
lines, electrical circuitry and components.
The cold transfer system is comprised of a circulating
pump, coolant hoses, coolant reservoir and a transfer
medium of 50/50 premixed extended service glycol
antifreeze and water mixture.
See Fig. 2 and Fig. 3 for reference.
The system is active during system discharge. The
temperature control knob of the sleeper control panel is
used to adjust bunk temperature.
2.2
A sensor mounted in the recirculated air duct monitors
the return air temperature in the sleeper. The A/C pump
is thus switched on and off to circulate coolant through
the air handler according to the desired cooling.
Storage Cooler Assembly
The storage cooler assembly is comprised of multiple
layers of a freeze medium in the form of a vacuum
sealed, water saturated, patented graphite matrix which
is interlaced with a refrigeration evaporator core and a
coolant circulation core.
See Fig. 4 and Fig. 6 for reference.
The entire storage unit is encapsulated in urethane foam
insulation and protected in a molded plastic housing.
There are no serviceable items inside.
Externally, a thermal expansion valve, refrigerant lines,
coolant lines, reservoir, coolant pump and a storage
cooler control unit (SCCU) with accompanying circuitry
make up the remaining serviceable components of the
storage cooler assembly.
6
2
1
See Fig. 4 for reference.
4 5
3
2.3
1 Supply from storage cooler
assembly
2 Coolant reservoir
3 A/C circulating pump 12 Volt
Air-handler Assembly
The air-handler assembly is mounted under the sleeper
bunk in the central compartment with the storage unit.
Figure 6. Coolant Circuit
The air-handler is comprised of a liquid to air heat
exchanger, a low power consumption, air circulation fan,
a fresh air intake and a recirculated air intake duct. A
motor actuated fresh air/recirc. mode door is built into
the plenum.
Fresh air, when desired, is drawn in from an opening in
the lower rear sleeper panel. A replaceable Hepa air filter
cartridge is also provided for improved air quality.
An opening in the bottom of the air handler housing and
the vehicle floor allows for condensation to drain.
See Fig. 5 for reference.
9
4 Inlet to air handler
5 Return from air handler
6 Return to storage cooler
assembly
General Description
To control and monitor the storage cooler system, it uses
–
a Storage Cooler Control Unit (SCCU)
–
a temperature control thermostat
–
an ambient temperature limiter
–
a high refrigerant pressure switch
–
a low refrigerant pressure switch
–
a charge enable switch located on the dash (Fig. 13)
–
a system control panel located in the sleeper (Fig. 12)
To prevent serious damage to the compressor, a
compressor overheat/overload protector is also provided.
2.5
Storage Cooler Control Unit (SCCU)
Situated on top of the storage unit, the SCCU is central
to ensuring the correct function of the storage cooler
portion of the Kenworth Clean Power™ System.
Figure 8. Temperature Control Thermostat
See Fig. 4 and Fig. 7 for reference.
2.7
Ambient Temperature Limiter
A bi-metal ambient temperature limiter, located on the
condenser fan shroud, is provided for the purpose of
deactivating the bunk cooling system during cold
weather periods when bunk cooling is not required.
TRQ= 3.3 lb-ft / 40 lb-in
4.5 Nm
See Fig. 3 and Fig. 9 for reference.
Switch Points – Ambient Temperature Limiter
Figure 7. Storage Cooler Control Unit (SCCU)
2.6
Closes at:
≥ 12.8°C (Tolerance of ± 3.3°C)
≥ 55°F (Tolerance of ± 6°F)
Opens at:
7.2°C
45°F
Temperature Control Thermostat
A bi-metal temperature control thermostat is mounted
on the refrigerant suction line as shown in Fig. 8.
The control thermostat will allow system charging or no
system charging dependant on the storage core
temperature at the suction line.
Switch Points – Temperature Control Thermostat
Opens at:
-3.3°C (Tolerance of + 3°C, - 2°C)
26.1°F (Tolerance of + 5.4°F, - 3.6°F)
Closes at:
13.6°C
56.5°F
Figure 9. Ambient Temperature Limiter - with Harness
10
General Description
2.8
High Refrigerant Pressure Switch
2.10 External Thermal Protector – Hermetic
Compressor Motor
Located in the high-pressure line before the condenser,
the high refrigerant pressure switch will deactivate the
compressor in the event of high pressure.
WARNING! 120 VAC Device. Lethal current may
be present. Switch off the DC to AC power
inverter before servicing.
See Fig. 2 for a location reference and Fig. 10 for an
illustration.
The compressor motor is protected from overheating by
a thermal protector mounted on top and in firm contact
with the compressor housing. The thermal protector
device quickly senses any unusual temperature rise or
excess current draw.
Switch Points (High Pressure Switch)
Opens at:
Closes at:
2.9
20.68 bar (Tolerance of ± 0.69 bar)
300 psig (Tolerance of ±10 psig)
The bi-metal disc within the thermal protector reacts to
either excess temperature and/or excess current draw by
flexing downward, and disconnecting the compressor
from the power source.
12.4 bar
180 psig
Low Refrigerant Pressure Switch
Located in the high-pressure line after the condenser, the
low refrigerant pressure switch will deactivate the
compressor in the event of low pressure due to a loss of
refrigerant.
Thermal Protector
See Fig. 2 for a location reference and Fig. 10 for an
illustration.
1.03 bar (Tolerance of ± 0.24 bar)
15 psig (Tolerance of ± 3 psig)
Closes at:
2.13 bar
31 psig
C
S
Opens at:
R
Switch Points (Low Pressure Switch)
Figure 11. Hermetic Compressor - Thermal Protection
1 Low Pressure
1 High Pressure
Figure 10. High pressure and low pressure switches
11
General Description
2.11 Sleeper Control Panel
2.13 Main Battery Box
Please refer to the “Kenworth Clean Power™ System
Operator’s Manual” for a complete description of
functions and operating instructions.
The electrical power required to operate the Kenworth
Clean Power™ System is supplied by a main battery box
consisting of four deep-cycle batteries, and a power
inverter to supply 120 VAC to the refrigerant compressor.
The main battery box is also equipped with a shore
power connection and a battery charger for stand-alone,
engine off operation.
1
9
2
NOTE: Information about maintenance and servicing of the
main battery box is not covered in this manual. For information
concerning the main battery box, please refer to the applicable
documentation supplied by the manufacturer of this
equipment.
OFF
3
4
5
Click here for more information
NORMAL
6
8
OFF/RESET
7
1. Temperature Control
Dial
6. Air Conditioning/
Heating Switch
2. AC Circulation Pump
ON Lamp
7. Inverter/Charger Switch
3. Green Snowflake
8. Fresh Air/Recirculated
Air Switch
4. Inverter/Charger Lamp
9. Fan Control Dial
5. Shore Power Lamp (120
VAC)
Figure 12. Kenworth Clean Power™ System Control
Panel
2.12 Charge Enable Switch
Please refer to the “Kenworth Clean Power™ System
Operator’s Manual” for a description of function.
Figure 14. Main Battery Box
Manufactured by DYNACRAFT®
A division of PACCAR
CHARGE
Figure 13. Charge Enable Switch (Located on dash)
12
Functional Description
3. Functional Description
3.1
Charging Under Inverter Power
With the vehicle engine running and the charging unit under inverter power only, the voltage regulator for the vehicle
alternator determines whether or not the batteries have an acceptable charge.
The voltage regulator will transition through several stages of battery charging, with the first is known as bulk
charging. The regulator ramps up the alternator to provide maximum current and will charge the batteries at 14.6V.
The regulator also monitors the battery temperature and battery voltage to determine the charging rate that the
batteries are accepting. Bulk charging lasts a minimum of 30 minutes. Once bulk charging is complete, the regulator
ramps the current and voltage down, and closes the ground circuit through relay K9, pin-2 which then closes the relay
and allows the compressor to start when all other conditions are satisfied (See Section 3.3).
3.2
Charging Under Shore Power
With the Clean Power system in shore power mode (shore power plugged into 120 VAC source) a signal is sent to relay
K10, pin-1 which then closes the relay and starts the compressor. There is no delay of operation when in the shore
power mode due to the fact that the system is receiving its power from an external 120 VAC source. In this case, the
inverter is bypassed altogether.
3.3
Charging Mode
3.3.1
Charging (Reference Charge State Diagram in Fig. 15)
3.3.1.1
Charging Conditions
3.3.1.1.1
The charging unit automatically charges the storage cooler assembly when all of
the following criteria are satisfied:
•
Charge enable switch located on dashboard is switched ON
•
Storage core temperature > -3.3°C + 3°C, - 2°C (26.1°F + 5.4°F, - 3.6°F)
•
Ambient temperature > 12.8°C ± 3.3°C (55°F ± 6°F)
•
High refrigerant pressure < 20.68 bar ± 0.69 bar (300 psig ± 10 psig)
•
Low refrigerant pressure > 1.03 bar ± 0.24 bar (15 psig ± 3 psig)
•
Battery voltage at acceptable level as determined by voltage regulator
when engine is running OR shore power is connected
•
Inverter AC voltage present
3.3.1.1.2
Once the criteria outlined in Section 3.3.1.1.1 are met, the charging process
starts. First, the compressor bypass solenoid valve opens for approximately two
minutes. This allows the pressures in the high and low sides of the refrigerant
system to equalize. At this same time the condenser fan will also turn on. After
approximately two minutes, the bypass solenoid valve closes and the compressor
starts operation.
3.3.1.1.3
The charging unit automatically stops charging the storage cooler assembly if
any of the following conditions are satisfied:
•
AC enable switch located on dashboard is switched OFF
•
Storage core temperature -3.3°C + 3°C, - 2°C (26.1°F + 5.4°F, - 3.6°F)
•
Ambient temperature 12.8°C ± 3.3°C (55°F ± 6°F)
•
High refrigerant pressure 20.68 bar ± 0.69 bar (300 psig ± 10 psig)
13
Functional Description
3.3.1.2
•
Low refrigerant pressure 1.03 bar ± 0.24 bar (15 psig ± 3 psig)
•
The voltage regulator determines that the batteries or alternator are not
operating at acceptable levels when the engine is running OR when
shore power is being used, shore power is disconnected
•
Inverter AC voltage not present
Charging Enable/Disable Control
3.3.1.2.1
A charge enable/disable switch mounted on the vehicle dashboard is used for
manually enabling/disabling the charging unit for charging the storage cooler
assembly. When the switch is in the ON position, the charging unit is enabled
and automatic charging of the storage cooler assembly occurs if the conditions
of Section 3.3.1.1.1 are satisfied. When the switch is in the OFF position, the
charging unit is disabled.
3.3.1.2.2
The switch contains one LED indicator which illuminate green when the charging
unit is charging the storage cooler assembly (see Section 3.3.1.1.1 for charging
conditions). This LED indicator will be illuminated only while the compressor is
powered on and running.
3.3.1.2.3
The LED indicator turns off when the charging unit stops charging the storage
cooler assembly (see Section 3.3.1.1.3 for stop charging conditions).
Approximate time to completely charge (freeze) the storage core is approximately 6 hours depending on the ambient
temperature.
3.4
Discharge Mode
3.4.1
Discharging (Reference Fresh Air and Recirculation State Diagram, Fig. 16 and Cooling Discharge State
Diagram, Fig. 17.)
3.4.1.1
Discharging Modes & Conditions
3.4.1.1.1
A linear voltage blower control is used for air conditioning and ventilation. The
blower control is manually operated. NOTE: This blower control does not
operate the heater blower since the heater blower is internal to the diesel-fired
air heater.
3.4.1.1.2
The maximum blower power draw is set not to exceed 5 amps.
3.4.1.1.3
Blower speed is controlled with a potentiometer knob (S3). When the knob is in
the off position, there is no electrical load (including the blower fan and
circulating pump).
3.4.1.1.4
Blower control is available when the storage cooler thermostat (TC1) is in the off
position for ventilation purposes.
3.4.1.1.5
The fresh air/recirc mode has two settings: fresh air and recirculating (no
blending of the two). The fresh air/recirc mode is manually operated via a twoway switch (S5) on the control panel.
3.4.1.1.6
The temperature control is a closed loop which allows for setting the
temperature at a comfortable level.
14
Functional Description
3.4.1.1.7
Temperature is controlled by a dual potentiometer. One potentiometer controls
air conditioning temperature and the other potentiometer controls heating
temperature. The required resistance values for the potentiometers are:
•
Air Conditioning
Minimum: +20°C = 1000Ω
Maximum: +26°C = 460Ω
•
Heating
Minimum: +5°C = 150Ω
Maximum: +35°C = 2150Ω
For both air conditioning and heating, resistance versus temperature has a linear
relation, i.e., middle of temperature range correlates with middle of resistance
range.
3.4.1.1.8
For each change in knob position, the temperature increases or decreases in
equal amounts throughout the full range of motion for air conditioning and
heating.
3.4.1.1.9
A return air temperature sensor is located in the air handling unit which will
control when the storage cooler assembly’s circulating pump turns on and off.
3.4.1.1.10 A green LED light is used on the control panel for indicating when the storage
cooler assembly circulating pump is running.
3.4.1.1.11 A green/yellow band shown on the control panel above the blue temperature
band indicates that when the temperature control is set in the green region of
this band, a temperature of 23.9°C (75°F) can be maintained for 8-10 hours of
storage cooler duration under the following conditions:
•
Outside ambient temperature = 35°C (95°F)
•
Sleeper pre-cooled to 23.9°C (75°F)
•
Relative humidity = 50%
•
No solar loading – e.g. truck parked in a shaded area or run system
during the evening
•
Airflow to lower and upper bunks
•
Recirculated air mode
3.4.1.1.12 A 3-way switch on the control panel is provided for selecting air conditioning
mode (top position), heating mode (bottom position), or off mode (middle
position). When the switch is set to the off mode, all loads will be off except for
those required for the blower and fresh/recirc actuator.
3.4.1.1.13 The 3-way air conditioning/heating selection switch is backlit with a blue LED for
air conditioning mode and a red LED for heating mode. The red heating LED
also provides diagnostic blinking codes for the diesel-fired air heater.
3.4.1.1.14 Air conditioning selection and air conditioning temperature control is only
functional when the blower control (S3) is in the on position.
3.4.2
The relay assembly (located in left side tool box) contains the K2 and K8 relays. The K2 relay is used for
controlling turn on of the compressor. The K8 relay is used for determining if inverter AC voltage is
present and will reset the bypass valve if 120 VAC power is lost. (Reference control schematic in Section
11.1.1)
15
Figure 15. Charge State Diagram
16
= Storage Cooler Charging
Id = DC Current (Amps)
Ia = AC Current (Amps)
S = Switch
K = Relay
MV = Magnetic Solenoid Valve
= Function OFF
Id = 0
Ia = 0
A/C Enable Switch Open (S1)
or
Storage Core Temperature
Control Thermostat Open (S4)
or
Ambient Temperature
Limiter Open (S6)
or
High & Low Pressure
Switches Open (S7/S2)
or
Battery or Alternator Not Operating at
Acceptable Levels per Voltage Regulator
or Shore Power Disconnected
or
Inverter 120 VAC Output Not Present
(K8 Open)
Id = 10
Ia = 0
Charging Unit
OFF
A/C Enable Switch Open (S1)
or
Storage Core Temperature
Control Thermostat Open (S4)
or
Ambient Temperature
Limiter Open (S6)
or
High & Low Pressure
Switches Open (S7/S2)
or
Battery or Alternator Not Operating at
Acceptable Levels per Voltage Regulator
or Shore Power Disconnected
or
Inverter 120 VAC Output Not Present
(K8 Open)
Id = 60-70
Ia = 8
Compressor Bypass (MV)
Valve OFF (valve closed)
Compressor (K2) ON
3.4.3
Condenser Fan (K1) ON
Time Delay Relay (K3) Counting Down
Compressor Bypass (MV)
Valve ON (valve opened)
A/C Enable Switch Closed (S1)
and
Storage Core Temperature
Control Thermostat Closed (S4)
and
Ambient Temperature
Limiter Closed (S6)
and
High & Low Pressure
Switches Closed (S7/S2)
and
Battery Voltage Acceptable per Voltage
Regulator or Shore Power Connected
and
Inverter 120 VAC Output Present
(K8 Closed)
A/C Enable Switch Closed (S1)
and
Storage Core Temperature
Control Thermostat Closed (S4)
and
Ambient Temperature
Limiter Closed (S6)
and
High & Low Pressure
Switches Closed (S7/S2)
and
Battery Voltage Acceptable per Voltage
Regulator or Shore Power Connected
and
Inverter 120 VAC Output Present
(K8 Closed)
and
Elapsed Time >2 min.
Time Delay Relay Closed (K3)
Functional Description
Charge State Diagram
Fresh Air / Recirc
Mode Switch (S5)
OFF
Figure 16. Fresh Air / Recirc. State Diagram
17
Recirculation Mode
Switch (S5) Position Down
Blower Switch (S3) ON
OFF
OR
Fresh Air Mode
Switch (S5) Position Up
Switch to
Fresh Air (S5)
Switch to
Recirculation (S5)
Fresh Air Mode
Switch (S5) Position Up
Recirculation Mode
Switch (S5) Position Down
OFF
Blower Switch (S3) OFF
Switch to
Recirculation (S5)
Switch to
Fresh Air (S5)
3.4.4
OFF
Blower Switch (S3) ON
Functional Description
Fresh Air, Recirculated Air State Diagram
Cooling System
and Blower OFF
Figure 17. Cooling Discharge State Diagram
18
Cooling System
ON
Blower Switch (S3) ON
Blower ON
(Minimum 10 CFM)
Cooling Switch ON
OR
Cooling System
ON
Cooling Switch ON
Blower ON
(Minimum 10 CFM)
Cooling Switch OFF
and
Blower Switch (S3) ON
Blower Switch (S3) OFF
and
Cooling Switch OFF
Blower Switch (S3) OFF
Coolant Circulating
Pump (M4) ON
Rotate Thermostat
CW to LED OFF
or
Return Air ≤
Thermostat (TS3)
Rotate Thermostat
CCW to LED ON
or
Return Air ≥
Thermostat (TS3)
Coolant Circulating
Pump (M4) OFF
Return Air ≤
Thermostat (TS3)
OR
Coolant Circulating
Pump (M4) OFF
Rotate Thermostat
CW to LED OFF
or
Return Air ≤
Thermostat (TS3)
Coolant Circulating
Pump (M4) ON
Return Air ≥
Thermostat (TS3)
Cooling Switch OFF
Rotate Thermostat
CCW to LED ON
or
Return Air ≥
Thermostat (TS3)
OR
OR
3.4.5
= Storage Cooler Circ. Pump ON
(Green LED ON)
= Storage Cooler Circ. Pump OFF
Functional Description
Cooling Discharge State Diagram
Troubleshooting
4. Troubleshooting
4.1
General Information
The following are to be considered and eliminated as
cause for malfunction:
This section describes how to identify and remedy faults
of the Kenworth Clean Power™ system.
1) Ensure that the “Charge Enable/Disable” switch
located on the dashboard is functional and in the
enabled up position. Note that the LED light will
not illuminate unless the compressor is running.
CAUTION: Troubleshooting work demands
precise knowledge of the structure and theory
of operation of the various components and
must be carried out by trained personnel only.
2) Ensure that battery voltage is at an acceptable level
as determined by voltage regulator when engine is
running OR shore power connected.
CAUTION: The troubleshooting guide is
restricted to the localization of defective
components. The following potential sources of
malfunctions have not been included and
should always be checked so that they can then
be excluded as the cause of the particular fault:
•
Tripped fuses or breakers
•
Corrosion on terminals
•
Loose terminal contact
•
Poor crimp contacts on terminals
•
Corroded cables and fuses
•
Open circuits or short circuits in cables and wiring
•
Corroded battery terminals
•
Malfunctioning controls (Refer to Kenworth Clean
Power™ System Service Manual)
•
Malfunction with main battery box (Refer to
Kenworth Clean Power™ System main battery box
unit technical documentation)
3) 120 VAC voltage present. Ensure that the in-truck
Clean Power 20A breaker is not tripped or the
GFCI.
4) Ensure that the control panel is operative and
functioning properly.
NOTE: As a minimum, all supporting components
e.g., main battery box, control panel, that the bunk
cooling system relies upon must be operational and
within required parameters before proper
troubleshooting of the system can be performed.
19
Troubleshooting
4.2
Storage Cooler Control Unit – SCCU
The following procedure will confirm the Storage Cooler
Control Unit’s (SCCU) functionality and eliminate it as
cause for system malfunctions.
3. Apply 12 volt power to pins G/12 and H/12 of
connector SCCU 1.
4. Apply ground to pins J/12 and K/12 of connector
SCCU 1.
Refer to the SCCU diagram in Sec. 4.2.2 "SCCU
Troubleshooting – Electrical Layout Diagram"
4.2.1
5. Follow Table 1, “Functional checks – SCCU,” on
page 20.
Preparation for Functional Checks
NOTE: Power and ground must be maintained
throughout the SCCU testing process.
1. Disconnect connectors SCCU 1 (12-pin) and SCCU 2
(16-pin).
2. Remove cover from SCCU.
Function Check
Possible Cause for Malfunction
Remedy
Check for power out (12V) on pin
F/12.
Check for open fuse F2.
Check for open or short circuit within SCCU wiring.
Replace fuse F2.
Repair SCCU wiring.
Check for power out (12V) on pin
M/16.
Check for open fuse F6.
Check for open or short circuit within SCCU wiring.
Replace fuse F6.
Repair SCCU wiring.
Check for power out (12V) on pin
Check for open fuse F3.
B/12 (Condenser fan) with power
Check relay K10 and socket for power (12V) on pins
(12V) applied to pins E/12 and M/12. 1, 3 and 5. Ground on pin 2.
Check relay K1 and socket for power (12V) on pins
86, 30 and 87. Ground on pin 85.
Replace fuse F3.
Repair open or short circuits. Replace defective relay
K10.
Repair open or short circuits. Replace defective relay
K1.
(1) Check for power out (12V) on pin
D/12 (Magnetic Valve) for first 2
minutes with power (12V) applied to
pins E/12 and M/12.
Check for open fuse F2.
Check relay K3 and socket for power (12V) on pins
30, 15 and 87a. Ground on pin 31.
Note: Pin 87a will have power for 2 minutes only
afterwhich, it will switch to pin 87.
Replace fuse F2.
Repair open or short circuits. Replace defective relay
K3.
(1) Check for power out (12V) on pin Check for open fuse F2.
A/12 (Compressor) after 2 minutes
Check relay K3 and socket for power (12V) on pins
with power (12V) applied to pins
30, 15 and 87. Ground on pin 31.
E/12 and M/12.
Replace fuse F2.
Repair open or short circuits. Replace defective relay
K3.
Check for power out (12V) on pin
A/3 (Blower Motor connector X3)
with power (12V) applied to pins
H/16 and variable voltage (0... 10V)
to pin L/16 (Blower control signal).
Replace fuse F6.
Repair open or short circuits. Replace defective relay
K6.
(2) Coolant pump circuit check:
Connect a 2K linear potentiometer
between pins K/16 and J/16.
Connect temperature sensor TS3 to
X5 connector pins A/2 and B/2.
Connect power (12V) to pin G/16.
Check for power out (12V) on pin
N/16 and power out (12V) on
connector X3, pin A/2.
Check for open fuse F6.
Check relay K6 and socket for power (12V) on pins
1, 3 and 5. Ground on pin 2.
Check for open fuse F5.
Replace fuse F5.
Check thermostat module TC1 and socket for power Repair open or short circuits. Replace defective
(12V) on pins 1, 2 and OUT.
thermostat module TC1.
Ground on pin 31.
Table 1. Functional checks – SCCU
20
Troubleshooting
Function Check
Fresh Air/Recirc. actuator circuit
check:
Connect power (12V) to pin A/16
and ground to pin B/16.
Check for power out (12V) on
connector X4, pin 5 (Actuator
rotation CW).
Connect power (12V) to pin B/16
and ground to pin A/16.
Check for power out (12V) on
connector X4, pin 6 (Actuator
rotation CCW).
Possible Cause for Malfunction
Remedy
Check for open or short circuit within SCCU wiring.
Repair open or short circuits.
Check for open or short circuit within SCCU wiring.
Repair open or short circuits.
Table 1. Functional checks – SCCU
NOTES:
(1) When E/12 and M/12 are powered the Condenser Fan (M2) is ON and the Magnetic Valve (MV) is open for the first two minutes. When
two minutes have elapsed the Condenser Fan is ON and Relay K2 is closed (Compressor ON) at this time MV remains closed (no power on
D/12) until power removed from pins E/12 and M/12.
(2) When potentiometer is set to 0 ohms, no power out on connector SCCU 2, pin N/16 and no power out on connector X3, pin A/2.
21
Troubleshooting
4.2.2
SCCU Troubleshooting – Electrical Layout Diagram
X4 (M5) FRESH/RECIRC
DOOR ACTUATOR
X5 (TS3) TEMPERATURE
SENSOR
K1
F3
F7
F5
F2
F6
K3
K7
K6
TC1
K10
K9
X2 (M3)
BLOWER FAN
X3 (M4)
COOLANT PUMP
A SCCU2
B
C
G
D F
E
H
SCCU1
C
B
A
G
H
J
D
E
F
K
L
SCCU1
SCCU2
M
L
K
J
22
N
M P
S
R
P,S,R NOT USED
Troubleshooting
4.3
Charge Unit Troubleshooting
NOTE: The control system has a built-in delayed operation feature. The charging unit compressor is delayed 2 minutes
before starting operation. During this 2 minute period, the condenser fan motor (M2) is activated and the by-pass valve
(MV) is opened to allow equalization of the refrigerant pressures between the suction circuit and discharge circuit.
4.3.1
Charge Unit Troubleshooting
Concern
Possible Cause
Remedy
Charge unit does not begin
operation.
Core temperature control thermostat (S4) OPEN
Opens at -3.3°C (26.1°F).
Closes at 13.6°C (56.5°F).
(1) Confirm charge state of storage cooler assembly. If
fully charged, it is normal for the thermostat (S4) to be
open.
If partly or fully discharged and thermostat remains
open, replace thermostat.
Charge unit does not begin
operation.
(1) Storage cooler assembly
discharged.
Open sensor / pressure switch circuits.
Disconnect 8-pin connector at the charge unit. Check
for continuity across pins A/8 and C/8 of the charge
unit side of connector. No continuity indicates one or
more sensors (S2, S6 or S7) are open. Check sensors
individually for open circuit.
Ambient temperature limiter (S6) OPEN.
Opens at 7.2°C (45°F)
Closes at 12.8°C (Tolerance of ± 3.3°C)
55°F (Tolerance of ± 6°F)
Replace limiter if open at temperatures above 16°C
(61°F)
Low refrigerant pressure switch (S2) OPEN
Opens at >1.03 bar (Tolerance of ± 0.24 bar)
>15 psig (Tolerance of ± 3 psig)
Closes at 2.13 bar (31 psig)
Confirm refrigerant pressures with A/C gauge set. If
pressure above 1.27 bar (18 psig), replace sensor. If
pressure below 0.8 bar (12 psig), check system for
leaks and repair. Perform complete refrigerant system
service.
High refrigerant pressure switch (S7) OPEN
Pressure switch defective - replace.
Charge unit shuts down after partial High refrigerant pressure switch (S7) OPEN.
system charge.
Opens at < 20.68 bar (Tolerance of ± 0.69 bar)
< 300 psig (Tolerance of ±10 psig)
Closes at 12.4 bar (180 psig)
Air flow over condenser blocked. Clear obstruction.
Open circuit to condenser fan. Check circuits and
repair.
Condenser fan defective. Replace fan.
Refrigerant circuit blocked. Confirm refrigerant
pressures with A/C gauge set. Clear obstruction.
Core temperature control thermostat (S4) OPENS
prematurely.
Confirm open state with digital ohm meter. Replace
thermostat.
Table 2. Charge unit troubleshooting
NOTES:
(1) TIP! The quickest way to determine the charge state of the storage cooler assembly is to simply switch the system on in cooling mode.
After a couple on minutes on maximum output, feel the air exiting the sleeper vents. If the air is cold, allow it to continue to discharge
until the charge unit compressor engages. If the air is warm and the charge unit is not responding, there is a system malfunction.
For this test, ensure that the “Charge Enable/Disable” switch located on the dashboard is functional and in the enabled up position. Note
that the lamp will not illuminate unless the compressor is running. It may also be necessary to connect the main battery box to a shorepower source depending on the charge state of the main batteries.
23
Troubleshooting
4.4
Discharging Mode Troubleshooting
4.4.1
Preparation for Troubleshooting
Set operator’s control panel for cooling by:
– placing AC/Heat switch to AC ( ) mode.
–
rotating temperature control dial counter clockwise to AC mode.
–
rotating fan control dial clockwise to turn fan on.
4.4.2
Discharge Mode Troubleshooting
Concern
Blower fan does not turn on
Possible Cause
No power to blower fan (M3).
Remedy
Check blower fan electrical connector X2 for power
out (12V) on pin A/3 and ground on pin C/3
Check for open fuse F6 and replace.
Check for damaged, open or shorted wiring and repair.
Replace blower fan
Blower fan defective.
Blower fan operates with little or no
air flow.
No cooling of air
Air ducts blocked.
Ensure correct vents and return grilles in sleeper are
open.
Air filter dirty.
Clean or replace air filter.
No power to coolant circulating pump (M4).
Check circulating pump electrical connector X3 for
power out (12V) on pin A/2 and ground on pin B/2
Check for open fuse F5 and replace.
Check for damaged, open or shorted wiring and repair.
Replace coolant circulating pump
Coolant circulating pump defective
Replenish coolant with premixed 50/50 solution of
water and antifreeze to proper level and purge air from
circuit.
Low coolant (Pump cavitation)
Cannot control sleeper cooling
temperature. Storage cooler
assembly quickly depleted.
No circulation due to ice-blocked storage core
coolant tubes. Weak antifreeze solution or water
added to system without prior mixing with
antifreeze as recommended.
Thaw system, drain and fill with correct strength of
premixed 50/50 antifreeze solution. Allow system to
circulate for minimum of 15 min. and check antifreeze
strength. If still weak, repeat drain, fill, circulate and
test.
Coolant circulating pump runs continuously
regardless of temperature setting.
Check for unplugged cabin temperature sensor (TS3)
connector X5 or open circuit in wiring.
Cabin temperature sensor defective.
Check sensor with digital ohm meter.
1.001kΩ at 24°C (75°F).
Replace sensor if reading is incorrect or sensor is open.
Table 3. Discharge mode troubleshooting
NOTES:
(1) The coolant circulating pump responds according to cabin temperature and position of the temperature control dial. The further
counter-clockwise the dial is turned, the more frequent and longer the pump is activated to circulate coolant through the heat
exchanger. For diagnostic purposes, it may be necessary to turn the dial full on to activate the pump depending on ambient
temperatures in the sleeper.
(2) Pure water must never be introduced into the coolant circuit under any circumstances! Doing so may cause freezing and blockage
within the storage cooler assembly resulting in no circulation and no sleeper cooling. Use a premixed 50/50 antifreeze and water
solution only!
24
Troubleshooting – Refrigerant Compressor
5. Troubleshooting – Refrigerant
Compressor
5.1
5.2.2
Refrigeration and air conditioning devices are extremely
complicated by nature. Servicing, repairing, and
troubleshooting these products should be done only by
those with the necessary knowledge, training, and
equipment.
General Information
WARNING! 120 VAC Device. Lethal current may
be present. Switch off the DC to AC power
inverter and the 20 Amp. breaker in driver’s side
tool compartment load center before servicing.
WARNING! Never service, repair, or
troubleshoot unless you are a professional air
conditioning/refrigeration service person.
Improper servicing can lead to serious injury or
death from fire, electric shock, or explosion.
The Kenworth Clean Power™ System uses a specifically
designed refrigerant compressor for this assembly. The
compressor electrical motor is the type, PSC with external
surface mounted thermal and current overload
protection.
5.2.3
*Current through the PTCR causes a small amount
of resistive heating. If the current is large enough to
generate more heat than the device can lose to its
surroundings, the device heats up, causing its
resistance to increase, and therefore causing even
more heating. This creates a self-reinforcing effect
that drives the resistance upwards, reducing the
current and voltage available to the compressor after
start-up.
5.2.4
Fire Hazard from Terminal Venting with
Ignition
Oil and refrigerant can spray out of the compressor if one
of the terminal pins is ejected from the hermetic
terminal. This “terminal venting” can occur as a result of
a ground fault (also known as a short circuit to ground)
in the compressor. The oil and refrigerant spray from
terminal venting can be ignited by electricity and produce
flames that can lead to serious burns or death. When
spray from terminal venting is ignited this is called
“terminal venting with ignition.”
The electrical system of this type of compressor motor is
shown in Fig. 22, on pg. 33.
5.2.1
Terminal Venting and Electrocution
WARNING! Improperly servicing, repairing, or
troubleshooting a compressor can lead to
electrocution or fire due to terminal venting
with ignition. Follow the precautions below to
avoid serious injury or death from electrocution
or terminal venting with ignition.
This system also uses a run capacitor and a *PTCR
(Positive Temperature Coefficient Resistor) to aid starting
performance.
5.2
Trained Personnel Only
5.2.5
General Service and Safety
Precautions Concerning Refrigerant
Compressors
Terminal Venting and Electrocution
Precautions
To reduce the risk of electrocution, serious burns, or
death from terminal venting with ignition:
•
Introduction
The following information and procedures are courtesy
of Tecumseh Products Company.
Disconnect ALL electrical power before
removing the protective terminal cover.
Make sure that all power legs are open.
(NOTE: The system may have more than one
power supply, e.g. Auxiliary Shore Power.)
Certain information that does not pertain to the
Kenworth Clean Power™ System may have been
intentionally omitted from the original text for purposes
of clarity.
•
In the interest of promoting safety in the refrigeration
and air conditioning industry, Tecumseh Products
Company has prepared the following information to
assist service personnel in safely installing and servicing
equipment. This section covers a number of topics
related to safety. However, it is not designed to be
comprehensive or to replace the training required for
professional service personnel.
Never energize the system unless: 1) the
protective terminal cover is securely fastened,
and 2) the compressor is properly connected
to ground.
Fig. 18 and Fig. 19 illustrates the means of
fastening the protective terminal cover.
•
25
Never reset a breaker or replace a fuse
without first checking for a ground fault (a
short circuit to ground).
Troubleshooting – Refrigerant Compressor
including burns and frostbite. For example, if refrigerant
contacts skin or eyes it can cause severe frostbite. Also,
in the event of a compressor motor failure, some
refrigerant and oil mixtures can be acidic and cause
chemical burns.
An open fuse or tripped circuit breaker is a strong
indication of a ground fault. To check for a ground
fault, use the procedure outlined in “Identifying
Compressor Electrical Problems” in Section 5.4.
•
•
Be alert for sounds of arcing (sizzling,
sputtering or popping) inside the compressor.
If you hear these sounds, IMMEDIATELY move
away from the area of the compressor.
To avoid injury, wear appropriate protective eye wear,
gloves, and clothing when servicing an air conditioning
or refrigeration system. Refer to your refrigerant supplier
for more information.
Disconnect power before servicing.
Always disconnect power before servicing, unless
it is required for a specific troubleshooting
technique. In these situations, use extreme
caution to avoid electric shock.
If refrigerant or mixtures of refrigerant and oil come in
contact with skin or eyes, flush the exposed area with
water and get medical attention immediately.
5.2.7
1
Compressor Removal
2
WARNING! Failure to properly remove the
compressor can result in serious injury or death
from electrocution, fire or sudden release of
refrigerant and oil.
Follow these precautions when removing a compressor
from a system:
•
Disconnect ALL electrical power.
Disconnect all electrical power supplies to the
system, making sure that all power legs are open.
(NOTE: The system may have more than one
power supply.)
•
Figure 18. Compressor with protective cover (1) held in
place by a hex-nut (2)
Be sure refrigerant is recovered using the
appropriate equipment before removing
compressor.
3
NOTE: It is recommended that the cold storage core
be completely discharged (brought up to room
temperature) before recovering the refrigerant.
Otherwise, the system will have to be evacuated for a
period not less than 2 hours to ensure any liquid
refrigerant lingering in the storage core is boiled off.
Place a temperature probe in one of the discharge
openings of the sleeper and turn the blower on to
determine the cold storage core charge state.
Servicing a charged or partially charged system will
give you inaccurate or false pressure readings.
4
•
Figure 19. Thermal protection (3) and hermetically sealed
terminals (4) shown with protective cover
removed.
5.2.6
Refrigerants and Other Chemicals
Attempting to remove the compressor before
removing all refrigerant from the system can
cause a sudden release of refrigerant and oil.
Among other things, this can:
•
Cause a variety of injuries including burns and
frost bite.
•
Expose service personnel to toxic gas.
To avoid serious injury or death, be sure to remove and
recover all refrigerant before removing the compressor.
Contact with refrigerant, mixtures of refrigerant and oil,
or other chemicals can cause a variety of injuries
26
Troubleshooting – Refrigerant Compressor
5.2.8
System Flushing, Purging, and Pressure
Testing for Leaks
WARNING! Failure to properly flush, purge, or
pressure test a system for leaks can result in
serious injury or death from explosion, fire or
contact with acid-saturated refrigerant or oil
mists.
It is recommended that the system be serviced
using a flush and purge station such as a Robinair®
unit or similar equipment designed for servicing
R134a refrigerant systems.
Follow these precautions when flushing/purging a system
or pressure testing a system for leaks:
•
Use flushing products according to the
manufacturer’s instructions.
•
To purge a system, use only dry nitrogen.
•
When pressure testing for leaks, use only
regulated dry nitrogen or dry nitrogen plus
trace amounts of the serial label refrigerant,
in this case, R134a.
•
•
•
Oxygen can explode on contact with oil.
•
Acetylene can decompose and explode when
exposed to pressures greater than
approximately 15 PSIG.
Use a pressure relief valve.
In addition to a pressure regulating valve and
gauges, always install a pressure relief valve. This
can also be a frangible disc type pressure relief
device. This device should have a discharge port of
at least 1/2” MPT size. The valve or frangible disc
device must be set to release at 175 PSIG (see Fig.
20).
When purging or pressure testing any
refrigeration or air conditioning system for
leaks, never use air, oxygen or acetylene.
•
•
Figure 20. Dry nitrogen cylinder with attached pressure
regulating and relief valves and pressure
gauges needed for pressure testing for leaks
and purging.
•
Combining an oxidizing gas, such as oxygen
or air, with an HCFC or HFC refrigerant under
pressure can result in a fire or explosion.
When field testing a system for leaks, 150
PSIG is adequate test pressure.
•
Use a pressure regulating valve and pressure
gauges.
Commercial cylinders of nitrogen contain pressures
in excess of 2000 PSIG at 70°F. At pressures much
lower than 2000 PSIG, compressors can explode
and cause serious injury or death. To avoid over
pressurizing the system, always use a pressure
regulating valve on the nitrogen cylinder discharge
(see Fig. 20). The pressure regulator must be able
to reduce the pressure down to 1 or 2 PSIG and
maintain this pressure.
one gauge to measure cylinder pressure, and
•
one gauge to measure discharge or down
stream pressure.
Disconnect nitrogen cylinder and evacuate the
system before connecting the refrigerant
container.
Disconnect the nitrogen cylinder and release
the pressure in the system before connecting a
refrigerant container to the system. The
higher pressure gas in the system can explode
the refrigerant container.
The regulating valve must be equipped with two
pressure gauges:
•
Do not pressurize the system beyond 150 PSIG
field leak test pressure.
27
Troubleshooting – Refrigerant Compressor
5.2.9
System Charging
5.2.10 Capacitor Overheating
WARNING! Failure to properly charge the
system can result in serious injury or death from
explosion or fire.
An overheated run/start capacitor can burst and spray or
splatter hot material which can cause burns. Applying
voltage to a run/start capacitor for more than a few
seconds can cause the capacitor to overheat.
Follow these precautions when charging a system.
•
Check capacitors with a capacitance meter, and never
check a capacitor with the power on.
Do not operate the compressor without a
charge in the system.
Operating the compressor without a charge in the
system can damage the hermetic terminal. As
always, to avoid serious injury or death from
terminal venting with ignition, never energize the
compressor unless the protective terminal cover is
securely fastened.
•
5.2.11 System Evacuation
Never use a compressor to evacuate a system. Instead,
use a high vacuum pump specifically designed for that
purpose.
Never start the compressor while it is under deep
vacuum. Always break a vacuum with refrigerant charge
before energizing the compressor.
Use proper refrigerant.
Use only the serial label refrigerant when charging
the system. Using a different refrigerant can lead
to excess system pressure and an explosion. Use of
a refrigerant other than the serial label refrigerant
will void the compressor warranty.
•
Failure to follow these instructions can damage the
hermetic terminal. As always, to avoid serious injury or
death from terminal venting with ignition, never energize
the compressor unless the protective terminal cover is
securely fastened.
Do not overcharge a refrigerant system.
Overcharging a refrigeration system can result in
an explosion. To avoid serious injury or death,
never overcharge the system. Always use proper
charging techniques. Limit charge amounts to
those specified on the system equipment serial
label or in the original equipment manufacturer’s
service information.
5.2.12 Follow the Labels
Tecumseh Products Company compressors have labels
and markings with important information. For your
safety and the safety of others, read the labels and
markings on the product.
Overcharging the system immerses the compressor
motor, rotor, and related parts in liquid refrigerant.
This creates a hydraulic block preventing the
compressor from starting. The hydraulic block is
also known as locked rotor.
Continued supply of electricity to the system
causes heat to build in the compressor. This heat
will eventually vaporize the refrigerant and rapidly
increase system pressure. If, for any reason, the
thermal protector fails to open the electrical circuit,
system pressure can rise to high enough levels to
cause a compressor housing explosion.
NOTE: It is recommended that the cold storage core
be completely discharged (brought up to room
temperature) before servicing the refrigerant circuit.
Place a temperature probe in one of the discharge
openings of the sleeper and turn the blower on to
determine the cold storage core charge state.
Servicing a charged (frozen) or partially charged
(cold) system will give you inaccurate or false pressure
readings.
28
Troubleshooting – Refrigerant Compressor
5.3
Troubleshooting Table – Refrigerant Compressor and Related Components
This section provides information to assist service personnel in identifying compressor problems. It provides a general
troubleshooting table that relates complaints or problems to possible causes and solutions. This section also provides
greater detail about specific compressor problems.
For your safety, read and follow the “General Service and Safety Precautions Concerning Refrigeration Compressors” in
Section 5.2.
This Troubleshooting Table is not designed to replace the training required for a professional air conditioning/
refrigeration service person, nor is it comprehensive.
Symptom
Possible Causes
Compressor will not start – Thermal protector not working properly.
no audible hum
Remedy
Refer to “Identifying Compressor Electrical
Problems” in Section 5.4.
Wiring improper or loose.
Check against wiring diagram and wire properly.
Compressor motor has a ground fault (also known as a short
circuit to ground).
Refer to “Identifying Compressor Electrical
Problems” in Section 5.4.
Compressor will not start – Improperly wired.
hums but trips on thermal
protector
Low voltage to compressor.
Check against wiring diagram and wire properly.
Turn off system until proper voltage is restored.
Compressor electrical problems:
a. Compressor motor has a winding open or shorted.
Refer to “Identifying Compressor Electrical
Problems” in Section 5.4.
b. Start capacitor or PTCR not working properly.
c. Relay does not close.
Internal mechanical troubles in compressor.
Compressor starts, but
Improperly wired.
does not switch off of start
winding
Low voltage to compressor.
Refer to “Checking for Adequate Compressor
Pumping” in Section 5.5.
Check against wiring diagram and wire properly.
Turn off system until proper voltage is restored.
Compressor electrical problems:
a. Compressor motor has a winding open or shorted.
b. Relay failing to open.
c. Run capacitor not working properly.
Refer to “Identifying Compressor Electrical
Problems” in Section 5.4.
Discharge pressure too high.
Internal mechanical trouble in compressor.
Refer to “Checking for Adequate Compressor
Pumping” in Section 5.5.
Table 4. Refrigerant compressor and related components troubleshooting
29
Troubleshooting – Refrigerant Compressor
Symptom
Compressor starts and
runs, but short cycles on
thermal protector
Possible Causes
Too much current passing through thermal protector:
a. Extra sources of current draw.
b. Compressor motor has winding shorted.
Remedy
Check for extra sources of current passing through
thermal protector, such as fan motors, pumps.
(This would be extremely rare as this system is not
designed for such use.)
Refer to “Identifying Compressor Electrical
Problems” in Section 5.4.
Low voltage to compressor.
Turn off system until proper voltage is restored.
Compressor electrical problems, such as thermal protector or
run capacitor not working properly.
Refer to “Identifying Compressor Electrical
Problems” in Section 5.4.
Discharge pressure too high.
Suction pressure too high.
Return gas too warm.
Check condenser fan for malfunction
Unit runs OK, but run cycle System components, such as storage temperature control
is shorter than normal (due thermostat, SCCU, relays, not functioning properly.
to component (s) other
than thermal protector)
High pressure cut-out due to:
a. Insufficient air flow over condenser.
b. Overcharge of refrigerant.
c. Air in system.
Low pressure cut-out due to:
a. Refrigerant leaking.
b. Undercharge of refrigerant.
c. Restriction in Thermal Expansion Valve.
Unit operates long or
continuously
Refer to the information contained within Section
4 “Troubleshooting”.
Refer to the information contained within Section
4 “Troubleshooting”.
Refer to the information contained within Section
4 “Troubleshooting”.
Undercharge of refrigerant.
Check for leak and correct. Perform full refrigerant
service on system.
System components, such as storage temperature control
thermostat, SCCU, relays, not functioning properly.
Refer to the information contained within Section
6 and Section 7.
Restriction in refrigeration circuit.
Refer to the information contained within Section
6 and Section 7.
Dirty condenser.
Refer to the information contained within Section
6 and Section 7.
Suction line frosted or
sweating
System problems, such as:
a. Expansion valve stuck open.
b. Overcharge of refrigerant.
Liquid line frosted or
sweating
System problems such as, restriction in dehydrator or strainer. Refer to the information contained within Section
6 and Section 7.
System rattles or vibrates
during operation.
Loose parts or mountings, tubing rattle, bent fan blade
causing vibration, fan motor bearings worn, etc.
Refer to the information contained within Section
6 and Section 7.
Repair or replace loose, worn, defective parts.
Table 4. Refrigerant compressor and related components troubleshooting
30
Troubleshooting – Refrigerant Compressor
5.4
Identifying Compressor Electrical
Problems
5.4.1
Step 1: Disconnect Power
Disconnect all electrical power supplies to the system,
making sure that all power legs are open.
(NOTE: The system may have more than one power
supply.)
This section describes procedures for checking the
compressor’s electrical circuits and components. Before
doing so, ensure that the Kenworth Clean Power™
System is operational and that all power sources are
present. Make sure the core temperature control
thermostat, SCCU, and relays are working properly.
Step 2: Check for a Ground Fault
Remove the protective terminal cover. If there is any
evidence of overheating at any lead, this is a good
indication that a compressor motor problem exists. At
this time, do not replace or attach leads or connectors
that have been damaged by overheating.
Disconnect leads and/or remove all components (such as
relays and capacitors) from the terminal pins.
Whenever you suspect that there is an electrical problem
with the compressor (for example, there has been a
tripped circuit breaker):
•
FIRST, check for a ground fault (also known as a
short circuit to ground) in the motor using a
megohmmeter (“megger”) or a Hi-Potential
Ground Tester (“Hi-Pot”) (Section 5.4.1).
•
SECOND, check the motor windings for proper
continuity and resistance (Section 5.4.2).
•
THIRD, check the compressor’s electrical
components (Section 5.4.3).
WARNING! If a capacitor is present, using a
20,000 ohm resistor, discharge it before
removing it from the system to avoid damage to
measuring devices and risk of electric shock.
When removing a current type relay, keep it
upright.
When checking for electrical problems, it is important to
follow all safety precautions (see warning below) and use
the proper equipment and procedures.
Check the compressor for a ground fault using either a
megohmmeter (“megger”) or a Hi-Potential Ground
Tester (“Hi-Pot”) (See examples in Fig. 21).
WARNING! Oil and refrigerant can spray out of
the compressor if one of the terminal pins is
ejected from the hermetic terminal.
This can occur as a result of a ground fault in the
compressor. The oil and refrigerant spray can be
ignited by electricity and produce flames that
can lead to serious burns or death. If this spray
is ignited it is called “terminal venting with
ignition”.
To reduce the risk of electrocution, serious burns or death
from terminal venting with ignition:
•
Disconnect ALL electrical power before removing
the protective terminal cover.
•
Never energize the system unless:
•
the protective terminal cover is securely
fastened, and
•
the compressor is properly connected to
ground.
•
Never reset a breaker or replace a fuse without first
checking for a ground fault. An open fuse or
tripped circuit breaker is a strong indication of a
ground fault.
•
Be alert for sounds of arcing (sputtering or
popping) inside the compressor. If you hear these
sounds, IMMEDIATELY move away from the area
of the compressor.
Checking for a Ground Fault (a Short to
Ground)
WARNING! To reduce the risk of electrocution,
always follow the manufacturers’ procedures
and safety rules when using these devices.
Connect one lead of either the megger or Hi-Pot to the
metal suction line or similar compressor ground point.
Connect the other lead to one of the terminal pins.
Repeat this procedure for the two remaining terminal
pins. If the instrument indicates any resistance less that 2
megohms between any pin and the housing (metal
suction line), a ground fault exists.
WARNING! To avoid electric shock,
electrocution, and terminal venting with
ignition do not energize a compressor that has a
ground fault.
If a ground fault exists, keep the power off and replace
the compressor. See “System Cleanup and Compressor
Replacement After Compressor Failure” starting on
Section 6.1.
If the compressor is not replaced immediately, mark and
red tag the compressor to indicate there is a ground
fault. Do not reconnect the power leads. Tape and
insulate each power lead separately.
31
Troubleshooting – Refrigerant Compressor
If a ground fault does not exist, leave the power off and all external components disconnected from the terminal pins.
Check for continuity and proper resistance using the procedure under Section 5.4.2.
Why use a megger or Hi-Pot?
A conventional ohmmeter will not reliably detect a
ground fault under certain circumstances.
A megohmmeter (“megger”) is a special type of
ohmmeter that is capable of measuring very high
resistances by using high voltages.
A Hi-Potential Ground Tester (“Hi-Pot”) is a device
that uses high voltages to measure the flow of
current across the insulation. Unlike an ohmmeter,
even one that can measure millions of ohms, a
megger or a Hi-Pot can detect a breakdown in motor
winding insulation before the motor fails.
“megger”
WARNING! To reduce the risk of
electrocution, always follow the
manufacturers’ procedures and safety rules.
“Hi-Pot”
Figure 21. “Megger” and “Hi-Pot”
5.4.2
Checking for Continuity and Proper Resistance
If no ground fault has been detected using the procedures under Section 5.4.2, determine whether there is an open or
short circuit in the motor windings or if the heater element of the thermal protector is open.
Use the procedures in Table 5 to check the single phase motor.
Step 1: Allow Thermal Protector When servicing single compressors with internal thermal protectors, be sure to
to Reset
allow time for the thermal protector to reset prior to starting these electrical
wiring checks.
Step 2: Check Continuity
Check the start winding by measuring continuity between terminal pins C and
S. (See “Identification of Hermetic Terminal” on page). If there is no continuity,
replace the compressor. See “System Cleanup and Compressor Replacement
After Compressor Failure” under Section 6.1.
Check the run winding by measuring continuity between terminal pins C and R.
If there is no continuity, replace the compressor.
Table 5. Checking for Proper Continuity and Resistance
32
Troubleshooting – Refrigerant Compressor
Step 3: Measure the Resistance
Measure the resistance (ohms) between each pair of terminal pins: C and S, C
and R, and S and R. Add the resistance between C and S to the resistance
between C and R. This sum should equal the resistance found between S and
R. A small deviation in this comparison is acceptable.
For this compressor, the resistance values at a nominal temperature of 21° C
(70° F) should be within:
C & S = 4.0 to 5.2 ohms
C & R = 0.7 to 0.85 ohms
S & R = 4.7 to 6.05 ohms
If the resistance is not correct, replace the compressor. See “System Cleanup
and Compressor Replacement After Compressor Failure” under Section 6.1.
If the resistance is correct, leave the leads off and follow the instructions in the
next section to check other compressor electrical components.
Table 5. Checking for Proper Continuity and Resistance
5.4.3
Checking for Other Electrical Problems in Single Phase Motors
This section provides procedures for checking the components such as the thermal protector, relay and capacitor in a
single phase compressor. Refer to Table 6, “Troubleshooting PSC Compressor Circuits,” on page 34.
The Kenworth Clean Power™ System uses a specifically designed refrigerant compressor for this assembly.
The compressor electrical motor is the type, PSC with external surface mounted thermal and current overload
protection. This system also uses a run capacitor and a PTC Resistor starting aid.
The electrical system of this type of compressor motor is shown in Fig. 22.
Compressor Casing
120 VAC
INPUT
C
White
Green
Red
X1 - 120 VAC RECEPTICLE
Run
Capacitor
Locking Tab
S
Blue
Black (Hot)
White (Neutral)
X2
Blue
PTC Resistor
Green (Ground)
White
White
Green
R
X4
Compressor Casing
Ground
PSC Compressor with:
- run capacitor
- external thermal protector
- PTC resistor (wired)
Figure 22. PSC Compressor Motor with External Thermal/Current Protector, Run Capacitor and PTCR
33
Main Motor Winding
Black
Black
Start Winding
X1
Overheat/Overload
Protector
Troubleshooting – Refrigerant Compressor
Step 1: Before Continuing with
Troubleshooting...
WARNING! All electric power should be disconnected and you
should have already made sure that the compressor does not
have a ground fault (refer to “Checking for a Ground Fault” under
Section 5.4.1).
You should have also checked the windings for continuity and proper
resistance (see “Checking for Continuity and Proper Resistance” under
Section 5.4.2) making sure the system is getting proper voltage and that all
controls, thermostats, etc. are working properly.
Step 2: Check Wiring
Confirm that there is continuity between C and the thermal protector
common lead wire.
Step 3: Check External Thermal
Protector
Check for continuity across the thermal protector. If there is no continuity,
then the thermal protector may be tripped. Wait at least 5 minutes, then
check continuity again. If there is still no continuity, replace the thermal
protector.
Step 4: Check Run Capacitor
WARNING! Using a 20,000 ohm resistor; discharge the capacitor
before removing it from the system to avoid damage to
measuring devices and risk of electric shock.
Disconnect the run capacitor from the system. Use a capacitance meter to
check capacitor. Capacitance should be ±10% of the marked capacitor
value.
As an alternative, check the run capacitor by measuring continuity across
the capacitor terminals:
a. Rx1 scale: If there is continuity, then the capacitor is shorted out and
needs to be replaced.
b. Rx100,000 scale: If a digital multi-meter (DMM) indicates infinite
resistance, then the run capacitor is open and needs to be replaced.
Possible reasons that a run capacitor is not working properly include:
• Use of incorrect run capacitor. Replace with proper run capacitor.
• Line voltage is too high (greater than 110% of rated voltage).
• Rust-through of capacitor housing or severe corrosion of terminals.
Replace with new capacitor (Webasto now offers a weather protected
replacement).
Step 5: Reconnect Run Capacitor
Reconnect the run capacitor into the circuit as before. (See wiring
schematic under Section 11.1.1.) Observe color code markings on
schematic.
Step 6: Continue Troubleshooting
If all the above tests prove satisfactory and unit still fails to operate
properly, check for adequate compressor pumping as outlined in the
procedure under Section 5.5.
Table 6. Troubleshooting PSC Compressor Circuits
34
Troubleshooting – Refrigerant Compressor
5.5
Checking for Adequate Compressor
Pumping
authorized wholesalers and notes the reason for failure.
In the field, it can be determined if a compressor is
eligible for return under warranty by FIRST checking for
adequate compressor pumping. If the compressor passes
all electrical troubleshooting tests and pumps adequately,
the compressor is operating properly and the problem
lies elsewhere in the system.
Before checking for adequate compressor pumping, you
should have already checked for compressor electrical
problems as outlined in “Identifying Compressor
Electrical Problems” under Section 5.4.
To check for adequate pumping, connect service gauges
to system. Then turn on power to system. If the system
has an adequate refrigerant charge, the compressor
should maintain at least 200 psig pressure differential
between the suction and discharge. If the compressor
does not pump adequately, it must be replaced with no
further testing.
A. Check the Compressor for Electrical
Problems
Using the procedures in “Identifying Compressor
Electrical Problems” under Section 5.4, check the
compressor for electrical problems.
B. Check for Adequate Compressor Pumping
5.6
Is Your Compressor Eligible for Return
Under Warranty?
Connect services gauges to the system. Turn on power
to system. If the system has an adequate refrigerant
charge, the compressor should maintain at least 200 psig
pressure differential between the suction and discharge.
If the compressor does not pump adequately, it must be
replaced with no further testing.
Authorized Tecumseh wholesalers are asked to test every
in-warranty compressor that is returned to them. The
Tecumseh factory tears down and examines a
representative sample of compressors returned by
35
Compressor Replacement and System Service
6. Compressor Replacement and
System Service
6.1
If, however, the discharge line or the suction line shows
evidence of contamination, the compressor was running
at the time of the motor failure and contaminants were
pumped throughout the system (System Contamination).
If System Contamination has occurred, several changes
of the liquid and suction line filter-driers will be needed
to cleanup the system. In addition, the thermal
expansion valve will need to be replaced.
System Cleanup and Compressor
Replacement After Compressor
Failure
Once you determine that a compressor needs to be
replaced you must then determine whether the system
has been contaminated. Compressor motor failure can
lead to such contamination. (While compressor motor
failure is sometimes referred to as motor “burnout”, it
does not mean that a fire actually occurs inside a
hermetic compressor.) Even small amounts of
contamination must be removed from the system to
avoid damaging the replacement compressor. Therefore,
it is important to thoroughly clean a refrigeration/air
conditioning system if system contamination is present.
B. Install Replacement Compressor and
Components
1. Install the replacement compressor with new
external electrical components (capacitors, relay,
overload, etc., where applicable).
2. Install an oversized liquid line filter-drier.
3. Install a generously sized suction line filter-drier
immediately upstream of the compressor. The drier
when permanently installed in a clean system must
have a pressure drop not more than 2 psi, or initially
installed in a dirty system temporarily, must have a
pressure drop not more than 9 psi. Pressure taps
must be supplied immediately before and after the
suction filter-drier to permit the pressure drop to be
measured.
CAUTION: If a compressor motor failure has
occurred, refrigerant or mixtures of refrigerant
and oil in the system can be acidic and cause
chemical burns.
As always, to avoid injury, wear appropriate
protective eye wear, gloves and clothing when
servicing an air conditioning or refrigeration
system. If refrigerant or mixtures of refrigerant
and oil come in contact with skin or eyes, flush
the exposed area with water and get medical
attention immediately.
If a suction line accumulator is present and System
Contamination has occurred, it must be thoroughly
flushed to remove any trapped sludge and thus
prevent if from plugging the oil return hole. The
filter-drier should be installed upstream of the
accumulator and the compressor.
The following outlines a process for compressor
replacement and system clean-up for a system equipped
with a Tecumseh compressor. You should refer to the
original equipment manufacturers (OEM) service
information.
In case of Compressor Housing Contamination, the
filter-drier should be installed between the
compressor and the suction line accumulator.
Rubber refrigeration hoses are not satisfactory for
temporarily hooking up the suction line filter-drier to
the system since the acid quickly breaks down the
rubber and plastic.
A. Determine Extent of System Contamination
Following the precautions in “Refrigerants and Other
Chemicals” under Section 5.2.6 and Compressor
Removal” under Section 5.2.7, remove the compressor.
4. Follow the Precautions in “System Flushing, Purging,
and Pressure Testing for Leaks” under Section 5.2.8,
to purge the system and pressure test for leaks.
Use the following guidelines to determine whether
contamination, if any, is limited to the compressor or
extends to the system.
E. Evacuate the System
Evacuate the system to less than 1000 microns, using a
good vacuum pump (not a compressor) and an accurate
high vacuum gauge. Operate the pump at 1000
microns, or less, for several hours to be sure the vacuum
is maintained.
If the discharge line shows no evidence of contamination
and the suctions tube is clean or has only light carbon
deposits, then the contaminants are limited to the
compressor housing (Compressor Housing
Contamination). A single installation of liquid and
suction line filter-driers should clean up the system.
Alternate method of removing moisture and noncondensable material from the systems is:
36
Compressor Replacement and System Service
1. Evacuate the system to 29 inches vacuum. Break
vacuum with refrigerant to be used for final charging
of system and vapor charge to 35-50 pounds gauge
pressure. Leave vapor charge in system for a
minimum of five minutes. Reduce pressure to 0
gauge pressure.
In the case of Compressor Housing Contamination, little
change should be noted. The pressure drop will, in most
instances, be below that tolerable (2 psi) for a permanent
installation as described under Section 6.1, paragraph B,
item 3.
2. Repeat step 1.
On the other hand, where Systems Contamination
occurred, an increased pressure drop will be measured.
Change the suction filter-drier and the liquid line filterdrier whenever the pressure drop approached or exceeds
9 psi allowed for temporary operation during cleanup.
3. Evacuate system to 29 inches vacuum. Charge
system with the specified kind and quantity of
refrigerant.
CAUTION: Never use a compressor to evacuate
a system. Instead, use a high vacuum pump
specifically designed for that purpose.
Keep changing both the suction and liquid line filterdriers until the pressure drop stabilizes at or below 2 psi
for permanent operations in a system. At this point, it is
the service person’s option as to whether to leave the
suction drier in the system or remove it from operation.
CAUTION: Never start the compressor while it is
under deep vacuum. Always break a vacuum
with refrigerant charge before energizing the
compressor.
If the system is to be opened to permit the permanent
removal of the suction filter-drier then the liquid line
filter-drier should be changed once more.
WARNING! Failure to follow these instructions
can damage the hermetic terminal and may
result in terminal venting. As always, to reduce
the risk of serious injury or death from fire due
to terminal venting, never energize the
compressor unless the protective terminal cover
is securely fastened.
F. Test for Acidity if Multiple Motor Failures
Have Occurred
If the system has suffered multiple motor failures, it is
advisable that the oil of the replacement be tested after
Section E and judged acid free before the system is
considered satisfactorily cleaned.
D. Charge the System and Check the Pressure
Drop
An oil sample may be taken from a hermetic system if at
the time the replacement compressor was installed an oil
trap is installed in the suction line (see Fig. 23).
Charge the system and place in operation. Follow the
safety precautions outlined under “System Charging”,
Section 5.2.9. Immediately after startup, check the
pressure drop across the suction line filter-drier. This will
serve two purposes:
•
Verify that the drier selection was correct; that is,
large enough.
•
Serve as a base point to which subsequent
pressure checks can be compared.
When the trapped oil level appears in the sight glass (less
than an ounce is needed) the oil may be slowly
transferred to the beaker of the acid test kit as available
from several manufacturers. A reading of less that 0.05
acid number is an indication that the system is free of
acid. A reading of higher than 0.05 means continued
cleaning is required. Return to Section 6.1, paragraph B,
item 2.
G. Monitor the System
Because the permissible pressure drop across the drier is
relatively small, it is suggested that a differential pressure
gauge be used for the measurement.
The above procedure for the cleanup of hermetic systems
after motor failure through the use of suction line filterdrier will prove satisfactory in most instances provided
the system is monitored and kept clean by repeated drier
changes, if such are needed. The failure to follow these
minimum cleanup recommendations will result in an
excessive risk of repeat motor failure.
E. Measure the Pressure Drop
After the system has been operating for an hour or so,
measure the pressure drop across the suction line filterdrier.
37
Compressor Replacement and System Service
Oil Sampler
At Least 6 Diameters
Schrader Valve Vertically Downward
Female Schrader Valve Connection
2” (50mm) Minimum
1/2” Liquid Sight Glass
1/2” Shut-off Valve
Figure 23. Mehtod of obtaining oils sample on a hermetic system. After satisfactory oil test, Schrader valve may be
capped and oil sampler retained for next job.
38
Component Replacement - Refrigeration Unit
7. Component Replacement Refrigeration Unit
7.1
•
Attempting to remove components before
removing all refrigerant from the system can cause
a sudden release of refrigerant and oil.
Among other things, this can:
General Information and Safety
Precautions
Refrigeration and air conditioning devices are extremely
complicated by nature. Servicing, repairing, and
troubleshooting these products should be done only by
those with the necessary knowledge, training, and
equipment.
Before replacement of components, a thorough
troubleshooting and diagnosis of the Kenworth Clean
Power™ System must be conducted to identify the
reason for the component failure and the correct remedy.
•
Cause a variety of injuries including burns and
frost bite.
•
Expose service personnel to toxic gas.
WARNING! To avoid serious injury or death, be
sure to remove and recover all refrigerant
before removing components of the
refrigeration circuit.
WARNING! Never service, repair, or
troubleshoot unless you are a professional air
conditioning/refrigeration service person.
Improper servicing can lead to serious injury or
death from fire, electric shock, or explosion.
7.2
Charging Unit Removal
Depending on the degree of service work required, it
may be advantageous to remove the charge unit for
repairs off the vehicle.
WARNING! Failure to properly remove the
compressor and related components can result
in serious injury or death from electrocution, fire
or sudden release of refrigerant and oil.
Removal steps:
1. Disable 120 VAC power according to instructions
under Section 7.1.
2. Remove left side fairings of vehicle if applicable.
Follow these precautions when removing components
from the refrigeration circuit:
•
Be sure refrigerant is recovered using the
appropriate equipment before removing any
of the refrigeration circuit components.
3. Remove charging unit housing top panel.
Disconnect electrical power.
Disable the 120 VAC power source by switching
off the DC to AC power inverter and the 20 Amp.
breaker in the driver’s side tool compartment load
center. Ensure it remains off while working on and
around the compressor. Observe Fig. 49 “120
VAC system” for reference.
20 Amp
Circuit Breaker
Circuit Breaker
Box (GFCI)
Figure 24. Breaker box inside driver side tool box
Figure 25. Top panel removed
39
Component Replacement - Refrigeration Unit
7. Disconnect 120 VAC power cable (e) and 12 VDC
4. Connect a refrigerant recovery station to the
charging ports and recover the refrigerant.
harness (f) connectors.
Be sure refrigerant is recovered using the
appropriate equipment. Webasto recommends that
the system be serviced using a recovery, recycling
and recharging station such as a Robinair® unit or
similar equipment designed for R134a refrigerant
systems.
e
f
Figure 28. 120 VAC and 12 VDC power harnesses
Figure 26. Refrigerant Recovery
Non-Fairing (Frame mount) application:
8. Loosen the two bolts, top and second from the top
on both sides of the charging unit to frame bracket.
5. Disconnect recovery station.
6. Disconnect the 5700 Series One-Shot™ suction line
(c) and liquid line (d) bulkhead connections of
charging unit. Seal open lines and fittings to prevent
the ingress of contaminates.
9. Remove the bottom bolt on both sides of the
charging unit and frame bracket.
c
d
Figure 27. Refrigerant line connections (Quick-Connect)
NOTE: See “Appendices” on page 59 for information
regarding reconnecting of the 5700 Series OneShot™ Brass Couplings.
40
Component Replacement - Refrigeration Unit
6
5
6
6
5
6
Figure 30. Fairing mount structure to frame attachment
14. Remove the fairing structure by removing the four
bolts i and one bolt with lock-nut j on each side.
TRQ= 28 lb-ft
38 Nm
Figure 29. Non-Fairing (Frame mount) application
8
7
Application with Fairing Mount Structure:
10. Loosen the top bolt (g), on both sides of the fairing
mount structure to frame bracket.
11. Remove the remaining two or three bolts (h) on
both sides.
Figure 31. Fairing mount structure removal
12. With assistance of a lifting device, lift the charging
unit up and off the two loosened bolt.
7.2.1
Installation
1. Reassemble and install in reverse order.
13. Place unit on workbench.
2. Service system according to the recommendations
under Section 5.2.8 and Section 5.2.9.
NOTE: See “Appendices” on page 59 for information
regarding reconnecting of the 5700 Series OneShot™ Brass Couplings.
41
Component Replacement - Refrigeration Unit
7.3
Side Panel Removal for Access
1. Remove two hex-nuts holding the refrigerant filter to
side panel.
2. Remove hex-nut holding the run capacitor to side
panel.
3. Remove seven hex-bolts, four along the back panel
(c), two under the side panel (d) and one at the
lower corner of the condenser shroud (e). See Fig.
32.
1
Figure 33. 120 VAC connections
6. Disconnect refrigerant lines from compressor.
7. Disconnect compressor discharge line at condenser.
Protect open lines with plastic caps or wrap to
prevent the ingress of moisture and contaminates.
3
8. Remove the 2 hex-nuts of the bracket securing the
compressor to the back-wall of the enclosure. See
Fig. 34.
2
9. Remove the 3 hex-nuts holding the compressor to
the enclosure base. See Fig. 35.
TRQ= 8.9 lb-ft
12 Nm
Figure 32. Side panel removal
7.4
Compressor Replacement
Replace the compressor only after all other possible
causes for compressor malfunction have been ruled out
according to the troubleshooting procedures under
Section 4 and Section 5.
Before beginning work, read information under Section 6
“Compressor Replacement and System Service”.
1. Disable 120 VAC power according to instructions
under Section 7.1.
Figure 34. Compressor bracket to side panel mounting (2)
2. Recover refrigerant and remove charging unit
according to instructions under Section 7.2.
3. Remove side panel according to instructions under
Section 7.3.
4. Remove protection cap on top of compressor.
5. Disconnect wiring. Refer to Fig. 22, on pg. 33 when
reconnecting wires after compressor replacement.
Figure 35. Compressor to base mounting (3)
42
Component Replacement - Refrigeration Unit
10. Remove compressor.
11. Inspect compressor for possible contamination by
dirt, water, etc. If contaminated, service system
according to the recommendations under Section
6.1 after replacing the compressor.
12. Install new compressor in reverse order of removal.
13. Inspect all sealing surfaces of refrigerant lines and
components for nicks and damage. Replace any
damaged lines, fittings, seals or O-rings.
14. Replace refrigerant filter where required and service
system according to the recommendations under
Section 5.2.8 and Section 5.2.9.
Critical torque values:
Compressor outlet fitting
Condenser inlet fitting
7.5
Figure 37. Fan shroud to base hex-nuts
43 Nm (32 lb-ft)
43 Nm (32 lb-ft)
8. Place on bench for further disassembly and
component replacement.
9. Inspect condenser for possible contamination by dirt,
water, etc. If contaminated, service system
according to the recommendations under Section
6.1 after replacing the condenser.
Condenser Replacement
1. Disable 120 VAC power according to instructions
under Section 7.1.
2. Recover refrigerant and remove charging unit
according to instructions under Section 7.2.
10. Install new condenser in reverse order of removal.
3. Remove side panel according to instructions under
Section 7.3.
11. Inspect all sealing surfaces of refrigerant lines and
components for nicks and damage. Replace any
damaged lines, fittings, seals or O-rings.
4. Disconnect refrigerant lines at condenser inlet/outlet.
Protect open lines with plastic caps or wrap to
prevent the ingress of moisture and contaminates.
12. Replace refrigerant filter where required and service
system according to the recommendations under
Section 5.2.8 and Section 5.2.9.
5. Remove the front lower hex-bolt securing the front
grille to the base. See Fig. 36.
Figure 36. Condenser asssembly
6. Remove the hex-bolts holding the electrical harness
to the fan shroud.
7. Loosen the two hex-nuts securing the fan shroud to
the base and slide condenser / fan assembly forward
and out. See Fig. 37
43
Component Replacement - Refrigeration Unit
7.6
Condenser Fan Replacement
3. Disconnect switch electrical harness at connector.
1. Disable 120 VAC power according to instructions
under Section 7.1.
4. Remove switch.
2. Remove charging unit housing top panel.
5. Install the replacement switch.
3. Remove side panel according to instructions under
Section 7.3.
6. Torque to specification. 9.5 lb-ft (12.8 Nm)
4. Remove left side fairings of vehicle if applicable.
7. Service refrigerant system as necessary in the event
of refrigerant loss and to confirm correct fill.
5. Disconnect the fan electrical connector.
8. Assemble remaining components in reverse order.
6. Remove the four hex-bolts securing the fan to the
condenser shroud. See Fig. 38.
Figure 38. Hex-bolts securing condenser fan to shroud
7. Lift the fan assembly up and out.
8. Reassembly in reverse order of removal.
9. Perform system checks to ensure proper operation.
7.7
Figure 39. Pressure switches
Low or High Pressure Switch
Replacement
7.8
1. Disable 120 VAC power according to instructions
under Section 7.1.
Ambient Temperature Switch
Replacement
1. Remove refrigeration unit cover.
2. Remove refrigeration unit cover.
2. Locate the ambient temperature switch. Refer to
Fig. 40.
NOTE: Refrigerant recovery is not required when
replacing the pressure switches. A schrader valve
under the switch will seat to close port during
removal.
3. Replace as required.
4. Perform system checks to ensure proper operation.
44
Component Replacement - Refrigeration Unit
Figure 40. Ambient temperature switch
7.9
Figure 42. Bypass valve - mounting hex-bolts
6. Dissasemble and replace defective parts.
Refrigerant Bypass Valve
Replacement
7. Inspect all sealing surfaces of refrigerant lines and
components for nicks and damage. Replace any
damaged lines, fittings, seals or O-rings.
1. Disable 120 VAC power according to instructions
under Section 7.1.
2. Remove charging unit housing top panel.
8. Torque lines to specification.
6.0 lb-ft / 72 lb-in (8.1 Nm)
3. Recover refrigerant.
9. Reassemble and install in reverse order.
10. Service system according to the recommendations
under Section 5.2.8 and Section 5.2.9.
4. Disconnect refrigerant lines at valve.
Figure 41. Bypass valve - refrigerant lines
5. Remove four hex-bolts securing the valve assembly
to the rear panel. See Fig. 42.
45
Component Replacement - Large Pallet Assembly
8. Component Replacement - Large
Pallet Assembly
8.1
15. Service system according to the recommendations
under Section 5.2.8 and Section 5.2.9.
Thermal Expansion Valve (TXV)
Replacement
TRQ= 12.5 lb-ft
17 Nm
Figure 44. Parts sequence - thermal expansion valve
8.2
Figure 43. Thermal Expansion Valve
Storage Cooler Control Unit
Replacement
1. Disable 120 VAC power according to instructions
under Section 7.1.
2. Remove charging unit housing top panel.
3. Recover refrigerant.
4. Remove the allen head bolt securing the refrigerant
lines to the TXV.
5. Pull refrigerant lines free. Protect open lines with
plastic caps or wrap to prevent the ingress of
moisture and contaminates.
6. Remove the 2 allen head bolts securing the TXV to
the storage core pipes.
7. Pull the TXV free of the storage core pipes.
8. Inspect TXV and lines for possible contamination by
dirt, water, etc. If contaminated, purge evaporator
using purging equipment designed for R134a
systems before installing the new TXV.
9. Before installing the new TXV and O-rings, inspect
the storage core pipes and refrigerant lines for any
burs. Clean up with fine emory or crocus cloth.
10. Coat storage core pipes and new O-rings with POE
oil and place O-rings on storage core pipes.
11. Install new TXV in reverse order of removal.
12. Torque to specification. 12.5 lb-ft (17 Nm)
13. Coat refrigerant line ends and new O-rings with POE
oil and connect to TXV.
14. Continue reassembly in reverse order of removal
Figure 45. Storage Cooler Control Unit (SCCU)
46
Component Replacement - Large Pallet Assembly
8.3
NOTE: Individual items of the SCCU can be replaced
without removal of the SCCU housing or complete
replacement of the SCCU assembly.
Coolant Circulation Pump
Replacement
CAUTION: UNDER NO CIRCUMSTANCES SHOULD
PURE WATER BE ALLOWED TO ENTER THE
COOLANT CIRCUIT.
To replace defective components of the SCCU:
1. Disable 120 VAC power according to instructions
under Section 7.1.
Allowing water to enter the system will lead to ice
formation in the storage cooler and possibly damaging
internal components. ALWAYS purchase and use a 50/50
premixed glycol based antifreeze where possible. If a
premixed antifreeze is not available, a pure antifreeze
mixed with water at a 50/50 ratio may be used as long as
it is premixed BEFORE filling the system. DO NOT rely on
the coolant circulation system to mix water and
antifreeze.
2. Remove SCCU cover.
3. Locate defective item. A legend of the contents is
provided under the cover.
4. After replacement of the defective item, perform a
complete system check to ensure proper operation.
To replace complete SCCU assembly:
1. Disable 120 VAC power according to instructions
under Section 7.1.
1. Drain the coolant from the system according to...
>>>> NEED TO DEFINE DRAIN PROCEDURE<<<<
2. Disconnect all connectors, cut wire ties and unscrew
P-clips where necessary.
2. Disconnect pump electrical connector.
3. Remove four screws securing SCCU to top of storage
cooler assembly.
3. Using spring clamp pliers, slide hose spring clamps
off of pump barbs.
4. Remove and replace SCCU assembly.
4. Remove two screws securing pump to storage cooler
assembly, pull pump free and twist off hoses.
5. After replacement of the SCCU assembly, perform a
complete system check to ensure proper operation.
5. Install new pump in reverse order of removal.
6. Refill system to proper level with 50/50 antifreeze,
water mixture.
7. Run coolant pump 10 minutes to purge air from
system. Inspect coolant circuit for leaks. Top up
reservoir to correct level as necessary.
TRQ= 3.3 lb-ft / 40 lb-in
4.5 Nm
Figure 46. Storage Cooler Control Unit - complete
Figure 47. Coolant circulation pump mounting
47
Component Replacement - Small Pallet Assembly
9. Component Replacement - Small
Pallet Assembly
9.1
Individual Component Replacement
Air Handler Assembly Removal
Refer to Fig. 48 for a complete break-down of parts and
their relationship with the assembly.
When required, the air handler can be removed for
disassemble on a bench. In most cases, removal is not
necessary for individual component replacement.
Refer to the Torque Values Table starting on page 51 for
fastener and component torque specifications.
Removal
Legend
1. Remove air ducts to free air handler assembly for
access and removal.
1. Cover - Air filter housing and filter
2. Drain the coolant from the system according to...
>>>> NEED TO DEFINE DRAIN PROCEDURE<<<<
2. Foam tape - Recirculated air inlet
3. Using spring clamp pliers, slide hose spring clamps
off of heat exchanger tubes.
4. Sensor - Cabin air temperature (Recirculated)
4. Disconnect cabin air temperature sensor connector,
mode door motor connector and blower motor
connector from control harness.
6. Door - Fresh air / recirculated mode selection
5. Remove the four hex-nuts securing the air handler to
the pallet.
8. Clips (9 total)
3. Housing - upper
5. Motor - Mode door actuator (Fresh/Recirculated)
7. Grommets (2 total)
9. Foam tape - Fresh air inlet
6. Lift air handler up and out while carefully working
hoses off of heat exchanger tubes.
10. Housing - lower
7. Place on bench for further disassembly if required.
12. Support - Wiring harness (2 total)
11. Hex-nut - Air handler to pallet (4 total)
13. Pallet - Small
14. Air filter
15. Cap - Access to heat-exchanger bleeder valve
16. Heat exchanger
17. Fan and motor
18. Foam tape - Conditioned air outlet
19. Scroll cover
20. Adapter harness with diode
21. Seal - Pallet (2 total)
48
Component Replacement - Small Pallet Assembly
1
14
2
15
3
4
5
16
6
17
7
18
8
19
9
10
11
20
12
21
13
Figure 48. Air Handler Assembly - Exploded View
49
Technical Data
10. Technical Data
10.1 General Information
Unless tolerances are shown within the technical data table, a tolerance of ± 10% applies at an ambient temperature
of +20°C (+68°F) and at the rated voltage and conditions.
10.1.1 Technical Data of the Storage Cooler Assembly
Storage Cooler Assembly
Specifications
Thermal Storage (storage A/C)
20,750 Btu (6.08 kWh)
Storage System Design
Maintenance free with patented graphite matrix
(no additional batteries required)
Storage Cooler Assembly Dimensions
L 38.8” x W/D 22.3” x H 13.3” (986 x 566 x 338 mm)
Storage Cooler Assembly Weight (Wet)
200 lb. (90.7 kg) - Target
Table 7. Technical Data - Storage Cooler Assembly
10.1.2 Technical Data of the Air Handler Unit
Air Handler Unit
Specifications
Power Consumption of Fan Motor
225... 320 mA @ 2 Volts
Maximum: 2.5... 3.7 Amps @ 12 Volts
Nominal: 2.8... 3.2 Amps @ 12 Volts
Air Flow at Maximum Setting
140 cfm (237.9m3/h)
Cooling Output
1,000 - 6,000 Btu/hr (0.30 - 1.75 kW)
Air Handler Dimensions
L 20.6” x W/D 14.3” x H 13.1” (522 x 363 x 333 mm)
Air Handler Weight
15 lb. (6.8 kg) - Target
Noise
<63 db (A)
Temperature
Operating environment temperature
Sleeper temperature control range
50... 110°F (10... 43.3°C)
68... 78°F (20... 25.5°C)
Table 8. Technical Data - Air Handler Unit
10.1.3 Technical Data of the Charging Unit
Charging Unit
Specifications
Refrigerant Circuit
- Refrigerant Type
- Refrigerant Charge Capacity
- Refrigerant Oil
- Refrigerant Oil Capacity
R134aUV (with UV leak detection capability)
2.3 lb. (1.04 kg)
POE Oil (Polyol Ester) R134a compatible
12 oz. (354.8 ml.)
Compressor
-Refrigerating Capacity
- Rated Voltage
- Maximum Continuous Current
8,600 BTU/hr (2.52 kW) at 95°F (35°C)
103.5-120 VAC
Not to exceed 8 amps AC.
Condenser Fan
- Rated Voltage
- Maximum Continuous Current
12 VDC
10 amps DC
Charging Unit Dimensions
L 14.1” x W/D 16.9” x H 16.7” (359 x 430 x 425 mm)
Charging Unit Weight
100 lb. (45.4 kg)
Table 9. Technical Data - Charging Unit
50
Technical Data
10.2 Torque Values Table
Torque tolerance +/-1.0 lb-ft. (1.35 Nm)
DESCRIPTION - Refrigerant Connections
TORQUE VALUE
LOW PRESSURE SIDE HOSE TO COMPRESSOR INLET
32 lb-ft
(43.4 Nm)
COMPRESSOR OUTLET HOSE AT COMPRESSOR
32 lb-ft
(43.4 Nm)
COMPRESSOR OUTLET TO CONDENSER INLET
32 lb-ft
(43.4 Nm)
CONDENSER OUTLET
32 lb-ft
(43.4 Nm)
CONDENSER OUTLET HOSE TO FILTER / DRIER INLET
30 lb-ft
(40.6 Nm)
FILTER / DRIER OUTLET TO QUICK CONNECT
30 lb-ft
(40.6 Nm)
HIGH PRESSURE SIDE BYPASS HOSE TO MAGNETIC BYPASS VALVE
FITTING (HIGH PRESSURE SIDE)
6.0 lb-ft / 72 lb-in
(8.1 Nm)
LOW PRESSURE SIDE BYPASS HOSE TO MAGNETIC BYPASS VALVE
(LOW PRESSURE SIDE)
6.0 lb-ft / 72 lb-in
(8.1 Nm)
LOW PRESSURE SIDE BYPASS HOSE (from magnetic valve) TO LOW
PRESSURE SIDE HOSE
32 lb-ft
(43.4 Nm)
HIGH PRESSURE SIDE BYPASS HOSE (from magnetic valve) TO
CONDENSER OUTLET HIGH PRESSURE SIDE HOSE
32 lb-ft
(43.4 Nm)
BULKHEAD NUT - LOW PRESSURE QUICK CONNECT HOSE
THROUGH-WALL FITTING
28 lb-ft
(38 Nm)
LOW PRESSURE QUICK CONNECT HOSE TO THROUGH-WALL
FITTING
32 lb-ft
(43.4 Nm)
LOW PRESSURE SWITCH
9.5 lb-ft / 114 lb-in
(12.8 Nm)
HIGH PRESSURE SWITCH
9.5 lb-ft / 114 lb-in
(12.8 Nm)
DESCRIPTION - Fasteners
WHERE USED
TORQUE VALUE
#8 x 5/8” (HI-LO) SELF-THREADING
SCREWS
AIR HANDLER HOUSING
1.8 lb-ft / 21.6 lb-in
(2.4 Nm)
M4 PAN HEAD SCREWS
AIR HANDLER BLOWER FAN MOTOR
3.0 lb-ft / 36 lb-in
(4.0 Nm)
M5 HEX SOCKET-HEAD SCREWS
STORAGE COOLER CONTROL UNIT (SCCU)
3.3 lb-ft / 40 lb-in
(4.5 Nm)
M6 HEX SOCKET-HEAD SCREWS
COOLANT RESERVOIR AND COOLANT CIRCULATING
PUMP
3.7 lb-ft / 44.4 lb-in
(5.0 Nm)
M6 METRIC HEX-HEAD BOLTS
CONDENSER FAN SCREWS
3.7 lb-ft / 44.4 lb-in
(5.0 Nm)
M6 HEX SOCKET CAP SCREWS
THERMAL EXPANSION VALVE (TXV)
12.5 lb-ft / 150 lb-in
(17 Nm)
M6 METRIC HEX-HEAD BOLTS
GENERAL USE FOR SHEET METAL PANELS AND FIXTURES
8.9 lb-ft / 107 lb-in
(12 Nm)
Continued on next page
51
Technical Data
DESCRIPTION - Fasteners
WHERE USED
TORQUE VALUE
M6 METRIC HEX NUTS
GENERAL USE FOR SHEET METAL PANELS AND FIXTURES
8.9 lb-ft / 107 lb-in
(12 Nm)
M8 METRIC HEX NUTS
COMPRESSOR AND CONDENSER TO FLOOR MOUNTING 15 lb-ft
(20.3 Nm)
M10 METRIC HEX-HEAD BOLTS
COLD STORAGE CORE TO PALLET AND LARGE PALLET
TO SMALL PALLET CONNECTION BOLTS
40.5 lb-ft
(54.9 Nm)
M10 METRIC HEX NUTS
AIR HANDLER TO PALLET STUDS
40.5 lb-ft
(54.9 Nm)
M10 METRIC HEX-HEAD BOLTS
FAIRING MOUNT STRUCTURE
28 lb-ft
(37.9 Nm)
M10 NYLON INSERT HEX NUTS
FAIRING MOUNT STRUCTURE
28 lb-ft
(37.9 Nm)
Torque values subject to revision. Torque tolerance +/-1.0 lb-ft. (1.35 Nm)
52
Circuit Diagrams
11. Circuit Diagrams
11.1 Legend
Position
Name
Function
CP1
Control Panel
PACCAR / Kenworth
C
Run Capacitor
Compressor Start Assist, Improve Power Factor
PTCR
Positive Temperature Coefficient
Resistor
Compressor Start Assist
F1
Fuse 20A
2 Pole, 120 VAC - Compressor Motor
F2
Fuse 5A
Magnetic Bypass Valve, Compressor Control
F3
Fuse 20A
Condenser Fan
F5
Fuse 5A
Coolant Pump
F6
Fuse 5A
Blower Fan
F7
Fuse 2A
Fresh Air / Recirculation Mode Door Motor
K1
Relay
Condenser Fan Control
K2
Relay
Compressor Control
K3
Relay
Time Delay
K6
Relay
Quiescent Current
K7
Relay
Quiescent Current
K8
120 VAC Relay
120 VAC Monitor
K9
Relay
Voltage Regulator
K10
Relay
Shore Power
MV
Bypass Valve — R134a
Solenoid Valve Closed
M2
Motor
Condenser Fan
M3
Motor — Speed Controlled
Evaporator Blower
M4
Motor
Circulating Pump
M5
Motor
Recirc / Fresh Air Mode Door Actuator
S1
Switch
Charge Enable / Disable Dash Switch
S2
Switch
Low Refrigerant Pressure Cutout
S3
Switch
0... 10V analog — Control
S4
Thermostat
Storage Cooler Core Temperature
S5
Switch
Recirc / Fresh Air Mode Door Control
S6
Thermostat
Temperature Limiter — External Ambient
S7
Switch
High Refrigerant Pressure Cutout
TC1
Thermostat Module
Temperature Regulation
TS3
Thermostat
Temperature Sensor — Sleeper Compartment
X1
12 VDC 8-Pin Connector
Charging Unit Connection
X2
120 VAC 3-Pin Receptacle
Charging Unit Connection
X3
Compressor Casing Ground
120 VAC Ground
53
Circuit Diagrams
11.1.1 Control Schematic Part A (Continued on Next Page)
30
PNIA–9
G/12
PNIA–10
H/12
DB_SW1
Shore Power 120 VAC
S1
F2
F3
DB_SW2
Power Inverter
DC
F/12
AC
C/8
SUTS1
CUTS1
30
S4
K1
S6
SUTS2
30
CUPS1_1
K8
F1
87
CUTS2
87
S7
87a
87a
Charging Unit
110V
60 Hz
CUPS1_2
CUPS2_1
S2
1 3
K8
2 4
K2
5
CUPS2_2
1
A/8
CS_K1_K3
2
E/12
Shore Power
M/12
Black
White
1
3
3
K9
Voltage Reg.
K10
2 5
4
30
15
4
5
86
K3
Black
White
D/12
Charging Unit
C
2
L/12
87a
PTCR
1
87
31
K1
85
A/12
CUSV1
D/8
Red
R
S
C
X2
Compressor
Charging Unit
31
CLAMP 31
MV
E/8
CUSV2
NNIA–8
NNIA–7
K/12
J/12
C/12
F/8
B/12
G/8
CUCF2 CUCF1
M
M2
54
Circuit Diagrams
11.1.2 Control Schematic Part B (Continued on Previous Page)
30
F7
F6
CPFPOT1
5
K7
F5
3
E/16
CPSOURCE
M/16
CP1
FRESHAIR
RECIRC
CPTPOT_HEAT
CPTPOT_HEAT2
CP_HEAT
S5
Air Top
2000 ST
CP_HEAT2
CP_AC Switch
S3
3
5/6
K7 1
1
2
2
B/3
S1
31
S2
OUT
1
M
M
55
AHTS1
AHTS2
31
A/2
M3
B/2
P2
2
C/3
6/6
A/2
G/16
K6
MPI2
M
M5
N/16
H/16
PUMP1
MPI1
J/16
TC1 P1
L/16
A/3
K/16
PUMP2
C/16
B/16
CPTPOT_AC
5
K6
A/16
CPLED
CPFPO2
CPON
CPSGND
CPDOOR2
CPDOOR1
Shore Power
CPTPOT_AC2
TS3
M4
D/16 B/2
F/16
18GA GRAY
Charge State Control Signal Forward C
Condenser Fan (+) G
12GA YELLOW
2
1
F
Condenser Fan (-)
M2
18GA GRAY
18GA GRAY
Not Used H
Not Used B
12GA WHITE
18GA GRAY
Charge State Control Signal Return A
By-Pass Valve (-)
18GA WHITE
18GA YELLOW
E
By-Pass Valve (+) D
X1
S2
2 1
MV
1 2
WIRING HARNESS FOR PPC CHARGE UNIT - 12 VOLT CIRCUITS
2
1
18GA GRAY
18GA GRAY
S7
56
IDENTIFICATION NUMBER: PPC301026_
CIRCUIT LEGEND
M2
Condenser Fan
MV
By-pass Valve
S2
Low Pressure Switch
S6
Ambient Temperature Limiter
S7
High Pressure Switch
X1
8-Pin Connector
1 2
S6
Circuit Diagrams
11.1.3 Charging Unit Wiring Harness - 12 VDC
14GA GREEN
14GA WHITE
14GA BLACK
57
GREEN (GROUND)
IDENTIFICATION NUMBER: PPC301093_
CIRCUIT LEGEND
C
To compressor Overload Limiter (Common)
R
To compressor “R” post
S
To compressor “S” post
C
Run Capacitor
PTCR PTCR (Starting Assist)
X2
3-Pin Receptacle (120 VAC)
X3
Compressor Casing Ground
CONNECTOR
FRONT VIEW
BLACK (HOT)
WHITE (NEUTRAL)
X1 - 120 VAC RECEPTACLE
LOCKING TAB
X2
C
14GA BLUE
14GA BLUE
14GA GREEN
14GA RED
14GA WHITE
14GA BLACK
WIRING HARNESS FOR PPC CHARGE UNIT - 120 VAC CIRCUIT
PTCR
X3
S
R
C
Circuit Diagrams
11.1.4 Charging Unit Wiring Harness - 120 VAC
14GA WHITE
14GA RED
14GA WHITE
Circuit Diagrams
11.1.5 120 Volt AC Connections and System
120 VAC feed to charging
unit compressor
Figure 49. 120 VAC system
58
Appendices
12. Appendices
12.1 5700 Series One-Shot™ Brass
Couplings
12.1.1 Reconnecting Instructions
6. Lubricate male half diaphragm and synthetic rubber
seal with system-compatible refrigerant oil. Thread
coupling halves together by hand to ensure proper
mating of threads. Use proper size wrenches (on
coupling body hex and on union nut) and tighten
until coupling bodies seat or a definite resistance is
felt.
NOTE: The O-ring is only an intermediate seal during
the initial connection of a pre-charged unit/line set
combination. The O-ring is only used for sealing
between the time the diaphragm is pierced and the
final metal-to-metal seal is made.
The final leak-proof seal is a metal-to-metal connection
made between the male and female coupling bodies.
7. Using a marker, make a line lengthwise from the
coupling union nut to the bulkhead or bracket. Then
tighten an additional 1/4 turn; the misalignment of
the line will show the amount the coupling has been
tightened. The final 1/4 turn is necessary to ensure
the formation of a leak-proof joint.
1. Upon disconnection, remove O-ring and discard.
2. If O-ring is missing from groove, ensure O-ring is not
lodged inside coupling halves and reconnect without
O-ring.
3. Route the suction and or liquid lines in their original
manner.
If a torque wrench is used, the following torque values
are recommended:
4. Remove any protector caps and plugs.
5. Carefully wipe coupling seats and threaded surfaces
with a clean cloth to prevent the inclusion of dirt or
any foreign material into the system.
59
Coupling Size
Lb/Ft (N m)
-6
10-12 (13.5-16.3)
-10
35-45
(47.5-61)
-11
35-45
(47.5-61)
-12
55-65
(74.5-88)
Org. 07/2009
Rev. 1.0
KCP_Service
© 2009 Webasto Product N.A., Inc.
Webasto Product N.A., Inc.
15083 North Road
Fenton, MI 48430
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