Carrier CAPRI-280 Operation And Service Manual
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Carrier CAPRI-280 Operation And Service Manual

Carrier CAPRI-280 Operation And Service Manual

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Bus Air
Conditioning
Equipment
Model
CAPRI-280
Septa
T-283

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Summary of Contents for Carrier CAPRI-280

  • Page 1 Bus Air Conditioning Equipment Model CAPRI-280 Septa T-283...

  • Page 2: Service Manual

    OPERATION AND SERVICE MANUAL AIR CONDITIONING UNIT Model CAPRI-280 Septa Carrier Transicold Division, Carrier Corporation, P .O. Box 4805, Syracuse, N.Y. 13221 Carrier Corporation 1997 D Printed in U. S. A. 1097...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section Page SAFETY SUMMARY ............DESCRIPTION .
  • Page 4 2.4.6 Temperature Key ..........2.4.7 Diagnostic Mode .
  • Page 5 ELECTRICAL ............. Introduction .

  • Page 6: Safety Summary

    SAFETY SUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First Aid, Operating Precautions and Maintenance Precautions.

  • Page 7: Description

    Electrical Data for the Model Capri 280 Air components furnished by the bus manufacturer to Conditioning and Heating equipment furnished by complete the system. Carrier Transicold Division. The Capri 280 consists of a condenser, evaporator and Figure 1-1. A/C Component Identification Compressor...

  • Page 8: General Description

    1.2 General description The receiver collects and stores liquid refrigerant. The receiver is fitted with upper and lower liquid level sight 1.2.1 Condenser Unit glasses to enable determining refrigerant liquid level in the receiver. The receiver is also fitted with a fusible plug The condenser unit includes condenser coils, fan and which protects the system from unsafe high refrigerant motor assemblies, filter-drier, receiver, liquid line...

  • Page 9: Evaporator Unit

    1.2.2 Evaporator Unit coils provide a heat transfer surface for transferring heat from engine coolant water circulating inside the tubes to The evaporator unit includes roadside and curbside air circulating over the outside surface of the tubes, thus evaporator coils. providing heating when required.

  • Page 10: Refrigeration System Component Specifications

    Replacement Compressor: 5.5 pints (2.6 liters) by unsafe operating conditions with safety devices. Safety Oil Level: devices with Carrier Transicold supplied equipment Level in sight glass between Min.---Max marks on include high pressure switch (HPS), low pressure switch compressor crankcase (curbside) (LPS), circuit breakers and fuses.

  • Page 11: Air Conditioning Refrigerant Cycle

    system using R-134a as a refrigerant. The main b. Pressure Switches components of the system are the reciprocating compressor, air-cooled condenser coils, receiver, High Pressure Switch (HPS) filter-drier, thermostatic expansion valves, liquid line During the A/C mode, HVAC system operation will solenoid valve and evaporator coils.

  • Page 12: Heater Flow Cycle

    1.8 HEATER FLOW CYCLE reheat cycles to maintain required temperatures inside the bus. Engine coolant (glycol solution) is circulated Heating circuit components furnished by Carrier through the heating circuit by the engine and auxiliary Transicold include heater cores and evaporator heat water pumps.

  • Page 13: Relay Board

    1.9 Relay Board -- Electronically Commutated DC Motors with 2-speed Input Signal CF2 CF1 EF2 EF1 EF HIGH HIGH SIGNAL EF3 EF4 SIGNAL CF2 CF2 EF6 EF5 CF6 CF5 K24 K22 K21 K23 Figure 1-5 Relay Board a. Relays c. Connectors Energizes evaporator fans 1 &...

  • Page 14: Logic Board

    1.10 Logic Board Figure 1-6 Logic Board J1 Logic board power in. J7 Diagnostics interface (RS232, DB9). J2 Display interface. D2 Blinks once per second in normal operation. J3 Manual control inputs. On steady to indicate alarms detected. J4 Interlock Inputs D3 Off In normal operation, blinks out alarm (WTS, low side pressure switch etc.) codes (2 digits each) when alarms detected.

  • Page 15: Control Panel (Diagnostic Module)

    1.11 Control Panel (Diagnostic Module) Figure 1-7. Diagnostic Module Display Heating Down --- decrease selection Fan Speed Selection Up --- increase selection Not used Ventilation 10. Temperature Inside / Outside Auto Control Selection 11. Turn On / Turn Off Air Conditioning T-283...

  • Page 16: Operation

    SECTION 2 OPERATION 2.1 STARTING, STOPPING AND OPERATING information. Refer to section 3 for definition of INSTRUCTIONS system errors and alarms and general troubleshooting procedures. 2.1.1 HVAC Power to Controller Before starting the system, electrical power must be 2.1.4 Stopping available from the bus power supply.

  • Page 17: Auto Reheat Mode

    Cool High Speed Loaded Cool High Speed 4 Cylinders Cool High Speed 2 Cylinders Reheat High Speed 2 Cylinders Heat Low Speed Heat High Speed Figure 2-1. Auto Reheat Mode T-283...

  • Page 18: Boost Pump

    2.3.1.2 Cooling/Reheat second compressor cylinder bank (two cylinders); this output will remain energized until the Cooling and reheat require various combinations of pressure increases to above 31 psig. compressor unloading. Cooling is accomplished by energizing the compressor and condenser fans, Discharge Pressure opening the liquid solenoid valve and closing the Head Pressure is also controlled by the unloaders:...

  • Page 19: Hour Meters

    Carrier Service or Engineering is contacted before any control 2.4.7 Diagnostic Mode configuration is changed. Carrier can not be Diagnostic mode can be entered by pressing the up responsible for changes made by the and down arrow keys simultaneously for 5 seconds.

  • Page 20: System Parameters

    2.4.8 SYSTEM PARAMETERS again indicate the setpoint setting. The parameters are shown in Table 2-2. When scrolling through the Pressing the up/down arrow keys will allow the user to parameters, the current parameter parameter will be scroll up or down through the parameters. If no key is displayed for two seconds.
  • Page 21 Table 2-2. Parameter Codes --- Continued Code Code Name Description Unloader/Heat Valve This is the minimum time (in seconds) that the unloaders and heat valve must Delay be in a particular state (open /closed) before changing to another state. This value can be modified between 1 and 60 seconds.

  • Page 22: Troubleshooting

    SECTION 3 TROUBLESHOOTING CAUTION DO NOT UNDER ANY CIRCUMSTANCES ATTEMPT TO SERVICE THE MICROPRO- CESSOR. SHOULD A PROBLEM DEVELOP WITH THE MICROPROCESSOR, REPLACE IT. 3.1 SELF DIAGNOSTICS with the code ER-X (X is the error number). The error codes can also be read by counting the number of times Self tests are executed on power up during operation.
  • Page 23 Table 3-2. Alarm Codes ALARM TITLE CAUSE REMEDY CONTROLLER RESPONSE Coil Freeze Coil temperature is less Check causes of coil An alarm will be generated than 32F and the com- freezing. (Refer to sec- and the system will shut- pressor is operating. tion 3.5.6) down.
  • Page 24 Table 3-2. Alarm Codes (Continued) ALARM TITLE CAUSE REMEDY CONTROLLER RESPONSE Motor Failure A motor has not reached Replace motor, or cor- Alarm displayed and the full operating speed or rect pressure shutdown. motor fail output is ener- the condenser motors gized.

  • Page 25: Electrical

    Table 3-3. General System Troubleshooting Procedures INDICATION/ REFERENCE POSSIBLE CAUSES TROUBLE SECTION SYSTEM WILL NOT COOL Compressor will not run Active system alarm V-Belt loose or defective Check Clutch coil defective Check/Replace Clutch malfunction Check/Replace Compressor malfunction See Note Electrical malfunction Coach power source defective Check/Repair Circuit Breaker/safety device open...
  • Page 26 Table 3-3. General System Troubleshooting Procedures - Continued INDICATION/ REFERENCE POSSIBLE CAUSES TROUBLE SECTION ABNORMAL NOISE OR VIBRATIONS --- Continued Condenser or evaporator fans Loose mounting hardware Check/Tighten Defective bearings Replace Blade interference Check Blade missing or broken Check/Replace CONTROL SYSTEM MALFUNCTION Will not control Sensor or transducer defective 4.14 or 4.15...

  • Page 27: Service

    SECTION 4 SERVICE WARNING BE SURE TO OBSERVE WARNINGS LISTED IN THE SAFETY SUMMARY IN THE FRONT OF THIS MANUAL BEFORE PERFORMING MAINTE- NANCE ON THE HVAC SYSTEM 4.1 MAINTENANCE SCHEDULE SYSTEM REFERENCE REFERENCE OPERATION OPERATION SECTION a. Daily Maintenance Pre-trip Inspection --- after starting Check tension and condition of V-belt None...

  • Page 28: Installing Manifold Gauges

    INSTALLING MANIFOLD GAUGES Open suction service valve counterclockwise approximately 1/4 to 1/2 turns. The manifold gauge set can be used to determine system operating pressures, add charge, equalize or evacuate the PUMPING THE SYSTEM DOWN OR system. (See figure 4-2.) REMOVING THE REFRIGERANT CHARGE NOTE Low Pressure...

  • Page 29: Evacuation And Dehydration

    c. Procedure for Evacuation and NOTE Dehydrating System It must be emphasized that only the correct 1. Remove refrigerant using a refrigerant recovery refrigerant drum should be connected to pressurize the system. Any other gas or system. vapor will contaminate the system, which 2.

  • Page 30: Adding Partial Charge

    CHECKING AND REPLACING HIGH Note weight of refrigerant and cylinder. PRESSURE CUTOUT SWITCH d. Open liquid valve on refrigerant container. Midseat 4.9.1 Checking High Pressure Switch filter-drier inlet valve and allow refrigerant to flow into the unit. Correct charge will be found in section WARNING 1.3.

  • Page 31: Filter-Drier

    4.10 FILTER-DRIER 12. Run the coach for approximately 30 minutes on fast idle. a. To Check Filter Drier 13. Check refrigerant level. (Refer to section 4.7.1.) Check for a restricted or plugged filter-drier by feeling 14. Check superheat. (Refer to section 4.11.b.) the liquid line inlet and outlet connections of the filter-drier.

  • Page 32: Model 05G Compressor Maintenance

    3. Loosen one TXV bulb clamp and make sure area 4. Reinstall power head and cage assemblies using new under clamp is clean. gaskets. 5. Tighten capscrews. 4. Place temperature thermocouple in contact with the suction tube and parallel to the TXV bulb, and then 6.

  • Page 33: Compressor Oil Level

    4. Check oil level in service replacement compressor. (Refer to section 1.3 and 4.12.2.) GASKET SPRING COMPRESSOR HEAD BYPASS FLANGE capscrews PISTON COVER (NOT INTERCHANGEABLE PLUG WITH CONTROL VALVE SCREWS) 1. Electric Unloader 6. Bottom Plate Figure 4-6. Removing Bypass Piston Plug 7.

  • Page 34: Adding Oil To Service Replacement Compressor

    2. When the compressor is in operation, the pump NOTE check valve prevents the loss of refrigerant while If oil drain plug is not accessible, it will be allowing servicemen to develop sufficient pressure to necessary to extract oil through the oil fill plug overcome the operating suction pressure to add oil, with a siphon tube.

  • Page 35: Replacing Sensors And Transducers

    When a controller is replaced it must be configured to work in the model of unit it is being installed in. Table 4-3 shows the configuration jumper settings that must be set to correctly operate the Capri-280 SEPTA unit. T-283...
  • Page 36 Table 4-3. Controller Configuration Configuration Description Jumper High Reheat --- When this configuration is removed the unit will default REMOVED to high speed in reheat mode and in the low speed cool band. If not removed heat reheat will default to low speed. High Vent --- When this configuration is removed the unit will default to REMOVED high speed in vent mode.
  • Page 37 Table 4-4. R-134a Temperature - Pressure Chart BOLD NO. = Inches Mercury Vacuum (cm Hg Vac) Temperature Pressure Temperature Pressure Psig Kg/cm@ Psig Kg/cm@ 14.6 49.4 37.08 0.49 ---40 ---40 ---1 26.1 180.0 1.84 1.80 ---35 ---37 12.3 41.6 31.25 0.42 27.8 191.7...
  • Page 38 SECTION 5 ELECTRICAL Figure 5-1 INTRODUCTION This section includes electrical wiring schematics. The schematic shown in this section is for R-134a refrigerant systems.

  • Page 39: Electrical Wiring Schematic Diagram

    Figure 5-1. Electrical Wiring Schematic Diagram Drawing No. 62-10112-00 Sheet 1 of 3...
  • Page 40 Figure 5-1. Electrical Wiring Schematic Diagram Drawing No. 62-10112-00 Sheet 2 of 3...
  • Page 41 Figure 5-1. Electrical Wiring Schematic Diagram Drawing No. 62-10112-00 Sheet 3 of 3...
  • Page 42 INDEX compressor, 1-4, 1-5 Compressor Clutch Control, 3 A/D, 3-1 Compressor Oil Level, 4-7 Abnormal Noise or Vibrations, 3-5 Compressor Unloader, 3 Activation, 3-1 Compressor Unloader Control, 3 Adding Full Charge, 4-3 Compressor will not run, 3-4 Adding Oil, 4-7 condensate drain connections, 1-3 Closed system method, 4-8 Condenser, 1-1...
  • Page 43 INDEX heat valve, 1-3 electric solenoid unloaders, 1-4 Heater Flow Cycle, 1-6 Electrical, 5-1 Heating, 3 Electrical Control, 1-1 heating coils, coils, 1-3 Electrical malfunction, 3-4 Heating Line, 1-3 Electrical Specifications, 1-4 Heating Malfunction, 3-5 Electronically Commutated DC Motors, 1-7 Heating system, 3-4 Error Codes, 3-1 High Pressure Cutout Switch , 4-4...
  • Page 44 INDEX Logic Board, 1-3, 1-8 Low discharge pressure, 3-4 receiver, 1-2, 1-5 Low Pressure Shutdown, 3-2 Receiver Tank, 1-2 low pressure switch, 1-4 Receiver Tank Support, 1-2 Low Pressure Switch (LPS), 1-5 Refrigerant Leak Check, 4-2 Low suction pressure, 3-4 Refrigeration Charge, 1-4 Low Voltage, 3-2 Refrigeration Cycle Diagram, 1-6...
  • Page 45 INDEX Troubleshooting, 3-1 Temperature --- Pressure Chart, 4-11 Temperature Sensor Checkout, 4-8 Thermal Circuit Breakers, 1-7 UV1 Relay, 3 thermal expansion valves, TXV, 1-3 UV2 Relay, 3 Thermal Switches, 1-4 Thermostatic Expansion Valve, 1-4 Thermostatic Expansion Valve , 4-5 Transducers, 1-4, 4-10 Weekly Inspection, 4-1 T-283 Index-4...

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