Carrier G Series Heating Service Manual

T-310 Rev-ACarrierTransicoldTransportAir ConditioningOperation&Service68G5-102 SERIESMCI G MODEL COACH

1-2T -3101.2 GENERAL DESCRIPTION1.2.1 Condenser AssemblyThe condenser assembly (See Figure 1-2) i ncludes acondenser coil, fan and motor assemblies, f

1-3T -310ROADSIDE VIEWTOP VIEWDRIVE END VIEWPUMP END VIEW1. Suction Pressure Port2 Bracket, Belt Guard3. Weatherpack Clutch Coil Connector4. Discharge

1-4T -3101.2.3 Evaporator AssembliesThe evaporator assemblies include the driver zoneevaporator assembly (See Figure 1-4), the passengerzone evaporato

1-5T -310two fan/motorassemblies with motor speedcontrollers,anairfilter, afreshair damper, andtwo condensate drainconnections. The evaporator motors

1-6T -3101.3 System Operating Controls AndComponentsThere are five controls on the driver’s station whichaffect the operation of the Carrier supplied

1-7T -3101. Display2. DOWN Button - decrease selection3. UP Button - increase selection4. TEMPERATURE (Inside/Outside) Button5. ON/OFF Button15432Figu

1-8T -310Model/SerialNumbera. RelaysK1 Energizes evaporator fansK2 Energizes evaporator fans in low speed(not energized in low speed).K 7 Energizes co

1-9T -310J1 Logic board power inJ2 Micromate Display interface.J3 Manual control inputs.J4 Interlock Inputs (WTS, etc.)J5 Relay board interface.J6 Sen

1-10T -3101. Power Stud (Ground)2. Main Power Stud (Positive)3. Control Panel Main Harness4. 35 Pin Connector Plug5. Evap. Motor Overload Connector6.

1-11T -3101.4 REFRIG ERATION SYSTEM COMPONENTSPECIFICATI ONSe. Refrigerant ChargeR-134a: 27 lb (12 kg)f. CompressorModel: 05GNo. of Cylinder: 6Weight

SERVICE MANUALOPERATION ANDModel 68G5-102 SeriesforMCI G Model CoachBUSAIR CONDITIONINGEQUI PM ENTCarrier Transicold. A member of the United Technolog

1-12T -3101.7 SAFET Y DEVICESSystem components are protected from damage causedby unsafe operating conditions with safety devices.Safety devices insta

1-13T -3101.8 HEATING (ENGINE COOLANT) FLOW CYCLEHeating circuit components furnished by CarrierTransicold include heater cores for the driver and mai

1-14T -310From the filter-drier, the liquid refrigerant then flowsthrough the main liquid solenoid valve to the passengerevaporator thermal expansion

2-1T--310SECTION 2OPERAT ION2.1 STARTING, STOPPING AND OPERATINGINSTRUCTIONS2.1.1 Power to Logic BoardBefore starting, electrical power must be availa

2-2T--3101 Two sliding switches are provided to control thedriver’s evaporator. The Defrost switch(Refer toFigure 1-6, item 2) controls evaporator blo

2-3T--310AUTOCOOLHIGH SPEEDLOADEDHEATAUTO2°F3°F1°F-- 2 °F-- 4 °F-- 3 °F-- 1 °F2°F3°F1°F-- 2 °F-- 3 °F-- 1 °FHEAT(LESS THAN 45 DEGF AMBIENT)SETPOINTHEA

2-4T--3102.3.4 Boost PumpWhen the unit is in the heat mode, the boost pump relayis energized, providing 24 VDC to activate the boostpump(supplied by t

2-5T--3102.3.9 Compressor Clutch ControlA belt driven electric clutch is employed to transmitengine power to the air conditioning compressor.De-energi

3-1 T -310SECTION 3TROUBLESHOOTINGCAUTIONDonotunderanycircumstancesattempttoservicethemicroprocessor. Shouldaproblemdevelopwiththe microprocessor , re

3-2T--310The Micromate (Figure 1-8) will allow t he user tointerface with the microprocessor based control fromthe driver’s control panel. The Microma

Safety - 1 T-310SAFETY SUMMARYGENERAL SAFETY NOTICESThe following general safety notices supplement the specific warnings and cautions appearing elsew

3-3 T -310Table 3-2. Alarm Codes -- ContinuedALARMNOTITLE CAUSE REMEDY CONTROLLERRESPONSEA22 Breaker Trip Alarm A breaker on the relayboard has trippe

3-4T--310Table 3-3. Controller Test ListTESTOUTPUT STATET00 All Relays Of fT01 Evaporator High OnT02 Evaporator Low OnT03 Condenser High OnT04 Condens

3-5 T -310Table 3-4. Parameter Codes -- ContinuedCODECODE NAME DESCRIPTIONP15 Reheat Valve Delay This is the minimum time (in seconds) that the reheat

3-6T--3103.4 TROUBLESHOOTINGGeneral procedures for system troubleshooting are provided in Table 3-5Table 3-5. General System Troubleshooting Procedure

3-7 T -310Table 3-5 General System Troubleshooting Procedures -- ContinuedINDICATION/TROUBLEPOSSIBLE CAUSESREFERENCESECTION3.4.4 Abnormal Noise Or Vib

4-1 T -310SECTION 4SERVICEWARNINGBE SURE TO OBSER VE WARNINGS LISTED IN THE SAFETY SUMMARY IN THE FRONT OFTHIS MANUAL BEFORE PERFORMING MAINTENANCE ON

4-2T -310GaugeConnectionValve CapValveStemTo Discharge orfrom Suction LinePort toCompressorService V alveFrontseated(clockwise)Service V alveBackseate

4-3 T -310g. Evacuate and dehydrate the low side. (Refer toparagraph 4.6.)h. Reconnect the suction pressure transducer(SPT).4.4.2 Removing the Refrige

4-4T -310NOTEIt must be emphasized that only the correctrefrigerant drum should be connected topressurize the system. Any other gas or vaporwill conta

4-5 T -310COMPRESSORFILTER DRIERTXVTXVBULBTXVBULBTXVRECEIVERFUSIBLEPLUGDISCHARGECHECK VALVECONDENSER MODULEPARCELEVAP.MODULEPASSENGER EVAP. MODULEDRIV

Safety - 2T -310SPECIFIC W ARNINGS AND CAUTIONSCAUTIONDo not under any circumstances attempt to service the microprocessor. Should a problem de-velop

4-6T -3104.7 ADDING REFRIGERANT TO SYSTEM4.7.1 Checking Refrigerant ChargeThe following conditions must be met to accuratelycheck the refrigerant char

4-7 T -3104.9 CHECKING AND REPLACING HIGHPRESSURE CUTOUT SWITCH4.9.1 Checking High Pressure SwitchWARNINGDO NOT USE A NITROGEN CYLINDERWITHOUT A PRESS

4-8T -3104.1 1.1 Replacing the Power Head/Bulb Assembly(See Figure 4 -6.)In the event that the power head and/or the bulb andcapillary tube loses its

4-9 T -3101. Suction Line (end view)2. TXV Bulb Clamp3. Nut and Bolt (clamp)4. Thermocouple5. TXV Bulb (Shown in thefour o’clock position)12345Figure

4-10T -310NOTES1. The service replacement 05G compressorsare sold without shutoff valves. Valve padsare installed in their place. The optionalunloader

4-11 T -310a. One compressor oil pump that may be purchased is aRobinair part no. 14388. This oil pump adapts to oneU.S. gallon (3.785 liters) metal r

4-12T -310Table 4-2. Suction and Discharge PressureT ransducer (SPT and DPT) VoltagePsig Voltage Psig Voltage Psig Voltage20” 0. 369 105 1.495 220 2.6

4-13 T-310d. Disconnect refrigerant lines at the refrigerant liquidinlet connection, the suction outlet connection, andthe liquid line driver’s connec

4-14T -310NOTEThe lower motor will need to be removed i f theupper motor needs to be serviced.e. Re-install by performing t he above procedure inrever

4-15 T-310Table 4-3. Logic Board ConfigurationConfigurationDescriptionA. High Reheat -- When this configuration is removed, the unit will default to h

iT -310 Rev-TABLE OF CONTENTSSection Page...SAFETY SUMMARY i...

4-16T -310Table 4-4. Torque Ratings - ORS ConnectionsORS SizeThread Torque-- 4 9/16”--18 85--110 IN/LBS-- 6 11/16”--16 125--160 IN/LBS-- 8 13/16”--16

T -3105-1SECTION 5ELECTRICAL SCHEMATIC DIAGRAMS5.1 INTRODUCTIONThis section contains Electrical Schematic Diagrams covering the Models listed in Table

52T -3105-2CONNECTOR LEGENDLED ASSEMBLYTEMPERATURE SWITCHMULTI--PLEX MODULERIBBON CABLEPOLY SWITCHMANUAL S WITCHPRESSURE SWITCHMANUAL RESET BREAKERREL

T -3105-3SeeFigure5-1forLegendandSymbols.Figure 5-2. Wiring Schematic - Power Circuit

54T -3105-4J6SPT(--)(+)(--)DPT(+)ATSRASF2023244J1222119786521K223COND FAN LOW RELAYCOND FAN HIGH RELAY54K24K23EVAP F AN HIGH RELAYEVAP F AN LOW RELAYB

T -3105-5JA-14 RELAY BOARD - SEEJ3-2 LOGIC BOARDJ3-6 LOGIC BOARDJ1-1 LOGIC BOARDSEESEE Figure 5-3SeeFigure5-1forLegendandSymbols.Figure 5-2DRIVERS EVA

56T -3105-6SeeFigure5-1forLegend and Symbols.Figure 5-5. Wiring Schematic Diagram

INDEXIndex-1 T-310AAir Conditioning Refrigerant Cycle, 1-13Air Filter , 4-12, 4-14Alarm, 2-5, 3-1Alarm Clear , 3-1Alarm Codes, 3-1Alarm Queue, 3-1Ambi

INDEXIndex-2T-310PPassengerEvaporator Assembly, 1-5Pre--Trip Inspection, 2-2Pressure T ransducer, 4-12RRefrigerant Charge, 1-11, 4-6Refrigerant Charge

iiT -310 Rev-TABLE OF CONTENTS -- ContinuedSection Page...3.2.4 Alarm Cle

iiiT -310 Rev-TABLE OF CONTENTS -- ContinuedSection Page...4.12.2 Compres

ivT -310 Rev-LIST OF ILLUSTRATIONS -- ContinuedFigure Page......Figure 4-5.

1-1T -310SECTION 1DESCRIPTION1.1 INTRODUCTIONThis manual contains Operating and ServiceInstructions and Electrical Data for the Model68G5-102 Coach Ai