COACHAIR Climate Control System Manual
Contents
1. TT otor akui Boost Pump ESP109 HPLP Cond Motor 1 Vbatt Supply Voltage Cond Motor 2 Main Relay 2 Fresh Air Clutch Voltage Dash Panel Displa Ground Communications Port CCC007 reads the dash panel switches accepts the instructions and makes decisions on what actions to take CCC007 decides what to display on the dash panel Normally the Return Air Probe temperature is displayed CCC007 will also display set point temperature all temperature readings Er codes Evaporator PWM frequencies and probe offsets at appropriate times CCC007 connects to return ambient supply air and two evaporator coil sensors for temperature sensing CCC007 connects to a power board for the operational control and monitoring of various functions e 007 can be connected to an external computer or data logger for communication and data logging 007 receives its power from the attached power board via the 20 way ribbon cable The power board is responsible for delivering a regulated 8V or 12V power supply Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 12 7 Climate Control System Manual CA COACHAIR When CCC007 is powered normally due to application of IGN on power board it performs a self check If the self check shows that the EPROM is damaged it will issue an Er7 to the dash p2. COACHAIR Rooftop Air Conditioner CCCO00 7 MATE CONTROL SYSTEM MANUAL For Bus and Coach A C Systems Document Number 5 423 3283 Issue Date Sep 2006 Uncontrolled Copy Please refer to the Network for the current issue of this manua 7 Climate Control System Manual CA COACHAIR nev ete einen VEN Mar 25 2002 First Release Manual No 55 001 A Sep 19 2006 Update CR 12098 Revise Layout update pictures and review information Section 5 4 Revise Error Message Descriptions Released by S Morley 20 09 06 Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 2 CCCO007 Climate Control System Manual CA COACHAIR NOTICE The information in this manual is subject to change without notice Air International Transit shall not be liable for technical or editorial errors or omissions contained herein No part of this manual may be photocopied or reproduced in any form without prior consent from Air International Transit COACHAIR CUSTOMER SUPPORT I NQUI RIES Australia Malaysia China Telephone 61 2 9830 7132 60 3 61208760 86 519 5125568 Facsimile 61 2 9672 1082 60 3 61208712 86 519 5113086 Address 3 Distillers Place Lot No 9 Jalan Empat No 268 West Hehai Road Huntingwood 2148 Kawasan Perindustrian Australia Selayang Off Jalan Besar Changzhou City iangsu Province P
3. 12 3 2 Temperature 14 3 3 Dash Control ERI ERES 15 3 4 Power Board Assembly ESP109 nn Ennn n nannan 19 3 5 Solid State Relay ERRODUL debe ii chiese 22 3 6 EIPCult BIedKe S asndaaccnaasainctsiamevesatanedacudsataraitbendsaccdaateadsgesenetelasvantccesasuecreals 24 3 7 Spike Protection Capacitor ao 24 SECTION 4 Unit Wiring Diagrams n ka natn nnn 25 4 1 Climate Control System 25 4 2 Solid State 26 SECTION 5 Maintenance and Service 27 DG eT spo PNE m TT 27 5 2 Recommended Spare Parts usce iced me pap utor FERE 27 5 3 Parts fol RR EOD 28 5 4 Dash Panel Error MeSSBU85 ek 30 5 5 EPROM REP SE E OPERE RAE 31 5 0 Trouble SEIN aetna T 34 SECTION 6 CCC007 Service Program 38 6 1 Connection to CCCOOT Emm 38 6 2 PC C mmMUNICAtON EE AEREE AAEE 39 6 3 LOJJET e EA DON 40 Document Number M423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 5 CCCO007 Clim
4. f there is no data in the data logger erased or new logger a message is displayed to indicate this e Erase the logger e When erasing the logger the current date and time are read from the PC s internal clock e The sampling rate may be set Generally a sampling rate of 10 seconds is preferred but the sampling rate can be set to 20 30 or 60 seconds e Save and open the data results for viewing The preferred file name format is XXXXMMDD LOG where is the logger ID number and MMDD is the month and the date logger has been returned For example if data logger number 1004 is returned from the field on 23rd of August then the file name should be 10040823 LOG A HELP facility is also available that lists the keyboard commands used to operate the software features Viewing Data for Analysis When a data logger file has been opened the computer screen displays the following information Data Traces The data readings are displayed on a graph showing Temperature Reading VS Time The display of the data readings can be toggled between individual readings and continuous line graphs The exact values for all readings can be viewed at any chosen time point By default all data traces are shown when a file is opened However they can individually be turned on or off to display only the desired information The temperature axis can be scaled and up and down for easier analysis of the line graphs 7 Information
5. Mid Pressure 2 Input MP2 The MP2 input is 5 V when the pressure switch is open circuited MP2 input could connect to a linear pressure transducer which all Version 2 CCC007 s can recognise This would allow actual system pressure to be read Thus condenser fan RPM could be varied with system pressure modulating from 0 to 100 Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 20 7 Climate Control System Manual CA COACHAIR OUTPUTS Evaporator Motor Trigger Output EV1 and EV2 These are low current outputs designed to power the solid state relay trigger inputs Condenser Motor Trigger Output CM1 and CM2 These are low current outputs designed to power the solid state relays trigger outputs They are protected against shorting to ground or Vbatt Clutch Output The pin 31 is powered via the clutch relay through its 7 5A fuse and via the main relay A reversed biased diode is on the output to quench inductive flyback from the clutch coil Unloader Output The unloaders share their own 7 5A fuse An unloader output must be powered to unload the compressor The controller will always attempt to unload a compressor before engaging the clutch to reduce start torque on the clutch Fresh Air Output The fresh air ram shares the same output plug with the water modulation valve Power is available to the fresh air output as soon as th
6. Notch EPROM Chip CCCO007 as viewed with cover removed 5 5 2 Removal Use a small screwdriver placed between chip and socket or a removal tool to carefully and evenly lever the chip from its socket Take care notto bend or damage the pins and socket case or remove the version label f Evenly lift at Use removal tool both ends if available Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 32 CCCO007 Climate Control System Manual CA COACHAIR 5 5 3 Replacement Note The new chip should be supplied with a printed version label which must not be removed Carefully align all the pins of the new EPROM chip with the socket base making sure that the chip is correctly placed as shown below EPROM Chip Note matching notches Socket Base Carefully line pins up Place the PCB on a flat surface and using light pressure push down on the chip until firmly seated PS Antistatic strap Jf Gently push on gt NA both ends To ground i 5 5 4 Checking Reconnect the Data cable plug to the CCC007 PCB socket Reconnect the probes and cables to the matching CCC007 PCB sockets Reconnect the PWR plug to the ESP109 Power Board Start the bus engine Place the ON OFF toggle switch on the control panel to the ON position turning on the ignition feed to the sys
7. R Bandar Selayang cun 213000 68100 Selangor D E Malaysia WEB www aitransit com Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 3 CCCO007 Climate Control System Manual CA COACHAIR IMPORTANT INFORMATION Beware of Automatic Operation When Working On The A C Unit Coachair s electronic climate controller is programmed with a leak stopper function When the bus engine is started the Coachair unit will start automatically after a three minute delay and run for 90 seconds before stopping Before performing any service procedures make sure that the ignition isolating switch on the unit control panel is set to OFF Handle Electronics With Care Do not attempt to remove repair or handle the climate control panel or any components in any way without referring to the correct procedures The electrical control panel houses sensitive equipment that may be damaged if handled incorrectly Refer to this CCC007 Climate Control System Manual for electronics service details before attempting any diagnosis or repair EPROM Version 2 ONLY The information in this book ONLY applies to CCC007 controllers with EPROM Version 2 or later with ESP1090 Power Board and Solid State Relays on the control panel N Temperature Probes Each temperature probe in the unit is factory calibrated Use Probes as they have been allocated CAU
8. 2 LOGOO7 Software 106007 LOGO007 EXE is a program that is used when a PC is correctly linked to CCC007 as detailed in Section 6 1 Connection to CCC007 The purpose of 06007 is to continually log the operating variables of the climate control system The system variables are shown on the computer screen and are continually updated after every sampling interval A typical sampling interval would be 1 minute When logging is finished the logged variables can be saved as a file for later examination and charting The variables logged include e Time e Set point temperature e Return air temperature Evaporator coil probe temperatures 1 and 2 e Air off temperature Ambient temperature e Heat e Air off required e Bus voltage e Clutch status on or off e Unloader 1 and 2 status on or off The 106007 software will be available on a single 3 1 4 computer disk MS DOS system only 6 3 Data Logger The Coachair CCC007 Data Logger is a self contained microprocessor device which connects to the CCC007 controller for continuous recording of system operating information The purpose of recording this information in the data logger is to aid system analysis and trouble shooting When the system is operating a connected data logger records a continuous log of the following information e All temperature inputs return air evaporator coils ambient and air off e Supply voltage e Percent heat modulation
9. 26 27 140 psi cut in condenser fan speed from high to medium 190 psi cut out condenser fan speed from medium to high The MP2 pressure switch is also a normally closed circuit type switch with the controlling pressures set as follows 100 psi cut in condenser fan speed from medium to low 150 psi cut out condenser fan speed from low to medium 1 2 CONDENSER FAN SPEED The clutch voltage is monitored at the clutch output pin to detect non requested clutch powering Clutch voltage is checked when the system powers up and also 2 seconds after every clutch power removal If the voltage is more than 14 V a latched Er3 will occur and the main relay will disengage This will remove power from the clutch output pin provided the main relay is not faulty or bypassed The system input voltage is monitored to a resolution of 0 1V and an accuracy of 2 V If the voltage falls below 20 V for a 27 V system the clutch and condenser fans are turned off If the voltage falls below 18 V the evaporator fans are turned off If these errors occur more than 5 times this will result in a latched Er5 A powered unloader output will result in an unloaded compressor The unloader outputs always switch on 1 second before the clutch to ensure the compressor is unloaded for starting The unloader outputs normally remain powered when the clutch is off The fresh air output controls a relay which opens and closes an electric fresh air ram Output i
10. Decrease will reduce the fan speed of the evaporator blowers to approximately 6096 of maximum speed Increase will raise the fan speed of the evaporator blowers to maximum 100 AUTO setting will automatically and infinitely adjust the operating speed in relation to actual return air and set point temperatures anywhere in between 60 to 100 It will follow cooling only cooling and heating curves as decided by the microprocessor 8 Thecooling only and cooling and heating curves used by CCC007 to determine the AUTO fan speed are as follows 100 q High Oe 90 KC 096 Per Degree 8096 7096 AIRFLOW 60 Noe eem ne 5096 B 4096 30 Cool amp Heat 20 Cool Only 10 4 0 T SESS id RETURN AIR TEMPERATURE Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 8 7 Climate Control System Manual CA COACHAIR The temperature readout displayed on the dash panel can show either the actual return air temperature or the set point temperature in degrees Celsius C The set point temperature can be adjusted to a warmer or cooler setting by pushing the spring return rocker switch on the right hand side of the dash panel to WARM or COOL Briefly pressing and releasing switch to WARM or COOL will change the display from return air temperature to the current set point Holding
11. EAD1730 The FAN OFF A C and LOW HIGH switches and the WARM COOL temperature rocker potentiometer on the dash panel are the only three external controls to operate the system FAN OFF A C switch positions 3 position FAN Evaporator blowers are on Air conditioning is off Dash temperature display and set point is on OFF Air conditioning system is off Dash temperature display and set point is on A C Air conditioning system is on Dash temperature display and set point is on COACHAIR CLIMATE CONTROLLER c A Ww A Y Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 15 CCCO007 Climate Control System Manual CA COACHAIR LOW AUTO HI GH switch positions 3 position Functional only if FAN OFF A C switch is in FAN or A C positions LOW Evaporator blowers are on low speed 60 AUTO Evaporator blowers are on variable speed 60 to 100 HIGH Evaporator blowers are on high speed 100 COACHAIR CLIMATE CONTROLLER 228 se WARM COOL rocker potentiometer function Functional if ignition is activated WARM Increases the set point temperature in 0 5 C intervals when held COOL Decreases the set point temperature in 0 5 C intervals when held Pressing the switch on either WARM or COOL momentarily will cause the temperature set point for 30 seconds only The display will
12. P I D routine around the set point temperature The water modulation valve will open or close to provide a calculated amount of hot water to the heating coils The amount of heat to be added is calculated continuously with reference to the set point ambient return air and supply air temperatures P I D control responds very rapidly to changes and will keep the return air within 0 2 C of set point 14 The yellow LED on the dash panel and the yellow LED marked WV on the climate controller flash to indicate heating Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 9 7 Climate Control System Manual CA COACHAIR 15 16 17 18 19 20 21 22 The compressor will be unloaded during the cooling and heating mode Heating is determined by the P I D routines and there is no definite cut in or cut out point Operation is primarily determined by experience The boost pump is turned on whenever there is more than 296 water modulation and stays on for another 60 seconds after the last modulation Water Valve To be insulated Return to engine Heating Coil N From engine Each time the compressor clutch is energised the green light on the dash panel and clutch light on the climate controller illuminate When the clutch is de energised the control system will not allow the clu
13. e Air off required e Binary inputs clutch unloaders HP LP fault fresh air flap mid pressure switches e Time and date of sample The data logger also has 6 external temperature probe inputs for recording other system parameters Once the data logger is removed from the bus it can be connected to a personal computer and the logged information can be downloaded The procedures and requirements for connecting the data logger to a personal computer are the same as applies for CCC007 connection described in Section 6 1 Connection to CCC007 Special software is used for downloading to a PC Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 40 CCC007 Climate Control System Manual CA COACHAIR 6 3 1 Data Logger Software The data can be downloaded to the computer via special Data Logger software program Once it is downloaded the information can be analysed The data logger program DL EXE presents the selected information as a continuous graph for easy analysis The data logger software will be available on a single 3 1 4 computer disk MS DOS system only Data Downloading The Data Logger program can be used to e Read and down load the data from the data logger to the PC e When downloading the program reads all the information stored in the data logger When the program finishes downloading the data traces are displayed on the screen
14. the switch on WARM or COOL will increase or decrease the set point in 0 5 C steps When the switch is released the display will show the set point for another 10 seconds and then revert to displaying the return air temperature Note The temperature setting is limited to between 18 C and 27 C 10 11 12 13 CCC007 will operate the system in either cooling only or cooling and heating mode The mode to be used is determined from a relation between the ambient and set point temperatures The system will be cooling only when the ambient temperature is equal to or greater than set point 6 C There is a 2 differential on this cooling only to cool and heat operation change point The position of the fresh air door is determined by the ambient temperature CCC007 will open the fresh air door via the actuator when the ambient temperature is between 18 and 28 C When the temperature is outside the 18 28 range CCC007 will close the door This automatic fresh air door operation works independently and is not affected by the unit operating mode The following chart shows the temperature and capacity control logic for cooling only operation Standard System Temperature Temperature Decreasing Increasing CL UNI OFF UN2 OFF lt ON lt OFF UN2 ON Return Air Temperature SP Set Point When the system operation is cooling and heating the water modulation valve will be activated through a
15. C The display of each probe temperature is a handy field service feature 1 Set the dash mode to A C and hold the Reset button in for 8 seconds 2 The dash will display all 5 probes in sequence until the dash mode switch is returned to OFF The A C system operates normally while this is occurring Return Air c JI HT Li 3 m Ambient REFERENCE Evaporator MENS Nu E Air TEMPERATURES Coils 111 1 Evaporator c 53 Calls CC ord i H ou too Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 18 7 Climate Control System Manual CA COACHAIR 3 3 5 Error Messages See Section 5 4 Dash Panel Error Messages 3 4 Power Board Assembly ESP109 ESP109 is designed to connect to CCC007 and convert signal outputs to higher power outputs and gather inputs to feed back to the CCC007 3 4 1 ESP109 Layout Evaporator Fuse Box Ignition Relay amp Condenser Motors Y i zn Battery iin zz Main Relay Pump Relay
16. LT Clutch Relay Fresh Air amp Compressor Water Valve Harness Pressure Fresh Air amp Transducer Unloader Relays 3 4 2 ESP109 Inputs and Outputs Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 19 CCCO007 Climate Control System Manual CA COACHAIR Inputs Outputs Evaporator Motor Power pe Trigger X2 Condenser Motor HP LP pe gt Trigger X2 gt Clutch CCC007 ESP109 gt Unloader X2 MP1 amp MP2 gt pes s Fresh Air ANC gt pu Water Modulating Valve Ignition gem pu Boost Pump INPUTS Power Input PWR Power Vbatt is connected via a 15A circuit breaker Chassis ground is also connected Ignition Input Ignition input powers a small relay coil via a diode The contact of this relay supplies power from the PWR input to the 12 regulated power supply circuit ESP189 units use a 12V coil relay High Pressure Low Pressure Input HP LP Pin 13 is connected directly to ground Pin 15 will normally read 5 V when nothing is connected and when either switch is open a fault condition When both switches close Pin 15 will read OV Mid Pressure 1 Input MP1 The MP1 input is 5V when the pressure switch is open circuited Grounding this input will cause the condenser motors to modulate when the compressor is on normally via a pressure switch which opens as pressure rises
17. MBER CCC0074 Controller for Brushed Motors 24V CCC0075 Controller for Brushed Motors 12V CCC0077 Controller for Twin Compressors 24V CCC0078 Controller for Brushless Motors 24V Note Sensors are not included with the climate controller and must be purchased separately New sensors must be calibrated when they are installed 5 3 2 ESP109 Power Boards Note Power boards do not come complete with fuses nor automotive type mini relays Fuses and mini relays are purchased separately 5 3 3 Temperature Sensors c RETURN AIR SENSORS LENGTH DE ICE SENSORS PART NUMBER LENGTH mm ESP030 Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 28 CCCO007 Climate Control System Manual CA COACHAIR 5 3 4 Solid State Relays 7 gt ye Ke N N PART NUMBER DESCRI PTI ON ERR060 0 Standard SSR for Brushed Motors 25A 5 3 5 Circuit Breakers PART NUMBER DESCRI PTI ON ERC016 Circuit Breaker 10A Manual Break amp Reset ERC015 Circuit Breaker 15A Manual Break amp Reset 5 3 6 Dash Control Panels COACHAIR CLIMATE CONTROLLER AP Document Number 5 423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 29 CCCO007 Climate Control System
18. Manual CA COACHAIR 5 4 Dash Panel Error Messages The dash panel error messages are displayed when specific faults occur in the A C system The climate control system incorporates self diagnostic functions that can recognise specific faults in the A C system When these faults occur Error Messages are displayed on the driver dash panel to communicate the condition The illustrations on this page show the warning lights of the EAD176 dash panel Other dash panels may use warning lights instead of symbols However the fault LED may always be identified by its red colour Latched HP LP Fault The system has cut the clutch more than 6 times in 30 minutes due to detection of ttt oA high or low refrigerant pressure As a result the system has disabled operation clutch to avoid damage Red fault light flashing Erl message may be removed by resetting the unit Latched De I ce Fault The system has cut the clutch more than 6 times in 30 minutes due to detection of abnormally low evaporator temperatures a Nm n P RN As a result the system has disabled A C operation clutch to avoid damage Red fault light is on Er2 message may be removed by resetting the unit Frozen Clutch Relay A frozen clutch relay is supplying power to the clutch without control of the system Ww A The controller has disabled the main relay to avoid damage Red fault light is flashing There is Er4 message LI 1
19. NS OFF A C switch in the off position 2 Place the ON OFF toggle switch on the control panel to the OFF position This turns off the ignition feed to the system 3 Disconnect the PWR plug from the ESP109 Power Board Note To save confusion before removal identify the various probes and cables by marking them with a colour or tag 4 Disconnect all the probes and cables connected to the CCC007 controller board 5 Disconnect the data cable plug from the CCC007 PCB socket 6 Remove the CCC007 from the control panel by undoing the 4 retaining screws Note The spacers are separate do not loose them 7 Connectan anti static earthing strap to yourself and the bus frame 8 Undo the 4 retaining screws on the reverse side of the PCB under the insulation and remove the protective black plastic cover Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 31 CCCO007 Climate Control System Manual CA COACHAIR 5 5 1 Identification To identify the correct version EPROM chip required the following information is required 9 The type of control panel i e part number and componentry Use ONLY Version 2 26c for a control panel with CCC007 and solid state relays 10 The controller componentry EEPROM chip 93 06 1 is used ONLY with version 2 4 or prior EPROM chips EEPROM chip 93C46B1 is used with ANY version 2 X or prior EPROM chips
20. TI ON DO NOT swap or mix the probes as this may lead to unit damage and faulting 24V DC ONLY This unit is designed for a 24V DC electrical circuit ONLY Do not under any circumstances use another voltage as this may cause unit damage and faulting There is power to the motors all the time Never attempt to do repairs on motors or motor wiring without manually breaking the correct circuit breaker first WARNING N 7 Black Heat Sink zs The black heat sink built onto the ESP109 PCB is at earth potential DO NOT under any circumstances place an earth or a bridge circuit on the heat sink as this will cause serious unit CAUTI ON damage DO NOT use a test light Use a suitable multimeter only DO NOT push the red reset button for more than 2 seconds as this could provide unintentional access to the CCC007 memory settings Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 4 7 Climate Control System Manual CA COACHAIR CONTENTS ONE 1 General er 6 DUUM COU TION PER 6 1 2 Climate Control System 7 2 6pm te c m 8 FE Ng ro B Bere MR MERETRICEM TERN 8 SECTION 3 Component Details and 12 3 1 Climate Controller Board
21. X Ww oA Low Supply Voltage L l The power supply to the A C unit is below 18V DC 24V systems or 8 5V 12V X Uu systems The clutch and condenser motors are disabled at 20V power supply If voltage continues to drop error message is activated Red fault light is flashing Sensor s Out of Calibration an LI One or more temperature sensors are outside acceptable calibration limits Those sensors should be replaced CCCO007 EPROM Error Custom programmed system settings have been lost The system will use the default settings gt Message be removed by holding the control panel reset button for two seconds when bus is turned on Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 30 CCCO007 Climate Control System Manual CA COACHAIR 5 5 EPROM Replacement Sensitive electronic Componentry Static charges may cause serious damage to the controller Always wear anti static earthing trap before touching controller The EPROM program chip located in the climate controller The following steps explain the identification removal replacement and checking procedures for the correct EPROM replacement Toggle Switch Power Plug Cable CCCO007 Cover Dash and Probe Connections 1 BEFORE accessing the control panel place the dash FA
22. ace in cup of water A scientific glass thermometer is recommended for reference reading 3 Put dash to OFF and hold the reset button in for 8 seconds 4 Usethe set point switch to select the reference temperature 5 Plug the probes back into their correct sockets Each time a probe is plugged in the offset required to calibrate the probe is displayed on the dash 6 To save the calibration changes shift the mode switch to A C To discard changes shift mode switches to Fans Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 17 CCCO007 Climate Control System Manual CA COACHAIR Evaporator Fan Frequency Settings FANS This feature is used to overcoming chassis resonance problems Changing the frequency to an anti resonant point should make evaporator fan motor pulsing indiscernible at low speed It does not cause any change in high speed The frequency of the pulsing of the evaporator motors can be changed by 1 Set dash mode to FANS and fan speed to LOW and push reset switch in until you hear fans go to high speed 2 Use the set point switch to alter frequency limits are 1 0 2 2 3 Save change by moving dash switch to OFF The actual frequency can be calculated by dividing 50 with the dash number e g 50 1 2 41 6Hz 50 2 2 22 7Hz Calculate the new frequency and record it on the commissioning sheet Display of Sensor Readings A
23. anel and will load the default factory values as the operating variables e The probes will have no offset added to them e The reset button is for clearing a latched fault condition It also provides sequential entry code to the system for higher order data transfer such as temperature calibration reading of temperatures etc e The seven LED s on the climate controller will always indicate the operating mode of the system and is indeed a very useful tool for trouble shooting Display Description IGN Ignition FLT Fault ICE Defrost UN2 Unloader 2 UN1 CL2 Unloader 1 CL Clutch WV Water Valve Message This green LED will light when CCC007 is powered by ignition feed to terminal 2 on the power board This red LED will e Light when there is a HP or LP fault e Flash when there is a latched fault This red LED will e Light when there is a de ice condition de ice probe is below 2 C or above 80 open circuit e Flash when there is latched de ice condition e Flash at a slower rate when the system is in stop leak delay counting mode e Flash when CCC007 is sending data to a computer or data logger This yellow LED indicates the system is unloaded and the unloader from terminal 28 is energised The first one to unload in cooling down logic This yellow LED indicates the system is unloaded and the unloader from terminal 29 is energised The second one to unload in cooling down logic unloader for 4 cylinder co
24. aporator and condenser motors at frequency decided by the climate controller Under no condition can they be used to switch power to the motors The relay case is earth connection Back EMF from each motor is suppressed internally by each solid state relay If motor is not connected the relay will operate but there could be damage to relay motor and microprocessor as a result Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 23 CCCO007 Climate Control System Manual CA COACHAIR 3 6 Circuit Breakers ONLINE CLICK Push to Break OFFLINE Push to Reset The circuit breakers are a manual break manual reset type When the circuit breaker is in the normal online position push in the reset button until a click is heard the button will pop out and power to the rest of the circuit is cut There is power to the motors all the time Never attempt to do repairs on motors or motor wiring without manually breaking the correct circuit breaker first WARNING 3 7 Spike Protection Capacitor Negative a z7 e Positive The function of this capacitor is to overcome battery cable inductance When the solid state relays switch off the internal diode will be able to dump the back EMF from the motors inductance into the capacitor Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this man
25. ate Control System Manual CA COACHAIR SECTION 1 General 1 1 Introduction Coachair climate controller CCC007 is an advanced control system tool used to drive the Coachair bus and coach air conditioning units The built in microprocessor controls the operation of the total unit with reference to the dash panel settings and operating conditions The climate control system accepts many inputs and provides many outputs to control the system Air Conditioning System nputs and Outputs Comfort Requirement amp 59 D Condenser Set Point Fan Speed A C Operating System gt Evaporator A Conditions Return air temp Coil temp Ambient temp Air off temp Compressor Voltage gt The functions of the climate controller system include e Monitoring of return ambient and supply air and two evaporator coil temperatures e Monitoring of the discharge and suction pressures e Acceptance of instructions from drivers dash panel e Communication with an external computer a serial link e Intelligent control decision making e Display of return air and set point temperatures on the dash panel e Display of cooling heating and fault conditions on dash panel e Display of diagnostic information on climate controller e Control of the operation of compressor clutch and unloader s evaporator and condens
26. ce for recording system operating information To enable communication with CCC007 a personal computer or laptop must be connected to the climate controller via a serial data link This link consists of a special modular cable with the correct plugs wired up in a serial fashion This cable plugs into the CCC007 controller s COM PORT and then into the computer s serial port CCC007 can communicate with any computer capable of displaying and sending ASCII text at 9600 baud 8 data bits 1 Stop bit No Parity cable is required to adapt to the 4W4P RJ11 connector on CCC007 AMBIENT RESET IGNITION FAULT EVAP 2 DE ICE UNLOADER 1 EVAP 1 Climate Controller UNLOADER 2 CLUTCH 7 RETURN AIR e e O WATER VALVE DASH SERIAL Ni DATA CABLE Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 38 CCCO007 Climate Control System Manual CA COACHAIR 6 2 PC Communication Once the correct connections have been made as detailed in section 6 1 communication can be established with CCC007 6 2 1 Direct Commands Communication is established with CCC007 in the same manner as a standard PC linkup Once the protocols have been established commands can be typed in and CCC007 will respond There are many available commands for CCC007 communication These commands can program CCC007 operati
27. d ambient probe will permanently disable the heating and fresh air operation where as a short circuited ambient probe will run the unit on cooling and heating mode all the time with no fresh air Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 14 CCCO007 Climate Control System Manual CA COACHAIR 3 2 5 Probe Calibration Probes cannot be accurately calibrated in still or moving air due to the potential influence of radiated heat sources Probes are ideally calibrated in an insulated and stirred water bath in an air conditioned room Probes are typically within 1 5 C without calibration 3 3 Dash Control Panel COACHAIR CLIMATE CONTROLLER pod A 150 528 oi P Ww A Y f The dash panel is the user s control device It gives feedback to the user and allows them to control some aspects of the system The dash panel has no intelligence and makes no decisions Its operation is confined to multiplexing LED s and communicating with CCC007 The dash panel communicates to CCC007 the position of its switch settings and CCC007 instructs the dash panel on what LED s to light and what numbers to display If the dash panel does not receive valid data within 1 second it displays three dashes If CCC007 does not receive valid data within 6 seconds the system switches to dashless mode of operation 3 3 1 Dash Controls Details
28. does not run with the power cables 5 6 6 The dash set point display counts in unusual numbers e g 21 8 22 3 22 8 etc Cause e The program is still using the calibration set point Remedy e To restore the set point display to numbers that end 0 and 5 adjust the set point to the upper or lower limit i e 18 0 C or 26 0 C 5 6 7 Compressor is not unloading Cause e Faulty unloader e Faulty unloader relay e Blown fuse e System is in cool heat mode e Blown Remedy e Check set point and ambient temperatures e Removing the ambient probe should return the system to cooling only mode 5 6 8 Heat light flashes when the system Is cooling Cause e This symptom should only occur in heat cool mode As the minimum Air Off Required is set to 6 C CCC007 will inject a small amount of heat when the air temperature drops below 6 C in order to maintain that temperature 5 6 9 The temperature is different to displayed temperature Cause e Probe calibration is incorrect Remedy e Check the temperature probe calibration and recalibrate if necessary Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 36 7 Climate Control System Manual CA COACHAIR 5 6 10 A C Is on fans are running but clutch is not engaging Cause HP LP open circuit or latched e De ice fault or latched e Under
29. e Software version e Serial number e Clutch hours e Heat pump hours e Sampling interval Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 41 7 Climate Control System Manual CA COACHAIR VH O 1 95 ce LU a ERN MP1 O0PEN MP2 CLOSED FAF OPEN Heat Mode 0 RN 4322 Compressor Unloader 1 Unloader2 Help oftware F2 Read Logger Serial No 0 F3 Erase Logger Clutch Cucles 1714 F4 Save File Compressor Hrs Q File Boost Pump 5 0 Logging Interuvual 10 Secs Plotting The data log files may be plotted on a pen plotter via another program specifically used for plotting Sections of the entire graph can be plotted on paper at sizes between A4 and All data traces except bus voltage are turned on by default Most of the traces may be turned off The x and y scales can be adjusted to suit the range of readings and produce the best plot Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 42
30. e main relay is engaged Because the fresh air output is designed to run a motor bi directionally power and ground reverse on pins 34 35 when the relay engages Water Modulation Valve Output The top left pin of the modulation valve connects directly to a 3A fuse The bottom left pin is switched to ground by the mosfet Grounding the bottom left pin will cause the modulator valve to stay on 100 The mosfet is either on or off The frequency is high enough that measuring across the output pins will give an average voltage reading Boost Pump Output The comments apply as were discussed with the Clutch output except this output is not monitored by the CCC007 controller D2 is the inductive suppression diode for this output Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 21 CCC007 Climate Control System Manual CA COACHAIR 3 5 Solid State Relay 6 The Coachair solid state relay is designed to be used in ground switching inductive and resistive loads It combines the features of conventional solid state relays and circuit breakers for 24 V DC applications Coachair solid state relays are rated for 25A continuous loading at 27 V DC and employ solid state electronic device technology eliminating contact wear and fusing They are protected against water and dust and because there are no moving parts they are highly shock and
31. er motors water modulating valve and boost pump fresh air actuator The climate control system consists of e Microprocessor logic controller e Temperature sensors e Digital dash panel e Dash panel communication harness e Power board Solid state relays e Manual break manual reset circuit breakers e Pressure switches transducer e Spike protection capacitor e Wiring harness Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 6 CCCO007 Climate Control System Manual CA COACHAIR 1 2 Climate Control System Components COACHAIR CLIMATE CONTROLLER v Power Board Solid State Relay Climate Controller Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 7 CCCO007 Climate Control System Manual CA COACHAIR SECTION 2 Operation 2 1 Control Logic 1 Ignition feed from the bus coach engine controls the operation of the climate control system If there is no ignition feed or the ON OFF switch on the control panel in the unit is OFF the system will not operate 2 Theclimate controller will initialise when there is power from ignition and ON OFF switch to terminal 2 on the power board Climate controller will energise the main relay on the power board after a 7 second delay and
32. er to the Network for the current issue of this manual Issue Date September 2006 Page 25 CCCO007 Climate Control System Manual CA COACHAIR 4 2 Solid State Relay 3 o N NS s s s Tu Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 26 CCCO007 Climate Control System Manual CA COACHAIR SECTION 5 Maintenance and Service 5 1 CCC Service Tools e Multimeter e Wrist Strap e Scientific Thermometer e 1m Dash Cable e Dash Panel EAD1730 e Crimping Tools and Terminals e Dash Cable Tester e Service Manual Anti static Mat e Anti static Bags 5 2 Recommended Spare Parts e Circuit Breakers e Solid state relays e Fuses e Temperature sensors EPROM s e CCC007 e ESP109 1A Slow Blow Fuse Document Number 5 423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 27 CCCO007 Climate Control System Manual CA COACHAIR 5 3 Parts dentification 5 3 1 CCCOO7 Climate Controller PART NUMBER DESCRI PTI ON REVI SI ON NU
33. ill display a temperature between 80 C 85 C indicating an open circuit probe A short circuit return air probe would cause maximum heating unless the heating was disabled by high ambient The dash panel will display 10 3 2 2 Evaporator Coil De ce Probe The evaporator coil probes are inserted into the fins of evaporator coils They sense the actual coil temperature The de ice probes are housed in special probe holders that provide strength and better contact with coil fins As a safety feature a short circuited or open circuited de ice probe will cause a permanent de ice defrost condition 3 2 3 Air Off Probe The air off probe is located after the evaporator and heater coils It senses the temperature of supply air to the bus cabin interior The air off probe is only used in cooling and heating units and functions as a secondary control for perfect temperature stabilisation during heating mode An open circuited air off probe will cause permanent disabling of the heating function while a short circuited air off probe will cause maximum heating when the unit is in heating mode 3 2 4 Ambient Probe The ambient air probe is used on cooling and heating units and cooling only units with automatic fresh air operation It senses the air temperature outside the bus This temperature input determines whether the operation mode is cooling only or cooling and heating and whether fresh air is introduced to the system An open circuite
34. ir flow due to Condenser motor s not running Condenser motor s running backwards Bent or broken condenser fan Blocked condenser coil too much dirt or bent fins Faulty receiver excessive charge required for A C to cool Air present in system e Open circuit or intermittent wiring connection in pressure switch circuit Low pressure due to Blocked dirty return air filter Insufficient refrigerant charge Possible gas leak Hoses and pipes Flange seal Blocked liquid suction line or faulty suction valve Blocked drier Faulty TX valve Insufficient evaporator airflow due to Evaporator motor s running backwards Bent or broken fan wheel Blocked evaporator coil dirty Incorrect duct sizing and vent placement Faulty pressure relief valve High suction and low discharge pressure due to Compressor belt slipping from incorrect tension on adjuster Compressor damaged faulty Open circuit or intermittent wiring connection in pressure switch circuit Dirty evaporator coils Block return air filter Faulty TX valve poor evaporator refrigerant flow Low airflow over evaporator coil due to supply air fan motor failure Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 34 CCCO007 Climate Control System Manual CA COACHAIR Electrical Climate Control System Insufficient Capacity of bus alternator Loose powe
35. mpressor or second compressor clutch for twin compressor models This green LED will illuminate whenever clutch relay is energised This yellow LED will be energised whenever the water valve is being modulated The rate of flashing will depend on the amount of modulation calculated Note CL UN1 UN2 LED s may glow dull when main relay is off even though the individual relays are not on Document Number 5 423 3283 Issue Date September 2006 Uncontrolled Copy Please refer to the Network for the current issue of this manual Page 13 CCCO007 Climate Control System Manual CA COACHAIR 3 2 Temperature Probes Return Air Probe De lce Probe Coachair Climate Controllers currently use solid state temperature sensors There is a miniature integrated circuit at the tip of every probe The temperature sensors are fast acting integrated circuit type with a very linear and stable output Although the probes are replaceable they are not interchangeable within the system or replaceable without a reliable calibration The minimum temperature that can be read is 20 C and the maximum is 82 C The probes are read in 0 1 C steps 3 2 1 Return Air Probe Return air temperature probe senses the returning air temperature to the unit Return air temperature is used to control the cooling capacity and in a sense heating capacity in reference to set point value An open circuit return air probe will cause maximum cooling The dash panel w
36. oller and the dash panel will be on A latched fault is reset by removing the ignition feed to terminal 2 on power board or pushing the red reset button on the climate controller The reset switch is used to perform the following functions Cancel a latch fault condition Allow reading of all probe temperatures on the dash Allow setting of the evaporator fan PWM frequency Allow calibration of probes Whenever the compressor clutch is energised the condenser fans are activated Condenser fans run at HIGH speed in systems without mid pressure switches Condenser fans run at LOW MEDIUM or HIGH speed in systems with mid pressure switches The pressure switch contact open or closed determines the fan speed Clutch deactivation due to setting the dash mode switch to OFF causes condenser fans to stop immediately unless the unit is performing the leak stopper mode Clutch deactivation due to ignition being turned OFF causes condenser fans to stop immediately When the clutch is deactivated by CCC due to any other reason the condenser fans will run for a further 60 seconds and then stop Pressure Switches The MP1 pressure switch is a normally closed circuit type switch with the controlling pressures set as follows Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 10 7 Climate Control System Manual CA COACHAIR 23 24 25
37. onal parameters and display recorded system information The following table lists some of these commands comman wm maxner umrr pescmemOM C Display Probe temps bus volts and Status word in one ASCII line e si 2000 uos Jon um ur eos mw am mr o cx1o Evaporatariofset emos rw am mr o euo Evaporators Loos m am mr o i rw am mr o ambient ofset i Rw Jo ms o o0 minimum setpoint om dash Maximum set point from dash ONDEL RW 120 Secs Delay from Power up to Leak Stopper A C in seconds s ww wo Setpoint wil stay set unt dash panel changes RW fo hoo pwm Percent modulation before linearization of Heat w o mo wt Batteyvotase a o outen votage Snapshot A section in the CCC007 EEPROM memory is devoted to storing a snapshot of key system variables These variables can be accessed individually by using the appropriate commands The snapshot variables are as follows e Software version e CCC version e Total clutch hours e Total pump hours e Number of pressure switch faults e Number of de ice faults e Number of system latched faults Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 39 CCCO007 Climate Control System Manual CA COACHAIR 6 2
38. r cable Loose earth cable Electrical Climate Control System Electrical Climate Control System 5 6 2 Dash panel is displaying Cause e Dash panel is not receiving error free communications due to faulty dash harness e Dash panel is not receiving error free communications due to or excessive electronic noise Remedy e Replace dash harness e Replace end plugs e Remove electronic noise e Check plugs are secure on cable from dash controller to climate controller 5 6 3 Dash panel is displaying IO and unit is not cooling Cause e Faulty return air probe short circuit e Damaged EPROM Remedy e Remove return air probe Dash should show 80 0C Install a new return air probe and calibrate 5 6 4 Dash panel is displaying 82 unit cooling at full capacity Cause e Faulty return air probe open circuit e Damaged EPROM Remedy Install a new return air probe and calibrate Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 35 7 Climate Control System Manual CA COACHAIR 5 6 5 Display is showing abnormal reading and is not steady Cause e Communication between the dash and the climate controller is being interrupted by stray electromagnetic frequency Remedy e Remove and replace harness with blue shielded harness that will be earthed at CCC007 e Ensure that the dash harness
39. s on between 21 and 26 Output is off below 17 and above 29 This hysteresis is used to stop the ram opening and closing when the ambient temperature is near to the trigger points Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 11 7 Climate Control System Manual CA COACHAIR SECTION 3 Component Details and Functions 3 1 Climate Controller Board CCCO07 9 AMBIENT RESET I 5 AIR OFF O 9 r IGNITION 1 1 1 FAULT 1 2 0 1 I DE ICE 1 1 E1 UNLOADER 1 L Indicator Lights EVAP 1 ET 1 Q UNLOADER2 CLUTCH 1 RETURN AIR WATER VALVE Monum EP 2 2 DASH E a ES lt y 3 u lt lt CCC007 has been designed to be the intelligent brain of the Coachair Climate Control system This brain is adaptable to cooling only and cool and heat systems and is able to control different size systems through different power boards CCC007 takes many inputs makes sensible decisions based on these inputs and generates outputs to control the process Probes LED s Power Return Air Fault Evyap De ice Evap Unloader 1 IU Unloader 2 Ambient Clutch Water Valve Clutch Dash Panel Switches Unloader 1 Reset Button CCC007 Unloader 2 Inputs Water Valve ANC S OUI Evap 1 Mid Pressure 1
40. tch to be re energised during the next 10 seconds The following conditions prevent the clutch from powering HP LP open circuit or latched De ice fault or latched de ice Under voltage condition Er5 Return air lt set point for clutch offset Faulty dash panel Blown fuse faulty harness faulty relay bad connection faulty clutch etc A HP LP fault will always override any function and turn the clutch off The HP LP switches are wired in series and are normally in the closed position When either of the switches open CCC007 deactivates the clutch until the circuit is closed again The FLT LED on the controller and the red Fault LED on the dash panel will light up If a HP LP fault occurs 6 times in 30 minute period a latched fault will occur and an Er1 message will display on the dash panel The fault lights on the controller and the dash panel will flash A DE ICE fault will always override any other function Should the evaporator coil temperature drop too low ice may form When the evaporator coil de ice temperature sensors detect an abnormally low evaporator coil temperature initially the unloader s will be activated If the condition continues the clutch will be disengaged until the temperature rises If a de ice fault occurs more than 6 times in 30 minutes a latched fault will occur and the compressor clutch will be permanently disabled to avoid damage Er2 will display on the dash panel The fault lights on the contr
41. tem provided the bus engine is running Observe the dash display If Er7 is displayed Turn OFF the ON OFF toggle switch immediately Push and hold down the RESET button while turning ON the ON OFF toggle switch and observe the fault light on CCC007 When this light stops flashing release the RESET button within 1 second Re calibrate the probes see 3 2 5 Section Probe Calibration Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 33 CCCO007 Climate Control System Manual CA COACHAIR If Er7 is not displayed and the dash shows a normal temperature There is no need to initialise and re calibrate as the old settings have been accepted 11 Place the ON OFF toggle switch on the control panel to the OFF position 12 Replace the protective black plastic cover return the 4 retaining screws on the reverse side of the PCB under the insulation 13 Return the CCC007 controller to the control panel making sure that the spacers are placed underneath the PCB Do not over tighten these screws as this may cause PCB damage 14 Place the ON OFF toggle switch on the control panel to the ON position and check that the unit is functioning 5 6 Trouble Shooting 5 6 1 Dash Panel is Displaying Erx Possible Causes High pressure due to Overcharge of refrigerant Blocked discharge line or faulty discharge service valve Insufficient condenser a
42. then look for further instructions 3 Main relay provides power for clutch unloader s fresh air actuator and water modulating valve circuits t also supplies the feed for condenser motor control circuit Note If main relay is faulty or removed there will not be refrigeration A C but evaporator blower operation will be available 4 fadash panel is connected and its mode is OFF or FANS a leak stopper action will begin after a 3 minute delay After the 3 minute delay the clutch will power evaporator fans on low speed if the mode is OFF and condenser fans on for 90 seconds During the 3 minute delay the DE ICE light will flash once per second If the dash mode is changed to A C at any time the leaks topper action is cancelled and A C will operate normally 5 The system is controlled via the dash panel The mode of the system can be set FANS OFF A C switch e The evaporator fan speed can be selected Decrease Auto I ncrease switch The climate control set point temperature can be set spring return rocker switch 6 The FANS setting of main switch provides evaporator blowers only at the selected fan speed A C setting provides for operation of full climate control capability as dictated by the ambient conditions and dash panel settings 7 Adjusting the Evaporator Fan Speed switch changes the evaporator fan speed when the mode is set to FANS or A C unless this is overridden by another condition such as DE ICE fault
43. then revert to the default return air temperature display COACHAIR CLIMATE CONTROLLER 6 288 _ Y Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 16 CCC007 Climate Control System Manual CA COACHAIR 3 3 2 Display Modes COACHAIR CLIMATE CONTROLLER p ec A 1 AU J 1 1 1 Fault Warning Heating Mode Cooling Mode 3 3 3 Dashless Mode When no dash panel is connected or no communication is occurring the CCC007 enters dashless mode It uses the last saved dash mode and temperature setting as its mode and set point of operation CCC007 saves the mode of operation 5 seconds after the last set point change Thus if the mode switch on the dash was OFF when the temperature setting was changed the dashless mode will be off 3 3 4 Diagnostic Functions The CCC007 has three diagnostic modes These modes are accessed by first placing the dash mode switch in one of the three positions OFF FANS A C then holding the reset button on the CCC down for 8 seconds The position of the mode switch determines the diagnostic function accessed Probe Calibration OFF The procedure for probe calibration is as follows 1 Remove the probe s to be calibrated from their sockets 2 f possible tie the probe heads together with the reference probe and pl
44. ual Issue Date September 2006 Page 24 CCCO007 Climate Control System Manual CA COACHAIR SECTION 4 Unit Wiring Diagrams 4 1 Climate Control System all O at J i T l E e ulla m f L L d J i 5 M 14 d MENS a ll Orp _ Qu Lx r _ Cri _ ew 7n 1T E x3 p da SED em 0 Document Number 5 423 3283 Uncontrolled Copy Please ref
45. vibration resistant They could be switched up to 10 kHz frequency for resistive and 1 kHz for inductive loads Switching time is around 10 30 milliseconds making it quite reliable in case of short circuits Trigger current is 3mA y Trigger Battery Negative Through Case n 4 Overheat Light Yellow 4 F Fault Light Red Motor Positive Terminal Power Light Green Motor Negative Terminal Document Number 5 423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 22 CCCO007 Climate Control System Manual CA COACHAIR SOLID STATE RELAY TECHNICAL SPECI Fi CATIONS Operating Voltage 12 30 V DC Trigger Voltage 6 V DC Trigger Current 1mA per 10 V load voltage Rating Free Air 20A continuous ON Resistance 10 milliseconds 25 C Fault Trip Current Approximately 140A auto reset in 3 seconds Over Current Trip Time lt 10 milliseconds Temperature Cut out 85 C 105 C auto reset after cooling 20 C Switching Time 2 milliseconds Max Switching Frequency 10 kHz for resistive loads 1 kHz inductive loads depends upon inductance The green LED indicates relay switching as normal operation red LED indicates a short on the load circuit and relay not switching as a result and the yellow LED indicates that the relay is overheating due to overloading Coachair solid state relays are used in ground switching of ev
46. voltage condition Er5 e Return air is less than the set point e Faulty dash panel e Blown fuse faulty harness faulty relay bad connection faulty clutch etc 5 6 11 Return air temperature is changing up and down considerably Cause e Confirm that there are no other faults in the system Ambient temperature is changing considerably causing the system operating mode to change from cool only to cool heat or vice versa Note Cool only mode will cut cooling when the return air is 10C below the set point temperature Cool heat mode will keep the return air at the set point but will overshoot set point by at the very beginning of the P I D system Remedy e Change set point up or down by 1 C 5 6 12 No heating Cause e Ambient sensor is open circuit e Air off sensor is open circuit e Ambient sensor is out of calibration e Boost pump is not operating e Isolation valves closed Document Number SM423 3283 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date September 2006 Page 37 7 Climate Control System Manual CA COACHAIR SECTION 6 CCCOO7 Service Program 6 1 Connection to CCCO07 The serial port is the window through which we can see what the microcontroller is thinking The CCC007 can connect to a personal computer to allow for sending and receiving information CCC007 can also be connected to the Data Logger another Coachair devi
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