SERVICE MANUAL

SERVICE MANUAL SECTION Trans/Air EC3.0 Electronic Climate Control System Vendor: Trans/Air S16042 08/01/2008

S16042 Copyright 08/01/2008 Navistar, Inc.

Trans/Air EC3.0 Electronic Climate Control System

1. DESCRIPTION
This publication consists of information provided by Trans/Air, and is provided as is without warranty of any kind, either expressed or implied. Navistar, Inc. assumes no responsibility for errors or omissions in this publication or other documents that are referenced by or linked to this publication. In no event shall Navistar, Inc. be liable for any damages whatsoever (including special, incidental, direct or indirect, or consequential damages) arising out of or in connection with this publication and the use of the information contained herein.

S16042

Service Manual For Trans/Air EC3.0 Electronic Climate Control System

Specification
Operating Voltage: 9~16 VDC Current capacity: Evaporator: 40 amp Condenser: 40 amp Compressor: 10 amp Tie-in Condenser: 40 amp Tie-in Compressor: 10 amp Heat Relay: 10 amp Setpoint range: 60F ~ 90F

Component:
EC3.0 system consist of two major components: driver control switches and relay board. A communication cable connects the switches to the board. Switches EC3.0 control switches: Mode switch (701426), Thermostat (701425).
ON/OF & MODE SELECT A/C-DEFOG-HEAT-OFF DEFOG HEAT A/C FAN SPEED INDICATOR FAN SPEED SELECT AUTO-L-M-H-OFF SET POINT ADJUST DISPLAY

Figure 1 Control Switches

Relay Board The layout of an EC3.0 relay board is shown below. It has five relays, one 12 position terminal block, three 10 amp fuses, two connectors and seven LED indicators. The function of each component are listed in table below

EC3 Service Manual Jan. 8, 2008

Figure 2 Relay Board Layout Table 1 Relay Configuration

RELAY COMPR. TIE-IN COMPR HEAT TIE-IN COND. COND.

Table 2 Fuse List

FUNCTION Compressor clutch relay OEM tie-in compressor clutch relay Heat valve control relay Tie-in condenser fan control relay Condenser fan control relay Description Comp. Clutch fuse Tie-in Comp. clutch fuse Heat relay output fuse FUNCTION Compressor clutch output Tie-in compressor clutch output Heat control relay output (optional) Dash signal input Ignition power input Tie-in condenser power input Tie-in compressor power output Condenser power input Condenser power output EC3 Service Manual Jan. 8, 2008

Currant rating 10 amp 10 amp 10 amp 40 amp 40 amp Rating 10 amp 10 amp 10 amp

Fuse F1 F2 F3
Table 3 Terminal Configuration

TERMINAL 1 2 3 4 5 6 7 8 9

10 11 12
Table 4 LED List

Ground Evaporator power return Evaporator power input INDICATOR Comp. Cond. Tie-in comp. Tie-in cond. Heat Com. Evap. FUNCTION Illuminates when compressor relay is engaged. Illuminates when condenser is engaged Illuminates when tie-in compressor relay is engaged Illuminates when tie-in condenser is engaged Illuminates when heat relay is engaged Illuminates and flickers when board is powered up Illuminates when evaporator is on

D25 D26 D27 D28 D29 D30 D31

System Operation
Basic system operations are covered by the instruction manual (701465).

Thermostat Control Logic:

Temperature sensing EC3.0 system has two thermistor type temperature sensors: cabin (internal) air temperature sensor and ambient (external) air temperature sensor. The cabin air temperature sensor is mounted in front of the main evaporator return air filter and the external temperature is mounted externally but the location varies depending on vehicle models. The electric resistance of the temperature sensor changes with the temperature. The sensing circuit on the relay board can read the resistance and convert it to temperature reading. The resistance of the temperature sensor is about 500 ohms at 70F. This can be uses as a reference to determine if a temperature sensor is functional. EC3.0 system only displays the temperature between 60 F and 90 F. If the actual temperature is lower than 60 F, the display will show Lo. If the temperature is above 90F, the display will show Hi. The setpoint range is also set to be 60 F to 90 F. Thermostat control logic The compressor clutch, condenser and heat output are controlled by the thermostat based on the temperature differential between cabin air temperature, Tin, and set point temperature, Tset. The control logics are listed in Table 5.
Table 5 Thermostat control logic

MODE COOL HEAT DEFOG

CONTORLLED COMPONENT Clutch, condenser Heat relay Heat relay

LOGIC Tin>Tset+2 clutch & condenser turn on TinTset+2 clutch & condenser turn off Tin<Tset-3 heat relay engage TinTset+1 heat relay disengage Clutch & condenser stay on Heat relay regulate same as in heat mode

External temperature protection

EC3 Service Manual Jan. 8, 2008

When the external temperature is below 34F, the compressor clutch and condenser will be locked out to prevent condenser motor damages. If the external temperature sensor is damaged, it may feed false low temperature signal to the board and cause the system malfunction.

Fan Speed Control

EC3.0 system has two speed control modes. Auto fan speed control and manual fan speed control. In manual fan speed control, there are three settings High, Medium and Low. In auto fan speed control mode, evaporator blower speed is controlled based on the temperature differential between Tin and Tset. The greater the temperature differential is the higher the blower speed is. The evaporator blower is controlled by a series of transistors instead of relays. By changing the duty ratio of the transistors, the supply voltage to the blower can be varied. As the blower speed is proportional to the input voltage, the blower speed can be controlled by duty ratio. The fan speed control setting are listed in Table 6.
Table 6 Fan speed control settings

Mode Auto

Manual

Setting | Tin-Tset | 2F 2F<| Tin-Tset | < 4F 4F| Tin-Tset | < 6F 6F| Tin-Tset | < 8F 8F| Tin-Tset | High Mediu, Low

Duty Ratio 60% 70% 80% 90% 100% 100% 80% 60%

Tie-In Configuration
The EC3.0 system has three designated terminals (terminal 2,4 and 7) to control an additional tie-in system. Terminal 4 senses the tie-in signal (+12 vdc). Terminal 2 and 7 control tie-in compressor and tie-in condenser respectively. The status of the tie-in system does not affect the operation of the stand along system.
Table 7 Tie-In Configurations

System EC3.0 ON EC3.0 ON EC3.0 OFF

Tie-in terminal Open (dash off) +12 VDC (dash on) +12 VDC (dash on)

Clutch & Condenser relays Tie-in condenser and tie-in compressor remain OFF. Rest of system controlled by EC3.0 board All system components controlled by EC3.0 board Tie-in condenser and tie-in compressor ON Rest of system OFF

Safety and Fault Protections

There are two or three safety switches in a EC3 system. High pressure switch, low pressure switch and freezestat (if equipped). Safety switches are wired in parallel to the safety harness. There are 4 wires in the safety harness: one common wire, and 3 switch wires. Refer to installation drawing for detailed wiring diagram. The common wire carries +5 vdc and it is connected to all the safety switches through a comment joint. If a safety is closed EC3 Service Manual Jan. 8, 2008 4

the safety wire it is connected to will have the same voltage as the common wire. If a safety switch is open the respective safety wire will be open (floating). Therefore the EC3 system can identify which safety switch is open. In the event of safety fault(s), the compressor clutch and condenser fan will be turned off and remained off until the fault code is cleared. The evaporator blower speed will be changed to high speed and the thermostat will display specific fault code to alert the operator. Beside safety switches, EC3.0 also monitors two other electrical faults: low clutch voltage and blown fuse. The EC3.0 system senses the voltage on terminal 8 (clutch power input terminal). If the voltage on terminal drops below 11.9 vdc, EC3.0 system will turn off condenser output and compressor clutch output and display Lu low voltage fault code on the thermostat display. EC3.0 system also sense the status of fuses including 3 on-board fuses (ATC blade type fuses), and external fuses. The system actions under these two fault modes are also listed in Table 8.
Table 8 Faulty codes list

Fault Type Safety

Electrical

Code HP LP Fr Lu bF Lu

Description High pressure switch open Low pressure switch open Freezstat open (if equipped) Two or more safety switches open Blown fuse or No voltage on terminal 6, 8 or 12. Low compressor clutch voltage

System Actions Display fault code Clutch output OFF Condenser output OFF Evap. speed High Display fault code Clutch output OFF Condenser output OFF Evap. speed High

Note: Lu code has two possible causes. Turn the system off to clear the fault code. Fault code does not affect operation of tie-in condenser and tie-in compressor. EC3.0 system automatically records the fault history to its non-volatile memory resided in the thermostat. A special device can be used to read out the fault history.

Clutch engagement delay

EC3.0 board has built-in timer to prevent compressor clutch short cycling. After the compressor clutch turns off, it has to remain off for 30 seconds before it turns on again.

Service timer
Every 1000 hours, the thermostat will flash Sr for 5 seconds when the system is powered up. The thermostat then will return to displaying cabin temperature. The Sr code will be displayed for 15 seconds every 5 minutes. This does not affect the normal operation. It just reminds the operator the routine A/C system maintenance. The service timer can be reset by following procedures: Push Mode button to turn on system Push or button on the thermostat to go into set point mode Adjust the set point to 90 Push and simultaneously Turn off the system and cycle ignition power Turn system on to verify the Sr code is cleared. (Thermostat does not display Sr when it was powered up first time.) Reset the default set point to original value (see operation manual.) EC3 Service Manual Jan. 8, 2008 5

Slave board configuration

In some large systems where the electrical load exceeds the current capability of a single board, a slave board can be used. A typical wiring diagram is 5031xxxx. In a slave system, the switches are connected to the master board and the slave board is connected to the master board through a harness 701442. The slave board mimics the actions of the master board. The slave board normally is used to drive the additional evaporators and condensers.

Trouble shooting
Use Table 8 to identify the problem if there is a fault code. Other common problems are listed in Table 9. Refer to previous sections for detailed action procedures.
Table 9 Trouble Shooting

Symptom Switch does not turn on

Action Check COM LED Check terminal 5 for +12vdc and 10 for ground Faulty communication cable Replace cable Faulty switch Replace switch Faulty board Replace board Clutch does not engage Tset> Tin Adjust set point Faulty external temperature Replace temp. sensor or sensor sensor cable Bad connection Check LED on board and voltage on terminal 1 Faulty board Replace board Fan / Blower do not run Bad connection Check LED and power output terminal Faulty board Replace board Blower does not stop Faulty board Replace board Fault code persists Bad connection Check safety harness connections at evap. & board Fault condition persists Check pressure and voltage 1000 hr service timer Reset service timer Faulty board Replace board Thermostat shows Lo all the Low cabin temperature Verify cabin temperature is time below 60F Temperature sensor cable Verify shortage short Repair or replace cable Faulty temperature sensor Replace sensor Thermostat shows Hi all the High cabin temperature Verify cabin temperature is time above 90F Temperature sensor open Verify open circuit circuit Repair or replace cable Faulty temperature sensor Replace sensor

Probable causes No power

EC3 Service Manual Jan. 8, 2008