Carrier ComfortPro 200INT User manual

Operator’s Manual
ComfortPro
200INT, 210STA, 220PWR, 230SKY
Diesel Auxiliary Power Unit
62-12076
Rev C
TM


© 2020 Carrier Corporation ●Printed in U. S. A. April 2020
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ComfortPro
Auxiliary Power Unit
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ManualRevision History62-12076
Rev Date Reason for Release
4/2018 Initial Release
A 8/2018 UpdatedtoaddProp65warninglabel on back
cover.
B 4/2019 Updatedtoaddinstructionson Stand-Alone APU
block heater
C 4/2020 Full edit (DM); updatedAFCI/GFCIimage;updated
MaintenanceTable;

Table of Contents
Introduction ..............................................................................................1
Safety .......................................................................................................2
Overview ..................................................................................................6
Components .............................................................................................8
Operation ...............................................................................................14
Starting the APU.....................................................................................16
Stopping the APU ...................................................................................16
Turning the Heater ON or OFF...............................................................17
Turning the A/C ON or OFF....................................................................18
Fan Operation ........................................................................................18
DCP Configuration .................................................................................19
Setting Time and Date............................................................................21
Comfort Monitor......................................................................................22
Timer ......................................................................................................26
Temp Start .............................................................................................28
Maximum Run Time ...............................................................................30
Battery Monitoring ..................................................................................31
Heater Disable Feature ..........................................................................33
Stand-Alone APU Block Heater..............................................................37
DPF System (Optional)...........................................................................38
Maintenance Schedule ...........................................................................39
Pretrip Inspection................................................................................... 41
HVAC General Inspections ....................................................................42
Troubleshooting Fault Codes..................................................................44
Troubleshooting Symptoms ................................................................... 47
Specifications .........................................................................................50
62-12076


1 62-12076
I
NTRODUCTION
ComfortPro® Models
Integrated
(200INT)
APU provides sleeper cab air conditioning and
heating. 120 VAC is available to power
120VAC household accessories. APU coolant
lines connect to the tractor engine cooling
system, with engine warming provided via APU
coolant exchange.
Stand-Alone
(210STA)
Provides similar capabilities to the integrated
model, but tractor and APU coolant systems
are independent. Tractor engine warming can
be optionally done via the tractor’s block
heater, powered by the ComfortPro APU’s
generator or with an engine coolant heater.
Power Only
(220PWR)
Provides power for hotel loads in applications
where no cab climate control is needed.
Integrated with
ClearSky™ DPF
(230SKY)
Integrated APU based off the 200INT with the
ClearSky Diesel Particulate Filter (DPF).

62-12076 2
S
AFETY
These safety alerts alone cannot eliminate hazards that can occur. Strict
compliance with these special instructions when performing the installation
and maintenance, plus common sense, are major accident prevention
measures.
WARNING
!
WARNING: Warns against hazards or unsafe conditions
which COULD result in severe personal injury or death.
CAUTION
!
CAUTION: Warns against potential hazard or unsafe
practices which could result in minor personal injury.
NOTICE
NOTICE: Warns against potential product or property
damage.
EXHAUST
Inhalation of exhaust gas (containing carbon monoxide) may cause severe
personal injury and/or death. Anyone suspected of suffering from carbon
monoxide inhalation should be removed from the hazardous area and given
medical assistance immediately.
WARNING
!
California Proposition 65 Warning: The APU and CCU
components of this product contain lead, a chemical
known to the State of California to cause cancer and birth
defects, and other reproductive harm.

3 62-12076
FUEL/ BATTERIES
Exercise extreme caution when working near fuel or fuel-filled equipment. Do
not operate equipment during fueling operations. Use eye protection when
working near batteries, which contain acid and can explode. Do not smoke or
use open flames near batteries.
ELECTRICAL
Electric shock can cause severe personal injury, burns, and death.
Disconnect the batteries before working on any unit. Use only approved
materials and methods when working on the electrical system, and follow
local electrical codes. Never work on the APU or the electrical circuitry when
the APU is running. Never work with electricity in wet conditions.
TOXIC SUBSTANCES
Fuel, oil, coolant, and refrigerant are toxic and in some cases, carcinogenic.
Wear eye and hand protection at all times. Remove contaminated clothing
immediately and wash contaminated skin. Do not breathe in vapors.
HOT OR MOVING PARTS
Moving parts can cause severe injury and/or death. Before working on any
unit, shut it off and disconnect it from the truck batteries. Do not start until
protective covers have been replaced. Also, loose parts and tools falling into
machinery can cause severe accidents. Always ensure bolts and clamps are
correctly torqued and secured. Inspect mechanical components periodically
for damage, corrosion, and proper torque.
MISUSE
The APU is designed to provide electrical power, and power for heating and
cooling vehicles in normal on-road conditions. Never use the APU to power
critical medical equipment or sensitive electronic equipment without the
manufacturer’s express written approval.
WARNING
!
DO NOT open the APU enclosure when the APU is running.
Moving parts inside the APU can cause severe injury and/
or death. DO NOT restart the APU until the covers have
been replaced.

62-12076 4
WARNING
!
Danger from moving parts: In order to perform these
maintenance checks, you must open the access covers to
the APU. Before doing so, shut off the APU and disconnect
it from the truck batteries. Never observe the inside of the
APU enclosure or insert your fingers or a tool into the
enclosure when the APU is running.
CAUTION
!
DO NOT open the CCU enclosure. There are no operator-
serviceable parts inside.
CAUTION
!
Stand-Alone APU only: Truck engine oil/block heater
connector is energized along with APU engine start.
WARNING
!
DO NOT start the APU when the enclosure cover is
removed. Operating with the cover off may result in injury
and/or death.
WARNING
!
When the APU is about to start, a buzzer sounds. Make
sure no one is standing near the APU or touching it.
WARNING
!
Once automatic functions are set, the system could start at
any time. Before servicing the unit, disconnect the unit
from the batteries to prevent injury should the unit attempt
to start while servicing. All presets will remain once battery
cable is reconnected.

5 62-12076
CAUTION
!
Stand-Alone APU only: DO NOT open the radiator surge tank
cap when engine and coolant is HOT.
CAUTION
!
If you are not qualified to perform the specified check or the
required maintenance task, consult your dealer about
servicing.

62-12076 6
O
VERVIEW
Key Features
• Provides heating or air conditioning to the truck bunk
• Provides power to run 120VAC appliances in the truck bunk
• Charges the truck battery: It is more efficient to charge the battery by
running the ComfortPro than by running the truck engine.
• Integrated APU only: Warms the truck engine by passing coolant that
has been warmed by the APU into the engine.
ComfortPro Options
•Main Engine Interlock: The main engine interlock option is available to
prevent the APU from operating when the truck engine is running. The
APU is designed to be started when the truck engine is not running. When
the main engine interlock option is enabled, the only situation in which the
APU and truck engine can both be running is during ComfortPro
Options.
•
Shore Power: The ComfortPro Shore Power option lets you plug your
ComfortPro into standard 120VAC electrical outlet (shore power) and
use the HVAC without having to run the APU. This option provides
additional fuel savings.
ComfortPro Functions
The ComfortPro includes the following HVAC system functions:
•Manual Operation: Manual control of the HVAC to provide a
comfortable temperature in the truck bunk.
•Comfort Monitor: Automatically turn on the APU and HVAC as
required in order to maintain a comfortable temperature in the truck
bunk.
•Timer: Automatically turn on HVAC at specific times and days of the
week, and for a specific length of time. There are two timers.

7 62-12076
The ComfortPro also includes the following APU functions:
•Temp Start: Automatically turn on the APU and HVAC periodically
whenever the temperature goes below a specified value. This will
prevent the APU engine and truck engine from getting so cold that they
will not start. In the event that the truck alternator malfunctions, this
feature will allow the truck to “limp home.”
•Battery Monitor: The ComfortPro can be programmed to detect when
the truck batteries are running low and automatically turn on the APU in
order to recharge the batteries.
•Maximum Run Time: Set the maximum time that the APU will run.
A password can be set up to restrict the ability to set up or change the
operation of any or all automatic functions (see DCP Configuration).
NOTICE
Stand-Alone APU only: The truck engine oil/block heater
connector is independent from the APU “comfort system”
functions and is energized along with the APU engine start.

62-12076 8
Components
The APU is mounted on the frame rail of the truck. It consists of an engine
and belt driven generator. The engine draws fuel from the truck’s fuel tank,
independent of the truck’s main engine. The APU provides power to the
Climate Control Unit (CCU)
Driver Control Panel (DCP)
Climate Control Unit (CCU)
Vehicle Fuel Tank
Condenser
Integrated Auxiliary
Power Unit (APU)
Battery
110VAC
Receptacle Panel
Fuel Supply
and Return
Coolant Supply
and Return
Battery
Vehicle Fuel Tank
Fuel Supply
and Return
Surge Tank
for Radiator
Stand-Alone
Auxiliary Power Unit (APU)
with Radiator in Rear
Outlet for
Block Heater
Condenser
Climate Control Unit (CCU)
110VAC
Receptacle Panel
Integrated Unit Components
Stand-Alone Unit Components
Driver Control Panel (DCP)

9 62-12076
Simple maintenance and inspection, such as checking oil level, belt tensions
and general cleanliness, can be performed by removing the upper and lower
access panels. Turn off the APU, unscrew the hand wheel bolts, and carefully
remove either access cover.
Integrated Cooling System
The integrated APU is plumbed into the truck’s coolant system. The APU and
the tractor share the same coolant reservoir. When the integrated APU is
running, it provides heat to the truck’s engine and when the truck’s engine is
running, the truck provides heat to the APU.
Stand-Alone APU Cooling System
The Stand-Alone APU does not plumb into the truck’s cooling system.
However, a connector is provided to supply power for the engine block heater
to warm the truck engine.
Coolant level can be checked through the sight glass on the surge tank
(ensure the coolant is visible). The surge tank is mounted remotely away from
and above the APU, where the sight-glass is easily visible. The surge tank is
connected to the APU with coolant hoses.
WARNING
!
Do not open the APU enclosure when the APU is running.
Moving parts inside the APU can cause severe injury and/
or death. Do not restart the APU until the covers have been
replaced.
SLJKW*ODVV
Stand-Alone APU
only – Surge Tank
Sight Glass.

62-12076 10
E
LECTRICAL
S
YSTEM
The APU electrical system is connected to the truck’s batteries and uses the
batteries to start its engine. The APU engine’s alternator charges the
batteries.
NOTICE
If equipped, the truck engine oil or block heater connector
is independent from APU “comfort system” functions, and
is energized as soon as APU engine starts. The block or oil
heater must be plugged into the connector when required
during cold weather operation. Unplug the block heater
connector from the block heater receptacle when not in
use.
WARNING
!
Danger from moving parts! In order to perform these
maintenance checks, you must open the access covers to
the APU. Before doing so, shut off the APU and disconnect
it from the truck batteries. Never observe the inside of the
APU enclosure or insert your fingers or a tool into the
enclosure when the APU is running.
Power Outlet (AFCI/GFCI)
The power outlet is mounted in truck sleeper. Provides 120 VAC (15A max) to
power hotel loads. Outlet is arc fault and ground fault protected.

11 62-12076
Driver Control Panel (DCP)
Mounted inside the truck bunk, the DCP controls the APU and the CCU. The
DCP provides status information using words and icons:
1. When visible, system is heating.
2. Battery Monitor enabled.
3. Maximum run time enabled.
4. Temp Start enabled.
5. Comfort Monitor enabled.
6. Timer 1 or Timer 2 enabled.
7. The ComfortPro is connected to shore
power.
APU
ON/OFF
HV AC
OFF
MENU
A/C FA N HEA T
HOURS
00000
APU
SP
1
2 3 4 5
T2T1
APU
ON/OFF HVAC
OFF
ESC/
RESET
MENU
A/C FAN HEAT
High heat breaker tripped.

62-12076 12
HVAC System
The HVAC System consists of the following components:
• The CCU provides heat and air conditioning to the truck sleeper. This
unit is typically installed underneath the bunk.
• Three air ducts in the truck sleeper connected to the CCU.
• The condenser is mounted on the outside of the truck and is connected
to the CCU.
CAUTION
!
Do not open the CCU enclosure. There are no operator-
serviceable parts inside.
Condenser
CCU
AFCI/GFCI

13 62-12076
O
PERATION
The APU has two modes of operation - manual and automatic.
Manual Mode: The APU is started and stopped using the APU ON/Off button
located on the DCP. Once the APU is running, use the DCP to start and stop
the fan, heater and air conditioning (see Starting the APU).
Once the heater or A/C is running, it will cycle (automatically turn on and off)
in order to keep the truck bunk at the specified temperature. The HVAC will
continue to cycle until it is turned off. While the HVAC is cycling, the APU
remains on and will only turn off when it is manually turned off using the ON/
OFF button on the DCP.
In manual mode, the APU will continue to run until turned off or the maximum
run time is reached. When the APU is running, power is supplied to the power
outlet in the truck bunk (except in high heat).
Automatic Mode (Comfort Monitor): Intended to maintain the truck cabin
temperature at a desired setpoint by cycling both the APU and HVAC on and
off as required. When operating in Comfort Monitor mode, the HVAC operates
in high heat or high A/C depending on cabin temperature.
There is an option to allow the selection of High or Low heating and air
conditioning. This option is owner selectable (see Comfort Monitor).
NOTE
Comfort Monitor mode and manual APU operation are mutually
exclusive. An ON setting enables Comfort Monitor mode and
disables Manual APU operation. An OFF setting disables
Comfort Monitor mode and enables Manual APU operation.
Comfort Monitor Operation
•APU ON/OFF Button: With Comfort Monitor enabled and the duration
timer set to a nonzero value, the APU ON/OFF button may be used to
activate / de-activate Comfort Monitor mode.
•Duration Timer: The Comfort Monitor duration timer begins each time
that Comfort Monitor mode is activated via the APU ON/OFF button.
When the timer has elapsed, Comfort Monitor mode will de-activate.
The driver may re-activate Comfort Monitor by pressing the APU ON/
OFF button.

62-12076 14
NOTE
If Comfort Monitor is not manually de-activated, it will continue to
operate until the duration timer has expired.
Set Duration: Allows the user to set the maximum run time that the APU can
remain in Comfort Monitor mode. The duration timer may be set between 0.0
HRS to 24.0 HRS in increments of 0.5 HRS.
Set Temp: Allows the user to set the desired ambient temperature in the
range from 64°F (18°C) to 86°F (30°C).
Other Control Panel Buttons: The MENU, ESC/RESET and ARROW
buttons may continue to be used for accessing and navigating the menu. The
balance of front panel buttons, including HVAC OFF, A/C, FAN, and HEAT,
have no associated functionality while the system operates in Comfort
Monitor. Additionally the ARROW buttons may not be used to adjust the
temperature setpoint.
Other Automatic Modes: If enabled in the menu, other automatic modes
may become active while the APU operates in Comfort Monitor mode or is
OFF in manual mode. Activation of any of the other automatic modes will
temporarily override Comfort Monitor, however APU operation will return to
Comfort Monitor mode if all automatic mode duration timers have expired but
the Comfort Monitor duration timer has not expired.
Timer: The APU and HVAC turn on automatically at the specified time and
period, and the HVAC cycles to maintain the desired temperature. When the
time expires, both the APU and HVAC turn off automatically. During the
specified timer duration, the HVAC cycles on and off to maintain the desired
temperature. When the timer duration expires, both the APU and HVAC turn
off automatically.
Temp Start: The APU will run when the cab temperature drops below a set
value. This feature warms the APU and tractor engine to assist with cold
starting. After the timer duration expires, both the APU and HVAC turn off
automatically.
Battery Monitor: When the truck battery voltage drops below a specified
level, the APU runs for 90 minutes to charge the batteries. The HVAC does
not turn on when battery monitor is active.
This manual suits for next models
3
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