Carrier 69NT40-511-199 Service manual

Container Refrigeration
OPERATION AND SERVICE
for
69NT40-561-001 to 199
Container Refrigeration Units
T−340 Rev D
OPERATION AND SERVICE MANUAL
CONTAINER REFRIGERATION UNIT
Models
69NT40−561−001 to 199
©Carrier Corporation, 2012 Printed in U. S. A. May 2012
TABLE OF CONTENTS
PARAGRAPH NUMBER
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
1.3
CONFIGURATION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURE DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−1
1−1
1−1
1−1
1.3.1
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−1
1.3.2
1.3.3
Temperature Readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−1
1−1
1.3.4
1.3.5
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−1
1−1
1.3.6
1.3.7
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−1
1−1
1.3.8 Plate Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 OPTION DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−1
1−1
1.4.1
1.4.2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−1
1−1
1.4.3
1.4.4
USDA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interrogator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−1
1−1
1.4.5
1.4.6
Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quest − CCPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−1
1−2
1.4.7
1.4.8
Communications Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Autotransformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−2
1−2
1.4.9 Temperature Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.10 Gutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−2
1−2
1.4.11 Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.12 Thermometer Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−2
1−2
1.4.13 Water Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.14 Back Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−2
1−2
1.4.15 460 Volt Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.16 230 Volt Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−2
1−2
1.4.17 Cable Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.18 Upper Air (Fresh Air Make Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−2
1−2
1.4.19 Lower Air (Fresh Air Make Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.20 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−2
1−2
1.4.21 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.22 Condenser Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−2
1−2
1.4.23 Emergency Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.24 eAutoFresh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1−2
1−2
i
T-340
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−1
2−1
2.1.1
Refrigeration Unit − Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−1
2.1.2
Fresh Air Makeup Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−1
2.1.3
Evaporator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−2
2.1.4
Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−3
2.1.5
Air−Cooled Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−4
2.1.6
Water−Cooled Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−5
2.1.7
Control Box Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−6
2.1.8
Communications Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−6
2.2
REFRIGERATION SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−7
2.3
ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−8
2.4
SAFETY AND PROTECTIVE DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−9
2.5
REFRIGERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−10
2.5.1
Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−10
2.5.2
Economized Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−10
2.5.3
Electronic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−10
MICROPROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−1
3.1
3.2
3.3
T-340
TEMPERATURE CONTROL MICROPROCESSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−1
3.1.1
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−2
3.1.2
Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−2
3.1.3
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−3
CONTROLLER SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−3
3.2.1
Configuration Software (CnF Variables) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−3
3.2.2
Operational Software (Cd Function Codes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−4
MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−4
3.3.1
Start up - Compressor Phase Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−4
3.3.2
Start up - Compressor Bump Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−4
3.3.3
Perishable Mode Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−4
3.3.4
Perishable Pulldown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−4
3.3.5
Perishable Steady State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−4
3.3.6
Perishable Idle, Air Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−4
3.3.7
Perishable Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−4
3.3.8
Perishable Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−5
3.3.9
Perishable Dehumidification - Bulb Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−6
3.3.10 Perishable Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−6
3.3.11 Perishable Mode Cooling - Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−6
3.3.12 Perishable Mode Heating - Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−7
3.3.13 Perishable Mode - Trim Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−7
3.3.14 Frozen Mode - Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−7
3.3.15 Frozen Steady State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−7
3.3.16 Frozen Idle Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−7
3.3.17 Frozen “Heat” Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−8
ii
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
Page
3.3.18 Frozen Economy Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−8
3.3.19 Frozen Mode Cooling - Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−8
3.3.20 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−9
3.3.21 Automatic Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−9
3.3.22 Defrost Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−9
3.3.23 Defrost Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10
3.3.24 Defrost Related Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10
3.4 PROTECTION MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11
3.4.1 Evaporator Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11
3.4.2 Failure Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11
3.4.3 Generator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11
3.4.4 Compressor High Temperature, Low Pressure Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11
3.4.5 Perishable Mode - System Pressure Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11
3.4.6 Condenser Fan Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11
3.5 QUEST − CCPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−12
3.6 CONTROLLER ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−12
3.7 PRE−TRIP DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−12
3.8 DataCORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−13
3.8.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−13
3.8.2 DataCORDER Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−13
3.8.3 Sensor Configuration (dCF02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14
3.8.4 Logging Interval (dCF03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14
3.8.5 Thermistor Format (dCF04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14
3.8.6 Sampling Type (dCF05 & dCF06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−16
3.8.7 Alarm Configuration (dCF07 - dCF10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−16
3.8.8 DataCORDER Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−16
3.8.9 Pre-trip Data Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−16
3.8.10 DataCORDER Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−16
3.8.11 USDA Cold Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−17
3.8.12 USDA Cold Treatment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−17
3.8.13 DataCORDER Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−18
3.8.14 ISO Trip Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−18
3.9 CONTROLLER CONFIGURATION VARIABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−19
3.10 CONTROLLER FUNCTION CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−20
3.11 CONTROLLER ALARM INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−29
3.12 CONTROLLER PRE−TRIP TEST CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−1
4.1 INSPECTION (Before Loading) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−1
4.2 CONNECT POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−1
4.2.1 Connection To 380/460 VAC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−1
4.2.2 Connection To 190/230 VAC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−1
4.3 ADJUST FRESH AIR MAKEUP VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−1
4.3.1 Upper Fresh Air Makeup Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−2
4.3.2 Lower Fresh Air Makeup Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−2
4.3.3 Vent Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−3
iii
T-340
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
4.4
Page
eAutoFresh OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−3
4.4.1
eAutoFresh Pre−Trip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−3
4.4.2
eAutoFresh Start−Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−3
4.4.3
eAutoFresh Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−3
CONNECT WATER-COOLED CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−4
4.5
4.5.1
Water-Cooled Condenser with Water Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−4
4.5.2
Water−Cooled Condenser with Condenser Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−5
4.6
CONNECT REMOTE MONITORING RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−5
4.7
STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−5
4.7.1
Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−5
4.7.2
Stopping the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−5
START−UP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−5
4.8
4.8.1
Physical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−5
4.8.2
Check Controller Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−5
4.8.3
Start Temperature Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−5
4.8.4
Complete Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−5
PRE−TRIP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−6
4.10 PROBE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−7
4.11
EMERGENCY BYPASS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−1
4.9
5.1
UNIT WILL NOT START OR STARTS THEN STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−1
5.2
UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−1
5.3
UNIT RUNS BUT HAS INSUFFICIENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−2
5.4
UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−2
5.5
UNIT WILL NOT TERMINATE HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−2
5.6
UNIT WILL NOT DEFROST PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−2
5.7
ABNORMAL PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−3
5.8
ABNORMAL NOISE OR VIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−3
5.9
MICROPROCESSOR MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−3
5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−4
5.11
EAUTOFRESH NOT OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−4
5.12 ELECTRONIC EXPANSION VALVE MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−4
5.13 AUTOTRANSFORMER MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−5
5.14 WATER−COOLED CONDENSER OR WATER PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . .
5−5
5.15 COMPRESSOR OPERATING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−5
5.16 ABNORMAL TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−5
5.17 ABNORMAL CURRENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5−5
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−1
6.1
SECTION LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−1
6.2
MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−1
6.3
SERVICE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−2
6.4
PUMP DOWN THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−2
T-340
iv
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
6.5
6.6
Page
REFRIGERANT LEAK CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVACUATION AND DEHYDRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−3
6−3
6.6.1
6.6.2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−3
6−3
6.6.3
Complete System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−3
6.6.4 Partial System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−4
6−4
6.7.1
6.7.2
Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding Refrigerant to System (Full Charge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−4
6−4
6.7.3 Adding Refrigerant to System (Partial Charge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8 COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−4
6−5
6.8.1 Removal and Replacement of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9 HIGH PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−5
6−6
6.9.1
6.9.2
Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−6
6−6
6.10 CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.11 CONDENSER FAN AND MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−7
6−7
6.12 WATER−COOLED CONDENSER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.13 FILTER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−7
6−9
6.14 EVAPORATOR COIL & HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.1 Evaporator Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−9
6−9
6.14.2 Evaporator Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.15 EVAPORATOR FAN AND MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−10
6−10
6.15.1 Replacing the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.15.2 Disassemble the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−10
6−10
6.15.3 Assemble the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.16 EVAPORATOR SECTION CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−11
6−11
6.17 ELECTRONIC EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.17.1 Replacing Electronic Expansion Valve and Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−12
6−12
6.18 ECONOMIZER SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.19 ECONOMIZER EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−13
6−13
6.19.1 Economizer Expansion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.20 DIGITAL UNLOADER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−13
6−14
6.21 VALVE OVERRIDE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.22 AUTOTRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−15
6−16
6.23 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.23.1 Handling Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−16
6−16
6.23.2 Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.23.3 Controller Programming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−16
6−17
6.23.4 Removing and Installing a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.23.5 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−19
6−19
v
T-340
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
Page
6.24 TEMPERATURE SENSOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−19
6.24.1 Sensor Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−19
6.24.2 Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−22
6.24.3 Sensor Re-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−22
6.25 VENT POSITION SENSOR (VPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−24
6.26 eAutoFresh SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−25
6.26.1 Servicing the eAutoFresh Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−25
6.26.2 Checking eAutoFresh Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−25
6.26.3 Checking the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−26
6.26.4 Servicing the eAutoFresh Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−26
6.27 ELECTRONIC PARTLOW TEMPERATURE RECORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−28
6.28 MAINTENANCE OF PAINTED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−29
6.29 COMMUNICATIONS INTERFACE MODULE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−29
ELECTRICAL WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7−1
7.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7−1
LIST OF ILLUSTRATIONS
FIGURE NUMBER
Page
Figure 2−1 Refrigeration Unit − Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−1
Figure 2−2 Evaporator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−2
Figure 2−3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−3
Figure 2−4 Air−Cooled Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−4
Figure 2−5 Water−Cooled Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−5
Figure 2−6 Control Box Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−6
Figure 2−7 Refrigeration Circuit Schematic − Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−11
Figure 2−8 Refrigeration Circuit Schematic − Economized Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−12
Figure 3−1 Temperature Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−1
Figure 3−2 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−2
Figure 3−3 Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−3
Figure 3−4 Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−3
Figure 3−5 Controller Operation - Perishable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−5
Figure 3−6 Perishable Mode Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−6
Figure 3−7 Perishable Mode Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−7
Figure 3−8 Controller Operation - Frozen Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−8
Figure 3−9 Frozen Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−9
Figure 3−10 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−10
Figure 3−11 Standard Configuration Download Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−15
Figure 3−12 DataReader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−17
Figure 3−13 Alarm Troubleshooting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−28
Figure 4−1 Autotransformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−1
Figure 4−2 Upper Fresh Air Make Up Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−2
T-340
vi
LIST OF ILLUSTRATIONS (Continued)
FIGURE NUMBER
Page
Figure 4−3 Diagram of Emergency Bypass Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4−8
Figure 6−1 Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−1
Figure 6−2 R-134a Manifold Gauge/Hose Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−1
Figure 6−3 Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−2
Figure 6−4 Refrigeration System Service Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−3
Figure 6−5 Compressor Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−5
Figure 6−6 High Pressure Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−6
Figure 6−7 Water-Cooled Condenser Cleaning, Forced Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−8
Figure 6−8 Water-Cooled Condenser Cleaning - Gravity Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−9
Figure 6−9 5+1 Heater Arrangement − Omega Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−10
Figure 6−10 Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−11
Figure 6−11 Electronic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−12
Figure 6−12 Coil View of Economizer Solenoid Valve (ESV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−13
Figure 6−13 Economizer Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−13
Figure 6−14 View of Digital Unloader Valve (DUV) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−14
Figure 6−15 Autotransformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−16
Figure 6−16 Controller Section of the Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−17
Figure 6−17 Sensor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−22
Figure 6−18 Sensor and Cable Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−22
Figure 6−19 Supply Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−23
Figure 6−20 Return Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−23
Figure 6−21 Evaporator Temperature Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−23
Figure 6−22 Compressor Discharge Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−24
Figure 6−23 Stepper Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−25
Figure 6−24 Jumper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−26
Figure 6−25 Motor Cup Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−27
Figure 6−26 Electronic Partlow Temperature Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−28
Figure 6−27 Communications Interface Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−29
Figure 7−1 LEGEND − Standard Unit Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7−2
Figure 7−2 SCHEMATIC DIAGRAM − Standard Unit Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7−3
Figure 7−3 LEGEND − Configuration Includes Available Options
(Except Vent Positioning System, eAutoFresh, Emergency Bypass Options) . . . . . . . . . . . . . .
7−4
Figure 7−4 SCHEMATIC DIAGRAM − Configuration Includes Available Options
(Except Vent Positioning System, eAutoFresh, Emergency Bypass Options) . . . . . . . . . . . . . .
7−5
Figure 7−5 LEGEND − Configuration Includes eAutoFresh and Emergency Bypass Options . . . . . . . . . . . .
7−6
Figure 7−6 SCHEMATIC DIAGRAM − Configuration Includes eAutoFresh and Emergency Bypass Options
7−7
Figure 7−7 SCHEMATIC AND WIRING DIAGRAM − Upper Vent Position Sensor (VPS) Option . . . . . . . . .
7−8
Figure 7−8 SCHEMATIC AND WIRING DIAGRAM − Lower Vent Position Sensor (VPS) Option . . . . . . . . .
7−9
Figure 7−9 UNIT WIRING DIAGRAM − Standard Unit Configuration with 3−Phase Condenser Fan Motors
7−10
Figure 7−10 UNIT WIRING DIAGRAM − Configuration Includes Single Phase Condenser Fan Motor
& Optional Heater Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7−12
Figure 7−11 UNIT WIRING DIAGRAM − Configuration Includes eAutoFresh & Emergency Bypass Options
7−14
Figure 7−11 UNIT WIRING DIAGRAM − Configuration Includes eAutoFresh & Emergency Bypass Options
7−15
vii
T-340
LIST OF TABLES
TABLE NUMBER
Page
Table 2−1 Safety and Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3−1 Keypad Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2−9
3−2
Table 3−2 DataCORDER Configuration Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3−3 DataCORDER Standard Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−14
3−16
Table 3−4 Controller Configuration Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−19
Table 3−5 Controller Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3−6 Controller Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−20
3−29
Table 3−7 Controller Pre-trip Test Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3−8 DataCORDER Function Code Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−37
3−43
Table 3−9 DataCORDER Pre-trip Result Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3−10 DataCORDER Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3−44
3−45
Table 6−1 Valve Override Control Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 6−2 Sensor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−15
6−20
Table 6−3 Sensor Resistance (CPDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 6−4 R-134a Temperature - Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−21
6−30
Table 6−5 Recommended Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6−31
T-340
viii
SAFETY SUMMARY
SPECIFIC WARNING AND CAUTION STATEMENTS
GENERAL SAFETY NOTICES
The following general safety notices supplement specific warnings and cautions appearing elsewhere in this
manual. They are recommended precautions that must
be understood and applied during operation and maintenance of the equipment covered herein. The general
safety notices are presented in the following three sections labeled: First Aid, Operating Precautions and
Maintenance Precautions. A listing of the specific warnings and cautions appearing elsewhere in the manual
follows the general safety notices.
FIRST AID
An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.
To help identify the label hazards on the unit and explain
the level of awareness each one carries, an explanation
is given with the appropriate consequences:
DANGER - means an immediate hazard that WILL result in severe personal injury or death.
WARNING - means to warn against hazards or unsafe
conditions that COULD result in severe personal injury
or death.
CAUTION - means to warn against potential hazard or
unsafe practice that could result in minor personal injury,
product or property damage.
The statements listed below are applicable to the refrigeration unit and appear elsewhere in this manual. These
recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein.
WARNING
OPERATING PRECAUTIONS
Always wear safety glasses.
Keep hands, clothing and tools clear of the evaporator
and condenser fans.
No work should be performed on the unit until all circuit
breakers and start-stop switches are turned off, and
power supply is disconnected.
In case of severe vibration or unusual noise, stop the
unit and investigate.
MAINTENANCE PRECAUTIONS
Beware of unannounced starting of the evaporator and
condenser fans. Do not open the condenser fan grille or
evaporator access panels before turning power off, disconnecting and securing the power plug.
Be sure power is turned off before working on motors,
controllers, solenoid valves and electrical control
switches. Tag circuit breaker and power supply to prevent accidental energizing of circuit.
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with the system should be diagnosed, and any
necessary repairs performed by qualified service personnel.
When performing any arc welding on the unit or container, disconnect all wire harness connectors from the
modules in control boxes. Do not remove wire harness
from the modules unless you are grounded to the unit
frame with a static safe wrist strap.
In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).
Safety−1
EXPLOSION HAZARD: Failure to follow this
WARNING can result in death, serious
personal injury and / or property damage.
Never use air or gas mixtures containing
oxygen (O2) for leak testing or operating the
product.
Charge Only With R−134a: Refrigerant must
conform
to
AHRI
Standard
700
specification.
WARNING
Beware of unannounced starting of the
evaporator and condenser fans. The unit
may cycle the fans and compressor unexpectedly as control requirements dictate.
WARNING
Do not attempt to remove power plug(s) before turning OFF start-stop switch (ST), unit
circuit breaker(s) and external power
source.
WARNING
Make sure the power plugs are clean and
dry before connecting to power receptacle.
WARNING
Make sure that the unit circuit breaker(s)
(CB-1 & CB-2) and the START-STOP switch
(ST) are in the “O” (OFF) position before
connecting to any electrical power source.
T−340
WARNING
CAUTION
Make sure power to the unit is OFF and
power plug disconnected before replacing
the compressor.
Charge water−cooled condenser or receiver according to nameplate specifications to
ensure optimal unit performance.
WARNING
CAUTION
Before disassembly of the compressor, be
sure to relieve the internal pressure very
carefully by slightly loosening the couplings to break the seal.
Do not remove wire harnesses from controller modules unless you are grounded to
the unit frame with a static safe wrist strap.
WARNING
CAUTION
Do not use a nitrogen cylinder without a
pressure regulator.
Unplug all controller module wire harness
connectors before performing arc welding
on any part of the container.
WARNING
CAUTION
Do not open the condenser fan grille before
turning power OFF and disconnecting
power plug.
Do not attempt to use an ML2i PC card in an
ML3 equipped unit. The PC cards are physically different and will result in damage to
the controller.
WARNING
Oakite No. 32 is an acid. Be sure that the
acid is slowly added to the water. DO NOT
PUT WATER INTO THE ACID - this will cause
spattering and excessive heat.
CAUTION
Pre-trip inspection should not be performed with critical temperature cargoes in
the container.
WARNING
Wear rubber gloves and wash the solution
from the skin immediately if accidental contact occurs. Do not allow the solution to
splash onto concrete.
CAUTION
When Pre-Trip key is pressed, economy, dehumidification and bulb mode will be deactivated. At the completion of Pre-Trip activity, economy, dehumidification and bulb
mode must be reactivated.
WARNING
Always turn OFF the unit circuit breakers
(CB-1 & CB-2) and disconnect main power
supply before working on moving parts.
CAUTION
WARNING
When condenser water flow is below 11 lpm
(3 gpm) or when water-cooled operation is
not in use, the CFS switch MUST be set to
position “1” or the unit will not operate
properly.
Installation requires wiring to the main unit
circuit breaker, CB1. Make sure the power to
the unit is off and power plug disconnected
before beginning installation.
T−340
Safety−2
CAUTION
CAUTION
The scroll compressor achieves low
suction pressure very quickly. Do not use
the compressor to evacuate the system
below 0 psig. Never operate the
compressor with the suction or discharge
service valves closed (frontseated). Internal
damage will result from operating the
compressor in a deep vacuum.
When a failure occurs during automatic
testing, the unit will suspend operation
awaiting operator intervention.
CAUTION
When Pre-Trip test Auto 2 runs to completion without being interrupted, the unit will
terminate pre-trip and display “Auto 2”
“end.” The unit will suspend operation until
the user depresses the ENTER key!
CAUTION
Take necessary steps (place plywood over
coil or use sling on motor) to prevent motor
from falling into condenser coil.
CAUTION
CAUTION
Do not remove wire harnesses from module
unless you are grounded to the unit frame
with a static safe wrist strap.
The unit will remain in the full cooling mode
as long as the EB switch is in the On position and the Mode Switch is in the Full Cool
position. If the cargo can be damaged by
low temperatures, the operator must monitor container temperature and manually
cycle operation as required to maintain
temperature within required limits.
CAUTION
Unplug all module connectors before performing arc welding on any part of the container.
CAUTION
CAUTION
The unit must be OFF whenever a programming card is inserted or removed from the
controller programming port.
Allowing the scroll compressor to operate
in reverse for more than two minutes will result in internal compressor damage. Turn
the start-stop switch OFF immediately.
CAUTION
Use care when cutting wire ties to avoid
nicking or cutting wires.
CAUTION
CAUTION
To prevent trapping liquid refrigerant in the
manifold gauge set be sure set is brought to
suction pressure before disconnecting.
Do not allow moisture to enter wire splice
area as this may affect sensor resistance.
Safety−3
T−340
SECTION 1
INTRODUCTION
1.1 INTRODUCTION
1.3.4 Compressor
The unit is fitted with a scroll compressor equipped with
suction and discharge service connections.
1.3.5 Condenser Coil
The Carrier Transicold model 69NT40−561−001 to 199
series units are of lightweight aluminum frame
construction, designed to fit in the front of a container
and serve as the container’s front wall.
The unit is fitted with a four−row condenser coil using
7mm tubing.
They are one piece, self−contained, all electric units,
which include cooling and heating systems to provide
precise temperature control.
The units are supplied with a complete charge of
refrigerant R−134a and compressor lubricating oil, and
are ready for operation upon installation. Forklift
pockets are provided for unit installation and removal.
1.3.6 Evaporator
Evaporator section is equipped with an electronic
expansion valve (EEV).
1.3.7 Evaporator Fan Operation
Units are equipped with three−phase evaporator fan
motors. Opening of an evaporator fan internal protector
will shut down the unit.
1.3.8 Plate Set
The base unit operates on nominal 380/460 volt,
3−phase, 50/60 hertz (Hz) power. An optional
autotransformer may be fitted to allow operation on
nominal 190/230, 3−phase, 50/60 Hz power. Control
system power is provided by a transformer which steps
the supply power down to 18 and 24 volts, single phase.
Each unit is equipped with a tethered set of wiring
schematics and wiring diagram plates. The plate sets
are ordered using a seven−digit base part number and a
two−digit dash number.
The controller is a Carrier Transicold Micro−Link 3
microprocessor. The controller operates automatically
to select cooling, holding or heating as required to
maintain the desired set point temperature within very
close limits. The unit may also be equipped with an
electronic temperature recorder.
The controller has a keypad and display for viewing or
changing operating parameters. The display is also
equipped with lights to indicate various modes of
operation.
1.4 OPTION DESCRIPTIONS
Various options may be factory or field equipped to the
base unit. These options are described in the following
sub−paragraphs.
1.4.1 Battery
The refrigeration controller may be fitted with standard
replaceable batteries or a rechargeable battery pack.
Rechargeable battery packs may be fitted in the
standard location or in a secure location.
1.4.2 Dehumidification
1.2 CONFIGURATION IDENTIFICATION
Unit identification information is provided on a plate
located to the left of the receiver or water−cooled
condenser, on the back wall of the condenser section.
The plate provides the unit model number, the unit serial
number and the unit parts identification number (PID).
The model number identifies the overall unit
configuration, while the PID number provides
information on specific optional equipment, factory
provisioned to allow for field installation of optional
equipment and differences in detailed parts.
The unit may be fitted with a humidity sensor. This
sensor allows setting of a humidity set point in the
controller. In dehumidification mode, the controller will
operate to reduce internal container moisture level.
1.4.3 USDA
The unit may be supplied with fittings for additional
temperature probes, which allow recording of USDA
Cold Treatment data by the integral DataCORDER
function of the Micro−Link refrigeration controller.
1.3 FEATURE DESCRIPTIONS
1.3.1 Control Box
1.4.4 Interrogator
Units that use the DataCORDER function are fitted with
interrogator receptacles for connection of equipment to
download the recorded data. Two receptacles may be
fitted; one is accessible from the front of the container
and the other is mounted inside the container (with the
USDA receptacles).
1.4.5 Remote Monitoring
Units are equipped with either an aluminum or
composite material box, and may be fitted with a
lockable door.
1.3.2 Temperature Readout
The unit is fitted with suction and discharge temperature
sensors. The sensor readings may be viewed on the
controller display.
The unit may be fitted with a remote monitoring
receptacle. This item allows connection of remote
indicators for COOL, DEFROST and IN RANGE.
Unless otherwise indicated, the receptacle is mounted
at the control box location.
1.3.3 Pressure Readout
The unit is fitted with evaporator and discharge
transducers. The transducer readings may be viewed
on the controller display.
1−1
T−340
1.4.6 Quest − CCPC
1.4.15 460 Volt Cable
Various power cable and plug designs are available for
the main 460 volt supply. The plug options tailor the
cables to each customer’s requirements.
Compressor−Cycle Perishable Cooling (CCPC) is a
method of temperature control used during
steady−state perishable cooling that cycles the
compressor on and off according to supply / return air
temperature conditions.
1.4.16 230 Volt Cable
Units equipped with an autotransformer require an
additional power cable for connection to the 230 volt
source. Various power cable and plug designs are
available. The plug options tailor the cables to each
customer’s requirements.
1.4.7 Communications Interface Module
The unit may be fitted with a communications interface
module. The communications interface module is a
slave module, which allows communication with a
master central monitoring station. The module will
respond to communication and return information over
the main power line. Refer to the ship master system
technical manual for further information.
1.4.17 Cable Restraint
Various designs are available for storage of the power
cables. These options are variations of the compressor
section cable guard.
1.4.8 Autotransformer
An autotransformer may be provided to allow operation
on 190/230, 3−phase, 50/60 Hz power. The
autotransformer raises the supply voltage to the
nominal 380/460 volt power required by the base unit.
The autotransformer may also be fitted with an
individual circuit breaker for the 230 volt power.
1.4.18 Upper Air (Fresh Air Make Up)
The unit may be fitted with an upper fresh air makeup
assembly. The fresh air makeup assembly is available
with a vent positioning sensor (VPS) and may also be
fitted with screens.
1.4.19 Lower Air (Fresh Air Make Up)
If the unit is equipped with an autotransformer and
communications module, the autotransformer will be
fitted with a transformer bridge unit (TBU) to assist in
communications.
The unit may be fitted with a lower fresh air makeup
assembly. The fresh air makeup assembly is available
with a vent positioning sensor (VPS) and may also be
fitted with screens.
1.4.9 Temperature Recorder
1.4.20 Labels
Safety Instruction and Function Code listing labels
differ, depending on the options installed. Labels
available with additional languages are listed in the parts
list.
1.4.21 Controller
The unit may be fitted with an electronic temperature
recording device.
1.4.10 Gutters
Rain gutters may be fitted over the control box and
recorder section to divert rain away form the controls.
The different gutters include standard length bolted
gutters, extended length gutters, and riveted gutters.
Two replacement controllers are available:
1. Re−manufactured − Controller is the equivalent of a
new OEM controller and is supplied with a 12−month
warranty.
1.4.11 Handles
The unit may be equipped with handles to facilitate
access to stacked containers. These fixed handles are
located on either side of the unit.
2. Repaired − Controller has had previous faults repaired and upgraded with the latest software.
Note: Repaired controllers are NOT to be used for
warranty repairs; only full OEM Remanufactured
controllers are to be used.
1.4.12 Thermometer Port
The unit may be fitted with ports in the front of the frame
for insertion of a thermometer to measure supply and/or
return air temperature. If fitted, the port(s) will require a
cap and chain.
Controllers will be factory−equipped with the latest
version of operational software, but will NOT be
configured for a specific model number and will need to
be configured at the time of installation or sale.
1.4.13 Water Cooling
1.4.22 Condenser Grille
Two styles of condenser grilles are available: direct
bolted grilles and hinged grilles.
1.4.23 Emergency Bypass
The refrigeration system may be fitted with a
water−cooled condenser. The condenser is constructed
using copper−nickel tube for sea water applications.
The water−cooled condenser is in series with the air
cooled condenser and replaces the standard unit
receiver. When operating on the water−cooled
condenser, the condenser fan is deactivated by a water
pressure switch or condenser fan switch.
The optional Emergency Bypass switch (EB) functions
to bypass the controller in the event of controller failure.
1.4.24 eAutoFresh
The optional eAutoFresh venting system moderates the
atmospheric level inside the container unit in response
to cargo respiration.
1.4.14 Back Panels
Aluminum back panels may have access doors and/or
hinge mounting.
T−340
1−2
SECTION 2
DESCRIPTION
2.1 GENERAL DESCRIPTION
2.1.2 Fresh Air Makeup Vent
The function of the upper or lower makeup air vent is to
provide ventilation for commodities that require fresh air
circulation. A manually operated venting system is located in the upper left access panel.
The optional eAutoFresh vent system is to moderate the
atmospheric level in the container in response to cargo
respiration. When transporting frozen cargo loads the
vent will be closed. The upper left access panel contains
the vent slide and motor assembly. It may be removed to
allow entry into the evaporator section where the CO2
sensor and drive pack are located.
2.1.1 Refrigeration Unit − Front Section
The unit is designed so that the majority of the components are accessible from the front (see Figure 2−1).
The unit model number, serial number and parts identification number can be found on the serial plate to the left
of the receiver or water−cooled condenser on the back
wall of the condenser section.
19
18
1
17
2
16
15
3
14
13
12
11
10
4
9
8
1.
2.
3.
4.
5.
6.
7.
8.
9.
Access Panel (Evap. Fan #1)
Fork Lift Pockets
Control Box
Compressor
Ambient Sensor (AMBS)
Economizer
Filter Drier
Receiver or Water Cooled Condenser
Unit Serial Number, Model Number and
Parts Identification Number (PID) Plate
10. Power Cables and Plug (Location)
11. Condenser Fan
Figure 2−1 Refrigeration
2−1
12.
13.
14.
15.
16.
17.
18.
19.
7
6
5
Autotransformer (Location)
TransFRESH Communications Connector
Interrogator Connector (Front left)
Temperature Recorder
Lower Fresh Air Makeup Vent Location
(Blank Cover Shown)
TIR (Transports Internationaux Routiers)
Sealing Provisions − Typical All Panels
Upper Fresh Air Makeup Vent or eAutoFresh
(Automatic Vent) panel
Access Panel (Evap. Fan #2)
Unit − Front Section
T-340
If the unit is equipped with eAutoFresh, system components are mounted in addition to the standard refrigeration unit components. The stepper motor component is
installed in the vent; the air filter, CO2 sensor, stepper
motor drive and CO2 sensing lines are installed on the
rib of the upper grill.
2.1.3 Evaporator Section
The evaporator section (Figure 2−2) contains the return
temperature sensor, humidity sensor, electronic expansion valve, dual speed evaporator fans (EM1 and EM2),
evaporator coil and heaters, defrost temperature sensor, heat termination thermostat and evaporator temperature sensors (ETS1 and ETS2).
The evaporator fans circulate air through the container
by pulling it in the top of the unit, directing it through the
evaporator coil, where it is heated or cooled, and
discharging it at the bottom.
Most evaporator components are accessible by removing the upper rear panel (as shown in the illustration) or
by removing the evaporator fan access panels (see
Figure 2−1, Items 1 and 19).
15
14
13
12
3
2
11
4
1
16
9
10
21
20
6
19
18
17
7
8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
5
Evaporator Fan Motor #1 (EM1)
Return Recorder Sensor/Temperature Sensor
(RRS/RTS)
Humidity Sensor (HS)
Evaporator Fan Motor #2 (EM2)
Evaporator Coil
Evaporator Coil Heaters (Underside of Coil)
Heater Termination Thermostat (HTT)
Defrost Temperature Sensor (DTS)
Electronic Expansion Valve (EEV)
Evaporator Temperature Sensors (Location)
(ETS1 and ETS2)
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Air Filter
CO2 Sensor Sensing Line
CO2 Sensor (COS)
CO2 Sensor Outlet Line
Stepper Motor Drive (SD)
Stepper Motor (AF)
Interrogator Connector (Rear) (ICR)
USDA Probe Receptacle PR2
USDA Probe Receptacle PR1
USDA Probe Receptacle PR3
Cargo Probe Receptacle PR4
Figure 2−2 Evaporator Section
T-340
2−2
2.1.4 Compressor Section
pressure transducer (EPT) and the suction pressure
transducer (SPT).
The compressor section includes the compressor,
digital unloader valve (DUV), high pressure switch,
discharge pressure transducer (DPT), evaporator
The supply temperature sensor, supply recorder sensor
and ambient sensor are located to the left of the compressor.
16
11
2
1
3
10
12
9
13
8
14
4
5
6
15
7
1.
2.
3.
4.
5.
6.
7.
8.
Compressor
Compressor Discharge Temperature Sensor
(CPDS) (Location)
Discharge Connection
Suction Connection (Location)
Compressor Terminal Box
Oil Drain (Location)
Economizer Connection
Discharge Pressure Transducer (DPT)
9.
10.
11.
12.
13.
14.
15.
16.
Suction Pressure Transducer (SPT)
Digital Unloader Valve (DUV)
Evaporator Pressure Transducer (EPT)
Discharge Service Valve
High Pressure Switch (HPS)
Warning Label
Suction Service Valve
Supply Temperature/Supply Recorder Sensor
Assembly (STS/SRS)
Figure 2−3 Compressor Section
2−3
T-340
solenoid valve (ESV), and sight glass/moisture
indicator.
2.1.5 Air−Cooled Condenser Section
The air−cooled condenser section (Figure 2−4)
consists of the condenser fan, condenser coil, receiver,
liquid line service valve, filter drier, fusible plug,
economizer, economizer expansion valve, economizer
2
The condenser fan pulls air through the bottom of the
coil and discharges it horizontally through the condenser fan grille.
4
3
1
5
6
8
9
10
7
16
11
12
15
13
14
1.
2.
3.
4.
5.
6.
7.
8.
Grille and Venturi Assembly
Condenser Fan
Key
Condenser Fan Motor
Condenser Coil
Condenser Coil Cover
Receiver
Sight Glass
9.
10.
11.
12.
13.
14.
15.
16.
Filter Drier
Economizer
Economizer Solenoid Valve (ESV)
Economizer Expansion Valve
Warning Label
Service Access Valve
Liquid Level/Moisture Indicator
Fusible Plug
Figure 2−4 Air−Cooled Condenser Section
T-340
2−4
economizer solenoid valve (ESV), and moisture/liquid
indicator.
2.1.6 Water−Cooled Condenser Section
The water−cooled condenser section (Figure 2−5)
consists of a water−cooled condenser, sight glass,
rupture disc, filter drier, water couplings, water pressure
switch, economizer, economizer expansion valve,
2
The water−cooled condenser replaces the standard unit
receiver.
3
4
5
1
6
7
12
1.
2.
3.
4.
5.
6.
11
10
Water−Cooled Condenser
Rupture Disc
Moisture/Liquid Indicator
Filter Drier
Economizer
Economizer Solenoid Valve (ESV)
9
7.
8.
9.
10.
11.
12.
8
Economizer Expansion Valve
Coupling (Water In)
Liquid Line Service Valve/Connection
Self Draining Coupling (Water Out)
Water Pressure Switch (WP)
Sight Glass
Figure 2−5 Water−Cooled Condenser Section
2−5
T-340
2.1.8 Communications Interface Module
The communications interface module is a slave
module which allows communication between the
refrigeration unit and a ship system master central
monitoring station. The module will respond to
communication, and return information over the ships
main power line. Refer to the master system technical
manual for further information.
2.1.7 Control Box Section
The control box (Figure 2−6) includes: the manual
operation
switches,
circuit
breaker
(CB−1),
compressor, fan and heater contactors, control power
transformer, fuses, key pad, display module, current
sensor module, controller module and the
communications interface module.
1
2
3
4
5
6
7
8
9
10
18
1.
2.
3.
4.
5.
6.
7.
8.
9.
17
16
15
14
13
12
10.
11.
12.
13.
14.
15.
16.
17.
18.
Compressor Contactor − CH
Compressor Phase A Contactor − PA
Compressor Phase B Contactor − PB
Heater Contactor − HR
Display Module
Communications Interface Module
Controller/DataCORDER Module (Controller)
Key Pad
Remote Monitoring Receptacle
Start−Stop Switch, ST
Controller Battery Pack (Standard Location)
Interrogator Connector (Box Location)
Control Transformer
High Speed Evaporator Fan Contactor − EF
Low Speed Evaporator Fan Contactor − ES
Condenser Fan Contactor − CF
Circuit Breaker − 460V
Current Sensor Module
Figure 2−6 Control Box Section
T-340
2−6
11
2.2 REFRIGERATION SYSTEM DATA
a.
b.
c.
d.
e.
Model Number
Weight (With Oil)
Compressor/Motor
Assembly
Approved Oil
Oil Charge
Verify at −18C
Electronic Expansion Valve
(0F) container box
Superheat (Evaporator)
temperature
Verify
at −18C
Economizer Expansion
(0F)
container
box
Valve Superheat
temperature
Opens
Heater Termination Thermostat
Closes
Cut−Out
High Pressure Switch
Cut−In
ZMD26KVE−TFD−272
42.9 kg (95 lb)
Uniqema Emkarate RL−32−3MAF
1774 ml (60 ounces)
4.4 to 6.7C (8 to 12F)
4.4 to 11.1C (8 to 20F)
54 (+/− 3) C = 130 (+/− 5) F
38 (+/− 4) C = 100 (+/− 7) F
25 (+/− 1.0) kg/cm2 = 350 (+/− 10) psig
18 (+/− 0.7) kg/cm2 = 250 (+/− 10) psig
WARNING
EXPLOSION HAZARD: Failure to follow this WARNING can result in death, serious personal injury
and / or property damage.
Never use air or gas mixtures containing oxygen (O2) for leak testing or operating the product.
Charge Only With R−134a: Refrigerant must conform to AHRI Standard 700 specification.
Conforming to AHRI standard 700
f. Refrigerant
R−134a
specifications.
CAUTION
Charge water−cooled condenser or receiver
specifications to ensure optimal unit performance.
g. Refrigerant Charge
h. Fusible Plug
i. Rupture Disc
Water−Cooled
Condenser
to
nameplate
5.44 kg
(12 lbs)
4.99 kg
(11 lbs)
Receiver
Melting point
Torque
Bursts at
Torque
99C = (210F)
6.2 to 6.9 mkg (45 to 50 ft−lbs)
35 +/− 5% kg/cm2 = (500 +/− 5% psig)
6.2 to 6.9 mkg (45 to 50 ft−lbs)
Refer to unit model number plate.
0.5 +/− 0.2 kg/cm2 (7 +/− 3 psig)
1.6 +/− 0.4 kg/cm2 (22 +/− 5 psig)
j. Unit Weight
k. Water Pressure Switch
according
Cut−In
Cutout
2−7
T-340
2.3 ELECTRICAL DATA
CB−1 (25 amp)
CB−2 (50 amp)
a. Circuit Breaker
CB−2 (70 amp)
b. Compressor
Full Load Amps (FLA)
Motor
c. Condenser
Motor
d. Evaporator
Heaters
e. Evaporator
Motor(s)
f.
g.
h.
i.
Fan Full Load Amps
Horsepower
Rotations Per Minute
Voltage and Frequency
Bearing Lubrication
Rotation
Number of Heaters
Coil Rating
Resistance (cold)
Type
Fan
Full Load Amps
High Speed
Full Load Amps
Low Speed
Nominal Horsepower
High Speed
Nominal Horsepower
Evaporator Fan
Low Speed
Motor(s)
Rotations Per Minute
High Speed
Rotations Per Minute
Low Speed
Voltage and Frequency
Bearing Lubrication
Rotation
Control Circuit
Controller/DataCORDER
Fuses
Emergency Bypass
Electrical Output
Vent Positioning Supply Voltage
Sensor
Supply Current
Solenoid
Valve Nominal Resistance @
77F (25C)
Coils (ESV)
24 VDC
Maximum Current Draw
j. DUV Coils
12 VDC
Trips at 29 amps
Trips at 62.5 amps
Trips at 87.5 amps
13 amps @ 460 VAC
380 VAC, Single Phase,
460 VAC, Single Phase,
50 Hz
60 Hz
1.3 amps
1.6 amps
0.43 hp
0.75 hp
1425 rpm
1725 rpm
360 − 460 VAC +/− 2.5 Hz
400 − 500 VAC +/− 2.5 Hz
Factory lubricated, additional grease not required.
Counter−clockwise when viewed from shaft end.
6
750 watts +5/−10% each @ 230 VAC
66.8 to 77.2 ohms @ 20C (68F)
Sheath
380 VAC/3 PH/50 Hz
460 VAC/3 PH/60 Hz
1.0
1.2
0.6
0.6
0.49
0.84
0.06
0.11
2850 rpm
3450 rpm
1425 rpm
1725 rpm
360 − 460 VAC +/− 1.25 Hz
400 − 500 VAC +/− 1.5 Hz
Factory lubricated, additional grease not required
CW when viewed from shaft end
7.5 amps (F3A,F3B)
5 amps (F1 & F2)
10 amps (FEB)
0.5 VDC to 4.5 VDC over 90 degree range
5 VDC +/− 10%
5 mA (typical)
7.7 ohms +/− 5%
0.7 amps
Nominal Resistance @
77F (20C)
14.8 ohms +/− 5%
Maximum Current Draw
Coil Feed to Ground
k. EEV
Nominal (Gray Wire)
Resistance
Coil Feed to Coil Feed
T-340
929 mA
47 ohms
95 ohms
2−8
Section 2.3 − ELECTRICAL DATA−CONTINUED
Orange wire
Power
Red wire
Output
Brown wire
Ground
Input voltage
5 VDC
Output voltage
0 to 3.3 VDC
l. Humidity Sensor
Output voltage readings verses relative humidity (RH) percentage:
30%
0.99 V
50%
1.65 V
70%
2.31 V
90%
2.97 V
2.4 SAFETY AND PROTECTIVE DEVICES
Unit components are protected from damage by safety
and protective devices listed in Table 2−1. These devices monitor the unit operating conditions and open a
set of electrical contacts when an unsafe condition occurs.
Open safety switch contacts on either or both of devices
IP−CP or HPS will shut down the compressor.
Open safety switch contacts on device IP−CM will shut
down the condenser fan motor.
The entire refrigeration unit will shut down if one of the
following safety devices open: (a) circuit breaker(s); (b)
fuse (F3A/F3B, 7.5A); or (c) evaporator fan motor internal protector(s) − (IP).
Table 2−1 Safety and Protective Devices
UNSAFE CONDITION
Excessive current draw
DEVICE
DEVICE SETTING
Circuit Breaker (CB−1, 25 amp) − Manual Reset
Trips at 29 amps (460 VAC)
Circuit Breaker (CB−2, 50 amp) − Manual Reset
Trips at 62.5 amps (230 VAC)
Circuit Breaker (CB−2, 70 amp) − Manual Reset
Trips at 87.5 amps (230 VAC)
Excessive current draw in the
control circuit
Fuse (F3A & F3B)
Excessive current draw by the
controller
Fuse (F1 & F2)
5 amp rating
Excessive current draw by the
Emergency Bypass module
Fuse (FEB)
10 amp rating
Excessive condenser fan
motor winding temperature
Internal Protector (IP−CM) − Automatic Reset
N/A
Excessive compressor motor
winding temperature
Internal Protector (IP−CP) − Automatic Reset
N/A
Excessive evaporator fan
motor(s) winding temperature
Internal Protector(s) (IP−EM) − Automatic Reset
N/A
Abnormal pressures/temperatures in the high refrigerant
side
Abnormally high discharge
pressure
7.5 amp rating
Fusible Plug − Used on the Receiver
99C = (210F)
Rupture Disc − Used on the Water−Cooled Con- 35 kg/cm2 = (500 psig)
denser
High Pressure Switch (HPS)
2−9
Opens at 25 kg/cm2
(350 psig)
T-340
During the standard mode of operation, the normally
closed digital unloader valve (DUV) controls the system
refrigerant flow and capacity by loading and unloading
the compressor in frequent discrete time intervals. If the
system capacity has been decreased to the lowest allowable capacity with the DUV, the unit will enter a trim
heat mode of operation, during which the controller will
pulse the evaporator heaters in sequence with the compressor digital signal in order to absorb the excess capacity.
2.5 REFRIGERATION CIRCUIT
2.5.1 Standard Operation
Starting at the compressor, (see Figure 2−7, upper
schematic) the suction gas is compressed to a higher
pressure and temperature.
The refrigerant gas flows through the discharge line and
continues into the air−cooled condenser. When operating with the air−cooled condenser active, air flowing
across the coil fins and tubes cools the gas to saturation
temperature. By removing latent heat, the gas condenses to a high pressure/high temperature liquid and
flows to the receiver, which stores the additional charge
necessary for low temperature operation.
2.5.2 Economized Operation
In the economized mode, (see Figure 2−8) the frozen
and pull down capacity of the unit is increased by subcooling the liquid refrigerant entering the electronic expansion valve. Overall efficiency is increased because
the gas leaving the economizer enters the compressor
at a higher pressure, therefore requiring less energy to
compress it to the required condensing conditions.
When operating with the water−cooled condenser active (see Figure 2−7, lower schematic), the refrigerant
gas passes through the air−cooled condenser and enters the water−cooled condenser shell. The water flowing inside the tubing cools the gas to saturation temperature in the same manner as the air passing over the
air−cooled condenser. The refrigerant condenses on
the outside of the tubes and exits as a high temperature
liquid. The water−cooled condenser also acts as a receiver, storing refrigerant for low temperature operation.
Liquid refrigerant for use in the economizer circuit is taken from the main liquid line as it leaves the filter drier.
The flow is activated when the controller energizes the
economizer solenoid valve (ESV).
The liquid refrigerant flows through the ESV to the expansion valve internal passages, absorbing heat from
the liquid refrigerant flowing to the electronic expansion
valve. The resultant “medium” temperature/pressure
gas enters the compressor at the economizer port fitting.
The liquid refrigerant continues through the liquid line,
the filter drier (which keeps refrigerant clean and dry)
and the economizer (not active during standard operation) to the electronic expansion valve.
When the control air temperature falls to 2.0C (3.6F)
above set point, the DUV unloads the compressor’s
scroll and begins to reduce the capacity of the unit. Percentage of the unit capacity is accessed through code
select 01 (Cd01). For example, if Cd01 displays 70, it indicates that the compressor is operating unloaded with
the DUV engaged 30% of the time.
As the liquid refrigerant passes through the variable
orifice of the expansion valve, the pressure drops to
suction pressure. In this process some of the liquid
vaporizes to a gas (flash gas), removing heat from the
remaining liquid. The liquid exits as a low pressure, low
temperature, saturated mix. Heat is then absorbed from
the return air by the balance of the liquid, causing it to
vaporize in the evaporator coil. The vapor then flows
through the suction tube back to the compressor.
2.5.3 Electronic Expansion Valve
The microprocessor controls the superheat leaving the
evaporator via the electronic expansion valve (EEV),
based on inputs from the evaporator pressure transducer (EPT). The microprocessor transmits electronic
pulses to the EEV stepper motor, which opens or closes
the valve orifice to maintain the superheat set point.
On systems fitted with a water pressure switch, the condenser fan will be off when there is sufficient pressure to
open the switch. If water pressure drops below the
switch cut out setting, the condenser fan will automatically start.
T-340
2−10
STANDARD OPERATION WITH RECEIVER
COMBO
ETS1 AND 2
EVAPORATOR
ELECTRONIC
EXPANSION
VALVE
CONDENSER
DIGITAL
UNLOADER
VALVE
ECON.
TXV
SENSING
BULB
DISCHARGE
TEMPERATURE
SENSOR
ECONOMIZER
SOLENOID
VALVE
DISCHARGE
SERVICE
VALVE
SIGHT
GLASS
ECONOMIZER
TXV
FILTER
DRIER
ECONOMIZER
LIQUID LINE
SERVICE
VALVE
EVAPORATOR
PRESSURE
TRANSDUCER
LIQUID LEVEL/
MOISTURE
INDICATOR
SUCTION
PRESSURE
TRANSDUCER
DISCHARGE
PRESSURE
TRANSDUCER
SUCTION
SERVICE
VALVE
RECEIVER
COMPRESSOR
STANDARD OPERATION WITH WATER−COOLED CONDENSER
EVAPORATOR
ETS1 AND 2
ELECTRONIC
EXPANSION
VALVE
CONDENSER
DIGITAL
UNLOADER
VALVE
DISCHARGE
TEMPERATURE
SENSOR
ECONOMIZER
SOLENOID
VALVE
DISCHARGE
SERVICE
VALVE
ECONOMIZER
TXV
EVAPORATOR
PRESSURE
TRANSDUCER
DISCHARGE
PRESSURE
TRANSDUCER
FILTER
DRIER
ECONOMIZER
MOISTURE
INDICATOR
LIQUID LINE
SERVICE
VALVE
SUCTION
PRESSURE
TRANSDUCER
SIGHT
GLASS
WATER−COOLED
CONDENSER
SUCTION
SERVICE
VALVE
COMPRESSOR
DISCHARGE
LIQUID
SUCTION
Figure 2−7 Refrigeration Circuit Schematic − Standard Operation
2−11
T-340
ELECTRONIC
EXPANSION
VALVE
ECON.
TXV
SENSING
BULB
ECONOMIZER
SOLENOID
VALVE
ECONOMIZER
TXV
ECONOMIZER
LIQUID LINE
SERVICE
VALVE
RECEIVER
COMPRESSOR
LIQUID
Figure 2−8 Refrigeration Circuit Schematic − Economized Operation
T-340
2−12
ECONOMIZER
PRESSURE
SECTION 3
MICROPROCESSOR
The DataCORDER software functions to record unit
operating
parameters
and
cargo temperature
parameters for future retrieval. Coverage of the
temperature control software begins with paragraph 3.2.
Coverage of the DataCORDER software is provided in
paragraph 3.8.
The keypad and display module serve to provide user
access and readouts for both of the controller functions,
temperature control and DataCORDER. The functions
are accessed by keypad selections and viewed on the
display module. The components are designed to
permit ease of installation and removal.
3.1 TEMPERATURE CONTROL
MICROPROCESSOR SYSTEM
The temperature control Micro-Link 3 microprocessor
system (see Figure 3−1) consists of a keypad, display
module, the control module (controller) and
interconnecting wiring. The controller houses the
temperature control software and the DataCORDER
software. The temperature control software functions to
operate the unit components as required to provide the
desired cargo temperature and humidity.
DISPLAY MODULE
CONTROL MODULE
TEMPERATURE CONTROL SOFTWARE
KEYPAD
CONFIGURATION
SOFTWARE
CONFIGURATION
VARIABLE
(CnF##)
OPERATIONAL
SOFTWARE
FUNCTION
CODE (Cd)
ALARMS
(AL<70)
Pre-trip
INTERROGATION
CONNECTOR
TO
DISPLAY
DATAREADER
DataCORDER SOFTWARE
CONFIGURATION
SOFTWARE
CONFIGURATION
VARIABLE
(dCF## read only)
OPERATIONAL
SOFTWARE
FUNCTION
CODE (dC)
ALARMS
(AL>68)
DATA
STORAGE
MEMORY
TO
DISPLAY
(Scrollback)
TO
DISPLAY
Computer Device
With DataLINE
Software
Operation/Config.
PCMCIA CARD
Data Bank
PCMCIA CARD
Figure 3−1 Temperature Control System
3−1
T-340
3.1.1 Keypad
Table 3−1 Keypad Function
KEY
The Keypad (Figure 3−2) is mounted on the right-hand
side of the control box. The keypad consists of eleven
push button switches that act as the user’s interface
with the controller. Descriptions of the switch functions
are provided in Table 3−1.
CODE SELECT Accesses function codes.
PRE TRIP
Displays Pre-trip selection menu.
Discontinues Pre-trip in progress.
ALARM LIST
Displays alarm list and clears the
alarm queue.
MANUAL
DEFROST /
INTERVAL
CODE
SELECT
PRE
TRIP
ALARM
LIST
MANUAL
DEFROST/
INTERVAL
ENTER
ENTER
RETURN
SUPPLY
C
F
BATTERY
POWER
ALT.
MODE
Figure 3−2 Keypad
3.1.2 Display Module
The display module (Figure 3−3) consists of two 5-digit
displays and seven indicator lights. The indicator lights
include:
Displays selected defrost mode.
Depress and hold the MANUAL
DEFROST / INTERVAL key for
five (5) seconds to initiate defrost
using the same logic as if the optional manual defrost switch was
toggled on.
Confirms a selection or saves a
selection to the controller.
Arrow Up
Change or scroll a selection up.
Pre-trip advance or test interrupt.
Arrow Down
Change or scroll selection downward. Pre-trip repeat backward.
RETURN /
SUPPLY
Display non-controlling probe temperature (momentary display).
Celsius /
Fahrenheit
Display alternate English/Metric
scale (momentary display). When
set to F, pressure is displayed in
psig and vacuum in “/hg.” “P” appears after the value to indicate
psig and “i” appears for inches of
mercury. When set to C, pressure
readings are in bars. “b” appears
after the value to indicate bars.
BATTERY
POWER
Initiate battery backup mode to allow set point & function code selection if AC power is not connected.
ALT MODE
This key is pressed to switch the
functions from temperature software to the DataCORDER software. The remaining keys function
the same as described above except the readings or changes are
made to the DataCORDER programming.
NOTE
The controlling probe in perishable range is the
SUPPLY air probe and the controlling probe in
frozen range is the RETURN air probe.
1. COOL - White or Blue LED: Energized when the refrigerant compressor is energized.
5. SUPPLY - Yellow LED: Energized when the supply
air probe is used for control. When this LED is illuminated, the temperature displayed in the AIR TEMPERATURE display is the reading at the supply air
probe. This LED will flash if dehumidification or humidification is enabled.
6. RETURN - Yellow LED: Energized when the return
air probe is used for control. When this LED is illuminated, the temperature displayed in the AIR TEMPERATURE display is the reading at the return air
probe.
7. ALARM - Red LED: Energized when an active or an
inactive shutdown alarm in the alarm queue.
2. HEAT - Orange LED: Energized to indicate heater
operation in heat mode, defrost mode, or
dehumidification.
3. DEFROST - Orange LED: Energized when the unit
is in defrost mode.
4. IN RANGE - Green LED: Energized when the controlled temperature probe is within the specified tolerance of set point.
T-340
FUNCTION
3−2
3.2 CONTROLLER SOFTWARE
COOL
HEAT DEFROST IN RANGE ALARM
SETPOINT/Code
The controller software is a custom designed program
that is subdivided into configuration software and operational software. The controller software performs the following functions:
SUPPLY RETURN
a. Control supply or return air temperature to required
limits, provide modulated refrigeration operation,
economized operation, unloaded operation, electric
heat control, and defrost. Defrost is performed to
clear buildup of frost and ice to ensure proper air flow
across the coil.
AIR TEMPERATURE/Data
b. Provide default independent readouts of set point and
supply or return air temperatures.
Figure 3−3 Display Module
3.1.3 Controller
c. Provide ability to read and (if applicable) modify the
configuration software variables, operating software
Function Codes and Alarm Code indications.
CAUTION
Do not remove wire harnesses from controller modules unless you are grounded to
the unit frame with a static safe wrist strap.
d. Provide a Pre-trip step-by-step checkout of refrigeration unit performance including: proper component
operation, electronic and refrigeration control operation, heater operation, probe calibration, pressure
limiting and current limiting settings.
CAUTION
e. Provide battery-powered ability to access or change
selected codes and set point without AC power
connected.
Unplug all controller module wire harness
connectors before performing arc welding
on any part of the container.
f. Provide the ability to reprogram the software through
the use of a memory card.
CAUTION
3.2.1 Configuration Software (CnF Variables)
Do not attempt to use an ML2i PC card in an
ML3 equipped unit. The PC cards are physically different and will result in damage to
the controller.
NOTE
Do not attempt to service the controller modules. Breaking the seal will void the warranty.
The Micro-Link 3 controller is a dual module microprocessor as shown in Figure 3−4. It is fitted with test
points, harness connectors and a software card programming port.
1
1.
2.
3.
4.
2
3
3
4
Configuration software is a variable listing of the
components available for use by the operational
software. This software is factory installed in
accordance with the equipment fitted and options listed
on the original purchase order. Changes to the
configuration software are required only when a new
controller has been installed or a physical change has
been made to the unit such as the addition or removal of
an option. A configuration variable list is provided in
Table 3−4. Change to the factory-installed configuration
software is achieved via a configuration card or by
communications.
5
Mounting Screw
Micro-Link 3 Control/DataCORDER Module
Connectors
Test Points
3
5.
6.
7.
8.
6
7
3
8
3
Fuses
Control Circuit Power Connection
Software Programming Port
Battery Pack (Standard Location)
Figure 3−4 Control Module
3−3
T-340
The compressor will start for 1 second, then pause for
five seconds. This sequence will be repeated two more
times. After the final bump start the unit will pre-position
the EEV to the correct starting position, pause and start
up.
3.2.2 Operational Software (Cd Function Codes)
The operational software is the actual operation
programming of the controller which activates or
deactivates components in accordance with current unit
operating conditions and selected modes of operation.
3.3.3 Perishable Mode Temperature Control
The programming is divided into function codes. Some
of the codes are read only, while the remaining codes
may be user configured. The value of the user
configurable codes can be assigned in accordance with
user desired mode of operation. A list of the function
codes is provided in Table 3−5.
In Perishable Mode, the controller maintains the supply
air temperature at set point, the SUPPLY indicator light
is illuminated and the default reading on the display window is the supply temperature sensor reading.
When the supply air temperature enters the in-range
temperature tolerance (Cd30), the green IN-RANGE
light will energize.
To access the function codes:
a. Press CODE SELECT, then press an arrow key until
the left window displays the desired function code.
When CnF26 (Heat Lockout Temperature) is set to
-10C, perishable mode is active with set points above
-10C (+14F). When CnF26 is set to -5C, perishable
mode is active with set points above -5C (+23F).
b. The right window will display the selected function
code value for five seconds before returning to normal display mode.
3.3.4 Perishable Pulldown
c. If additional time is required, pressing the ENTER key
will extend the display time to 30 seconds.
When the system is in Perishable Pulldown Mode, the
highest priority is given to bringing the container down to
set point. When cooling from a temperature that is more
than 2.5C (4.5F) above set point, the system will be in
perishable pulldown mode in economized operation.
3.3 MODES OF OPERATION
General operation sequences for cooling, heating and
defrost are provided in the following sub-paragraphs.
Schematic representation of controller operation is
provided in Figure 3−5 & Figure 3−8.
However, pressure and current limit functions may restrict the valve if either exceeds the preset value.
3.3.5 Perishable Steady State
Operational software responds to various inputs. These
inputs come from the temperature and pressure
sensors, the temperature set point, the settings of the
configuration variables and the function code
assignments. The action taken by the operational
software changes as the input values change. Overall
interaction of the inputs is described as a “mode” of
operation. The modes of operation include perishable
(chill) mode and frozen mode. Descriptions of the
controller interaction and modes of operation are
provided in the following sub paragraphs.
Perishable Steady State is used to maintain the control
temperature near a setpoint that is above the heat lockout temperature.
Once set point is reached, the unit will transition to perishable steady state mode. This results in unloaded operation by cycling the DUV to limit capacity and maintain
steady temperature control.
The unit is capable of maintaining supply air temperature to within +/-0.2C (+/-0.36F) of set point. Supply
air temperature is controlled by positioning of the electronic expansion valve (EEV), cycling of the digital unloader valve (DUV), cycling of the compressor, and cycling of the heaters.
3.3.1 Start up - Compressor Phase Sequence
At start up, the controller logic checks for proper phase
sequencing and compressor rotation. If incorrect sequencing is causing the compressor and three-phase
evaporator fan motors to rotate in the wrong direction,
the controller will energize or de-energize relay TCP as
required (see Figure 7-2). Relay TCP will switch its contacts, energizing or de-energizing relays PA and PB.
Relay PA is wired to energize the circuits on L1, L2 and
L3. Relay PB is wired to energize the circuits on L3, L2,
and L1, thus providing reverse rotation.
3.3.6 Perishable Idle, Air Circulation
Perishable Idle Mode is used when it is unnecessary to
run the compressor to maintain control temperature. If
the controller has determined that cooling is not required
or the controller logic determines suction pressure is at
the low pressure limit, the unit will transition to Perishable Idle Mode. During Perishable Idle Mode, the compressor is turned off, but the evaporator fans continue to
run to circulate air throughout the container. If temperature rises +0.2C above set point, the unit will transition
back to perishable steady state.
3.3.2 Start up - Compressor Bump Start
At start up, the controller logic will initiate a compressor
bump start procedure to clear liquid refrigerant from the
compressor. If suction and discharge pressures have
equalized, the compressor will perform three compressor bump starts. A compressor bump start may also
occur after a defrost cycle has been completed.
3.3.7 Perishable Heating
When it is necessary to raise the control temperature,
the system will enter Perishable Heating Mode. If the
temperature drops to 0.5C (0.9F) below set point, the
unit will transition to Perishable Heating Mode, and the
heaters will be energized. The unit will transition back to
Perishable Idle Mode when the temperature rises to
0.2C (0.4F) below the set point, and the heaters will
de-energize.
During Bump Start, the EEV will close. Relays TS, TQ,
TN, TE, and TV will be de-energized (opened). The result of this action will close the ESV and shut all fans off.
T-340
3−4
Pull Down
Perishable Mode
(Only Applicable to Perishable Mode)
Controller Set Point ABOVE −10°C (+14°F),
or−5°C (+23°F) optionally
Controller Set Point ABOVE −10°C (+14°F),
or−5°C (+23°F) optionally
+2.5°C
(+4.5°F)
Cooling,
Unloaded
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
−.20°C
Air Circulation
Cooling,
Economized
+.20°C
−.20°C
−.50°C
−.20°C
−.50°C
Heating
Falling
Temperature
Cooling,
Unloaded
ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
Air Circulation
Set
Point
−.20°C
Heating
Rising
Temperature
Figure 3−5 Controller Operation - Perishable Mode
If any condition except item (1) becomes false OR if the
relative humidity sensed is 2% below the dehumidification set point, the high speed evaporator fans will be
energized.
3.3.8 Perishable Dehumidification
Dehumidification is provided to reduce the humidity
levels inside the container. Dehumidification is activated
when a humidity value is set at Cd33. The yellow
SUPPLY LED will flash ON and OFF every second to
indicate that dehumidification is active. Once
dehumidification is active and the following conditions
are satisfied, the controller will activate the heat relay to
begin dehumidification.
1. The humidity sensor reading is above the humidity
set point (Cd33).
2. The unit is in perishable steady state and supply air
temperature is less than 0.25_C (0.45_F) above set
point.
3. The heater debounce timer (three minutes) has
timed out.
4. Heater termination thermostat (HTT) is closed.
If the above conditions are true for at least one hour the
evaporator fans will switch from high speed to low
speed. Evaporator fan speed will then switch every
hour, as long as the 4 conditions are met (see Bulb
Mode, Section 3.3.9 for different evaporator fan speed
options).
During dehumidification power is applied to the defrost
heaters. This added heat load causes the controller to
open the EEV to match the increased heat load while
still holding the supply air temperature very close to the
set point.
Opening the EEV reduces the temperature of the
evaporator coil surface, which increases the rate at
which water is condensed and removes water from the
passing air. Removing water from the air reduces the
relative humidity. When the relative humidity sensed is
2% below set point, the controller de-energizes the heat
relay. The controller will continue to cycle heating to
maintain relative humidity below the selected set point.
If dehumidification is terminated by a condition other
than the humidity sensor, e.g., an out-of-range or
compressor shutdown condition, the heat relay is
de-energized immediately.
3−5
T-340
Two timers are activated during dehumidification to prevent rapid cycling and consequent contactor wear:
In order to initiate economy fan mode, a perishable set
point must be selected prior to activation. When economy fan mode is active, the evaporator fans will be controlled as follows:
At the start of each cooling or heating cycle, the
evaporator fans will run in high speed for three
minutes. They will then be switched to low speed any
time the supply air temperature is within +/- 0.2C
(0.36F) of the set point and the return air temperature
is less than or equal to the supply air temperature
+3C (5.4F). The fans will continue to run in low
speed for one hour. At the end of the hour, the
evaporator fans will switch back to high speed and the
cycle will be repeated. If bulb mode is active, economy
fan mode will be overridden.
1. Heater debounce timer (three minutes) - The heater
debounce timer is started whenever the heater
contactor status is changed. The heat contactor remains energized (or de-energized) for at least three
minutes even if the set point criteria are satisfied.
2. Out-of-range timer (five minutes) - The out-of-range
timer is started to maintain heater operation during a
temporary out-of-range condition. If supply air temperature remains outside of the user selected
in-range setting for more than five minutes, the heaters will be de-energized to allow the system to recover. The out-of-range timer starts as soon as temperature exceeds in-range tolerance value set by Cd30.
3.3.9 Perishable Dehumidification - Bulb Mode
3.3.11 Perishable Mode Cooling - Sequence of
Operation
Bulb mode is an extension of dehumidification which
allows changes to the evaporator fan speed and/or
defrost termination set points.
NOTE
In Standard Perishable Mode, the evaporator
motors run in high speed. In Economy Fan
Mode, the fan speed is varied.
Bulb mode is active when Cd35 is set to “Bulb.” Once
bulb mode is activated, the user may then change
dehumidification evaporator fan operation from the
default (speed alternates from low to high each hour) to
constant low or constant high speed. This is done by
toggling Cd36 from its default of “alt” to “Lo” or “Hi” as
desired. If low speed evaporator fan operation is
selected, this gives the user the additional capability of
selecting dehumidification set points from 60 to 95%
(instead of the normal 65 to 95%).
a. When supply air temperature is above set point and
decreasing, the unit will cool with the condenser fan
motor (CF), compressor motor (CH), and evaporator
fan motors (EF) energized, and the white COOL light
illuminated. (See Figure 3−6). Also, if current or
pressure limiting is not active, the controller will close
contacts TS to open the economizer solenoid valve
(ESV) and place the unit in economized operation.
In addition, if bulb mode is active, Cd37 may be set to
override the previous defrost termination thermostat
(DTT) settings. The temperature at which the DTT will
be considered “open” may be changed [in 0.1C (0.2F)
increments] to any value between 25.6C (78F) and
4C (39.2F). The temperature at which the DTT is
considered closed for interval timer start or demand
defrost is 10C for “open” values from 25.6C (78F)
down to a 10C setting. For “open” values lower than
10C, the “closed” values will decrease to the same
value as the “open” setting. Bulb mode is terminated
when:
ENERGIZED
DE-ENERGIZED
ST
TC
HPS
CH
CF
TN
IP-CM
TV
1. Bulb mode code Cd35 is set to “Nor.”
IP-EM1
2. Dehumidification code Cd33 is set to “Off.”
TS
When bulb mode is disabled by any of the above conditions, evaporator fan operation for dehumidification
reverts to “alt” and the DTS termination setting resets to
the value determined by CnF41.
EF
ES
TE
IP-EM2
TH
HTT
3. The user changes the set point to one that is in the
frozen range.
EF
HR
ESV
Figure 3−6 Perishable Mode Cooling
b. When supply air temperature decreases to a predetermined tolerance above set point (Cd30), the green
IN RANGE light is illuminated.
3.3.10 Perishable Economy
Economy fan mode is an extension of the Perishable
Mode, and is provided for power saving purposes. Economy fan mode is activated when Cd34 (also used for
Frozen Economy Mode) is set to “ON.” Economy fan
mode is used in the transportation of temperature-tolerant cargo or non-respiration items which do not require
high airflow for removing respiration heat.
There is no active display that indicates that economy
fan mode has been initiated. To check for economy fan
mode, perform a manual display of Cd34.
T-340
24 VOLT POWER
F
c. As air temperature continues to fall, unloaded cooling
starts (DUV pulses opens) as the supply air temperature approaches set point. (See Figure 3−5).
d. When unloaded cooling starts, EEV control will transition from a full cool superheat set point to a lower
modulated cool superheat set point. Once unloading
starts, the EEV controls evaporator superheat based
on the system duty cycle where instantaneous superheat will vary.
3−6
e. When the supply air temperature has fallen to within
1.9C (3.4F) of set point temperature and the average capacity of the system has fallen below 70%, the
unit will open contacts TS to close the ESV and take
the unit out of economized operation.
ENERGIZED
DE-ENERGIZED
ST
F
TC
HPS
f. The controller continuously monitors supply air temperature. Once the supply air temperature falls below
set point, the controller periodically records supply air
temperature, set point and time. A calculation is then
performed to determine temperature drift from set
point over time. If the calculation determines that
cooling is no longer required, contacts TC and TN are
opened to de-energize the compressor motor and the
condenser fan motor. In addition the controller will
close the EEV.
24 VOLT POWER
CH
CF
TN
IP-CM
TV
IP-EM1
TS
ES
TE
IP-EM2
TH
HTT
EF
EF
HR
ESV
Figure 3−7 Perishable Mode Heating
g. The evaporator fan motors continue to run to circulate
air throughout the container. The green IN RANGE
light remains illuminated as long as the supply air
temperature is within tolerance of the set point.
NOTE
The EEV and DUV are independently operated
by the microprocessor. For full diagrams and
legend, see Section 7.
h. If the supply air temperature increases to 1.0C
(1.8F) above set point and three minutes have
elapsed, contacts TC and TN close to restart the
compressor and condenser fan motors in standard
mode (non-economized) operation. The white COOL
light is also illuminated.
3.3.13 Perishable Mode - Trim Heat
If the system capacity has been decreased to the lowest
allowable capacity and conditions exist that warrant maximum temperature stability the controller will pulse the HR
relay to energize the evaporator heaters in sequence with
the compressor digital signal.
3.3.14 Frozen Mode - Temperature Control
In Frozen Mode, the controller maintains the return air
temperature at set point, the yellow RETURN indicator
light is illuminated, and the default reading on the display
window is the return temperature sensor (RTS) reading.
When the return air temperature enters the in-range
temperature tolerance (Cd30), the green IN-RANGE
light will energize.
When CnF26 (Heat Lockout Temperature) is set to
-10C, frozen mode is active with set points below
-10C (+14F). When CnF26 is set to -5C, frozen
mode is active with set points below -5C (+23F).
When the system is in Frozen Mode, the highest priority
is given to bringing the container down to set point, the
system will remain in economized operation.
3.3.15 Frozen Steady State
Frozen cargos are not sensitive to minor temperature
changes, and the frozen temperature control system
takes advantage of this to greatly improve the energy efficiency of the unit. Frozen range temperature control is
accomplished by cycling the compressor on and off as
the load demand requires.
Once the frozen set point is reached, the unit will transition to frozen steady state (economized operation).
3.3.16 Frozen Idle Mode
When temperature drops to set point minus 0.2C and
the compressor has run for at least five minutes, the unit
will transition to the frozen idle mode. The compressor is
turned off and the evaporator fans continue to run to circulate air throughout the container. If temperature rises
above set point +0.2C, the unit will transition back to
the frozen steady state mode.
i. If the average system capacity has risen to 100% during unloaded cooling and three minutes off time has
elapsed, relay TS will energize to open the ESV, placing the unit in economized mode.
j. If the supply air increases more than 2.5C (4.5F)
above set point temperature, the microprocessor will
transition the evaporator superheat control from
modulation back to full cool control.
3.3.12 Perishable Mode Heating - Sequence of
Operation
a. If the supply air temperature decreases 0.5C
(0.9F) below set point, the system enters the heating
mode. (See Figure 3−5). The controller closes contacts TH (see Figure 3−7) to allow power flow through
the heat termination thermostat (HTT) to energize the
heaters (HR). The orange HEAT light is also illuminated. The evaporator fans continue to run to circulate
air throughout the container.
b. When the supply air temperature rises to 0.2C
(0.4F) below set point, contact TH opens to de-energize the heaters. The orange HEAT light is also
de-energized. The evaporator fans continue to run to
circulate air throughout the container.
c. The safety heater termination thermostat (HTT) is attached to an evaporator coil circuit and will open the
heating circuit if overheating occurs.
3−7
T-340
Frozen Mode
Controller Set Point at or BELOW −10°C (+14°F),
or −5°C (+23°F) optionally
+2.5°C
(+4.5°F)
Cooling,
Economized
−.20°C
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍÍ
Falling
Rising
+.20°C
Set Point
Air Circulation
Temperature
Temperature
Figure 3−8 Controller Operation - Frozen Mode
3.3.19 Frozen Mode
Operation
3.3.17 Frozen “Heat” Mode
If the temperature drops 10_C below set point, the unit
will transition to the frozen “heating” mode. The evaporator fans are brought to high speed, and the heat from
the fans is circulated through the container. The unit will
transition back to frozen steady state when the temperature rises back to the transition point.
-
Sequence
of
a. When the return air temperature is above set point
and decreasing, the unit will transition to economized
cooling with the condenser fan motor (CF), compressor motor (CH), economizer solenoid valve
(ESV), low speed evaporator fan motors (ES) energized and the white COOL light illuminated. (See
Figure 3−9).
3.3.18 Frozen Economy Mode
In order to activate Frozen Economy Mode, a frozen set
point temperature must be selected, and Cd34
(Economy Mode) set to “ON.” When economy mode is
active, the system will perform normal frozen mode
operations except that the entire refrigeration system,
excluding the controller, will be turned off when the
control temperature is less than or equal to the set point
-2C. After an off-cycle period of 60 minutes, the unit will
turn on high speed evaporator fans for three minutes,
and then check the control temperature. If the control
temperature is greater than or equal to the frozen set
point +0.2C, the unit will restart the refrigeration
system and continue to cool until the off-cycle
temperature criteria are met. If the control temperature
is less than the frozen set point +0.2C, the unit will turn
off the evaporator fans and restart another 60 minute
off-cycle.
T-340
Cooling
b. When the return air temperature decreases to a predetermined tolerance above set point, the green INRANGE light is illuminated.
c. When the return air temperature decreases to 0.2C
(0.4F) below set point, contacts TC, TS and TN are
opened to de-energize the compressor, economizer
solenoid valve and condenser fan motor. The white
COOL light is also de-energized. The EEV will close.
d. The evaporator fan motors continue to run in low
speed to circulate air throughout the container. The
green IN-RANGE light remains illuminated as long as
the return air is within tolerance of set point.
e. If return air temperature drops to 10C (18F) or
more below set point, the evaporator fans increase to
high speed.
3−8
f. When the return air temperature increases to 0.2C
(0.4F) above set point and three minutes have
elapsed, the EEV opens and contacts TC, TS and TN
close to restart the compressor, open the ESV and
restart the condenser fan motor. The white COOL is
illuminated.
3.3.21 Automatic Defrost
In perishable mode, perishable-pull down mode, or
frozen mode, automatic defrost starts with an initial defrost set to three hours and then adjusts the interval to
the next defrost based on the accumulation of ice on the
evaporator coil. In this way, defrosts are scheduled to
occur only when necessary.
ENERGIZED
DE-ENERGIZED
ST
F
TC
HPS
IP-CM
CH
CF
TN
TV
IP-EM1
TS
EF
TH
HTT
All defrost interval times reflect the number of compressor run time hours since the last defrost cycle. The
minimum defrost interval in the automatic setting is
three hours while the maximum is 24, refer to Section
3.3.22, Defrost Intervals for more information.
ES
TE
IP-EM2
In frozen mode, once the frozen set point has been
reached, automatic defrost will set the time interval to 12
hours for the first two defrosts, and then adjust to 24
hours thereafter.
24 VOLT POWER
EF
In frozen mode the amount of actual time necessary to
accumulate defrost interval time will exceed the defrost
interval time by a factor of two to three depending on the
compressor duty-cycle. Defrost interval time is only accumulated when the compressor is running, and the Defrost Termination Sensor (DTS) reads less than 10C
(50F), at which point the Defrost Termination Thermostat (DTT) is considered closed.
HR
ESV
Figure 3−9 Frozen Mode
If defrost does not terminate correctly and temperature
reaches the set point of the Heat Termination Thermostat (HTT), the HTT will open to de-energize the heaters
(AL59 & AL60). If the HTT does not open and termination does not occur within two hours, the controller will
terminate defrost. AL60 will be activated to inform of a
possible DTS failure.
NOTE
The EEV and DUV are independently operated
by the microprocessor. Complete schematics
and legends are located in Section 7.
3.3.22 Defrost Initiation
3.3.20 Defrost
Initiation of defrost is dependent on the state of the Defrost Temperature Thermostat (DTT). The functionality
of the DTT is controlled by the system software, based
on the temperature reading of the Defrost Termination
Sensor (DTS). In the case of a failed DTS, the RTS may
be used to determine the state of the DTT.
Defrost is initiated to remove ice buildup from the evaporator coil which can obstruct air flow and reduce the
cooling capacity of the unit. The defrost cycle may consist of up to three distinct operations. The first is de-icing
of the coil, the second is a probe check cycle and the
third is snap freeze.
Defrost cannot be initiated when the DTT is considered
OPEN, because an open DTT indicates that the temperature is too high for ice to build up. Defrost can only occur when the temperature sensed by the DTS is low
enough to CLOSE the DTT.
De-icing of the coil consists of removing power to the
cooling components (compressor, evaporator fans,
condenser fan), closing the EEV, and turning on the
heaters, which are located below the evaporator coil.
During normal operation, de-icing will continue until
temperatures indicate that the ice on the coil has been
removed, proper air flow has been restored, and the unit
is ready to control temperature efficiently.
If the DTT is closed, the unit is in Perishable or Frozen
Mode, and the Controlled Atmosphere Vent is closed (if
applicable), then defrost can be initiated when any one
of the following additional conditions become true:
After de-icing, and depending on unit configuration, a
Defrost/Probe Check and/or Snap Freeze may occur:
1. Manual defrost is initiated by the operator. The
Manual Defrost Switch (MDS), located on the front of
the unit, is a momentary toggle switch that must be
held closed until defrost is initiated. The MDS is ignored during Pretrip, and the DTT must be considered CLOSED for MDS activation to work.
During Defrost / Probe Check, the evaporator fans
are allowed to run for a period of time after de-icing in
order to validate the accuracy of the temperature
sensors, and confirm that defrost was executed properly. Refer to Section 4.10, Probe Diagnostics for additional information.
Manual defrost can also be initiated by pressing the
MANUAL DEFROST/INTERVAL key for greater
than 5 seconds, or pressing the PRE TRIP key and
the ALT MODE key for greater than 5 seconds. If the
two key method is used the display may show “P” or
“Dc” while waiting for defrost to initiate.
Defrost / Snap Freeze allows the system to cool for a
period of time after de-icing, with the evaporator fans
turned off. This allows for the removal of latent
de-icing heat from the evaporator coils, and freezes
any remaining moisture that might otherwise be
blown into the container.
2. The Defrost Interval Timer reaches or exceeds the
Defrost Interval.
3−9
T-340
3. During Pretrip, defrost may occur during tests P-8,
and P-10. Defrost is forced during Pretrip test P-9.
When defrost is initiated, the controller closes the EEV,
opens contacts TC, TN and TE (or TV) to de-energize
the compressor, condenser fan and evaporator fans.
The white COOL light is also de-energized. The controller then closes contacts TH to supply power to the heaters, and the orange DEFROST light is illuminated.
When the DTS reading rises to the DTT setting, the
de-icing operation is terminated.
4. Temperature Probe Diagnostics logic determines
that a Probe Check is necessary based on temperature values currently reported by the supply and return probes.
5. An Initiate Defrost command is sent via communications.
ENERGIZED
DE-ENERGIZED
6. The microprocessor can determine if defrost is required by calculating the difference between return
air temperature and supply air temperature (Delta
T). If the temperature difference between return air
and supply air is too great, it indicates reduced airflow over the evaporator coil, and a defrost cycle
may be required:
ST
24 VOLT POWER
F
TC
HPS
PB
CF
TN
IP-CM
TV
a. In Perishable Pull Down - Defrost will be initiated if
Delta T increases to greater than 12C, DTT is
closed, and 90 minutes of compressor run time
have been recorded.
IP-EM1
b. In Frozen Mode - Defrost will be initiated if Delta T
increases to greater than 16C, DTT is closed, and
90 minutes of compressor run time have been recorded.
TS
c. In Perishable Steady State – A baseline Delta T is
used to determine when defrost should be activated. The baseline is recorded after completion of
an initial defrost cycle. In order to record a baseline
Delta T, the unit must be cooling, and the evaporator fans and heaters must remain in a stable state
for a period of five minutes. Defrost will then be initiated if Delta T increases to greater than 4C above
the baseline, the DTT is closed, and 90 minutes of
compressor run time have been recorded.
ES
TE
IP-EM2
TH
HTT
EF
EF
HR
ESV
Figure 3−10 Defrost
NOTE
The EEV and DUV are independently operated
by the microprocessor. Complete schematics
and legends are located in Section 7.
3.3.23 Defrost Interval
NOTE
During defrost, the Defrost Relay is energized,
the orange DEFROST light is illuminated, and
the orange HEAT light is illuminated.
There are two modes for defrost initiation, user-selected
timed intervals and automatic control.
The user-selected values are (OFF), 3, 6, 9, 12, 24
hours, AUTO, or PuLS; factory default is 3 hours.
Defrost may be initiated any time the defrost temperature sensor reading falls below the controller DTT set
point. Defrost will terminate when the defrost temperature sensor reading rises above the DTT set point. The
DTT is not a physical component. It is a controller setting
that acts as a thermostat, “closing” (allowing defrost)
when the defrost temperature sensor reading is below
the set point and “opening” (terminating or preventing
defrost) when the sensor temperature reading is above
set point. When the unit is operating in bulb mode (refer
to paragraph 3.3.9), special settings may be applicable.
Automatic defrost starts with an initial defrost at three
hours and then adjusts the interval to the next defrost
based on the accumulation of ice on the evaporator coil.
Following a start-up or after termination of defrost, the
time will not begin counting down until the DTS reading
falls below set point (DTT closed). If the reading of DTS
rises above set point (DTT open) any time during the
timer count down, the interval is reset and the countdown starts over.
3.3.24 Defrost Related Settings
If the controller is programmed with the Lower DTT setting option, the defrost termination thermostat set point
may be configured to the default of 25.6C (78F) or
lowered to 18C (64F). When a request for defrost is
made through the manual defrost switch, communications or probe check the unit will enter defrost if the DTT
reading is at or below the DTT setting. Defrost will terminate when the DTS reading rises above the DTT setting. When a request for defrost is made with the defrost
interval timer or by demand defrost, the defrost temperature setting must be below 10C (50F).
T-340
If probe check (CnF31) is configured to SPECIAL, the
unit will proceed to the next operation (snap freeze or
terminate defrost). If CnF31 is configured to STANDARD, the unit will perform a probe check. The probe
check is a test that compares temperature sensor readings to determine if any sensors have failed.
If probe check fails, the system will run for eight minutes
to validate. At the end of eight minutes, probe alarms will
be set or cleared based on the current conditions.
3−10
When the return air temperature falls to 7C (45F), the
controller ensures that the defrost temperature sensor
(DTS) reading has dropped to 10C or below. If it has
not it indicates a failed DTS, a DTS failure alarm is
triggered and the defrost mode is operated by the return
temperature sensor (RTS).
3.4.4 Compressor
High
Pressure Protection
Temperature,
Low
The controller continuously monitors compressor discharge pressure and temperature, and suction pressure. If discharge pressure or temperature rises above
the allowed limit or suction pressure falls below the allowed limit, the compressor will be cycled off and on
every 3 minutes. Condenser and evaporator fans will
continue to operate during the compressor off cycle.
If controller function code CnF33 is configured to snap
freeze, the controller will sequence to this operation.
The snap freeze consists of running the compressor
without the evaporator fans in operation for a period of 4
minutes at 100% capacity. When the snap freeze is
completed, defrost is terminated.
If high compressor dome temperature occurs, as measured by the CPDS, the controller will allow additional refrigerant to be released into the system in order to
provide cooling to the evaporator coil and compressor
dome. The controller is alerted to high compressor
dome temperatures via the CPDS when ambient temperature is greater than 43.3C, return air temperature
is less than -17.5C and the compressor discharge temperature is greater than 117.7C.
If CnF23 is configured to “SAv” (save), then the value of
the defrost interval timer will be saved at power down
and restored at power up. This option prevents short
power interruptions from resetting an almost expired defrost interval, and possibly delaying a needed defrost
cycle.
CnF11 determines whether the operator will be allowed
to chose “OFF” as a defrost interval option.
Dome temperature control logic will disengage when return air temperature and ambient temperature return to
allowed limits or when the compressor turns off.
CnF64 determines whether the operator will be allowed
to choose “PuLS” as a defrost interval option. For units
operating with “PuLS” selected, defrost interval is determined by the unit temperature setpoint and the Evaporator Fan Pulsing Temperature Setting (Cd60). When
the unit temperature setpoint is equal to or less than the
Evaporator Fan Pulsing Temperature Setting, the defrost interval is set to 6 hours. Otherwise, the defrost interval is determined using the Automatic Defrost Interval Determination logic. In either case, “PuLS” remains
displayed in this function select code.
If the suction pressure low limit is triggered, the DUV will
energize to raise the suction pressure.
3.4.5 Perishable
Regulation
Mode
-
System
Pressure
In perishable mode, system pressures may need to be
regulated at ambient temperatures of 20C (68F) and
below. Once below this ambient temperature, the condenser fan may cycle on and off based on limits imposed
for discharge pressure. For extremely cold ambient
temperatures, -18C (0F), heater cycling may occur
within normal system operation based on discharge
pressure limits.
After a new Defrost Interval is selected, the previously
selected Interval is used until the next defrost termination, the next time the DTT contacts are OPEN, or the
next time power to the control is interrupted. If the previous value or the new value is “OFF”, the newly selected
value will be used immediately.
If any Auto Pretrip sequence is initiated, Cd27 will be set
to ’AUTO’ unless CnF49 (OEM Reset) is set to “Custom” AND CnF64 (Evaporator Fan Pulsing Logic) configuration variable is set to IN, in which case Cd27 will be
set to “PuLS”.
3.4.6 Condenser Fan Override
When CnF17 (Discharge Temperature Sensor) is set to
“In” and CnF48 (Condenser Fan Switch Override) is set
to “On”, the condenser fan switch override logic is activated. If condenser cooling water pressure is sufficient
to open the water pressure switch (de-energizing the
condenser fan) when water flow or pressure conditions
are not maintaining discharge temperature, the logic will
energize the condenser fan as follows:
3.4 PROTECTION MODES OF OPERATION
3.4.1 Evaporator Fan Operation
Opening of an evaporator fan internal protector will shut
down the unit.
3.4.2 Failure Action
1. If the DUV is less than 80% open when the controller
calls for it to be100% open, the condenser fan is energized. When the DUV is 100% open, the fan will
de-energize.
Function code Cd29 may be operator set to select the
action the controller will take upon a system failure. The
factory default is full system shutdown. Refer to
Table 3−5.
2. If DPT reading is invalid or out of range (AL65), the
condenser fan is energized and will remain energized until system power is cycled.
3.4.3 Generator Protection
Function codes Cd31(Stagger Start, Offset Time) and
Cd32 (Current Limit) may be operator set to control the
start up sequence of multiple units and operating current
draw. The factory default allows on demand starting (no
delay) of units and normal current draw. Refer to
Table 3−5.
3. If the system is running on condenser fan override
and the high pressure switch opens, the condenser
fan is energized and will remain energized until the
system power is cycled.
3−11
T-340
c. The left display will show “AL##,” where ## is the
alarm number sequentially in the queue.
3.5 QUEST − CCPC
Compressor-Cycle Perishable Cooling (CCPC) is a
method of temperature control used during steady-state
perishable cooling that cycles the compressor on and off
according to return air temperature.
d. The right display will show the actual alarm code.
“AA##” will display for an active alarm, where “##” is
the alarm code. Or “IA##” will display for an inactive
alarm, see Table 3−6.
To be eligible for steady-state control the unit must first
complete a setpoint pulldown phase and a CCPC
pulldown phase:
e. “END” is displayed to indicate the end of the alarm list
if any alarms are active.
During setpoint pulldown supply air temperature is
controlled according to the unit’s nominal supply air
setpoint.
f. “CLEAr” is displayed if all alarms are inactive. The
alarm queue may then be cleared by pressing
ENTER. The alarm list will clear and “‐‐‐‐‐” will be displayed.
During CCPC pulldown the supply air temperature is
lowered somewhat relative to the nominal setpoint.
Evaporator fans are forced to operate at high speed.
NOTE
AL26 is active when none of the sensors are responding. Check the connector at the back of the
controller; if it is loose or unplugged, reconnect it,
then run a Pre-trip test (P5) to clear AL26.
Steady-state CCPC control maintains the same
lowered supply air temperature that was used during
CCPC pulldown. The compressor cycles on and off
according to return air high and low limits. Depending on
the fan mode of operation selected, the evaporator fans
may be programmed to run at low speed some or all of
the time according to the control logic.
3.7
Pre-trip Diagnostics is an independent controller function that suspends normal refrigeration controller activities and provides preprogrammed test routines. The
test routine can be run in Auto Mode, which automatically performs a pre programmed sequence of tests, or
Manual Mode, which allows the operator to select and
run any of the individual tests.
3.6 CONTROLLER ALARMS
Alarm display is an independent controller software
function. If an operating parameter is outside of expected range or a component does not return the correct signals back to the controller, an alarm is generated. A listing of the alarms is provided in Table 3−6.
The alarm philosophy balances the protection of the refrigeration unit and that of the refrigerated cargo. The
action taken when an error is detected always considers
the survival of the cargo. Rechecks are made to confirm
that an error actually exists.
CAUTION
Pre-trip inspection should not be performed with critical temperature cargoes in
the container.
Some alarms requiring compressor shutdown have
time delays before and after to try to keep the compressor on line. An example is alarm code “LO,” (low main
voltage), when a voltage drop of over 25% occurs, an indication is given on the display, but the unit will continue
to run.
CAUTION
When an Alarm Occurs:
When the Pre-trip key is pressed economy,
dehumidification and bulb mode will be deactivated. At the completion of the Pre-trip
test, economy, dehumidification and bulb
mode must be reactivated.
a. The red alarm light will illuminate for alarm code numbers 15, 17, 20, 21, 22, 23, 24, 25, 26, and 27.
b. If a detectable problem exists, its alarm code will be
alternately displayed with the set point on the left
display.
A Pre-trip test may be initiated by use of the keypad or
via communication, but when initiated by communication the controller will execute the entire battery of tests
(auto mode).
c. The user should scroll through the alarm list to determine what alarms exist or have existed. Alarms must
be diagnosed and corrected before the Alarm List can
be cleared.
To Display Alarm Codes:
At the end of a Pre-trip test, the message “P,” “rSLts”
(pretest results) will be displayed. Pressing ENTER will
allow the user to see the results for each of the
sub-tests. The results will be displayed as “PASS” or
“FAIL” for each test run to completion.
a. While in the Default Display mode, press the ALARM
LIST key. This accesses the Alarm List Display Mode,
which displays any alarms archived in the alarm
queue.
A detailed description of the Pre-trip tests and test
codes is provided in Table 3−7. Detailed operating instructions are provided in Paragraph 4.9.
b. The alarm queue stores up to 16 alarms in the sequence in which they occurred. The user may scroll
through the list by depressing an ARROW key.
T-340
PRE−TRIP DIAGNOSTICS
3−12
3.8 DataCORDER
3.8.1 Description
Supply Air Temperature
Real Time Clock Battery (Internal) Replacement
Carrier Transicold “DataCORDER” software is integrated into the controller and serves to eliminate the
temperature recorder and paper chart. DataCORDER
functions may be accessed by keypad selections and
viewed on the display module. The unit is also fitted with
interrogation connections (see Figure 3−1) which may
be used with the Carrier Transicold DataReader to
download data. A personal computer with Carrier Transicold DataLINE software installed may also be used to
download data and configure settings.
Real Time Clock Modification
Trip Start
ISO Trip Header (When entered via Interrogation
program)
Economy Mode Start and End
“Auto 1/Auto 2/Auto 3” Pre-trip Start and End
Bulb Mode Start
The DataCORDER consists of:
Configuration Software
Bulb Mode Changes
Operational Software
Bulb Mode End
Data Storage Memory
USDA Trip Comment
Real Time Clock (with internal battery backup)
Humidification Start and End
Six Thermistor Inputs
USDA Probe Calibration
Interrogation Connections
Fresh Air Vent Position
Power Supply (battery pack)
3.8.2 DataCORDER Software
The DataCORDER Software is subdivided into
Operational Software, Configuration Software, and the
Data Memory.
a. Operational Software
The Operational Software reads and interprets inputs
for use by the Configuration Software. The inputs are
labeled Function Codes. Controller functions (see
Table 3−8, page 3−43) which the operator may access
to examine the current input data or stored data. To
access these codes, do the following:
1. Press the ALT. MODE and CODE SELECT keys.
2. Press an arrow key until the left window displays the
desired code number. The right window will display
the value of this item for five seconds before returning to the normal display mode.
3. If a longer display time is desired, press the ENTER
key to extend the display time to 30 seconds.
b. Configuration Software
The configuration software controls the recording and
alarm functions of the DataCORDER. Reprogramming
to the factory-installed configuration is achieved via a
configuration card. Changes to the unit DataCORDER
configuration may be made using the DataLINE
interrogation software.
A list of the configuration variables is provided in
Table 3−2. Descriptions of DataCORDER operation for
each variable setting are provided in the following paragraphs.
The DataCORDER performs the following functions:
a. Logs data at 15, 30, 60 or 120 minute intervals and
stores two years of data (based on one hour interval).
b. Records and displays alarms on the display module.
c. Records results of Pre-trip testing.
d. Records DataCORDER and temperature control
software generated data and events as follows:
Container ID Change
Software Upgrades
Alarm Activity
Battery Low (battery pack)
Data Retrieval
Defrost Start and End
Dehumidification Start and End
Power Loss (with and without battery pack)
Power Up (with and without battery pack)
Remote Probe Temperatures in the Container
(USDA Cold treatment and Cargo probe recording)
Return Air Temperature
Set Point Change
3−13
T-340
8. Main voltage
3.8.3 Sensor Configuration (dCF02)
Two modes of operation may be configured, the Standard Mode and the Generic Mode.
a. Standard Mode
In the standard mode, the user may configure the DataCORDER to record data using one of seven standard
configurations. The seven standard configuration variables, with their descriptions, are listed in Table 3−3.
The inputs of the six thermistors (supply, return, USDA
#1, #2, #3 and cargo probe) and the humidity sensor input will be generated by the DataCORDER. See
Figure 3−11.
9. Evaporator expansion valve percentage
10. Discrete outputs (Bit mapped - require special
handling if used)
11. Discrete inputs (Bit mapped - require special
handling if used)
12. Ambient sensor
13. Evaporator temperature sensor
14. Compressor discharge sensor
NOTE
The DataCORDER software uses the supply
and return recorder sensors (SRS, RRS). The
temperature control software uses the supply
and return temperature sensors (STS, RTS).
15. Return temperature sensor (RTS)
16. Supply temperature sensor (STS)
17. Defrost temperature sensor
18. Discharge pressure transducer
b. Generic Mode
The generic recording mode allows user selection of the
network data points to be recorded. The user may select
up to a total of eight data points for recording. A list of the
data points available for recording follows. Changing the
configuration to generic and selecting which data points
to record may be done using the Carrier Transicold Data
Retrieval Program.
19. Suction pressure transducer
20. Condenser pressure transducer
21. Vent position sensor (VPS)
3.8.4 Logging Interval (dCF03)
The user may select four different time intervals between data recordings. Data is logged at exact intervals
in accordance with the real time clock. The clock is factory set at Greenwich Mean Time (GMT).
3.8.5 Thermistor Format (dCF04)
The user may configure the format in which the thermistor readings are recorded. The short resolution is a 1
byte format and the long resolution is a 2 byte format.
The short requires less memory and records temperature with variable resolutions depending on temperature
range. The long records temperature in 0.01C
(0.02F) steps for the entire range.
1. Control mode
2. Control temperature
3. Frequency
4. Humidity
5. Phase A current
6. Phase B current
7. Phase C current
Table 3−2 DataCORDER Configuration Variables
CONFIGURATION NO.
T-340
TITLE
DEFAULT
OPTION
dCF01
(Future Use)
--
--
dCF02
Sensor Configuration
2
2,5,6,9,54,64,94
dCF03
Logging Interval (Minutes)
60
15,30,60,120
dCF04
Thermistor Format
Short
Long
dCF05
Thermistor Sampling Type
A
A,b,C
dCF06
Controlled Atmosphere/Humidity Sampling Type
A
A,b
dCF07
Alarm Configuration USDA Sensor 1
A
Auto, On, Off
dCF08
Alarm Configuration USDA Sensor 2
A
Auto, On, Off
dCF09
Alarm Configuration USDA Sensor 3
A
Auto, On, Off
dCF10
Alarm Configuration Cargo Sensor
A
Auto, On, Off
3−14
Raw Data Report for ABC1234567
May 31, 2007 to Jun 04, 2007
System Configuration at the Time of Interrogation:
Interrogated On May 05, 2007
Extracted by DataLINE Rev 1.0.0
Controller Software: 5327
Controller Serial #: 04163552
Bill of Lading #: 1
Origin:
Origin Date:
Destination:
Discharge Date:
Comment: DataLINE Tool
Probe Calibration Readings: USDA1: 0.0 USDA2: 0.0 USDA3: 0.0 Cargo: 0.0
Temperature Units: Centigrade
________________________________________________________________________________________
May 31, 2007
Setpoint: 1.66, Container :
Serial : 04189552
9 Sensors Logged at 15 Minute Interval
Sensor
Format
Resolution
Figure 3−11 Standard Configuration Download Report
3−15
T-340
2. Controller DC battery pack power: If a battery pack is
installed, the DataCORDER will power up for
communication when an interrogation cable is
plugged into an interrogation receptacle.
Table 3−3 DataCORDER Standard Configurations
Standard
Config.
Description
2 sensors
(dCF02=2)
2 thermistor inputs (supply & return)
5 sensors
(dCF02=5)
2 thermistor inputs (supply & return)
3 USDA thermistor inputs
6 sensors
(dCF02=6)
2 thermistor inputs (supply & return)
3 USDA thermistor inputs
1 humidity input
9 sensors
(dCF02=9)
Not Applicable
3. External DC battery pack power: A 12 volt battery
pack may also be plugged into the back of the
interrogation cable, which is then plugged into an
interrogation port. No controller battery pack is
required with this method.
4. Real Time Clock demand: If the DataCORDER is
equipped with a charged battery pack and AC power
is not present, the DataCORDER will power up when
the real time clock indicates that a data recording
should take place. When the DataCORDER is finished recording, it will power down.
6 sensors 2 thermistor inputs (supply & return)
(dCF02=54) 3 USDA thermistor inputs
1 cargo probe (thermistor input)
2 thermistor inputs (supply & return)
7 sensors 3 USDA thermistor inputs
(dCF02=64) 1 humidity input
1 cargo probe (thermistor input)
During DataCORDER power-up, while using battery-pack power, the controller will perform a hardware
voltage check on the battery. If the hardware check
passes, the controller will energize and perform a software battery voltage check before DataCORDER logging. If either test fails, the real time clock battery
power-up will be disabled until the next AC power cycle.
Further DataCORDER temperature logging will be prohibited until that time.
2 thermistor inputs (supply & return)
3 USDA thermistor inputs
10 sensors
(dCF02=94) 1 humidity input
1 cargo probe (thermistor input)
3 C.A. inputs (NOT APPLICABLE)
An alarm will be generated when the battery voltage
transitions from good to bad indicating that the battery
pack needs recharging. If the alarm condition persists
for more than 24 hours on continuous AC power, it indicates that the battery pack needs replacement.
3.8.6 Sampling Type (dCF05 & dCF06)
Three types of data sampling are available: average,
snapshot and USDA. When configured to average, the average of readings taken every minute over the recording
period is recorded. When configured to snapshot, the
sensor reading at the log interval time is recorded. When
USDA is configured, supply and return temperature readings are averaged and the three USDA probe readings are
snapshot.
3.8.9 Pre-trip Data Recording
3.8.7 Alarm Configuration (dCF07 - dCF10)
3.8.10 DataCORDER Communications
USDA and cargo probe alarms may be configured to
OFF, ON or AUTO.
Data retrieval from the DataCORDER can be
accomplished by using the DataReader, DataLINE,
DataBANK Card, or a communications interface
module.
NOTE
A DataReader, DataLINE or a communications
interface module display of Communication
Failed is caused by faulty data transfer between
the DataCORDER and the data retrieval device. Common causes include:
The DataCORDER will record the initiation of a Pre-trip
test (refer to paragraph 3.7) and the results of each test
included in Pre-trip. The data is time-stamped and may
be extracted via the Data Retrieval program. Refer to
Table 3−9 for a description of the data stored in the DataCORDER for each corresponding Pre-trip test.
If a probe alarm is configured to OFF, the alarm for this
probe is always disabled.
If a probe alarm is configured to ON, the associated
alarm is always enabled.
If the probes are configured to AUTO, they act as a
group. This function is designed to assist users who
keep the DataCORDER configured for USDA recording, but do not install the probes for every trip. If all the
probes are disconnected, no alarms are activated. As
soon as one of the probes is installed, all of the alarms
are enabled and the remaining probes that are not
installed will give active alarm indications.
1. Bad cable or connection between DataCORDER
and data retrieval device.
2. PC communication
misassigned.
3.8.8 DataCORDER Power Up
unavailable
or
3. Chart Recorder Fuse (FCR) blown.
The DataCORDER may be powered up in any one of
four ways:
Configuration identification for the models covered
herein may be obtained on the Container Products
Group Information Center by authorized Carrier Transicold Service Centers.
1. Normal AC power: The DataCORDER is powered
up when the unit is turned on via the Stop-Start
switch.
T-340
port(s)
3−16
With a communications interface module installed, all
functions and selectable features that are accessible at
the unit may be performed at the master station. Retrieval of all DataCORDER reports may also be performed. Refer to the master system technical manual
for further information.
a. DataReader
The Carrier Transicold Data Reader (see Figure 3−12)
is a simple to operate handheld device designed to extract data from the DataCORDER and upload it to a PC.
The DataReader has the ability to store multiple data
files. Refer to Data Retrieval manual 62-10629 for a
more detailed explanation of the DataReader.
3.8.11 USDA Cold Treatment
Sustained cold temperature has been employed as an
effective postharvest method for the control of Mediterranean and certain other tropical fruit flies. Exposing infested fruit to temperatures of 2.2C (36F) or below for
specific periods results in the mortality of the various
stages of this group of insects.
In response to the demand to replace fumigation with
this environmentally sound process, Carrier has integrated Cold Treatment capability into its microprocessor
system. These units have the ability to maintain supply
air temperature within one quarter degree Celsius of set
point and record minute changes in product temperature within the DataCORDER memory, thus meeting
USDA criteria. Information on USDA is provided in the
following sub-paragraphs.
DataReader
1
2
8
3
7
4
OFF
ON
UP Arrow
RIGHT Arrow
A special type of recording is used for USDA cold treatment purposes. Cold treatment recording requires three
remote temperature probes be placed at prescribed
locations in the cargo. Provision is made to connect
these probes to the DataCORDER via receptacles located at the rear left-hand side of the unit. Four or five receptacles are provided. The four 3-pin receptacles are
for the probes. The 5-pin receptacle is the rear connection for the Interrogator. The probe receptacles are
sized to accept plugs with tricam coupling locking devices. A label on the back panel of the unit shows which
receptacle is used for each probe.
5
6
1.
2.
3.
4.
a. USDA Recording
5.
6.
7.
8.
ENTER
Escape
DOWN Arrow
LEFT Arrow
The standard DataCORDER report displays the supply
and return air temperatures. The cold treatment report
displays USDA #1, #2, #3 and the supply and return air
temperatures. Cold treatment recording is backed up by
a battery so recording can continue if AC power is lost.
Figure 3−12 DataReader
b. DataBANKE Card
b. USDA/ Message Trip Comment
The DataBANK™ card is a PCMCIA card that interfaces
with the controller through the programming slot and
can download the data at a much faster rate, when
compared to the PC or DataReader. Files downloaded
to DataBANK card files are accessible through an Omni
PC Card Drive. The files can then be viewed using the
DataLINE software.
A special feature in DataLINE allows the user to enter a
USDA (or other) message in the header of a data report.
The maximum message length is 78 characters. Only
one message will be recorded per day.
3.8.12 USDA Cold Treatment Procedure
The following is a summary of the steps required to initiate a USDA Cold Treatment:
c. DataLINE
The DataLINE software for a personal computer is supplied on both floppy disks and CD. This software allows
interrogation, configuration variable assignment,
screen view of the data, hard copy report generation,
cold treatment probe calibration and file management.
Refer to Data Retrieval manual 62-10629 for a more
detailed explanation of the DataLINE interrogation software. The DataLINE manual may be found on the internet at www.container.carrier.com.
a. Calibrate the three USDA probes by ice bathing the
probes and performing the calibration function with
the DataReader or DataLINE. This calibration procedure determines the probe offsets and stores them in
the controller for use in generating the cold treatment
report. Refer to the Data Retrieval manual 62-10629
for more details.
b. Pre-cool the container to the treatment temperature
or below.
d. Communications Interface Module
c. Install the DataCORDER module battery pack (if not
already installed).
The communications interface module is a slave module, which allows communication with a master central
monitoring station. The module will respond to communication and return information over the main power line.
d. Place the three probes. The probes are placed into
the pulp of the product (at the locations defined in the
following table) as the product is loaded.
3−17
T-340
Sensor 1
Sensor 2
Sensor 3
e. If no alarms are active, the alarm queue may be
cleared. The exception to this rule is the DataCORDER alarm queue Full alarm (AL91), which does not
have to be inactive in order to clear the alarm list. To
clear the alarm list:
Place in pulp of the product located next
to the return air intake.
Place in pulp of the product five feet
from the end of the load for 40 foot containers, or three feet from the end of the
load for 20 foot containers. This probe
should be placed in a center carton at
one-half the height of the load.
Place in pulp of product five feet from
the end of the load for 40 foot containers
or three feet from the end of the load for
20 foot containers. This probe should be
placed in a carton at a side wall at
one-half the height of the load.
1. Press the ALT. MODE & ALARM LIST keys.
2. Press the UP/DOWN ARROW key until “CLEAr” is
displayed.
3. Press the ENTER key. The alarm list will clear and
“‐‐‐‐‐” will be displayed.
4. Press the ALARM LIST key. “AL” will show on the left
display and “‐‐‐‐‐” on the right display when there are
no alarms in the list.
e. To initiate USDA recording, connect the personal
computer and perform the configuration as follows,
using the DataLINE software:
1. Enter ISO header information.
5. Upon clearing of the alarm queue, the alarm light will
be turned off.
2. Enter a trip comment if desired.
3. Configure the DataCORDER for five probes (s, r, P1,
P2, P3) (dcf02=5).
4. Configure the logging interval for one hour.
3.8.14 ISO Trip Header
DataLINE provides the user with an interface to view/
modify current settings of the ISO trip header through
the ISO Trip Header screen.
5. Set the sensor configuration to “USDA.”
6. Configure for two byte memory storage format
(dcf04=LONG).
7. Perform a “trip start.”
The ISO Trip Header screen is displayed when the user
clicks on the “ISO Trip Header” button in the “Trip Functions” Group Box on the System Tools screen.
3.8.13 DataCORDER Alarms
The alarm display is an independent DataCORDER
function. If an operating parameter is outside of the expected range or a component does not return the correct values to the DataCORDER, an alarm is generated.
The DataCORDER contains a buffer of up to eight
alarms. A listing of the DataCORDER alarms is provided in Table 3−10, page 3−45. Refer to paragraph
3.8.7 for configuration information.
To display alarm codes:
F9 function - Provides the user with a shortcut for manually triggering the refresh operation. Before sending
modified parameter values, the user must ensure that a
successful connection is established with the controller.
If the connection is established with the DataCORDER,
the current contents of the ISO Trip Header from the DataCORDER will be displayed in each field. If the connection is not established with the DataCORDER, all fields
on the screen will be displayed as “Xs.” If at any time during the display of the ISO Trip Header screen the connection is not established or is lost, the user is alerted to
the status of the connection.
a. While in the Default Display mode, press the ALT.
MODE & ALARM LIST keys. This accesses the DataCORDER Alarm List Display Mode, which displays
any alarms stored in the alarm queue.
b. To scroll to the end of the alarm list, press the UP ARROW. Depressing the DOWN ARROW key will scroll
the list backward.
c. The left display will show “AL#” where # is the alarms
number in the queue. The right display will show
“AA##,” if the alarm is active, where ## is the alarm
number. “IA##,” will show if the alarm is inactive
d. “END” is displayed to indicate the end of the alarm list
if any alarms are active. “CLEAr” is displayed if all the
alarms in the list are inactive.
T-340
After modifying the values and ensuring a successful
connection has been made with the DataCORDER,
click on the “Send” button to send the modified parameter values.
The maximum allowed length of the ISO Trip Header is
128 characters. If the user tries to refresh the screen or
close the utility without sending the changes made on
the screen to the DataCORDER, the user is alerted with
a message.
3−18
3.9 CONTROLLER CONFIGURATION VARIABLES
Table 3−4 Controller Configuration Variables
CONFIGURATION
NUMBER
CnF02
CnF03
CnF04
CnF08
CnF09
CnF11
CnF15
CnF16
CnF17
CnF18
CnF20
CnF22
CnF23
CnF24
CnF25
CnF26
CnF27
CnF28
CnF31
CnF32
CnF33
CnF34
CnF37
CnF41
CnF44
CnF45
CnF46
CnF47
CnF49
CnF50
CnF51
CnF52
CnF53
CnF55
CnF56
CnF57
CnF59
Evaporator Fan Speed
Control Temperature Sensors
Enable Dehumidification
Evaporator Motor Type
Refrigerant Type
Defrost “Off” Selection
Enable Discharge Temperature Sensor
Enable DataCORDER
Enable Discharge Pressure Sensor
Heater Type
Enable Suction Pressure Sensor
Economy Mode
Enable Defrost Interval Save
Enable Long Pre-trip Test Series
Enable Pre-trip Data Recording
Heat Lockout Temperature
Enable Suction Temperature Sensor
Enable Bulb Mode
Probe Check
Enable Single Evaporator Fan Option
Enable Snap Freeze
Temperature Unit Display
Electronic Chart Probe
Enable Low DTT Setting
Autoslide Enable
Low Humidity Enabled
Quench/liquid Injection Valve Type
Vent Position
OEM Reset Option
Enhanced Bulb Mode Interface
Timed Defrost Disable
Oil Return Algorithm
Water Cool Oil Return Logic
TXV Boost Relay
TXV Boost Circuit
PWM Compressor Control
Electronic Evaporator Expansion Valve
dS (Dual)
FOUr
On
1Ph
r134a
noOFF
Out
On (Yes)
Out (No)
Old (Low Watt)
Out (No)
OFF
noSAv
Auto
rSLtS
Set to -10C
Out
NOr
SPEC
2EF0
OFF
bOth
rEtUR
Out
Out
Out
nO=0=no
OFF
OFF
0
0
0
0
0
0
0
0
CnF61
CnF62
CnF63
CnF64
CnF66
CnF67
ACT ASC Control Enable
Extended Temperature Control Enable
CCPC Pre-trip/Tripstart Default State
Enable Fan Pulsing Logic
High Speed Evaporator Fan Option
Air Heaters
0
0
0
0
0
0
TITLE
DEFAULT
OPTION
SS (Single)
duAL
OFF
3Ph
r744
OFF
In
(Not Allowed)
In (Yes)
nEW (High Watt)
In (Yes)
Std, Full
SAv
Auto2, Auto 3
dAtA
Set to -5C
In
bULb
Std
(Not Allowed)
SnAP
F
SUPPL, bOth
In
LO, UP
In
nC=1=nc
UP, LOW, CUStOM
0-off,1-std, 2-spec,3-cust
0-out, 1-in
0-out, 1-in
0-out, 1-in
0-out, 1-in
0-out, 1-in
0-out, 1-in
0-out, 1-in
0-none, 1-EC, 2-KE, 3NA
0-out, 1-in
0-out, 1-in
0-on, 1-off
0-in, 1-out
0-off, 1-on
0-out, 1-in
Note: Configuration numbers not listed are not used in this application. These items may appear when loading
configuration software to the controller but changes will not be recognized by the controller programming.
3−19
T-340
3.10 CONTROLLER FUNCTION CODES
Table 3−5 Controller Function Codes (Sheet 1 of 8)
Code
No.
TITLE
DESCRIPTION
Note: If the function is not applicable, the display will read “‐‐‐‐‐”
Display Only Functions − Cd01 through Cd26 are display only functions.
Display Only Functions
Digital Unloader
Cd01 Valve Closed (%)
Displays the DUV percent closed. The right display reads 100% when the valve is
fully closed. The valve will usually be at 10% on start up of the unit except in very
high ambient temperatures.
Compressor Motor
Cd03 Current
Cd07 Main Power Voltage
Main Power
Cd08 Frequency
The current sensor measures current draw in lines L1 & L2 by all of the high voltage components. It also measures current draw in compressor motor leg T3. The
compressor leg T3 current is displayed.
The current sensor measures current on two legs. The third unmeasured leg is calculated based on a current algorithm. The current measured is used for control and
diagnostic purposes. For control processing, the highest of the Phase A and B current values is used for current limiting purposes. For diagnostic processing, the current draws are used to monitor component energization. Whenever a heater or a motor is turned ON or OFF, the current draw increase/reduction for that activity is measured. The current draw is then tested to determine if it falls within the expected range
of values for the component. Failure of this test will result in a Pre-trip failure or a control alarm indication.
The main supply voltage is displayed.
The value of the main power frequency is displayed in Hertz. The frequency displayed will be halved if either fuse F1 or F2 is bad (alarm code AL21).
Ambient
Cd09 Temperature
The ambient sensor reading is displayed.
Evaporator TemperCd10 ature Sensor
Evaporator temperature sensor reading is shown on the right display.
Compressor DisCd11 charge Temperature
Compressor discharge temperature sensor reading, using compressor dome temperature, is displayed.
Compressor Suction
Cd12 Pressure
Reading for evaporator pressure transducer (EPT) is shown on the left display;
Press ENTER at Cd12 to show reading for compressor suction port pressure on
right display.
Compressor DisCd14 charge Pressure
Compressor discharges pressure transducer reading is displayed.
Digital Unloader
Cd15 Valve
The status of the valve is displayed (Open - Closed).
Cd04 Line Current,
Phase A
Cd05 Line Current,
Phase B
Cd06 Line Current,
Phase C
This code displays the compressor motor hours. User can view unit run time by
pressing the ENTER key while in Cd16. Total hours are recorded in increments of
Compressor Motor
10 hours (i.e., 3000 hours is displayed as 300).
Cd16 Hour Meter/Unit Run
The Compressor Motor Hour Meter display can be reset to 0 by pressing and
Time Hour Meter
holding the ENTER key for 5 seconds. The Unit Run Time Hour Meter cannot be
reset.
Humidity sensor reading is displayed. This code displays the relative humidity, as
Cd17 Relative Humidity % a percent value.
Cd18 Software Revision #
Cd19 Battery Check
Cd20 Config/Model #
T-340
The software revision number is displayed.
This code checks the Controller/DataCORDER battery pack. While the test is running, “btest” will flash on the right display, followed by the result. “PASS” will be displayed for battery voltages greater than 7.0 volts. “FAIL” will be displayed for battery
voltages between 4.5 and 7.0 volts, and “‐‐‐‐‐” will be displayed for battery voltages
less than 4.5 volts. After the result is displayed for four seconds, “btest” will again be
displayed, and the user may continue to scroll through the various codes.
This code indicates the dash number of the model for which the Controller is configured (i.e., if the unit is a 69NT40-551-100, the display will show “51100”). To
display controller configuration database information, press ENTER. Values in
“CFYYMMDD” format are displayed if the controller was configured with a configuration card or with a valid OEM serial port configuration update; YYMMDD represents the publication date of the model configuration database.
3−20
Table 3−5 Controller Function Codes (Sheet 2 of 8)
Cd21 Capacity Mode
The mode of operation is displayed (Unloaded - Standard - Economized).
Cd22 Compressor State
The status of the compressor is displayed (OFF, On).
Cd23 Evaporator Fan
Displays the current evaporator fan state (OFF, LOW, HIGH).
Compressor Run
Cd25 Time Remaining
Until Defrost
This code displays the time remaining until the unit goes into defrost (in tenths of
an hour). This value is based on the actual accumulated compressor running
time.
Defrost Temperature
Cd26 Sensor Reading
Defrost temperature sensor reading is displayed.
Configurable Functions − Cd27 through Cd37 are user-selectable functions. The operator can change the value of
these functions to meet the operational needs of the container.
This is the desired period of time between defrost cycles. Factory default is 3 hours.
Refer to Section 3.3.23 for information on Defrost Interval.
CnF11 determines whether the operator will be allowed to chose “OFF” as a defrost interval option.
CnF64 determines whether the operator will be allowed to choose “PuLS” as a
defrost interval option. For units operating with “PuLS” selected, defrost interval
is determined by the unit temperature setpoint and the Evaporator Fan Pulsing
Temperature Setting (Cd60). When the unit temperature setpoint is equal to or
less than the Evaporator Fan Pulsing Temperature Setting, the defrost interval is
Defrost Interval
Cd27 (Hours or Automatic) set to 6 hours. Otherwise, the defrost interval is determined using the Automatic
Defrost Interval Determination logic. In either case, “PuLS” remains displayed in
this function select code.
After a new Defrost Interval is selected, the previously selected Interval is used
until the next defrost termination, the next time the DTT contacts are OPEN, or
the next time power to the control is interrupted. If the previous value or the new
value is “OFF”, the newly selected value will be used immediately.
If any Auto Pretrip sequence is initiated, Cd27 will be set to ’AUTO’ unless CnF49
(OEM Reset) is set to “Custom” AND CnF64 (Evaporator Fan Pulsing Logic) configuration variable is set to IN, in which case Cd27 will be set to “PuLS”.
Temperature Units
Cd28 (Degrees C or
Degrees F)
This code determines the temperature units (C or F) that will be used for all
temperature displays. The user selects C or F by selecting function code Cd28
and pushing the ENTER key. The factory default value is Celsius units. This
function code will display “‐‐‐‐‐“ if CnF34 is set to F.
Failure Action
Cd29 (Mode)
If all of the control sensors are out of range (alarm code AL26) or there is a probe
circuit calibration failure (alarm code AL27), the unit will enter the shutdown state
defined by this setting. The user selects one of four possible actions as follows:
A - Full Cooling (Compressor is on, economized operation.)
b - Partial Cooling (Compressor is on, standard operation.)
C - Evaporator Fan Only (Evaporator fans on high speed, not applicable with frozen
set points.)
d - Full System Shutdown - Factory Default (Shut down every component in the unit.)
Cd30 In-Range Tolerance
The in-range tolerance will determine the temperature band around the set point
which will be designated as in-range.
For normal temperature control, control temperature is considered in range if it is
within setpoint in-range Tolerance. There are four possible values:
1 = +/- 0.5°C (+/-0.9°F)
2 = +/- 1.0°C (+/-1.8°F)
3 = +/- 1.5°C (+/-2.7°F)
4 = +/- 2.0°C (+/-3.6°F) - Factory Default
If the control temperature is in-range, the green IN-RANGE light will be illuminated.
In-range tolerance shall be set to +/- 2.0°C upon activation of dehumidification or
bulb mode (Cd33, Cd35, Cd48).
When CCPC is actively controlling, in-range tolerance is not considered.
“-----“ will be displayed whenever Dehumidification or Bulb mode is enabled or
when CCPC with six hour re-activation is actively controlling.
“-----“ will be displayed whenever Frozen Economy Mode is operating.
3−21
T-340
Table 3−5 Controller Function Codes (Sheet 3 of 8)
The stagger start offset time is the amount of time that the unit will delay at
start-up, thus allowing multiple units to stagger their control initiation when all
units are powered up together. The eight possible offset values are 0 (Factory Default), 3, 6, 9, 12, 15, 18 or 21 seconds.
The current limit is the maximum current draw allowed on any phase at any time. Limiting the unit’s current reduces the load on the main power supply. When desirable,
Current Limit
the limit can be lowered. Note, however, that capacity is also reduced. The five values
(Amperes)
for 460 VAC operation are: 15, 17, 19, 21, or 23 amperes. The factory default setting
is 21 amperes.
This is the value in percent to which the system will dehumidify or humidify. There
are configuration variables that determine whether dehumidification/humidification
capabilities are installed. In the test mode, the setpoint will be temporarily set to 1%,
allowing the test of dehumidification. After 5 minutes, the normal setpoint is restored.
If unit is configured for HUMIDIFICATION MODE then selection of a setpoint greater
Humidity Setpoint
than 75% will activate humidification, and a setpoint less than or equal to 75% will
activate dehumidification. If the unit is configured for dehumidification only, then the
entire setpoint range will apply to dehumidification. If Pretrip is initiated, this value will
be set to “OFF” automatically.
(Replaced by Cd48 interface if CnF50 Enhanced Bulb Mode Interface is active.)
The current state of the economy mode option, “-----”, On, or Off. CnF22 determEconomy Mode
ines whether economy mode offered. Economy mode is a user selectable mode
(On-Off)
of operation provided for power saving purposes.
The current state of the bulb mode option, “-----”, nOr, or bULb.
(Replaced by Cd48 if CnF50, Enhanced Bulb Mode, is active.)
Bulb mode is an extension of dehumidification control (Cd33). If dehumidification
(CnF04) is set to “Off,” Cd35 will display “Nor” and the user will be unable to
Bulb Mode
change it. CnF28 determines whether the bulb mode selection is offered.
After a dehumidification set point has been selected and entered for code Cd33,
the user may then change Cd35 to “bulb.” After Bulb Mode has been selected
and entered, the user may then utilize function codes Cd36 and Cd37 to make
the desired changes.
This is the desired evaporator fan speed for use during the bulb Dehumidification
and Humidification mode option.
(Replaced by Cd48 if CnF50, Enhanced Bulb Mode, is active.)
This code is enabled only if in the dehumidification mode (Cd33) and bulb mode
(Cd35) has been set to “bulb.” If these conditions are not met, “alt” will be displayed (indicating that the evaporator fans will alternate their speed) and the disEvaporator Fan
Speed Select
play cannot be changed.
If a dehumidification set point has been selected along with bulb mode then “alt”
may be selected for alternating speed, “Lo” for low speed evaporator fan only, or
“Hi” for high speed evaporator fan only.
If a setting other than “alt” has been selected and bulb mode is deactivated in any
manner, then selection reverts back to “alt.”
This is the variable defrost termination thermostat setting to be used with the opVariable DTT Setting tional bulb mode functionality. This item is only displayed if the bulb mode option
is configured on.
(Bulb Mode)
(Replaced by Cd48 interface if CnF50 Enhanced Bulb Mode Interface is active.)
Stagger Start Offset
Cd31 Time (Seconds)
Cd32
Cd33
Cd34
Cd35
Cd36
Cd37
Display Only Functions − Cd38 through Cd40 are display only functions.
Cd38 will display the current supply recorder sensor (SRS) reading for units configured for four probes. If the unit is configured with a DataCORDER, Cd38 will
Secondary Supply
Cd38 Temperature Sensor display “‐‐‐‐‐.” If the DataCORDER suffers a failure, (AL55) Cd38 will display the
supply recorder sensor reading.
Cd39 will display the current return recorder sensor (RRS) reading for units configured for four probes. If the unit is configured with a DataCORDER, Cd39 will
Secondary Return
Cd39 Temperature Sensor display “‐‐‐‐‐.” If the DataCORDER suffers a failure, (AL55) Cd39 will display the
return recorder sensor reading.
T-340
3−22
Table 3−5 Controller Function Codes (Sheet 4 of 8)
Container
Cd40 Identification
Number
If a valid container id exists, the default display for Cd40 will be “cd40_XXXXX”
where “XXXXX” is the 5th character through the 9th character of the container id.
Pressing the Enter key on Cd40 will display “id_YYYYYYY” where “YYYYYYY” is
the 5th character to the 11th character of the container id.
If no valid container id exists or the container id is blank, the default display will
have Cd40 on the left display and the right display will alternate between “_nEEd”
and “___id”. Pressing the enter key while on Cd40 in the state will prompt the Set
Id Interface.
On start up if the container id is not valid, Cd40 will be brought up on the display
for the first minute of power up. This can be left by either entering a container id
or leaving the code select normally.
Cd40 is configured at commissioning to read a valid container identification number. The reading will not display alpha characters; only the numeric portion of the
number will display.
Cd41 Valve Override
SERVICE FUNCTION: This code is used for troubleshooting, and allows manual
positioning of the economizer solenoid valve, electronic expansion valve, and digital unloader valve. Provides readings such as: Percent Capacity, EEV, Capacity
Mode, LIV and DUV. Refer to paragraph 6.21 for operating instructions.
Configurable Functions − Cd43 is a user-selectable function. The operator can change the value of this function to
meet the operational needs of the container.
Cd43 eAutoFresh Mode
Cd43 is a user selectable mode of operation that allows the opening and closing
of a mechanical air vent door via a stepper motor. These selection modes are as
follows:
OFF - Air makeup vent will remain closed.
USER - Allows for manual selection of the setting.
DELAY -The opening of the door is based on selected time, return temperature
and flow rate (percent opened).
gASLM - The opening is based percent open and CO2 and O2 selectable limits
(LM). This selection is only active if the unit has a CO2 sensor.
TEST / CAL (CO2 sensor option units only) - The door will fully open and close
to allow the user to inspect its operation. If CAL is selected, the controller will
zero calibrate the CO2 sensor input.
If the unit is not configured with AutoFresh, the Cd43 will display “----”
Refer to section 4.4.3 for description of operational parameters.
Display Only Function − Cd44 is a display only function.
Code Cd44 displays the eAutoFresh CO2 and O2 values (CO2 and O2) and CO2
and O2 limits (CO2 LIM and O2 LIM), respectively.
This function code will be dashed out if not configured for eAutofresh.
This function code will be dashed if CO2 sensor is not detected, and a sensor is
not expected (didn’t have one previously).
eAutoFresh Values /
Cd44 CO Sensor Status
This function code will display “ChECK” if a CO2 sensor has not been auto-detec2
ted at the most recent power-up and was detected at a previous power-up. If
“ChECK” is displayed and the ENTER key is pressed, “SEnSr” is displayed with
the choices of “YES” and “no”:
“YES” – sensor should be remembered as detected (present)
“no” – sensor should not be remembered as being detected (not present)
Configurable Functions − Cd45 through Cd48 are user-selectable functions. The operator can change the value of
these functions to meet the operational needs of the container.
Values: 0 to 240 for UPPER / 0 to 225 for LOWER
This function code will be dashed out if not configured for VPS.
When configured for VPS, Cd45 displays the current vent position in units of 5
Vent Position Sensor CMH (units displayed as “CM”) or CFM (units displayed as “CF”) depending on
Cd45 (VPS) Position
the selection of Cd46 (Airflow display units), Cd28 (Metric/Imperial) or the pressing of the deg C/F key.
Cd45 will display whenever the control detects movement via the sensor unless
AL50 is active. Cd45 will display for 30 seconds, then time out and return to the
normal display mode.
3−23
T-340
Table 3−5 Controller Function Codes (Sheet 5 of 8)
Selects the airflow units to be displayed by Cd45 if configured for Vent Position
Sensor or displayed by “USER/FLO” under Cd43 if configured for Autoslide.
CF= Cubic Feet per Minute
Cd46 Airflow Display Units
CM=Cubic Meters per Hour
bOth=Displays CF or CM depending on the setting of Cd28 (Metric/Imperial) or
the pressing of the degree C/F key.
Variable Economy
Cd47 Temperature Setting
The variable temperature “degrees C or degrees F” setting is used with economy
mode. Function code is “----” when unit is not configured for economy mode.
Initially Cd48 will display current dehumidification-mode; bUlb - bulb cargo mode,
dEhUM - normal dehumidification, or OFF - off. This display is steady.
Pressing ENTER key will take the interface down into a hierarchy of parameter
selection menus (mode, setpoint, evaporator speed, DTT setting). Pressing
ENTER key in any parameter selection menu commits to selection of the
currently displayed parameter and causes the interface to descend into the next
parameter selection menu. All parameter selection menus alternate between a
blank display and the current selection in the right hand display.
Pressing CODE SELECT key in a selection menu cancels the current selection
activity and ascends back up to the next higher selection menu (or to Cd48
display mode if that is the next higher).
If the operator does not press any key for five seconds the interface reverts to
normal system display and the current selection menu is cancelled, but any
previously committed changes are retained.
Available parameters and parameter ranges are a function of configuration
options and previously selected parameters as indicated above.
Whenever any pretrip test is initiated, dehumidification-mode goes to OFF.
Whenever dehumidification-mode goes to OFF:
Dehumidification /
Cd48 Bulb Cargo Mode
Parameter Selection
- Dehumidification control setpoint goes to 0% RH internally but will then initialize to
95% RH when dehumidification-mode leaves OFF.
- Evaporator speed select goes to Alt for units without PWM Compressor Control
(Cnf57 = Out), Evaporator speed select goes to Hi for units with PWM
Compressor Control (Cnf57 = In).
- DTT setting goes to 25.6C or 18.0C, depending on Cnf41.
Whenever dehumidification-mode is set to bUlb, DTT setting goes to 18.0C if it
had been set higher.
Whenever dehumidification-mode is set to dEhUM, DTT setting goes to 25.6C or
18.0C, depending on Cnf41.
For units without PWM Compressor Control (Cnf57 = Out):
- Whenever dehumidification control setpoint is set below 65% RH evaporator
speed select goes to LO if it had been set to Hi.
- Whenever dehumidification control setpoint is set above 64% RH evaporator
speed select goes to Alt if it had been set to LO.
For units with PWM Compressor Control (Cnf57 = In):
- Whenever dehumidification control set point is set below 60% RH, the evaporator
fan speed is set to LO, the user has the ability to set the evaporator fan speed to Hi
via the keypad.
- Whenever dehumidification control set point is set equal to or above 60% RH, the
evaporator fan speed is set to Hi, the user has the ability to set the evaporator fan
speed to LO via the keypad.
Display Only Function − Cd49 is a display only function.
Days Since Last
Cd49 Successful Pre-trip
T-340
Displays the number of days since last successful pretrip sequence.
Press ENTER to view the number of days since the last successful pretrip for
Auto1, Auto2, and Auto2 in sequence.
Press CODE SELECT to step back through the list and ultimately to exit the
Cd49 display.
3−24
Table 3−5 Controller Function Codes (Sheet 6 of 8)
Configurable Functions − Cd50 through Cd53 are user-selectable functions. The operator can change the value of
these functions to meet the operational needs of the container.
Cd50 CCPC Disabled
Automatic Cold
Cd51 Treatment
Parameter Selection
”OFF” = disabled.
”On” = enabled.
”SEtPt” = suspended by setpoint too low.
”CAHUM” = suspended by CA or humidity control.
”ACt” = suspended by ACT active.
”FAIL” = all return temperature probe failure for CCPC.
”PrtrP” = pretrip active.
”C LIM” = suspended by cool limit logic.
”PULL” = pulldown active.
“ALArM ” = suspended by shutdown alarm
Press enter, arrow keys, and then enter to select ”OFF” or ”On”.
If ”On” is selected, CCPC operation may be suspended as indicated by one of the
suspension codes listed above. If CCPC is not ”OFF” and is not suspended, ”On”
will be displayed.
ACT-mode:
Cd51 increments of (1 day)_(1hr), Display: default “0_0 “
“done” mm-dd this will be display is ACT has completed
“ACt” value “On” “OFF” or “----“Display /Select: default “OFF“
“trEAt” value C / F on 0.1 degree increments Display/Select: default “0.0C“
“DAyS” value “0 – 99” increments of 1 Display/Select: default “0“
“ProbE” value Probe positions ex ’1 2 _ 4’ ’1 _ 3 _’ Display: default “---- “
“SPnEW” value C / F on 0.1 increments Display/Select: default “10.0C “
Initially Cd51 will display current countdown timer increments of (1 day)_(1hr), default “0_0
Pressing ENTER key will take the interface down into a hierarchy of parameter
selection menus (act, treat, days, probe and spnew setting).
Pressing ENTER key in any of the parameter selection menus commits to selection of the currently displayed parameter and causes the interface to descend into
the next parameter selection menu. All parameter selection menus alternate
between a blank display and the current selection in the right hand display.
Pressing CODE SELECT key in a selection menu cancels the current selection
activity and ascends back up to the next higher selection menu (or to Cd51 display mode if that is the next higher).
If the operator does not press any key for five seconds the interface reverts to
normal system display and the current selection menu is cancelled, but any previously committed changes are retained.
Available parameters and parameter ranges are a function of configuration options and previously selected parameters as indicated above.
Parameter with the exception of “Act” may not be altered if Cd51 is re-entered if
“Act” is “On”. When ACT has completed including reaching the new setpoint
“done” on the left display and the MONTH DAY of completion on the right display
will be displayed as the second entry in the menu. Turning ACT off clears this
entry. This action also resets Cd51 to initial time remaining. ACT must then be
turned on to view or modify the additional parameters.
Whenever any auto Pre-trip test or Trip Start is initiated, ACT mode goes to OFF.
3−25
T-340
Table 3−5 Controller Function Codes (Sheet 7 of 8)
Automatic Set point
Cd53 Change Mode
Parameter Selection
ASC-mode:
Cd53 increments of (1 day)_(1hr), Display: default “0_0 “
“done” mm-dd this will be display is ASC has completed
“ASC” value “On” “OFF” Display /Select: default “OFF“
“nSC” value “1 - 6“ (This is the value “n” for the subsequent entries).
“SP (n-1)” value C / F on 0.1 degree increments Display/Select: default
“10.0C“
“DAY (n-1)” value “1 – 99” increments of 1 Display/Select: default “1“
“SP (n)” value C / F on 0.1 degree increments Display/Select: default “10.0C
Initially Cd53 will display current count down timer increments of (1 day)_(1hr),
default “0_0
Pressing ENTER key will take the interface down into a hierarchy of parameter
selection menus, (mode, act, treat, days, probe and spnew setting). Pressing
ENTER key in any of the parameter selection menus selects the currently displayed parameter and causes the interface to descend into the next parameter
selection menu. All parameter selection menus alternate between a blank display
and the current selection in the right hand display.
Pressing CODE SELECT key in a selection menu cancels the current selection
activity and ascends back up to the next higher selection menu (or to Cd53 display mode if that is the next higher).
If the operator does not press any key for five seconds the interface reverts to
normal system display and the current selection menu is cancelled, but any previously committed changes are retained.
Available parameters and parameter ranges are a function of configuration options and previously selected parameters as indicated above.
Parameter with the exception of “ASC” may not be altered if Cd53 is re-entered if
“ASC” is “On”. When ASC has completed including reaching the last setpoint
“done” on the left display and the MONTH DAY of completion on the right display
will be displayed as the second entry in the menu. Turning ASC off clears this
entry. This action also resets Cd53 to initial time remaining. ASC must then be
turned on to view or modify the additional parameters.
Whenever any auto pretrip test or Trip Start is initiated, ASC mode goes to OFF.
Display Only Functions − Cd54 through Cd58 are display only functions.
Suction Port
Superheat /
Cd54 Electronic
Expansion Valve
Status
Reading for evaporator superheat (suction temperature minus suction saturation
temperature as calculated from suction pressure) is shown on the right display.
Press ENTER at Cd54 to show reading for EEV position (in %) on left display.
Discharge SuperCd55 heat
Cd55 will display discharge superheat (discharge temperature minus discharge
saturation temperature as calculated from discharge pressure) values in C /F as
calculated by the discharge temperature minus the discharge saturation temperature as calculated from discharge pressure. “-----” will be displayed if selection is
not valid.
Cd58 will display “CLOSE” if the WPS or CFS switch contacts are closed or if
these options are not installed. “OPEn” is displayed when the WPS or CFS switch
contacts are open. When the WPS/CFS Override Logic is “TRUE”, the right display will flash on all units.
NOTE:
1.
Water Pressure
Switch / Condenser
Cd58 Fan Switch State or
Override Logic State 2.
This CLOSE/OPEn state displayed in this Code Select function only applies to
units that have the ability to detect the state of a WPS/CFS. This function should
not be relied upon to display the condition of the switch on units that don’t have a
WPS/CFS switch connected to ECG2 exclusively.
The right display will flash if the WPS/CFS Override Logic is TRUE on all units.
This is always the case, whether the unit has a WPS or CFS installed or not.
3. The ability of the WPS/CFS Override Logic to control the condenser fan is limited.
It is not possible for this logic to control the fan on units that have the WPS or CFS
wired in series with the fan contactor. Units wired in this configuration can indicate
that the WPS/CFS Override Logic is active by flashing the right display, however,
the wiring will not allow for control of the condenser fan.
T-340
3−26
Table 3−5 Controller Function Codes (Sheet 8 of 8)
Configurable Functions − Cd59 through Cd61 are user-selectable functions. The operator can change the value of
these functions to meet the operational needs of the container.
Cd59 allows operation of the pump down logic control. The display will flash
between “STArT PdN” and “PrESS EnTEr”.
Upon entering Cd59 the operator will be required to acknowledge that they want
to initiate the pump down control. The display will flash between “STArT P dN”
and “PrESS EnTEr”. Once the decision to continue is confirmed pump down logic will begin, and will take complete control of the unit until pump down either
succeeds or fails. This operation can not be halted once it begins without power
cycling the unit.
After pump down logic has been initiated, the operator will be notified to close the
Cd59 Pump Down Logic
Liquid Line Valve, the display will flash between “CLOSE LLV” and “PrESS
EnTEr”. Once complete the display will read “P dN” to the left, and the current
suction pressure to the right.
If the automatic pump down logic succeeds within 20 minutes, the unit will turn itself off, and the display will notify the operator that pump down is complete by
flashing between “P dN DOnE” and “SHUT OFF”. The operator must then shut
off the unit.
If the automatic pump down logic does not complete within 20 minutes, the unit
will drop out of Cd59 and return to its previous control condition.
Cd60 contains a selectable temperature range used to determine the engagement point of the Evaporator Fan Pulsing logic. Default setting is -18.1C. The
Evaporator Fan
user
may change the temperature by pressing enter, then scrolling to the desired
Cd60 Pulsing Temperature temperature using either arrow key. Press Enter to accept the change. The temSetting
perature setting will be retained until either a Pretrip or Trip Start is initiated at
which time the temperature will set to the default setting.
Cd61 is used to force evaporator fan speed to high while temperature control is
being performed in the perishable setpoint range. When set to “On”, evaporator
fans operate in high speed regardless of any other active option that can control
High Speed
evaporator fan speed.
Cd61 Evaporator Fan
Following a power cycle, the state of the function select code is retained at its
Setting
state prior to the power cycle. If “On”, this function select code will be set to
“OFF” when any trip start occurs or any pretrip test is initiated.
“-----” will be displayed if setpoint is in frozen range or if CnF66 is configured OFF.
3−27
T-340
Start
Troubleshooting
Unit does
self test?
No
Check Power
Supply
Refer to CONNECT POWER
Section 4.2
No
Check Power
Supply
Refer to CONNECT POWER
Section 4.2
No
Install Latest
Software
Revision
Refer to CONTROLLER SOFTWARE
Section 3.2
No
Load correct
unit
configuration
Refer to Configuration Software (Variables)
Section 3.2.1
Yes
See alarm
details &
repair
Yes
Did
Evaporator
fans start?
Yes
Correct
software
version?
Yes
Unit
configured
correctly?
Yes
Active
Alarms?
Refer to Controller Alarm Indications
Table 3−6
No
Pass
Pre-trip
inspection?
No
Correct
all faults
No
Correct
Refrigerant
issue
Refer to Pre-trip Diagnostics
Section 3.7
Yes
Operating
pressures
normal?
Refer to REFRIGERATION SYSTEM
SERVICE Section 6.3
Yes
Unit OK
Figure 3−13 Alarm Troubleshooting Sequence
T-340
3−28
3.11 CONTROLLER ALARM INDICATIONS
Alarm Code
AL03
Loss of
Superheat
Control
Table 3−6 Controller Alarm Indications (Sheet 1 of 8)
Cause
Components
Troubleshooting
Superheat has
Electronic
Check the operation of the
remained below
Expansion Valve
EEV using Cd41.
1.66C (3F) degrees (EEV)
for five minutes
Evaporator
Verify accuracy of
continuously while
Temperature
temperature sensors, refer
compressor running.
Sensor(s) ETS & to Sensor Checkout
Compressor drawing
ETS1.
Procedure Section 6.24.
more than 2.0 amps,
compressor pressure Evaporator Fans
Confirm fans operating
ratio is greater than
properly.
1.8, and Electronic
Expansion Valve
(EEV) is at 0% open.
Corrective Actions
Replace EEV if
defective.
Replace ETS or ETS1 if
defective.
Replace fan(s) if
defective, refer to
EVAPORATOR FAN
MOTOR ASSEMBLY
Section 6.15.
AL05
Manual
Defrost
Switch Failure
Controller has
detected continuous
Manual Defrost
Switch activity for five
minutes or more.
Keypad
Power cycle the unit.
AL06
Keypad or
Keypad
Harness Fail
Controller has
detected one of the
keypad keys is
continuously activity.
Keypad or
Harness
Power cycle the unit.
AL07
Fresh Air Vent
Open with
Frozen Set
Point
AL08
High
Compressor
Pressure
Ratio
The VPS is reading
greater than 0 CMH
while unit is in frozen
mode.
Vent Position
Sensor (VPS)
Manually reposition vent
and confirm using Cd45.
Refer to VENT POSITION
SENSOR SERVICE
Section 6.25.
Controller detects
discharge pressure to
suction pressure ratio
is too high.
The controller will
attempt to correct the
situation by restarting
the compressor.
Alarm 10 is triggered
when the CO2 sensor
voltage is operating
outside of the 0.9 v to
4.7 v range, or if the
sensor is out of range.
Controller is unable to
determine the correct
phase relationship.
Discharge
Pressure
Transducer (DPT)
Confirm accurate DPT
Replace DPT if
pressure readings, refer to defective.
MANIFOLD GAUGE SET
Section 6.2.
This is a display
alarm and has no
associated failure
action.
Refer to eAutoFresh
manual.
The alarm is triggered
off when voltage is
within operating range.
N/A
Power cycle the unit.
Wiring
Resetting the unit may
correct problem,
monitor the unit.
Correct wiring.
Check unit wiring.
Confirm pressure readings
during start-up; suction
pressure should decrease
and discharge pressure
should increase.
Check Cd41, right most Replace current sensor
digit:
if defective.
If display is 3 or 4 check
compressor / sensor wiring.
AL10
CO2 Sensor
Failure
AL14
Phase
Sequence
Detect Fault
Current Sensor
Resetting the unit may
correct problem,
monitor the unit.
If the alarm reappears
after 5 minutes replace
the keypad.
Resetting the unit may
correct problem,
monitor the unit.
If the alarm reappears
replace the keypad and
harness.
If unable to obtain zero
reading, replace
defective VPS.
If display is 5 the current
sensor is defective.
3−29
T-340
Table 3−6 Controller Alarm Indications (Sheet 2 of 8)
Alarm Code
AL16
Compressor
Current High
Cause
Components
Compressor current Current Sensor
draw is over the
calculated maximum
for 10 minutes.
Amperage is
indeed too high.
Operating
Conditions
Make
sure
system Check air flow of
pressures are relevant to condenser.
operating conditions.
Check Refrigerant
charge, refer to
REFRIGERATION
SYSTEM SERVICE
Section 6.3
Monitor Unit
AL17
Compressor
Pressure
Delta Fault
T-340
Compressor has
attempted to start in
both directions and
fails to generate
sufficient pressure
differential between
SPT and DPT.
Troubleshooting
Corrective Actions
Compare Cd3 to actual Replace current sensor
measured current at wire if defective.
T1-T2 or T3 going to the
compressor contactor. If
there is a difference,
determine whether this is
caused by current sensor
or amp clamp tool.
Confirm supply voltage/fre- Correct power supply.
quency is within specification and balanced according to Electrical Data Section 2.3.
Alarm is display only the If alarm remains active
alarm may clear itself or is repetitive replace
during operation
compressor at next
available
opportunity,
refer to COMPRESSOR
Service Section 6.8.
N/A
Controller will attempt Resume normal
restart every 20 minutes operation.
and deactivate the alarm if
successful.
Discharge
Confirm accurate DPT Replace DPT if
Pressure
pressure readings, refer to defective.
Transducer (DPT) MANIFOLD GAUGE SET
Section 6.2.
Suction Pressure Confirm accurate SPT Replace SPT if
Transducer (SPT) pressure readings, refer to defective.
MANIFOLD GAUGE SET
Section 6.2.
Monitor unit
Alarm is display only the If alarm remains active
alarm may clear itself or is repetitive replace
during operation.
compressor at next
available opportunity.
3−30
Table 3−6 Controller Alarm Indications (Sheet 3 of 8)
Alarm Code
Cause
AL18
Discharge pressure is
over the maximum for
Discharge
Pressure High 10 minutes within the
last hour.
AL19
Discharge
Temperature
High
AL20
Control
Contactor
Fuse (F3)
Components
Restrictions in the
refrigeration
system.
Filter Drier
Troubleshooting
Corrective Actions
Ensure Liquid Line Service Open Liquid Line SerValve is fully open.
vice Valve as needed.
Check the filter drier, if it is
iced up or very cold it
indicates that the filter drier
needs replacement.
Condenser Fan
Check Condenser Fan for
proper operation.
Discharge
Confirm accurate DPT
Pressure
pressure readings, refer to
Transducer (DPT) MANIFOLD GAUGE SET
Section 6.2.
Non-condensWith the unit off allow
ables in the refri- system to stabilize to
geration system.
ambient temperature.
Check system pressure
against PT Chart for 134a,
refer to Table 6−4.
Refrigerant
Check refrigerant level.
Replace the filter drier if
needed, refer to FILTER
DRIER Service Section
6.13.
Correct as required.
Discharge temperat- Restrictions in the Ensure the Discharge Serure exceeds 135C refrigeration
vice Valve is fully open.
(275F) for 10 minutes system.
Check the unit for air flow
within the last hour.
restrictions.
Non-condensWith the unit off allow
ables in the refri- system to stabilize to
geration system.
ambient temperature.
Check system pressure
against PT Chart for 134a,
refer to Table 6−4.
Additional Alarms Check compressor
such as AL16, operation.
AL24.
Open the Discharge Service Valve as needed.
Clean or remove any
debris from coils.
Correct as required,
refer to Refrigerant
Charge Section 6.7.1.
Replace DPT if
defective.
Correct as required,
refer to Refrigerant
Charge Section 6.7.1.
Correct as required,
refer to Refrigerant
Charge Section 6.7.1.
If the alarm persists, it
may indicate a failing
compressor, replace the
compressor, refer to
COMPRESSOR
Service Section 6.8.
Control power fuse Check F3A, if the Check PA, PB, CH coils for Replace the defective
(F3A or F3B) is open. fuse is open:
short to ground, if short is coil.
found:
Replace the fuse.
Check F3B, if the Check ESV coil resistance Replace the defective
fuse is open:
at TP7 to TP9, if short to coil.
ground, or if resistance is Replace the fuse.
less than 4 ohms, coil is
defective.
Check CF, ES, EF, HR coils
for short to ground, if short
is found, coil is defective.
Check Voltage at If voltage is present, it Refer
to
Controller
QC1:
indicates
a
defective Service Section 6.23.
microprocessor.
3−31
T-340
Table 3−6 Controller Alarm Indications (Sheet 4 of 8)
Alarm Code
Cause
Components
AL21
One of the 18 VAC
System Sensors
Control Circuit controller fuses
Fuse (F1/F2) (F1/F2) is open. Refer Wiring
to Cd08.
Controller
Corrective Actions
Replace defective
sensor(s)
Repair as needed.
Replace controller, refer
to Controller Service
Section 6.23.
Shut down unit, disconnect Replace defective
power, & check Evaporator evaporator fan motor,
Motor IP at plug connection refer to EVAPORATOR
pins 4 & 6.
FAN MOTOR Service
Section 6.15.
AL22
Evaporator IP
Evaporator motor
internal protector (IP)
is open.
AL23
Loss of Phase
B
AL24
Compressor
IP
Controller
fails
to Incoming Power
detect current draw.
Check incoming
source.
Compressor internal Compressor
protector (IP) is open.
Shut down unit disconnect
power, & check resistance
of compressor windings at
contactor T1-T2, T2-T3.
Monitor unit, if alarm
remains active or is
repetitive replace the
compressor at the next
available
opportunity,
refer to COMPRESSOR
Service Section 6.8.
AL25
Condenser IP
Condenser fan motor Insufficient Air
internal protector (IP) Flow
is open.
Condenser Fan
Motor
Shut down unit and check
condenser fan for obstructions.
Shut down unit, disconnect
power, & check Condenser
Fan Motor IP at plug connection pins 1 & 2.
Remove obstructions.
AL26
Sensors out of range.
All Sensors
Failure:
Supply/Return
Probes
AL27
Analog to
Digital
Accuracy
Failure
T-340
Controller AD
converter faulty.
Evaporator Motor
Troubleshooting
Check system sensors for
short to ground.
Check wiring for short to
ground.
Controller may have an
internal short.
All sensors.
detected as out of
range
Controller
3−32
Perform Pre-trip P5:
power Correct power source as
required.
Replace defective
condenser fan motor,
refer to Condenser Fan
Motor Assembly
Service Section 6.11.
If P5 passes, no further
action is required.
If P5 fails, replace the
defective sensor as
determined by P5, refer
to TEMPERATURE
SENSOR Service
Section 6.24.
Power cycle the unit. If the Replace defective
alarm persists, it indicates microprocessor, refer to
a defective
Controller Service
microprocessor.
Section 6.23.
Table 3−6 Controller Alarm Indications (Sheet 5 of 8)
Alarm Code
AL28
Low Suction
Pressure
Cause
Suction pressure too
low for normal
operation.
Components
N/A
Suction Pressure
Transducer (SPT)
Discharge
Pressure
Transducer (DPT)
Alarm LED will be
activated and user
intervention is required.
Troubleshooting
Power cycle the unit.
Corrective Actions
Resetting the unit may
correct problem, monitor
the unit.
Confirm accurate SPT Replace SPT if
pressure readings, refer to defective.
MANIFOLD GAUGE SET
Section 6.2.
Confirm accurate DPT Replace DPT if
pressure readings, refer to defective.
MANIFOLD GAUGE SET
Section 6.2.
Refer
to
eAutoFresh The alarm is triggered off
manual.
when atmospheric conditions are within limit
settings.
AL29
AutoFresh
Failure
Alarm 29 is triggered
if CO2 or O2 level is
outside of the limit
range and the vent
position is at 100% for
longer than 90
minutes.
AL50
Air Vent
Position
Sensor (VPS)
VPS Sensor out of Vent Position
range.
Sensor (VPS)
Make sure VPS is secure.
AL51
EEPROM
Failure
Controller Memory
Failure
Pressing the ENTER key
when “CLEAr” is displayed
will result in an attempt to
clear the alarm.
Power cycle the unit. If the
alarm persists, it indicates
defective controller
memory.
Repair any alarms in the
queue that are active.
Indicated by “AA”.
If action is successful (all
alarms are inactive),
alarm 51 will be reset.
If this alarm occurs on start
up, allow a unit fitted with
rechargeable batteries to
operate for up to 24 hours
to charge rechargeable
batteries sufficiently. Once
fully charged, the alarm will
deactivate.
To clear the alarm press
ENTER and ALT simultaneously at the startup
of Cd19 (Battery Check).
Controller
AL52
Alarm list queue is full. Active Alarms
EEPROM
Alarm List Full
AL53
Battery voltage low
Battery
Battery Pack
Failure
AL54
Invalid Supply
Temperature Sensor
Primary
Supply Sensor (STS) reading.
(STS)
Supply
Temperature
Sensor (STS)
3−33
Manually tighten panel.
If the alarm persists, Replace VPS.
replace the sensor or the
assembly.
Perform Pre-trip P5:
Replace defective
controller, refer to
Controller Service
Section 6.23
Clear alarms, refer to
CONTROLLER
ALARMS Section 3.6.
If alarm persists, replace
the battery pack, refer to
Section 6.23.5 Battery
Replacement.
If P5 passes, no further
action is required.
If P5 fails, replace the
defective sensor as
determined by P5, refer
to TEMPERATURE
SENSOR Service
Section 6.24.
T-340
Table 3−6 Controller Alarm Indications (Sheet 6 of 8)
Alarm Code
Cause
AL56
Invalid Return
Temperature Sensor
Primary
Return Sensor (RTS) reading.
(RTS)
Components
Return
Temperature
Sensor (RTS)
Troubleshooting
Perform Pre-trip P5:
Invalid Ambient
Temperature Sensor
(AMBS) reading.
Ambient
Temperature
Sensor (AMBS)
Test the AMBS, refer to
Sensor Checkout
Procedure Section 6.24.1.
AL57
Ambient
Sensor
(AMBS)
AL58
High pressure safety High
Pressure
switch
remains
open
Switch
(HPS)
Compressor
High Pressure for at least one minute.
Safety (HPS)
Refrigeration
System
AL59
Heat Termination
Heat Termination
Thermostat
(HTT)
is
Thermostat (HTT)
Heater
open.
Termination
Thermostat
(HTT)
AL60
Defrost
Temperature
Sensor (DTS)
AL61
Heater
Current Draw
Fault
Failure of the Defrost
Temperature Sensor
(DTS) to open.
Defrost
Temperature
Sensor (DTS)
Improper current draw Heater(s)
during heat or defrost
mode.
Contactor
AL63
Current Limit
Unit operating above Refrigeration
current limit.
System
Power supply
AL64
Discharge
Temperature
Sensor
(CPDS)
T-340
Discharge
Temperature sensor
out of range.
Corrective Actions
If P5 passes, no further
action is required.
If P5 fails, replace the
defective sensor as
determined by P5, refer
to TEMPERATURE
SENSOR Service
Section 6.24.
Replace AMBS if
defective, refer to
TEMPERATURE
SENSOR Service
Section 6.24.2.
Test the HPS; refer to Replace HPS if
Checking High Pressure defective, refer to
Switch, Section 6.9.1.
Sensor Replacement,
Section 6.24.2.
Check unit for air flow Clean or remove any
restrictions.
debris from coils.
Check for 24 volts at test Replace HTT if
point TP10, if no voltage at defective, refer to
TP10 after unit has Sensor Replacement
reached set point HTT is Section 6.24.2.
open.
Test the DTS; refer to Replace the DTS if
Sensor Checkout Proced- defective, refer to
ure Section 6.24.1.
Sensor Replacement
Section 6.24.2.
While in heat or defrost
mode, check for proper
current draw at heater
contactors, refer to
ELECTRICAL DATA
Section 2.3.
Check voltage at heater
contactor on the heater
side. If no voltage present:
Check unit for air flow
restrictions.
Check unit for proper
operation.
Confirm supply voltage/frequency is within specification and balanced according to ELECTRICAL DATA
Section 2.3.
Replace heater(s) if
defective, refer to
section 6.14.2
Evaporator Heater
Removal and
Replacement.
Replace heater contactor if defective.
Clean or remove any
debris from coils.
Repair as needed.
Correct power supply.
Current limit set Check current limit setting The current limit can be
too low.
Code Cd32.
raised (maximum of 23
amps) using Cd32.
Discharge
Test the CPDS; refer to
Replace the CPDS if
temperature
Sensor Checkout
defective, refer to
sensor (CPDS).
Procedure, Section
Sensor Replacement
6.24.1.
Section 6.24.2.
3−34
Table 3−6 Controller Alarm Indications (Sheet 7 of 8)
Alarm Code
AL65
Discharge
Pressure
Transducer
(DPT)
Cause
Components
Compressor
Compressor
Discharge Transducer Discharge
is out of range.
Transducer (DPT)
AL66
Suction
Pressure Suction Pressure
(SPT) Suction Transducer (SPT) out Transducer (SPT)
of range.
Pressure
Transducer,
(EPT)
Evaporator
Pressure
Transducer
AL67
Humidity
Sensor
Humidity Sensor (HS)
reading out of range.
Troubleshooting
Corrective Actions
Confirm accurate DPT Replace DPT if
pressure readings, refer to defective.
MANIFOLD GAUGE SET
Section 6.2.
Confirm accurate EPT and Replace EPT/SPT if
SPT pressure readings, defective.
refer
to
MANIFOLD
GAUGE SET Section 6.2.
- Performing a Pre-trip 5-9
test will also check the
transducers.
Monitor
Humidity
(HS)
Sensor Make sure the humidity
sensor is properly connected in the socket.
Make sure the humidity
sensor wires have not been
damaged.
Evaporator Temperat- Evaporator Tem- Test the ETS1, refer to
ure Sensor (ETS1) out perature Sensor Sensor Checkout Procedof range.
(ETS1)
ure Section 6.14.2.
AL69
Evaporator
Temp Sensor
(ETS1)
AL70
Secondary
Supply Secondary Supply Perform Pre-trip P5:
Sensor (SRS) is out of Sensor (SRS)
Secondary
Supply Sensor range.
(SRS)
If the alarm persists, it
may indicate a failing
compressor, refer to
COMPRESSOR
Service Section 6.8.
Monitor, replace HS if
alarm persists.
Replace Evaporator
Temperature Sensor
(ETS1) if defective.
If P5 passes, no further
action is required.
If P5 fails, replace the
defective sensor as
determined by P5, refer
to TEMPERATURE
SENSOR Service
Section 6.24.
AL71
Secondary Return
Secondary Return Perform Pre-trip P5:
If P5 passes, no further
Sensor (RRS) is out
Sensor (RRS)
action is required.
Secondary
of
range.
If P5 fails, replace the
Return Sensor
defective sensor as
(RRS)
determined by P5, refer
to TEMPERATURE
SENSOR Service
Section 6.24.
AL72
After the unit goes
Refrigeration
Ensure unit is operating Power cycle unit.
System
correctly.
Control Temp in-range for 30
Control Temperature is
Out of Range minutes then out of
in In-range.
range for a continuous
Any Pre-trip mode, re120 minutes.
sets the timers.
3−35
T-340
Table 3−6 Controller Alarm Indications (Sheet 8 of 8)
NOTE
If the controller is configured for four probes without a DataCORDER, the DataCORDER alarms AL70 and
AL71 will be processed as Controller alarms AL70 and AL71. Refer to Table 3−10, page 3−45.
The controller performs self-check routines. If an internal failure occurs, an “ERR”
alarm will appear on the display. This is an indication the controller needs to be replaced.
ERROR
DESCRIPTION
ERR 0-RAM failure
Indicates that the controller working memory has failed.
ERR 1-Program Memory
Indicates a problem with the controller program.
failure
ERR 2-Watchdog
The controller program has entered a mode whereby
time-out
the controller program has stopped executing.
ERR 3-N/A
N/A
ERR 4-N/A
N/A
The controller’s Analog to Digital (A-D) converter has
ERR 5-A-D failure
failed.
ERR 6-IO Board failure
Internal program/update failure.
ERR Internal
ERR
7-Controller
failure
Internal version/firmware incompatible.
Microprocessor
#
Failure
ERR 8-DataCORDER
Internal DataCORDER memory failure.
failure
ERR 9-Controller failure
Internal controller memory failure.
In the event that a failure occurs and the display cannot be updated, the status
LED will indicate the appropriate ERR code using Morse code as shown below.
E R R 0 to 9
ERR0 = . .-. .-. ----ERR1 = . .-. .-. . ---ERR2 = . .-. .-. . . --ERR3 = . .-. .-. . . . -ERR4 = . .-. .-. . . . . ERR5 = . .-. .-. . . . . .
ERR6 = . .-. .-. -. . . .
ERR7 = . .-. .-. --. . .
ERR8 = . .-. .-. ---. .
ERR9 = . .-. .-. ---- .
Enter
Set
point
Entr
The controller is prompting the operator to enter a set point.
StPt (Press Arrow &
Enter)
Low Main Voltage
(Function Codes
This message will be alternately displayed with the set point whenever the supply
LO Cd27-38 disabled
voltage is less than 75% of its proper value.
and NO alarm
stored.)
T-340
3−36
3.12 CONTROLLER PRE−TRIP TEST CODES
Table 3−7 Controller Pre-trip Test Codes (Sheet 1 of 6)
NOTE
“Auto” or “Auto1” menu includes the: P0, P1, P2, P3, P4, P5, P6 and rSLts. “Auto2” menu includes P0, P1, P2, P3, P4, P5, P6, P7, P8, P9, P10 and rSLts. “Auto3” menu includes P0, P1,
P2, P3, P4, P5, P6, P7 and P8.
P0-0
Pre-Trip Initiated:
Configuration
Display, Indicator
Lamps, LEDs, and
Displays
Container identifier code, Cd18 Software Revision Number, Cd20 Container Unit
Model Number, & configuration database identifier CFMMYYDD are displayed in
sequence.
Next the unit will indicate the presence or non-presence of an RMU according to
whether any RMU inquiry messages have been received since the unit was
booted.
Units equipped with Autoslide Enabled (Cnf44) will cause the vent to seek to its
closed position, followed by two sequences of opening to 100% and returning to
the closed position. No other autoslide mode of operation will be available until
the two cycles of opening and closing have completed.
Since the system cannot recognize lights and display failures, there are no test
codes or results associated with this phase of Pretrip. To know if the test passes
the operator must observe that the LCD display elements and the indicator lights
behave as described below.
P1 Tests - Heaters Current Draw: Heater is turned on, then off. Current draw must fall within specified range.
No other system components will change state during this test.
P1-0
P1-1
Heaters Turned On
Heater starts in the off condition, current draw is measured, and then the heater
is turned on. After 15 seconds, the current draw is measured again. The
change in current draw is then recorded.
Test passes if the change in current draw test is in the range specified.
Heaters Turned Off
Heater starts in the off condition, current draw is measured, and then the heater
is turned on. After 15 seconds, the current draw is measured again. The
change in current draw is then recorded.
Test passes if the change in current draw test is in the range specified.
P2 Tests - Condenser Fan Current Draw: Condenser fan is turned on, then off. Current draw must fall within
specified range. No other system components will change state during this test. If the Water Pressure Switch is
open this test will be skipped.
P2-0
Condenser Fan On
Condenser fan starts in the off condition, current draw is measured, and condenser fan is then turned on. After 15 seconds the current draw is measured
again. The change in current draw is then recorded.
Test passes if change in current draw test is in the specified range.
P2-1
Condenser Fan Off
Condenser fan is then turned off. After 10 seconds the current draw is measured. The change in current draw is then recorded.
Test passes if change in current draw test is in the specified range.
P3 Tests - Low Speed Evaporator Fan Current Draw: The system must be equipped with a low speed evaporator fan, as determined by CnF02, the Evaporator Fan Speed Select configuration variable. Low speed evaporator fan is turned on, then off. Current draw must fall within specified range. No other system components will
change state during this test.
NOTE
If unit configured for single evaporator fan operation and either AL11 or AL12 is active at the start of either
test, then the test will fail immediately. If AL11 or AL12 become active during the test, then the test will fail
upon conclusion of the test.
P3-0
Low Speed
Evaporator Fan
Motors On
High speed evaporator fans will be turned on for 20 seconds, the fans will be
turned off for 4 seconds, current draw is measured, and then the low speed
evaporator fans are turned on. After 60 seconds the current draw is measured
again. The change in current draw is then recorded.
Test passes if change in current draw test is in the specified range.
P3-1
Low Speed
Evaporator Fan
Motors Off
Low speed evaporator fans are then turned off. After 10 seconds the current
draw is measured. The change in current draw is then recorded.
Test passes if change in current draw test is in the specified range.
3−37
T-340
Table 3−7 Controller Pre-trip Test Codes (Sheet 2 of 6)
P4 Tests - High Speed Evaporator Fans Current Draw: High speed evaporator fans are turned on, then off.
Current draw must fall within specified range and measured current changes must exceed specified ratios. No
other system components will change state during this test.
NOTE
If unit configured for single evaporator fan operation and either AL11 or AL12 is active at the start of either
test, the test will fail immediately. If AL11 or AL12 become active during the test, the test will fail upon conclusion of the test.
Evaporator fans start in the off condition, current draw is measured, then high
speed evaporator fans will be turned on. After 60 seconds the current draw is
High Speed
measured again. The change in current draw is then recorded.
P4-0 Evaporator Fan
Test passes if change in current draw in the specified range AND measured curMotors On
rent changes exceed specified ratios.
If the three phase motors are configured IN, the change ratio test is skipped.
High speed evaporator fans are then turned off. After 10 seconds the current
High Speed
draw is measured. The change in current draw is then recorded.
P4-1 Evaporator Fan
Motors Off
Test passes if change in current draw test is in the specified range.
P5 Tests - Air Stream Sensor Tests: Tests the validity of the Air Stream Sensors.
The High Speed Evaporator Fan is turned on and run for eight minutes, with all
other outputs de-energized. A temperature comparison is made between the
return and supply probes.
Supply/Return
Test passes if temperature comparison falls within the specified range.
P5-0 Probe Test
NOTE
If this test fails, “P5-0” and “FAIL” will be displayed. If both Probe tests (this
test and the PRIMARY/ SECONDARY) pass, display will read “P5” “PASS.”
This test if for units equipped with secondary supply probe only.
The temperature difference between primary supply probe and secondary supply
probe is compared.
Test passes if temperature comparison falls within the specified range.
P5-1 Supply Probe Test
NOTE
If this test fails, “P5-1” and “FAIL” will be displayed. If both Probe tests (this
and the SUPPLY/RETURN TEST) pass, because of the multiple tests, the
display will read “P5” “PASS.”
For units equipped with secondary return probe only.
The temperature difference between return temperature sensor (RTS) and return
temperature sensor (RRS) probe is compared.
Test passes if temperature comparison falls within the specified range.
P5-2
P5-3
T-340
Return Probe Test
Evaporator Fan
Direction Test
NOTES
1. If this test fails, “P5-2” and “FAIL” will be displayed. If both Probe tests
(this test and the SUPPLY/RETURN) pass, because of the multiple
tests, the display will read “P 5,” “PASS.”
2. The results of Pre-trip tests 5-0, 5-1 and 5-2 will be used to activate or
clear control probe alarms.
If configured for three phase evaporator fan motors:
With evaporator fan running on high speed, measure the temperature difference
between the primary supply and primary return probes. Turn the heaters on for
60 seconds then measure the temperature difference between the primary supply and primary return probes for up to 120 additional seconds.
This is a Pass/Fail test. The test passes if differential of STS is 0.25C higher
than RTS.
Test P5-0 must pass before this test is run.
3−38
Table 3−7 Controller Pre-trip Test Codes (Sheet 3 of 6)
P5-7
P5-8
P5-9
Primary .vs Secondary Evaporator
Temperature
Sensor Test
Primary Evaporator
Pressure Transducer Test
Suction (Evaporator) Pressure Transducer Test
This is a Pass/Fail test of the primary evaporator temperature sensor (ETS1) and
secondary evaporator temperature sensor (ETS2).
Test passes if secondary evaporator temperature sensor (ETS2) is within +/- 0.5C
of the primary evaporator temperature sensor (ETS1).
This is a Pass/Fail test of the Primary Evaporator Pressure Transducer.
Test passes if suction pressure transducer (SPT) is within +/- 0 psi of saturation
pressure at current evaporator temperature. Also passes if SPT is within +/- 1 psi of
discharge pressure 6 hours after a power interruption.
Test P5-7 must pass before this test is run.
Units equipped with a secondary Evaporator pressure transducer.
Test passes if suction pressure transducer (SPT) is within +/- 1.5 psi of the evaporator pressure transducer (EPT).
Test P5-8 must pass before this test is run.
P5-10
Humidity Sensor
Controller Configuration Verification
Test
This is a Pass/Fail/Skip test of the humidity sensor configuration.
Test passes if the controller configuration has humidity sensor in.
Test fails if the controller configuration has humidity sensor out and Vout is greater than 0.20 Volts for the humidity sensor.
Test is skipped if the controller configuration has the humidity sensor out and
Vout is less than 0.20 Volts.
Test P5-9 must pass before this test is run.
P5-11
Humidity Sensor
Installation Verification Test
This is a Pass/Fail test of humidity sensor installation (sensor is present).
Test passes if Vout is greater than 0.20 Volts for the humidity sensor.
Test fails if Vout is less than 0.20 Volts for the humidity sensor.
Test P5-10 must pass before this test is run.
Humidity Sensor
Range Check Test
This is a Pass/Fail test of the Humidity Sensor Range.
Test passes if Vout for the humidity sensor is between 0.33 Volts and 4 Volts.
Test fails if Vout is outside of this range.
Test P5-11 must pass before this test is run.
P5-12
P6 Tests - Refrigerant Probes, Compressor and Refrigerant Valves Tests: Pass/Fail testing is performed
for the compressor, EEV, DUV, LIV (if equipped), ESV, and the refrigerant pressure and temperature sensors.
P6-1
Discharge
Thermistor Test
Suction
Thermistor Test
P6-2
Discharge Pressure If Alarm 65 is active any time during the first 45 second period, the test fails.
Sensor Test
Otherwise, the test passes.
P6-3
Suction Pressure
Sensor Test
P6-4
Compressor Current Draw Test
P6-5
Compressor Leak
Test
P6-0
If Alarm 64 is active the test fails. Otherwise, the test passes.
If the Suction Temperature Sensor (CPSS) both is configured ON and is invalid,
the test fails. Otherwise the test passes.
If Alarm 66 is active the test fails. Otherwise the test passes.
Compressor current is tested before and 10 seconds after start up. If current
does not increase, the test fails. P6-7 is run at the end of P6-4. If this test fails,
P6-6 is skipped.
Pre-trip P6-5 ensures that the compressor holds pressure. After compressor
pump up and pump down, the compressor is turned off for 62 seconds. When
suction side pressure holds (less than 8 psi rise) for 10 seconds, P6-5 passes,
otherwise the Compressor Leak Test fails.
3−39
T-340
Table 3−7 Controller Pre-trip Test Codes (Sheet 4 of 6)
NOTE
P6-6 through P6-10 are conducted by changing status of each valve and comparing suction pressure change
and/or compressor current change with predetermined values. Tests will cause compressor and condenser
fans to cycle on and off as needed to generate the pressure required for individual Pre-trip sub tests. The compressor will start in order to build discharge pressure, followed by compressor pump down sequence. At the
conclusion of compressor pump down sequence, the compressor will shut down and the valve test will start.
Economizer
Passes if suction pressure increases a minimum of 4 psia when the valve opens
P6-6 Valve Test
for 15 seconds.
P6-7
Digital Unloader
Valve Test
P6-9
Liquid Injection
Valve Test
Passes if pressure and current changes are within 3 seconds of DUV switch signal and either the pressure change or the current draw change is above 5 psi or
above 1.5A, respectively.
(If equipped) Test passes if change of suction pressure is greater than 4 psia
when the valve opens for 10 seconds. Otherwise, it fails.
The test records the suction pressure during the open valve position and passes
if the suction pressure increase is above 3 psi when the valve opens for 10
seconds.
NOTE
P7-0 & P8 are included with “Auto 2 & Auto 3” only. P9-0 through P10 are included with “Auto2” only.
P6-10
Electronic
Expansion Valve
Test
P7 Tests - High Pressure Tests: Unit is run at full capacity without condenser fan running to make sure that
the HPS opens and closes properly.
P7-0
P7-1
T-340
High Pressure
Switch (HPS)
Opening Test
High Pressure
Switch (HPS)
Closing Test
Test is skipped if sensed ambient temperature is less than 7.2C (45F), return
air temperature is less than -17.8C (0F), or the water pressure switch is open.
With the unit running, the condenser fan is turned off and a 900 second (15 minute) timer is started. The right display shows Discharge Pressure if the sensor is
configured and valid, else Discharge Temperature. The unit needs to disable Discharge Pressure limit and enable Current Limit checks.
The test fails immediately if:
-Ambient Temperature Sensor invalid
-Composite Return Temperature Sensor invalid
-HPS is open
The test fails if:
-HPS fails to open before 900 seconds total test time.
-Evaporator or Compressor IP Alarm.
-Calculated Dome Temperature exceeds 137.78C (280F).
-Discharge pressure exceeds 370 psig.
-Compressor Current exceeds limits
The test passes if HPS opens within the 15 minute time limit.
If return temperature greater than -2.4C, set setpoint to -5.0C, else set setpoint to -30C. Restart unit according to normal startup logic. Run unit normally
for 120 seconds.
The test passes if the high pressure switch closes within 75 seconds after end of
Test 7-0, else the test fails.
Test P7-0 must pass for this test to execute.
3−40
Table 3−7 Controller Pre-trip Test Codes (Sheet 5 of 6)
P8 Tests - Perishable Mode Tests: Pretrip tests P7-0 and P7-1 must have passed or have been skipped for
these tests to execute.
P8-0
Perishable Mode
Test
P8-1
Perishable Mode
Pull Down Test /
eAutofresh CO2
Sensor Calibration
P8-2
Perishable Mode
Maintain Temperature Test
If the control temperature is below 15.6C., the setpoint is changed to 15.6C.,
and a 180 Minute timer is started. The control will then be placed in the equivalent of normal heating. If the control temperature is above 15.6C. at the start of
the test, then the test proceeds immediately to test 8-1. While in test 8-0 the right
display will show the value of the control temperature.”
The test fails if the 180 Minute timer expires before the control temperature
reaches setpoint - 0.3C. If the test fails, it will not auto-repeat. There is no pass
display for this test. Once the control temperature reaches setpoint, the test proceeds to test 8-1.
Control temperature must be at least 15.6°C (60°F).
The set point is changed to 0°C (32°F), and a 180-minute timer is started. The
left display will read “P8-1,” the right display will show the supply air temperature.
The unit will then start to pull down the temperature to the 0°C set point.
The test passes if the container temperature reaches set point before the
180-minute timer expires.
On units where the CO2 Sensor Status indicates that a CO2 sensor is present,
calibration of the CO2 sensor will be attempted during P8-1. Once P8-1 begins,
calibration will be attempted when the supply temperature goes below 5°C. If
the CO2 sensor voltage reads within the 0.95 <>1.15Vdc range before the end of
P8-1, the sensor will be calibrated by holding the CO2 zero line low for 4
seconds. Once calibration is performed, the sensor voltage will be verified to
make sure it is in the 0.95 to 1.05 Vdc range. If the voltage is not within this
range, CO2 sensor calibration fails.
Test P8-1 must pass for P8-2 to execute.
A fifteen minute timer is started, and the system will attempt to minimize control
temperature error (supply temperature minus setpoint) until the timer expires.
The control temperature will be sampled each minute starting at the beginning of
P8-2.
During P8-2, the left display will read “P8-2,” and the right display will show the
supply air temperature.
When the test is completed, the average control temperature error will be
compared to the pass/fail criteria.
Test passes if the average temperature error is within +/- 1.0°C.
Test fails if the average temperature error is greater than +/- 1.0°C, or if the
DataCORDER supply temperature probe is invalid. If the test fails, the control
probe temperature will be recorded as -50.0°C.
3−41
T-340
Table 3−7 Controller Pre-trip Test Codes (Sheet 6 of 6)
P9 Test - DTT Close and Open Test: The DTT in this control is not a physical device, with actual metallic contacts, it is a software function that acts similar to a thermostat. Using various temperature inputs, the DTT function determines whether a thermostat mounted on the Evaporator Coil would have OPEN or CLOSED contacts.
Primarily, the DTT function operates based on the temperature reading from the Defrost Termination Sensor.
P9-0
DTT Closed and
Open Test
During P9-0 the defrost temperature sensor (DTS) reading will be displayed on
the left display. The right display will show the supply air temperature.
The unit will run FULL COOL for 30 minutes maximum until the DTT is considered closed. This step may not have to be executed. Once the DTT is considered closed, the unit simulates defrost by running the heaters for up to two
hours, or until the DTT is considered open.
Test fails if:
The DTT is not considered closed after the 30 minutes of full cooling
HTT opens when DTT is considered closed or if return air temperature rises
above 248°C (120°F).
Test passes if the DTT is considered open within the 2 hour heat cycle time limit.
P10 Tests - Frozen Mode Tests:
If the container temperature is below 7.2C, the setpoint is changed to 7.2C.,
and a 180 Minute timer is started. The control will then be placed in the equivalent of normal heating. If the container temperature is above 7.2C. at the start of
the test, then the test proceeds immediately to test 10-1. During this test, the
Frozen Mode
control temperature will be shown on the right display.
P10-0 Heat Test
The test fails if the 180 Minute timer expires before the control temperature
reaches setpoint - 0.3C. If the test fails, it will not auto-repeat. There is no pass
display for this test. Once the control temperature reaches setpoint, the test proceeds to test 10-1.
Control temperature must be at least 7.2C (45F)
The setpoint is changed to -17.8C. The system will then attempt to pull down
the control temperature to setpoint using normal frozen mode cooling. During
Frozen Mode
this test, the control temperature will be shown on the right display.
P10-1 Pulldown Test
The test passes if the control temperature reaches setpoint minus 0.3C before
the 180 minute timer expires. Otherwise, the test fails. Upon failure and when initiated by an automatic Pre-trip sequence, P10-1 will auto-repeat once by starting
P10-0 over again.
Test P10-1 must pass for this test to execute.
Same as for test 8-2 except the control temperature is the return probe temperature.
Frozen Mode
P10-2 Maintain
The average error must be +/-1.6C. If the DataCORDER supply temperature
Temperature Test
probe is invalid, the test fails and the control probe temperature will be recorded
as -50C. Upon failure and when initiated by an automatic Pre-trip sequence,
P10-2 will auto-repeat by starting P10-0 over again.
T-340
3−42
Table 3−8 DataCORDER Function Code Assignments
NOTE
Inapplicable Functions Display “‐‐‐‐‐”
To Access: Press ALT. MODE key
Code
No.
TITLE
DESCRIPTION
dC1
Recorder Supply
Temperature
Current reading of the supply recorder sensor.
dC2
Recorder Return
Temperature
Current reading of the return recorder sensor.
dC3-5
USDA 1,2,3 TemperCurrent readings of the three USDA probes.
atures
dC6-13
Network Data
Points 1-8
Current values of the network data points (as configured). Data point 1
(Code 6) is generally the humidity sensor and its value is obtained from the
controller once every minute.
Cargo Probe 4 Temperature
Current reading of the cargo probe #4.
dC14
dC15-19 Future Expansion
Temperature SendC20-24 sors 1-5 Calibration
dC25
Future Expansion
These codes are for future expansion, and are not in use at this time.
Current calibration offset values for each of the five probes: supply, return,
USDA #1, #2, and #3. These values are entered via the interrogation program.
This code is for future expansion, and is not in use at this time.
The DataCORDER serial number consists of eight characters. Function
code dC26 contains the first four characters. Function code dC27 contains
the last four characters. (This serial number is the same as the controller
serial number.)
dC26,27
S/N, Left 4, Right 4
dC28
Minimum Days Left
dC29
Days Stored
dC30
Date of Last Trip
start
dC31
Battery Test Results
Shows the current status of the optional battery pack.
PASS: Battery pack is fully charged. FAIL: Battery pack voltage is low.
dC32
dC33
dC34
Time: Hour, Minute
Date: Month, Day
Date: Year
Cargo Probe 4
Calibration
Current time on the real time clock (RTC) in the DataCORDER.
Current date (month and day) on the RTC in the DataCORDER.
Current year on the RTC in the DataCORDER.
Current calibration value for the Cargo Probe. This value is an input via the
interrogation program.
dC35
An approximation of the number of logging days remaining until the DataCORDER starts to overwrite the existing data.
Number of days of data that are currently stored in the DataCORDER.
The date when a Trip Start was initiated by the user. In addition, if the system
goes without power for seven continuous days or longer, a trip start will automatically be generated on the next AC power up. Press and hold “ENTER”
key for five seconds to initiate a “Trip Start.”
3−43
T-340
Table 3−9 DataCORDER Pre-trip Result Records
Test
No.
TITLE
DATA
1-0
Heater On
Pass/Fail/Skip Result, Change in current for Phase A, B and C
1-1
Heater Off
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
2-0
Condenser Fan On
Pass/Fail/Skip Result, Water pressure switch (WPS) - Open/Closed,
Change in currents for Phase A, B and C
2-1
Condenser Fan Off
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
3-0
Low Speed Evaporator Fan
On
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
3-1
Low Speed Evaporator Fan
Off
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
4-0
High Speed Evaporator Fan
On
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
4-1
High Speed Evaporator Fan
Off
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
5-0
Supply/Return Probe Test
Pass/Fail/Skip Result, STS, RTS, SRS and RRS
5-1
Secondary Supply Probe
(SRS)Test
Pass/Fail/Skip
5-2
Secondary Return Probe
(RRS) Test
Pass/Fail/Skip
6-0
Discharge Thermistor Test
Pass/Fail/Skip
6-1
Suction Thermistor Test
Pass/Fail/Skip
6-2
Discharge Pressure Sensor
Test
Pass/Fail/Skip
6-3
Suction Pressure Sensor Test
Pass/Fail/Skip
6-4
Compressor Current Draw
Test
Pass/Fail/Skip
6-5
Compressor Leak Test
Pass/Fail/Skip
6-6
Economizer Valve Test
Pass/Fail/Skip
6-7
Digital Unloader Valve Test
Pass/Fail/Skip
6-9
Liquid Injection Valve Test (If
equipped)
Pass/Fail/Skip
6-10
Electronic Expansion Valve
Test
Pass/Fail/Skip
7-0
High Pressure Switch Closed
Pass/Fail/Skip Result, AMBS, DPT or CPT (if equipped)
Input values that component opens
7-1
High Pressure Switch Open
Pass/Fail/Skip Result, STS, DPT or CPT (if equipped)
Input values that component closes
8-0
Perishable Mode Heat Test
Pass/Fail/Skip Result, STS, time it takes to heat to 16C (60F)
8-1
Perishable Mode Pulldown
Test
Pass/Fail/Skip Result, STS, time it takes to pull down to 0C (32F)
8-2
Perishable Mode Maintain
Test
Pass/Fail/Skip Result, Averaged DataCORDER supply temperature
(SRS) over last recording interval.
9-0
Defrost Test
Pass/Fail/Skip Result, DTS reading at end of test, line voltage, line
frequency, time in defrost.
10-0
Frozen Mode Heat Test
Pass/Fail/Skip Result, STS, time unit is in heat.
10-1
Frozen Mode Pulldown Test
Pass/Fail/Skip Result, STS, time to pull down unit to -17.8C (0F).
10-2
Frozen Mode Maintain Test
Pass/Fail/Skip Result, Averaged DataCORDER return temperature
(RRS) over last recording interval.
T-340
3−44
Table 3−10 DataCORDER Alarm Indications
Code No.
dAL70
dAL71
TITLE
Recorder Supply
Temperature Out of
Range
Recorder Return
Temperature Out of
Range
To Access: Press ALT. MODE key
DESCRIPTION
The supply recorder sensor reading is outside of the range of -50C to
70C (-58F to +158F), or the probe check logic has determined there is
a fault with this sensor.
NOTE
The P5 Pre-trip test must be run to inactivate the alarm.
The return recorder sensor reading is outside of the range of -50C to
70C (-58F to +158F), or the probe check logic has determined there is
a fault with this sensor.
dAL72-74
USDA Temperatures
1, 2, 3 Out of Range
NOTE
The P5 Pre-trip test must be run to inactivate the alarm.
The USDA probe temperature reading is outside of -50C to 70C
(-58F to +158F) range.
dAL75
Cargo Probe 4 Out of
Range
The cargo probe temperature reading is outside of -50C to 70C
(-58F to +158F) range.
dAL76, 77
Future Expansion
dAL78-85
Network Data Point
1 - 8 Out of Range
These alarms are for future expansion and are not in use at this time.
The network data point is outside of its specified range. The DataCORDER is configured by default to record the supply and return recorder sensors. The DataCORDER may be configured to record up to eight additional network data points. An alarm number (AL78 to AL85) is assigned to
each configured point. When an alarm occurs, the DataCORDER must be
interrogated to identify the data point assigned. When a humidity sensor is
installed, it is usually assigned to AL78.
dAL86
RTC Battery Low
The real time clock (RTC) backup battery is too low to adequately
maintain the RTC reading.
A real time clock failure is critical to the operation of the unit. If this alarm
occurs, replace the RTC battery at the next available opportunity. After
replacing the battery the following actions are required:
− Update the RTC setting
− Update the unit’s software configuration
− Update the operational software
− Update all user selectable function code settings (defrost, setpoint, etc)
An invalid time has been detected. Either the DataCORDER run time hour
and minute have not changed at the start of the hour, or the real time
clock (RTC) time has gained or lost more than 2 minutes in the hour. This
situation may be corrected by cycling the power, setting the clock or meeting the above criteria for an hour.
dAL87
RTC Failure
dAL88
DataCORDER
EEPROM Failure
A write of critical DataCORDER information to the EEPROM has failed.
dAL89
Flash Memory Error
An error has been detected in the process of writing daily data to the
non-volatile FLASH memory.
dAL90
dAL91
Future Expansion
Alarm List Full
This alarm is for future expansion, and is not in use at this time.
The DataCORDER alarm queue is determined to be full (eight alarms).
3−45
T-340
SECTION 4
OPERATION
4.2.1 Connection To 380/460 VAC Power
1. Make sure start−stop switch (ST on control panel)
and circuit breaker (CB−1 in the control box) are in
position “0” (OFF).
2. Plug the 460 VAC (yellow) cable into a de−energized
380/460 VAC, 3−phase power source. Energize the
power source. Place circuit breaker (CB−1) in position “I” (ON). Close and secure control box door.
4.2.2 Connection To 190/230 VAC Power
An autotransformer (Figure 4−1) is required to allow
operation on nominal 230 volt power. It is fitted with a
230 VAC cable and a receptacle to accept the standard
460 VAC power plug. The 230 volt cable is black in color
while the 460 volt cable is yellow. The transformer may
also be equipped with a circuit breaker (CB−2). The
transformer is a step up transformer that will provide
380/460 VAC, 3−phase, 50/60 Hz power to the unit
when the 230 VAC power cable is connected to a
190/230 VAC, 3−phase power source.
1. Make sure that the start−stop switch (ST, on control
panel) and circuit breakers CB−1 (in the control box
and CB−2 (on the transformer) are in position “0”
(OFF). Plug in and lock the 460 VAC power plug at the
receptacle on the transformer.
2. Plug the 230 VAC (black) cable into a de−energized
190/230 VAC, 3−phase power source. Energize the
power source. Set circuit breakers CB−1 and CB−2 to
position “I” (ON). Close and secure control box door.
4.1 INSPECTION (Before Loading)
WARNING
Beware of unannounced starting of the
evaporator and condenser fans. The unit
may cycle the fans and compressor unexpectedly as control requirements dictate.
a. Check inside for the following:
1. Check channels or “T” bar floor for cleanliness.
Channels must be free of debris for proper air circulation.
2. Check container panels, insulation and door seals
for damage. Effect permanent or temporary repairs.
3. Visually check evaporator fan motor mounting bolts
for proper securement (refer to paragraph 6.15).
4. Check for visible corrosion on the evaporator stator
and fan deck (refer to paragraph 6.16).
5. Check for dirt or grease on evaporator fans or fan
deck and clean if necessary.
6. Check evaporator coil for cleanliness or obstructions. Wash with fresh water.
7. Check defrost drain pans and drain lines for obstructions and clear if necessary. Wash with fresh water.
2
8. Check panels on refrigeration unit for loose bolts and
condition of panels. Make sure T.I.R. devices are in
place on access panels.
3
1
b. Check condenser coil for cleanliness. Wash with
fresh water.
c. Open control box door. Check for loose electrical connections or hardware.
d. Check color of moisture−liquid indicator.
1. Dual Voltage Modular Autotransformer
2. Circuit Breaker (CB−2) 230−Volt
3. 460 VAC Power Receptacle
Figure 4−1 Autotransformer
4.2 CONNECT POWER
WARNING
4.3 ADJUST FRESH AIR MAKEUP VENT
The purpose of the fresh air makeup vent is to provide
ventilation for commodities that require fresh air
circulation. The vent must be closed when transporting
frozen foods.
Air exchange depends on static pressure differential,
which will vary depending on the container and how the
container is loaded.
Units may be equipped with a vent position sensor
(VPS). The VPS determines the position of the fresh air
vent (upper or lower, as equipped) and sends data to the
controller display.
Do not attempt to remove power plug(s) before turning OFF start−stop switch (ST),
unit circuit breaker(s) and external power
source.
WARNING
Make sure the power plugs are clean and
dry before connecting to power receptacle.
4−1
T-340
4.3.1 Upper Fresh Air Makeup Vent
Two slots and a stop are designed into the Upper Fresh
Air disc for air flow adjustments. The first slot allows for a
0 to 30% air flow; the second slot allows for a 30 to 100%
air flow.
To adjust the percentage of air flow, loosen the wing nut
and rotate the disc until the desired percentage of air
flow matches with the arrow. Tighten the wing nut.
4.3.2 Lower Fresh Air Makeup Vent
a. Full Open or Closed Positions
Maximum air flow is achieved by loosening the wing
nuts and moving the cover to the maximum open
position (100% position). The closed position is 0% air
flow position. The operator may also adjust the opening
to increase or decrease the air flow volume to meet the
required air flow.
To clear the gap between the slots, loosen the wing nut
until the disc clears the stop.
b. Reduced Flow for Lower Fresh Air Makeup
Figure 4−2 gives air exchange values for an empty
container.
NOTE
In order to prevent inaccurate display readings
on units equipped with a Vent Position Sensor
(VPS), ensure that the rack and pinion drive of
the VPS is not disrupted when adjusting the air
makeup vent.
Higher values can be expected for a fully loaded
container.
AIR
FLOW
(CMH)
250
50HZ
200
TBAR
1 1/2”
150
TBAR
2 5/8”
TBAR 3”
NOTE
Do not loosen the hex nut beyond its stop.
Doing so may cause inaccurate display
readings and errors in DataCORDER reports.
Similar to the Upper Fresh Air Makeup vent, two slots
and a stop are designed into the Lower Fresh Air slide
for air flow adjustments. The first slot allows for a 0 to
25% air flow; the second slot allows for a 25 to 100% air
flow. To adjust the percentage of air flow, loosen the hex
nut and rotate the disc until the desired percentage of air
flow matches with the arrow. Tighten the hex nut. To
clear the gap between the slots, loosen the hex nut until
the disc clears the stop.
100
50
0
0
10
20
AIR
FLOW
(CMH)
30 40 50 60 70
PERCENT OPEN
80
On some models the air slide is supplied with two
adjustable air control discs. The fresh air makeup can be
adjusted for 15, 35, 50 or 75 cubic meters per hour
(CMH). The air flow has been established at 60 Hz
power and 2−1/2 inch T bar and with 15 mm (0.6 inch)
H2O external static above free blow.
90 100
60HZ
300
250
TBAR
1 1/2”
200
TBAR
2 5/8”
TBAR 3”
Loosen the hex nut, adjust each disc to the required air
flow, then tighten hex nut.
NOTE
The main air slide is in the fully closed position
during reduced air flow operation when
equipped with air control discs.
150
c. Air Sampling for Carbon Dioxide (CO2) Level
100
Loosen hex nuts and move the cover until the arrow on
the cover is aligned with the “atmosphere sampling port”
label. Tighten the hex nuts and attach a 3/8 in. hose to
the sampling port.
50
0
0
10
20
30 40 50 60 70
PERCENT OPEN
80
If the internal atmosphere content has reached an
unacceptable level, the operator may adjust the disc
opening to meet the required air flow volume to ventilate
the container.
90 100
Figure 4−2 Upper Fresh Air Make Up Flow Chart
T-340
4−2
Upon initiation of Pre−Trip P0, the current state will be
saved and the vent will fully close. This will be followed
by two sequences of opening to 100% and returning to
the closed position. No other eAutoFresh mode of
operation will be available until the two cycles of opening
and closing have completed. Upon termination of the
test, the vent will open to the previous state and
operation will return to the previous mode.
4.3.3 Vent Position Sensor
The VPS allows the user to determine the position of the
fresh air vent via Cd45. This function code is accessible
via the Code Select key.
The vent position will display for 30 seconds whenever
motion corresponding to 5 CMH (3 CFM) or greater is
detected. It will scroll in intervals of 5 CMH (3 CFM).
Scrolling to Cd45 will display the Fresh Air Vent Position.
If the last mode was gASLM, the vent will open to the
preset FLO setting, the controller will start taking new
readings and control based on those readings.
The position of the vent will be recorded in the
DataCORDER whenever the unit is running under AC
power and any of the following:
4.4.2 eAutoFresh Start−Up Procedure
To start the system, do the following:
Trip start
a. Press the “CODE SELECT” key (see Figure 3−2).
On every power cycle
b. Press the “UP or DOWN“ arrow key until “Cd43“ is
displayed, then press “ENTER”.
Midnight
c. Press the “UP or DOWN“ arrow key to access the desired mode of operation. When the mode operation is
displayed press the enter key to access the submenu
parameters.
Manual changes greater than 5 CMH (3 CFM)
remaining in the new position for at least four minutes
4.4.3 eAutoFresh Modes of Operation
NOTE
The user has four minutes to make necessary
adjustments to the vent setting. This time calculation begins on the initial movement of the
sensor. The vent can be moved to any position
within the four minutes. On completion of the
first four minutes, the vent is required to remain
stable for the next four minutes. If vent position
changes are detected during the four−minute
stability period, AL50 will be generated. This
provides the user with the ability to change the
vent setting without generating multiple events
in the DataCORDER.
NOTE
When setting any mode of operation, complete
the entire process to ensure all parameters are
set.
a. OFF
A setting of OFF will disable all automatic venting
operations. The eAutoFresh vent will be driven fully
closed and the eAutoFresh opening set to 0 CMH in
Cd44. This is the default mode whenever a frozen mode
of operation has been selected. When the frozen set
point is selected, the current eAutoFresh setting is
saved. The vent position will be restored when a
perishable set point is selected.
b. USER
4.4 eAutoFresh OPERATION
The USER mode provides ventilation for commodities
that require fresh air circulation. The flow rate can be
accessed through the submenu if a perishable set point
has been selected. To set the flow rate, press the
ENTER key to activate the selection mode. When FLO
appears in the left hand window, use the UP or DOWN
arrow key to scroll to the desired opening. The range is
from 0 to 220CM (0 to 129CF) in increments of 5. Press
the ENTER key to set the value and begin operation.
The eAutoFresh system allows the opening and closing
of the mechanical air vent slide. The opening and
closing of the slide is determined by the mode selected
through Cd43.
The modes of operation are OFF, USER, TEST, DELAY,
and GASLIMIT. Each mode of operation has submenus
with selectable parameters. Not all parameters are
available in each submenu.
c. TEST
TEST mode allows the operator to test the movement of
the mechanical slide air vent and calibrate the CO2
sensor.
Upon power up, the controller will fully close the
eAutoFresh air vent. Nine seconds after power up, the
controller will check if there is a carbon dioxide (CO2)
sensor connected. When a CO2 sensor is detected, the
controller will enable access to the Gas Limit mode of
operation. If no sensor is detected, the only modes of
operation available will be Test, User, and Delay. The
controller will then resume operation in the last mode of
operation before power interruption.
tESt − When “tESt” appears in the left window, press the
ENTER key to begin the test. The eAutoFresh slide will
open fully and then return to the closed position. The
test may be observed by the operator to ensure proper
operation of the vent. After completion of the TEST, the
unit will return to the previous mode of operation.
4.4.1 eAutoFresh Pre−Trip Inspection
NOTE
It is recommended that the calibration procedure only be performed during Pre−trip or when
the container has been fully vented.
Pre−trip testing of the eAutoFresh system is performed
during Pre−Trip test P0. Operation of the system may be
observed during this test.
4−3
T-340
CAL will attempt to calibrate the CO2 sensor. When
“CAL“ is selected the display will flash “CAL“. The
operator is to hold the “ENTER“ key for 5 seconds. The
display will stop flashing and read “CAL“ for 5 seconds.
The microprocessor will read the CO2 value, and then
compare that value to a known zero value. If the sensor
is within the calibration parameter range, the
microprocessor will determine the appropriate offset for
the sensor. If the sensor is outside of this range, for
example if the container is loaded or has a high level of
CO2, the controller will flash “NOCAL“ for 5 seconds
then revert to the previous mode of operation.
To operate in GAS LIMIT mode, scroll until gASLM
appears in the left window, and press ENTER to activate
the submenu. The first selection is the maximum CO2
level (CO2LM). Select the maximum CO2 level by using
the UP and DOWN arrow keys. The range is from 0 to
19% in 1% increments. Press ENTER to set the value
and move to the minimum O2 level (O2LM). The range is
from 2% to 20% in 1% increments. Press ENTER to set
the value and move to the FLO rate. Use the UP or
DOWN arrow key to scroll to the desired FLO rate. The
range is from 0 to 220CM (0 to 129CF) in increments of 5
and 3 respectively. Press ENTER to set the value and
begin operation.
Operational Parameters (Sub Menu Options):
d. DELAY
In DELAY mode, the operation of the eAutoFresh
system will be delayed for a set amount of time. This
allows time for the cargo to reach set point. In DELAY
mode, the eAutoFresh vent will open to the stored (FLO)
value when the return air temperature sensor (RTS) is at
or below set point plus the return offset value (rtn) or the
delay time (tIM), whichever comes first. The
eAutoFresh vent will be fully closed when return air
temperature is greater than the set point plus the offset
temperature (rtn).
FLO indicates the opening to which the slide will move
based on the stored value in CMH (in increments of 5) or
CFM depending on the selection of Cd46 (Airflow display units), Cd28 (Metric/Imperial) or the pressing of the
deg C/F key. CFM is displayed as CF, CMH is displayed
as CM.
tIM is the time delay prior to the door opening. The time
range is from 1 to 72 hrs in 1 hr increments.
CO2LM is the maximum level of CO2 that is allowed for
the cargo. The range is from 0% to 19% in 1% increments, the default setting is 10.
O2LM is the minimum level of O2 that is allowed for the
cargo. The range is from 2% to 20% in 1% increments,
the default setting is 10.
To set the unit in Delay mode, scroll until “DELAY“
appears in the left window, press ENTER to activate the
submenu. The first selection is the amount of time (tIM)
for the delay. Select the amount of time for the delay by
using the UP and DOWN arrow keys. The range is from
1 to 72 hours in 1 hour increments. Press the ENTER
key to set the value and move to the FLO rate. Use the
UP or DOWN arrow key to scroll to the desired FLO rate.
The range is from 0 to 220CM (0 to 129CF) in
increments of 5 and 3 respectively. Press the ENTER
key to set the value and move to the return temperature
offset. Use the UP or DOWN arrow key to scroll to the
desired rtn rate. The range of offset is from 0.6C to
2.8C (1.0F to 2.8F) in 0.1 increments. Press
ENTER to set the value and begin operation.
Rtn is an offset value used to expand the return air temperature value to compensate for the fresh air entering
the container. The allowable range is from 0.6C to
2.8C or 1.0F to 5.0F in 0.1 increments the default
setting is 2.8C (5F).
4.5 CONNECT WATER-COOLED CONDENSER
The water−cooled condenser is used when cooling water is available and heating the surrounding air is objectionable, such as in a ship’s hold. If water−cooled operation is desired, connect in accordance with the following
subparagraphs.
e. GAS LIMIT (gASLM)
In GAS LIMIT mode, access to the submenu is available
provided a perishable set point has been selected, and a
valid reading is detected from the CO2 sensor. In “Gas
limit” mode the microprocessor will monitor and limit the
level of CO2 in the container by opening and closing the
eAutoFresh vent. The vent will open to the (FLO) setting
once the unit has completed initial temperature pull
down or if the cargo temperature is within 5C of set
point and the CO2 level has reached the max limit or if
the O2 level has reached the lower limit. After the first 15
minutes of the vent opening the controller will again
evaluate the level of CO2, and/or O2 levels. If after the
first 15 minutes the gas limit values are satisfied, the
vent will close, if either gas limit has not been satisfied
within 15 minutes the air exchange vent will open in 10
CMH increments every 15 minutes until both gas
concentrations are satisfied. Once all limits are satisfied
the vent will return to the closed position. If conditions
are not met with the slide open 100% for 90 minutes
AL29 will be activated.
T-340
4.5.1 Water-Cooled
Condenser
Pressure Switch
with
Water
a. Connect the water supply line to the inlet side of condenser and the discharge line to the outlet side of the
condenser. (See Figure 2−5).
b. Maintain a flow rate of 11 to 26 liters per minute (3 to 7
gallons per minute). The water pressure switch will
open to de-energize the condenser fan relay. The
condenser fan motor will stop and will remain stopped
until the water pressure switch closes.
c. To shift to air-cooled condenser operation, disconnect the water supply and the discharge line to the
water-cooled condenser. The refrigeration unit will
shift to air-cooled condenser operation when the water pressure switch closes.
4−4
4.5.2 Water−Cooled Condenser with Condenser
Fan Switch
4.7.1 Starting the Unit
a. With power properly applied, the fresh air vent position set and (if required) the water−cooled condenser
connected (refer to paragraphs 4.2, 4.3 & 4.5), place
the START−STOP switch to “I” (ON), see Figure 2−6.
a. Connect the water supply line to the inlet side of condenser and the discharge line to the outlet side of the
condenser. (See Figure 2−5.)
b. Maintain a flow rate of 11 to 26 lpm (3 to 7 gpm).
b. The Controller Function Codes for the container ID
(Cd40), software version (Cd18) and unit model number (Cd20) will be displayed in sequence.
c. Set the condenser fan switch to position “O.” This will
de−energize the condenser fan relay. The condenser
fan motor will stop and remain stopped until the CFS
switch is set to position “I.”
c. Continue with Start Up Inspection, paragraph 4.8.
4.7.2 Stopping the Unit
CAUTION
To stop the unit, place the START−STOP switch in position “0” (OFF).
When condenser water flow is below 11 lpm
(3 gpm) or when water−cooled operation is
not in use, the CFS switch MUST be set to
position “1” or the unit will not operate
properly.
d. To shift to air−cooled condenser operation, stop the
unit, set the CFS switch to position ”I” and restart the
unit. Disconnect the water lines to the water−cooled
condenser.
4.8 START−UP INSPECTION
4.8.1 Physical Inspection
Check rotation of condenser and evaporator fans.
4.8.2 Check Controller Function Codes
Check, and if required, reset controller Function Codes
(Cd27 through Cd39) in accordance with desired
operating parameters. Refer to Table 3−5.
4.6 CONNECT REMOTE MONITORING
RECEPTACLE
If remote monitoring is required, connect the remote
monitor plug at the unit receptacle, see item 9,
Figure 2−6.
4.8.3 Start Temperature Recorder
Partlow Recorders
When the remote monitor plug is connected to the remote monitoring receptacle, the following remote circuits are energized:
CIRCUIT
a. Open recorder door and check battery of electronic
recorder. Be sure key is returned to storage clip of
mechanical recorder.
b. Lift stylus (pen) by pulling the marking tip outward until the stylus arm snaps into the retracted position.
FUNCTION
Sockets B to A
Energizes remote cool light
Sockets C to A
Energizes remote defrost light
c. Install new chart, making sure chart is under the four
corner tabs. Lower the stylus until it has made contact
with the chart. Close and secure the recorder door.
Sockets D to A
Energizes remote in−range light
DataCORDER
a. Check and, if required, set the DataCORDER Configuration in accordance with desired recording parameter. Refer to paragraph 3.8.3.
4.7 STARTING AND STOPPING INSTRUCTIONS
WARNING
b. Enter a “Trip Start.” To enter a “Trip Start,” do the following:
Make sure that the unit circuit breaker(s)
(CB−1 & CB−2) and the START−STOP
switch (ST) are in the “O” (OFF) position before connecting to any electrical power
source.
1. Depress the ALT MODE key. When the left display
shows, dC, depress the ENTER key.
2. Scroll to Code dC30.
3. Depress and hold the ENTER key for five seconds.
NOTE
The electronic phase detection system will
check for proper compressor rotation within the
first 30 seconds. If rotation is not correct, the
compressor will be stopped and restarted in the
opposite direction. If the compressor is producing unusually loud and continuous noise after
the first 30 seconds of operation, stop the unit
and investigate.
4. The “Trip Start” event will be entered in the DataCORDER.
4.8.4 Complete Inspection
Allow the unit to run for five minutes to stabilize conditions, and then perform a Pre−trip diagnosis in accordance with Section 4.9.
4−5
T-340
3. Pre−trip may also be initiated via
communications. The operation is the
same as for the keypad initiation described
below except that should a test fail, the
Pre−trip mode will automatically terminate.
When initiated via communications, a
Pre−trip test may not be interrupted with an
arrow key, but the Pre−trip test can be
terminated with the PRE−TRIP key.
4.9 PRE−TRIP DIAGNOSIS
CAUTION
Pre−trip inspection should not be performed with critical temperature cargoes in
the container.
a. Press the PRE−TRIP key to accesses the Pre−trip
test selection menu.
CAUTION
b. TO RUN AN AUTOMATIC TEST: Scroll through the
selections by pressing the UP ARROW or DOWN
ARROW keys to display AUTO, AUTO 1, AUTO 2 or
AUTO 3 as desired, then press ENTER.
When Pre−trip key is pressed, economy,
dehumidification and bulb mode will be
deactivated. At the completion of Pre−trip
activity, economy, dehumidification and
bulb mode must be reactivated.
Pre−trip diagnosis provides automatic testing of the unit
components using internal measurements and
comparison logic. The program will provide a “PASS” or
“FAIL” display to indicate test results.
The testing begins with access to a Pre−trip selection
menu. The user may have the option of selecting one of
two automatic tests.
1. The unit will execute the series of tests without any
need for direct user interface. These tests vary in
length, depending on the component under test.
2. While tests are running, “P#−#” will appear on the
left display; the #’s indicate the test number and
sub−test. The right display will show a countdown
time in minutes and seconds, indicating the
amount of time remaining in the test.
These tests will automatically perform a series of
individual Pre−trip tests. The user may also scroll down
to select any of the individual tests.
When only the short sequence is configured, it will
appear as “AUtO” in the display. Otherwise “AUtO1” will
indicate the short sequence and “AUtO2” will indicate
the long sequence. The test short sequence will run
tests P0 through P6. The long test sequence will run
tests P0 through P10.
CAUTION
When a failure occurs during automatic
testing, the unit will suspend operation
awaiting operator intervention.
When an automatic test fails, it will be repeated once. A
repeated test failure will cause “FAIL” to be shown on
the right display, with the corresponding test number to
the left.
A detailed description of the Pre−trip test codes is listed
in Table 3−7, page 3−37. If no selection is made, the
Pre−trip menu selection process will terminate
automatically. However, dehumidification and bulb
mode must be reactivated manually if required.
Scrolling down to the “rSLts” code and pressing ENTER
will allow the user to scroll through the results of the last
Pre−trip testing run. If no Pre−testing has been run (or
an individual test has not been run) since the unit was
powered up, “−−−−” will be displayed.
The user may then press the DOWN ARROW to repeat
the test, the UP ARROW to skip to the next test, or the
PRE−TRIP key to terminate testing. The unit will wait indefinitely or until the user manually enters a command.
CAUTION
To start a Pre−trip test, do the following:
When Pre−trip test Auto2 runs to completion without being interrupted, the unit will
terminate Pre−trip and display “Auto 2”
“end.” The unit will suspend operation until
the user depresses the ENTER key!
NOTE
1. Prior to starting a Pre−trip test, verify that
unit voltage (Cd07) is within tolerance and
unit amperage draw (Cd04, Cd05, Cd06)
are within expected limits. Otherwise, tests
may fail incorrectly.
When an Auto 1 Pre−trip test runs to completion without
a failure, the unit will exit Pre−trip mode and return to
normal control operation. However, dehumidification
and bulb mode must be reactivated manually if required.
2. All alarms must be rectified and cleared
before starting tests.
T-340
4−6
c. TO RUN AN INDIVIDUAL TEST: Scroll through the
selections by pressing the UP ARROW or DOWN
ARROW keys to display an individual test code.
Pressing ENTER when the desired test code is
displayed.
The probe check procedure consists of running the
evaporator fans for up to eight minutes in order to compare the readings from the adjacent temperature
probes. If a significant difference in temperature readings is detected between probes, a defrost cycle, followed by another probe check may be initiated. Any
continued disagreement between probes will prompt
the controller to invalidate the failed temperature probe,
and the backup probe will be used for temperature control.
1. Individually selected tests, other than the
LED/Display test, will perform the operations
necessary to verify the operation of the
component. At the conclusion, PASS or FAIL will
be displayed. This message will remain displayed
for up to three minutes, during which time a user
may select another test. If the three minute time
period expires, the unit will terminate pre−trip and
return to control mode operation.
In Perishable Mode, both pairs of supply and return
probes are monitored for probe disagreement. Probe
disagreement is considered a difference of 0.5C
(0.9F) or greater between the supply air sensors and/
or a difference of 2.0C (3.6F) between the return air
sensors. Probe disagreement found in either pair can
trigger a defrost probe check.
In Frozen Mode, only the controlling probes are
considered. Disagreement of the controlling probes can
trigger a defrost probe check, which will occur when the
difference between the sensors is greater than 2.0C
(3.6F). Normally, the controlling probes are the return
probes but if both return probes are invalidated, the
supply probes are used for control purposes. Probe
disagreement of the non−controlling probe pair will not
trigger a defrost probe check.
2. While the tests are being executed, the user may
terminate the pre−trip diagnostics by pressing and
holding the PRE−TRIP key. The unit will then
resume normal operation. If the user decides to
terminate a test but remain at the test selection
menu, the user may press the UP ARROW key.
When this is done, all test outputs will be
de−energized and the test selection menu will be
displayed.
3. During Pre−trip testing, current limiting and pressure limiting are both active, except during P−7
(High Pressure Switch Testing) when pressure limiting is turned off.
If after the defrost probe check the supply probes agree
and return probes agree, all supply and return sensors
are considered valid and the unit returns to normal control.
d. Pre−Trip Test Results
At the end of the pre−trip test selection menu, the message “P,” “rSLts” (Pre−trip results) will be displayed.
Pressing the ENTER key will allow the user to see the
results for all subtests (i.e., 1−0, 1−1, etc).
In the Case of Probe Disagreement:
If the supply probes disagree and the return probes
agree, the controller will invalidate the worst supply
probe. If the probe check is run as part of Pre−trip P−5,
an alarm will be triggered for the invalidated probe. If it is
a run time defrost probe check, the invalidated probe will
be passed over and no alarm will be triggered. However,
if the best supply probe is greater than 1.2C (2.2F) difference with respect to its return probes, the best supply
probe is also invalidated. If unit is in Perishable Mode, a
probe alarm will be triggered for both supply probes.
The results will be displayed as “PASS” or “FAIL” for all
the tests run to completion since power up. If a test has
not been run since power up, “-----” will be displayed.
Once all Pre-test activity is completed, dehumidification
and bulb mode must be reactivated manually if required.
If the supply probes agree and the return probes disagree, invalidate the worst return probe. If the probe
check is being run as part of Pre−trip P−5, an alarm will
be triggered for the invalidated probe. If it is a run time
defrost probe check, the invalidated probe will be
passed over and no alarm will be necessary. If the best
return probe is greater than 1.2C (2.2F) difference
with respect to its supply probes, then the best return
probe is also invalidated. If the unit is in perishable
mode, a probe alarm will be triggered for both return
probes.
4.10 PROBE DIAGNOSTICS
A complete temperature probe check is performed during the P5 Pre−trip test. A probe check is also run at the
end of a defrost cycle; the defrost light will remain on
during this period. If supply probes are within limits and
return probes are within limits, the unit will return to normal operation. During normal operation, the controller
continuously monitors and compares adjacent temperature probe readings.
4−7
T-340
4.11 EMERGENCY BYPASS OPERATION
When the Emergency Bypass switch is in the Bypass
position, the EBS will be enabled. With the Mode switch
in Full Cool mode, the following will occur
simultaneously:
Emergency Bypass operation is used to override the
controller, in the case of a controller malfunction, to keep
the unit cooling. When Emergency Bypass is installed
and turned on, the unit will remain in a continuous state
of full cool until the Emergency Bypass switch is turned
off.
a. The EBS switch will enable EBS input.
b. The phase detection circuit will detect the phase
rotation and close to provide power to the compressor
contactor.
c. The condenser fan contact will close to energize the
condenser contactor and provide power to the condenser fan motor.
To place the unit in the Emergency Bypass Operation:
a. Locate the connection diagram and connectors for
the emergency bypass (EB) sensors behind the top
left side of the compressor.
d. The evaporator fan contact will close to energize the
high speed evaporator contactor and provide power
to the evaporator fan motor.
e. The EBS electronic module will operate the EEV to
control superheat.
To return the unit to normal operation:
b. Disconnect the emergency bypass connector from
the controller connector and attach it to the emergency bypass module connector. See Figure 4−3.
c. Locate the wire tire located at the EB switch in the
control box.
d. Cut the wire tie, then place the EB switch in the On position.
1. Locate the connectors behind the compressor.
2. Disconnect the Emergency Bypass connector from
the EBS module connector and reconnect it to the
controller connector. See Figure 4−3.
e. Place the Mode Switch (MS) in the Full Cool position
to enable the system for cooling.
f. Manually control container air temperature by cycling
the Mode switch between Full Cool and evaporator
Fans Only.
3. Inside the control box, place the EB switch in the Off
position.
4. Re-install the wire tie at the switch mounting.
To operate the fans only, the MODE switch must be in
the FANS ONLY position and the EMERGENCY
BYPASS switch must be in the Bypass position.
EMERGENCY BYPASS
CONNECTOR
The EBS module uses the system’s safety devices (high
pressure switch, motor internal protectors, and heat
termination thermostat) to protect the system while in
Emergency Bypass Mode.
CAUTION
The unit will remain in the full cooling mode
as long as the EB switch is in the On position and the Mode Switch is in the Full Cool
position. If the cargo can be damaged by
low temperatures, the operator must monitor container temperature and manually
cycle operation as required to maintain
temperature within required limits.
T-340
Figure 4−3 Diagram of Emergency Bypass
Connections
4−8
SECTION 5
TROUBLESHOOTING
CONDITION
POSSIBLE CAUSE
REMEDY/
REFERENCE
SECTION
5.1 UNIT WILL NOT START OR STARTS THEN STOPS
External power source OFF
Start−Stop switch OFF or defective
No power to unit
Circuit breaker tripped or OFF
Autotransformer not connected
Circuit breaker OFF or defective
Control transformer defective
Loss of control power
Fuse (F3A/F3B) blown
Start−Stop switch OFF or defective
Evaporator fan motor internal protector open
Condenser fan motor internal protector open
Compressor internal protector open
Component(s) not operating
High pressure switch open
Heat termination thermostat open
Malfunction of current sensor
Low line voltage
Compressor hums, but does not Single phasing
start
Shorted or grounded motor windings
Compressor seized
Turn on
Check
Check
4.2.2
Check
Replace
Check
Check
6.15
6.11
6.8
5.7
Replace
Replace
Check
Check
6.8
6.8
5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING
Container
Refrigeration system
Hot load
Defective box insulation or air leak
Shortage of refrigerant
Evaporator coil covered with ice
Evaporator coil plugged with debris
Evaporator fan(s) rotating backwards
Air bypass around evaporator coil
Controller set too low
Compressor service valves or liquid line shutoff valve
partially closed
Normal
Repair
6.3
5.6
6.14
6.14/6.15
Check
Reset
Open valves
completely
Dirty condenser
Compressor worn
Current limit (function code Cd32) set to wrong value
Economizer solenoid valve malfunction
Digital unloader valve stuck open
Electronic expansion valve
6.10
6.8
3.4.3
6.21
Replace
Replace
5−1
T-340
CONDITION
POSSIBLE CAUSE
REMEDY/
REFERENCE
SECTION
5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING
Refrigeration system
Abnormal pressures
Abnormal temperatures
Abnormal currents
Controller malfunction
Evaporator fan or motor defective
Compressor service valves or liquid line shutoff valve
partially closed
5.7
5.16
5.17
5.9
6.15
Open valves
completely
Frost on coil
Digital unloader valve stuck open
Electronic expansion valve
5.10
Replace
Replace
5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING
No operation of any kind
No control power
Unit will not heat or has insufficient heat
Start−Stop switch OFF or defective
Circuit breaker OFF or defective
External power source OFF
Circuit breaker or fuse defective
Control Transformer defective
Evaporator fan internal motor protector open
Heat relay defective
Heater termination thermostat open
Heater(s) defective
Heater contactor or coil defective
Evaporator fan motor(s) defective or rotating backwards
Evaporator fan motor contactor defective
Controller malfunction
Defective wiring
Loose terminal connections
Low line voltage
Check
Check
Turn ON
Replace
Replace
6.15
Check
6.14
6.14
Replace
6.14/6.15
Replace
5.9
Replace
Tighten
2.3
5.5 UNIT WILL NOT TERMINATE HEATING
Unit fails to stop heating
Controller improperly set
Controller malfunction
Heater termination thermostat remains closed along with
the heat relay
Reset
5.9
6.14
5.6 UNIT WILL NOT DEFROST PROPERLY
Will not initiate defrost
automatically
Will not initiate defrost
manually
Initiates but relay (DR) drops out
T-340
Defrost timer malfunction (Cd27)
Loose terminal connections
Defective wiring
Defrost temperature sensor defective or heat termination
thermostat open
Table 3−5
Tighten
Replace
Heater contactor or coil defective
Manual defrost switch defective
Keypad is defective
Defrost temperature sensor open
Low line voltage
Replace
Replace
Replace
Replace
2.3
5−2
Replace
CONDITION
POSSIBLE CAUSE
REMEDY/
REFERENCE
SECTION
5.6 UNIT WILL NOT DEFROST PROPERLY (Continued)
Initiates but does not defrost
Frequent defrost
Heater contactor or coil defective
Heater(s) burned out
Wet load
Replace
6.14
Normal
Condenser coil dirty
Condenser fan rotating backwards
Condenser fan inoperative
Refrigerant overcharge or noncondensibles
Discharge service valve partially closed
Electronic expansion valve (EEV) control malfunction
Incorrect software and/or controller configuration
Failed suction pressure transducer (SPT) or evaporator
pressure transducer (EPT)
6.10
6.11
6.11
6.3
Open
Replace
Check
5.7 ABNORMAL PRESSURES
High discharge pressure
Suction service valve partially closed
Filter drier partially plugged
Low refrigerant charge
Low suction pressure
No evaporator air flow or restricted air flow
Excessive frost on evaporator coil
Evaporator fan(s) rotating backwards
EEV control malfunction
Failed digital unloader valve (DUV)
Compressor operating in reverse
Suction and discharge pressures tend to equalize when unit Compressor cycling/stopped
is operating
Failed digital unloader valve (DUV)
Replace
Open
6.13
6.3
6.14
5.6
6.15.3
Replace
Replace
5.15
Check
Replace
5.8 ABNORMAL NOISE OR VIBRATIONS
Compressor
Condenser or Evaporator Fan
Compressor start up after an extended shutdown
Brief chattering when manually shut down
Compressor operating in reverse
Loose mounting bolts or worn resilient mounts
Loose upper mounting
Liquid slugging
Bent, loose or striking venturi
Worn motor bearings
Bent motor shaft
Normal
5.15
Tighten/Replace
6.8.1
6.14
Check
6.11/6.15
6.11/6.15
5.9 MICROPROCESSOR MALFUNCTION
Will not control
Incorrect software and/or controller configuration
Defective sensor
Defective wiring
Low refrigerant charge
5−3
Check
6.24
Check
6.3
T-340
CONDITION
POSSIBLE CAUSE
REMEDY/
REFERENCE
SECTION
5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW
Frost on coil
Dirty coil
Evaporator fan motor internal protector open
Evaporator fan motor(s) defective
No or partial evaporator air flow
Evaporator fan(s) loose or defective
Evaporator fan contactor defective
5.11 EAUTOFRESH NOT OPERATING
Unit not Configured for eAutoFresh Operation
Cd43 in Off mode
Wiring disconnected
Vent not opening
Stepper drive defective
Stepper motor defective
Unit operating in frozen mode
Check CO2 sensor
Wiring disconnected
Gas Limit mode unavailable
Unit operating in frozen mode
“Enter“ Key not held for sufficient length of time
Unable to calibrate CO2 sensor CO2 outside of acceptable levels
Check CO2 sensor
Unit not Configured for eAutoFresh Operation
Code 44 displays “−−−−−”
Check CO2 sensor
Evaporator coil blocked
5.6
6.14
6.15
6.15
6.15
Replace
No action
4.4.2
Check wiring
6.26.2
6.26.4
4.4.3
4.4.3
Check wiring
4.4.3
4.4.3
Check
4.4.3
No action
4.4.3
5.12 ELECTRONIC EXPANSION VALVE MALFUNCTION
Low suction pressure
High suction pressure with low
superheat
Incorrect software and/or controller configuration
Failed suction pressure transducer (SPT) or evaporator
pressure transducer (EPT)
Check
Suction service valve partially closed
Filter drier partially plugged
Low refrigerant charge
No evaporator air flow or restricted air flow
Excessive frost on evaporator coil
Evaporator fan(s) rotating backwards
EEV control malfunction
Failed digital unloader valve (DUV)
Loose or insufficiently clamped sensor
Foreign material in valve
Failed suction pressure transducer (SPT) or evaporator
pressure transducer (EPT)
Open
6.13
6.3
6.14
5.6
6.15.3
6.17
Replace
Replace
6.17
EEV control malfunction
Replace
Ensure powerhead is locked
and in place
Improperly seated powerhead
Liquid slugging in compressor
T-340
Replace
Replace
Failed suction pressure transducer (SPT) or evaporator
pressure transducer (EPT)
Replace
Failed EEV
Replace
5−4
CONDITION
POSSIBLE CAUSE
REMEDY/
REFERENCE
SECTION
5.13 AUTOTRANSFORMER MALFUNCTION
Unit will not start
Circuit breaker (CB−1 or CB−2) tripped
Autotransformer defective
Power source not turned ON
460 VAC power plug is not inserted into the receptacle
Check
6.22
Check
4.2.2
5.14 WATER−COOLED CONDENSER OR WATER PRESSURE SWITCH
High discharge pressure
Condenser fan starts and stops
Dirty coil
Noncondensibles
Water pressure switch malfunction
Water supply interruption
6.12
Check
Check
5.15 COMPRESSOR OPERATING IN REVERSE
NOTE
The compressor may start in reverse for up to 10 seconds to determine correct phase rotation if
required for phase detection.
CAUTION
Allowing the scroll compressor to operate in reverse for more than two minutes will result in internal
compressor damage. Turn the start−stop switch OFF immediately.
Incorrect wiring of compressor
Incorrect wiring of compressor contactor(s)
Electrical
Check
Incorrect wiring of current sensor
5.16 ABNORMAL TEMPERATURES
High discharge temperature
Condenser coil dirty
Condenser fan rotating backwards
Condenser fan inoperative
Refrigerant overcharge or noncondensibles
Discharge service valve partially closed
Electronic expansion valve (EEV) control malfunction
Failed suction pressure transducer (SPT) or evaporator
pressure transducer (EPT)
6.10
6.11
6.11
6.3
Open
Replace
Discharge temperature sensor drifting high
Failed economizer expansion valve, economizer coil, or
economizer solenoid valve
Replace
Replace
Replace
Plugged economizer expansion valve, economizer coil, or
economizer solenoid valve
Replace
Loose or insufficiently clamped sensor
Replace
Current sensor wiring
Check
5.17 ABNORMAL CURRENTS
Unit reads abnormal currents
5−5
T-340
SECTION 6
SERVICE
NOTE
Use a refrigerant recovery system whenever removing refrigerant. When working with refrigerants you must
comply with all local government environmental laws. In the U.S.A., refer to EPA section 608.
When both valves are backseated (all the way out), high
pressure vapor will flow into the low side.
When the Suction Pressure Valve (1) is open and the
Discharge Pressure Valve (4) shut, the system can be
charged through the Utility Connection (6). Oil can also
be added to the system.
A R-134a manifold gauge/hose set with self-sealing hoses (see Figure 6−2) is required for service of the models covered within this manual. The manifold gauge/
hose set is available from Carrier Transicold. (Carrier
Transicold part number 07-00294-00, which includes
items 1 through 6, Figure 6−2.)
If the manifold gauge/hose set is new or was exposed to
the atmosphere, it will need to be evacuated to remove
contaminants and air as follows:
1. Backseat (turn counterclockwise) both field service
couplings (see Figure 6−2) and midseat both hand
valves.
2. Connect the yellow hose to a vacuum pump and refrigerant 134a cylinder.
WARNING
EXPLOSION HAZARD Failure to follow this
WARNING can result in death, serious
personal injury and / or property damage.
Never use air or gas mixtures containing
oxygen (O2) for leak testing or operating the
product.
Charge only with R−134a: Refrigerant must
conform
to
AHRI
Standard
700
specification.
6.1 SECTION LAYOUT
Service procedures are provided herein beginning with
refrigeration system service, then refrigeration system
component service, electrical system service, temperature recorder service and general service. Refer to the
Table of Contents to locate specific topics.
6.2 MANIFOLD GAUGE SET
The manifold gauge set (see Figure 6−1) is used to
determine system operating pressure, add refrigerant
charge, and to equalize or evacuate the system.
3
2
Â
Â
ÂÂ
 ÂÂÂ
To Low Side
Access Valve
2
6
1
7
6
5
4
7
1. Suction Pressure Valve (shown backseated)
2. Suction Pressure Gauge
3. Discharge Pressure Gauge
4. Discharge Pressure Valve (shown frontseated)
5. High Side Connection
6. Utility Connection to:
a. Refrigerant cylinder
b. Vacuum Pump
c. Oil Container
7. Low Side Connection
Figure 6−1 Manifold Gauge Set
4
To High Side
Access Valve
1
Â
3
2
4
5
1. RED Refrigeration and/or Evacuation Hose
(SAE J2196/R-134a)
2. Hose Fitting (0.5-16 Acme)
3. YELLOW Refrigeration and/or Evacuation Hose
(SAE J2196/R-134a)
4. Hose Fitting with O-ring (M14 x 1.5)
5. High Side Field Service Coupling (Red Knob)
6. BLUE Refrigeration and/or Evacuation Hose
(SAE J2196/R-134a)
7. Low Side Field Service Coupling (Blue Knob)
Figure 6−2 R-134a Manifold Gauge/Hose Set
3. Evacuate to 10 inches of vacuum and then charge
with R-134a to a slightly positive pressure of 0.1 kg/
cm2 (1.0 psig).
4. Frontseat both manifold gauge set valves and disconnect from cylinder. The gauge set is now ready
for use.
When the Suction Pressure Valve (1) is frontseated
(turned all the way in), the suction (low) pressure can be
checked at the Suction Pressure Gauge (2).
When the Discharge Pressure Valve (4) is frontseated,
the discharge (high) pressure can be checked at the
Discharge Pressure Gauge (3).
6−1
T-340
6.3 SERVICE CONNECTIONS
CAUTION
The compressor suction, compressor discharge, and
the liquid line service valves (see Figure 6−3) are provided with a double seat and an access valve which enables servicing of the compressor and refrigerant lines.
To prevent trapping liquid refrigerant in the
manifold gauge set be sure set is brought to
suction pressure before disconnecting.
Turning the valve stem clockwise (all the way forward)
will frontseat the valve to close off the line connection
and open a path to the access valve. Turning the stem
counterclockwise (all the way out) will backseat the
valve to open the line connection and close off the path
to the access valve.
Removing the Manifold Gauge Set:
a. While the compressor is still ON, backseat the high
side service valve.
b. Midseat both hand valves on the manifold gauge set
and allow the pressure in the manifold gauge set to be
drawn down to low side pressure. This returns any liquid that may be in the high side hose to the system.
With the valve stem midway between frontseat and
backseat, both of the service valve connections are
open to the access valve path.
For example, the valve stem is first fully backseated
when connecting a manifold gauge to measure
pressure. Then, the valve is opened 1/4 to 1/2 turn to
measure the pressure.
2
1
6
1.
2.
3.
4.
4
5
Line Connection
Access Valve
Stem Cap
Valve stem
c. Backseat the low side service valve. Backseat both
field service couplings and frontseat both manifold
hand valves. Remove couplings from access valves.
d. Install both service valve stem caps and service port
caps (finger-tight only).
6.4 PUMP DOWN THE UNIT
3
To service the filter drier, economizer, expansion valves,
economizer solenoid valve, digital unloader valve or
evaporator coil, pump the refrigerant into the high side
as follows:
CAUTION
7
The scroll compressor achieves low suction pressure very quickly. Do not use the
compressor to evacuate the system below
0 psig. Never operate the compressor with
the suction or discharge service valves
closed (frontseated). Internal damage will
result from operating the compressor in a
deep vacuum.
5. Compressor Or Filter
Drier Inlet Connection
6. Valve (Frontseated)
7. Valve (Backseated)
Figure 6−3 Service Valve
Connection of the manifold gauge/hose set (see
Figure 6−4) is dependent on the component being
serviced. If only the compressor is being serviced, the
high side coupling is connected to the discharge service
valve.
a. Attach manifold gauge set to the compressor suction
and discharge service valves. Refer to paragraph 6.2.
b. Start the unit and run in the frozen mode (controller
set below -10C (14F) for 10 to 15 minutes.
For service of the low side (after pump down), the high
side coupling is connected to the liquid line service
valve. The center hose connection is brought to the tool
being used (vacuum, tank, etc.).
c. Check function code Cd21 (refer to paragraph 3.2.2).
The economizer solenoid valve should be open. If
not, continue to run until the valve opens.
d. Frontseat the liquid line service valve. Place StartStop switch in the OFF position when the suction
reaches a positive pressure of 0.1 bar (1.4 psig).
Connecting the manifold gauge set:
a. Remove service valve stem cap and to make sure the
valve is backseated.
e. Frontseat the suction and discharge service valves.
The refrigerant will be trapped between the compressor discharge service valves and the liquid line valve.
b. Remove access valve cap (See Figure 6−3).
c. Connect the field service coupling (see Figure 6−2) to
the access valve.
f. Before opening up any part of the system, a slight
positive pressure should be indicated on the pressure
gauge. Remove power from the unit before opening
any part of the system. If a vacuum is indicated, emit
refrigerant by cracking the liquid line valve momentarily to build up a slight positive pressure.
d. Turn the field service coupling knob clockwise, which
will open the system to the gauge set.
e. To read system pressures, slightly midseat the service valve.
g. When opening up the refrigerant system, certain
parts may frost. Allow the part to warm to ambient
temperature before dismantling. This avoids internal
condensation which puts moisture in the system.
f. Repeat the procedure to connect the other side of the
gauge set.
T-340
6−2
h. After repairs have been made, be sure to perform a
refrigerant leak check (refer to Section 6.5), and
evacuate and dehydrate the low side (refer to
paragraph 6.6.1).
c. If possible, keep the ambient temperature above
15.6C (60F) to speed evaporation of moisture. If
the ambient temperature is lower than 15.6C
(60F), ice might form before moisture removal is
complete. Heat lamps or alternate sources of heat
may be used to raise the system temperature.
i. Check refrigerant charge (refer to Section 6.6).
6.5 REFRIGERANT LEAK CHECKING
d. Additional time may be saved during a complete system pump down by replacing the filter drier with a section of copper tubing and the appropriate fittings.
Installation of a new drier may be performed during
the charging procedure.
WARNING
EXPLOSION HAZARD Failure to follow this
WARNING can result in death, serious
personal injury and / or property damage.
Never use air or gas mixtures containing
oxygen (O2) for leak testing or operating the
product.
Charge only with R−134a: Refrigerant must
conform
to
AHRI
Standard
700
specification.
3
2
1
ÉÉ
É
4
É
5
É
a. The recommended procedure for finding leaks in a
system is with a R-134a electronic leak detector.
Testing joints with soapsuds is satisfactory only for
locating large leaks.
S D
b. If the system is without refrigerant, charge the system
with refrigerant 134a to build up pressure between 2.1
to 3.5 bar (30.5 to 50.8 psig). To ensure complete
pressurization of the system, refrigerant should be
charged at the compressor suction valve and the liquid line service valve. Remove refrigerant cylinder
and leak-check all connections.
10
ÂÂÂ
ÂÂÂ
ÂÂÂ
NOTE
Only refrigerant 134a should be used to
pressurize the system. Any other gas or vapor
will contaminate the system, which will require
additional purging and evacuation of the
system.
8
1. Liquid Service
Connection
2. Receiver or Water
Cooled Condenser
3. Compressor
4. Discharge Service
Connection
c. If required, remove refrigerant using a refrigerant
recovery system and repair any leaks. Check for
leaks.
d. Evacuate and dehydrate the unit. (Refer to paragraph
6.6.1.)
e. Charge unit per paragraph 6.7.1.
6
9
7
5. Suction Service
Connection
6. Vacuum Pump
7. Electronic Vacuum
Gauge
8. Manifold Gauge Set
9. Refrigerant Cylinder
10. Reclaimer
Figure 6−4 Refrigeration System Service
Connections
6.6 EVACUATION AND DEHYDRATION
6.6.1 General
6.6.3 Complete System
Moisture is detrimental to refrigeration systems. The
presence of moisture in a refrigeration system can have
many undesirable effects. The most common are copper plating, acid sludge formation, “freezing-up” of
metering devices by free water, and formation of acids,
resulting in metal corrosion.
NOTE
Refer to Partial System procedure for information pertaining to partial system evacuation and
dehydration.
6.6.2 Preparation
a. Evacuate and dehydrate only after pressure leak test
(refer to Section 6.5).
a. Remove all refrigerant using a refrigerant recovery
system.
b. Essential tools to properly evacuate and dehydrate
any system include a vacuum pump (8 m/hr = 5 cfm
volume displacement) and an electronic vacuum
gauge. The pump is available from Carrier
Transicold, (P/N 07-00176-11).
b. The recommended method to evacuate and dehydrate the system is to connect evacuation hoses at
the compressor suction and liquid line service valve
(see Figure 6−4). Be sure the service hoses are
suited for evacuation purposes.
6−3
T-340
c. Test the evacuation setup for leaks by backseating
the unit service valves and drawing a deep vacuum
with the vacuum pump and gauge valves open. Shut
off the pump and check to see if the vacuum holds.
Repair leaks if necessary.
6.7.1 Checking the Refrigerant Charge
NOTE
Use a refrigerant recovery system whenever
removing refrigerant. When working with refrigerants you must comply with all local government environmental laws. In the U.S.A., refer to
EPA Section 608.
d. Midseat the refrigerant system service valves.
e. Open the vacuum pump and electronic vacuum
gauge valves, if they are not already open. Start the
vacuum pump. Evacuate unit until the electronic vacuum gauge indicates 2000 microns. Close the electronic vacuum gauge and vacuum pump valves. Shut
off the vacuum pump. Wait a few minutes to be sure
the vacuum holds.
a. Connect the gauge manifold to the compressor discharge and suction service valves. For units operating on a water cooled condenser, change over to air
cooled operation.
b. Bring the container temperature to approximately
0C (32F) or below. Then set the controller set point
to -25C (-13F).
c. Partially block the condenser coil inlet air. Increase the
area blocked until the compressor discharge pressure
is raised to approximately 12.8 bar (185 psig).
d. On units equipped with a receiver, the level should be
between the glasses. On units equipped with a watercooled condenser, the level should be at the center of
the glass. If the refrigerant level is not correct, continue with the following paragraphs to add or remove refrigerant as required.
6.7.2 Adding Refrigerant to System (Full Charge)
a. Evacuate unit and leave in deep vacuum. (Refer to
paragraph 6.6.1.)
b. Place cylinder of R-134a on scale and connect charging line from cylinder to liquid line valve. Purge charging line at liquid line valve and then note weight of cylinder and refrigerant.
c. Open liquid valve on cylinder. Open liquid line valve
half-way and allow the liquid refrigerant to flow into
the unit until the correct weight of refrigerant (refer to
paragraph 2.2) has been added as indicated by
scales.
f. Break the vacuum with clean dry refrigerant 134a gas.
Raise system pressure to roughly 0.14 bar (2 psig),
monitoring it with the compound gauge.
g. Remove refrigerant using a refrigerant recovery system.
h. Repeat steps e. and f. one time.
i. Remove the copper tubing and change the filter drier.
Evacuate unit to 500 microns. Close the electronic
vacuum gauge and vacuum pump valves. Shut off the
vacuum pump. Wait five minutes to see if vacuum
holds. This procedure checks for residual moisture
and/or leaks.
j. With a vacuum still in the unit, the refrigerant charge
may be drawn into the system from a refrigerant container on weight scales.
6.6.4 Partial System
a. If refrigerant charge has been removed from the low
side only, evacuate the low side by connecting the
evacuation set-up at the compressor suction valve
and the liquid service valve but leave the service
valves frontseated until evacuation is completed.
NOTE
It may be necessary to finish charging unit
through suction service valve in gas form, due
to pressure rise in high side of the system.
b. Once evacuation has been completed and the pump
has been isolated, fully backseat the service valves to
isolate the service connections and then continue
with checking and, if required, adding refrigerant in
accordance with normal procedures.
d. Backseat manual liquid line valve (to close off gauge
port). Close liquid valve on cylinder.
e. Start unit in cooling mode. Run for approximately 10
minutes and check the refrigerant charge.
6.7.3 Adding Refrigerant to System (Partial
Charge)
a. Examine the unit refrigerant system for any evidence
of leaks. Repair as necessary. (Refer to paragraph
6.5.).
b. Maintain the conditions outlined in paragraph 6.7.1.
c. Fully backseat the suction service valve and remove
the service port cap.
d. Connect charging line between suction service valve
port and cylinder of refrigerant R-134a. Open VAPOR
valve.
e. Partially frontseat (turn clockwise) the suction service
valve and slowly add charge until the refrigerant
appears at the proper level. Be careful not to frontseat
the suction valve fully, if the compressor is operated in
a vacuum, internal damage may result.
6.7 REFRIGERANT CHARGE
WARNING
EXPLOSION HAZARD Failure to follow this
WARNING can result in death, serious
personal injury and / or property damage.
Never use air or gases containing oxygen
(O2) for leak testing or operating the
product.
Charge only with R−134a: Refrigerant must
conform
to
AHRI
Standard
700
specification.
T-340
6−4
g. Remove the Rotalock fittings from the suction and
discharge service connections, and uncouple the
unloader and economizer lines from the compressor.
6.8 COMPRESSOR
WARNING
h. Cut the dome temperature sensor (CPDS) wires.
The replacement compressor comes with a CPDS
already assembled.
Make sure power to the unit is OFF and
power plug disconnected before replacing
the compressor.
i. Remove and save the compressor base mounting
bolts. Discard the 4 top resilient mounts and washers.
j. Remove (slide out) the old compressor from the unit.
WARNING
k. Inspect compressor base plate for wear. Replace, if
necessary.
l. Wire tie the compressor base plate to the compressor, and slide the new compressor into the unit.
Refer to Figure 6−5.
Before disassembly of the compressor, be
sure to relieve the internal pressure very
carefully by slightly loosening the couplings to break the seal.
3
4
2
1
CAUTION
The scroll compressor achieves low suction pressure very quickly. Do not use the
compressor to evacuate the system below
0 psig. Never operate the compressor with
the suction or discharge service valves
closed (frontseated). Internal damage will
result from operating the compressor in a
deep vacuum.
5
2
11
12
6
7
8
7
9
10
6.8.1 Removal and Replacement of Compressor
a. Turn the unit ON and run it in full cool mode for 10
minutes.
1. Compressor
2. Teflon Seal for Valve
Connection (2)
3. O−Ring (Unloader
Connection)
4. Compressor Dis−
charge Temperature
Sensor
5. O−Ring (Economizer
Connection)
6. Base Mounting Bolts
NOTE
If the compressor is not operational, front−seat
the suction and discharge service valves and
go to step e. below.
b. Frontseat the manual liquid line valve and allow the
unit to pull−down to 0.1 kg/cm2 (1 psig).
c. Turn the unit start−stop switch (ST) and unit circuit
breaker (CB−1) OFF, and disconnect power to the
unit.
d. Frontseat the discharge and suction service valves.
7.
8.
9.
10.
11.
12.
SST Washers
Resilient Mount
Mylar Washers
Wire Ties
Power Cable Gasket
Ground Connection
Screw
13. Power Cable
Lubricant − Krytox
(Not Shown)
Figure 6−5 Compressor Kit
e. Remove all remaining refrigerant from the compressor using a refrigerant recovery system.
NOTE
DO NOT add any oil to the replacement compressor. Replacement compressor is shipped
with full oil charge of 60 oz.
f. Remove the compressor terminal cover, disconnect
the ground wire and pull the cable plug from the compressor terminals. Install the terminal cover back
after removing the power cable.
m. Cut and discard the wire ties used to hold the base
plate to the compressor.
NOTE
Inspect the power cable (plug) terminals to ensure they are not deformed or have any signs of
heat or arcing. If any damage is noted, replace
the power cable.
n. Place the new SST washers on each side of the resilient mounts, and the new Mylar washer on the bottom of it as shown in Figure 6−5. Install the four base
mounting bolts loosely.
6−5
T-340
o. Place the new Teflon seals at the compressor suction and discharge ports as well as the O−rings at the
unloader and economizer line connection ports.
Hand tighten all four connections.
6.9 HIGH PRESSURE SWITCH
6.9.1 Checking High Pressure Switch
WARNING
p. Torque the four base−mounting screws to 6.2 mkg
(45 ft−lbs).
Do not use a nitrogen cylinder without a
pressure regulator.
q. Torque the compressor ports / connections to:
NOTE
The high pressure switch is non-adjustable.
Service Valve / Connection
Suction and Discharge
Rotalocks
Unloader connection
Economized connection
a. Remove switch as outlined in paragraph 6.9.2.
b. Connect ohmmeter or continuity light across switch
terminals. Ohm meter will indicate no resistance or
continuity light will be illuminated if the switch closed
after relieving compressor pressure.
c. Connect hose to a cylinder of dry nitrogen. (See
Figure 6−6.
Torque Value
108.5 to 135.5 Nm
(80 to 100 ft−lbs.)
24.5 to 27 Nm
(18 to 20 ft−lbs.)
32.5 to 35 Nm
(24 to 26 ft−lbs.)
1
r. Connect (butt−splice and heat shrink) the new compressor dome temperature sensor with the old
sensor wires removed in step h. Wire−tie any loose
wiring as appropriate.
2
s. Evacuate the compressor to 1000 microns if the unit
was pumped down before the replaced compressor
was removed. Otherwise, evacuate the complete
unit and charge it with R−134a refrigerant (see Sections 6.6.1 and 6.7.1).
3
1. Cylinder Valve
4.
and Gauge
2. Pressure Regulator
3. Nitrogen Cylinder
5.
6.
t. Open the compressor terminal cover and connect
the compressor power cable following the steps below:
u. Liberally coat the orange gasket surfaces with the
Krytox lubricant.
5
6
Pressure Gauge
(0 to 36 kg/cm2 =
0 to 400 psig)
Bleed-Off Valve
1/4 inch Connection
Figure 6−6 High Pressure Switch Testing
d. Set nitrogen pressure regulator at 26.4 kg/cm2 (375
psig) with bleed-off valve closed.
e. Close valve on cylinder and open bleed-off valve.
f. Open cylinder valve. Slowly close bleed-off valve to
increase pressure on switch. The switch should open
at a static pressure up to 25 kg/cm2 (350 psig). If a
light is used, the light will go out. If an ohmmeter is
used, the meter will indicate open circuit.
g. Slowly open bleed-off valve to decrease the pressure.
The switch should close at 18 kg/cm2 (250 psig).
6.9.2 Replacing High Pressure Switch
a. Remove the refrigerant charge.
b. Disconnect wiring from defective switch. The high
pressure switch is located on the discharge connection or line and is removed by turning counterclockwise.
c. Install a new high pressure switch after verifying
switch settings.
d. Evacuate, dehydrate and recharge the system.
e. Start the unit, verify refrigeration charge and oil level.
v. Install the orange gasket part onto the compressor
fusite with the grooved or threaded side out. Ensure
that the gasket is seated onto the fusite base.
w. Coat the inside of the power plug (female) connector
pins with the Krytox lubricant, and insert the plug
onto the compressor terminal connections. Make
sure, the orange gasket has bottomed out onto the
fusite and it fits securely onto the terminal pins while
fully inserted into the orange plug.
x. Connect the green ground wire to the grounding tab
located inside the terminal box of the compressor using the self−tapping grounding screw. Close the
compressor terminal box using the terminal cover removed in step t.
y. Backseat all service valves, connect the power to the
unit and run it for at least 20 minutes.
z. Perform a leak check of the system.
T-340
4
6−6
f. Install fan loosely on motor shaft (hub side in). DO
NOT USE FORCE. If necessary, tap the hub only, not
the hub nuts or bolts. Install venturi. Apply “Loctite H”
to fan set screws. Adjust fan within venturi so that the
outer edge of the fan is within 2.0 +/- 0.07 mm (0.08”
+/- 0.03”) from the outside of the orifice opening. Spin
fan by hand to check clearance.
6.10 CONDENSER COIL
The condenser coil consists of a series of parallel copper tubes expanded into copper fins. The condenser coil
must be cleaned with fresh water or steam so the air flow
is not restricted. To replace the coil, do the following:
WARNING
g. Close and secure condenser fan screen guard.
Do not open the condenser fan grille before
turning power OFF and disconnecting the
power plug.
6.12 WATER−COOLED CONDENSER CLEANING
The water-cooled condenser is of the shell and coil type
with water circulating through the cupro-nickel coil. The
refrigerant vapor is admitted to the shell side and is condensed on the outer surface of the coil.
a. Using a refrigerant reclaim system, remove the refrigerant charge.
b. Remove the condenser coil guard.
Rust, scale and slime on the water-cooling surfaces
inside of the coil interfere with the transfer of heat,
reduce system capacity, cause higher head pressures
and increase the load on the system.
c. Unsolder the lines and remove the line to the receiver
or water-cooled condenser.
d. Remove the coil mounting hardware and remove the
coil from the unit.
By checking the leaving water temperature and the
actual condensing temperature, it can be determined if
the condenser coil is becoming dirty. A larger than normal difference between leaving condensing water temperature and actual condensing temperature, coupled
with a small difference in temperature of entering and
leaving condensing water, is an indication of a dirty condensing coil.
e. Install the replacement coil and solder connections.
f. Leak-check the coil connections per paragraph 6.5.
Evacuate the unit then charge the unit with refrigerant.
6.11 CONDENSER FAN AND MOTOR ASSEMBLY
To find the approximate condensing temperature, with
the unit running in the cooling mode, install a gauge 0 to
36.2 kg/cm2 (0 to 500 psig) on the compressor discharge service valve.
WARNING
Do not open condenser fan grille before
turning power OFF and disconnecting
power plug.
Example: Discharge pressure is 10.3 kg/cm2 (146.4
psig). Referring to Table 6−4 (R-134a pressure/ temperature chart), the 10.3 kg/cm2 (146.4 psig) value converts to 43C (110F).
The condenser fan rotates counter-clockwise (viewed
from front of unit), pulls air through the condenser coil,
and discharges horizontally through the front of the unit.
If the water-cooled condenser is dirty, it may be cleaned
and de-scaled by the following procedure:
To replace the condenser fan motor assembly:
a. Open condenser fan screen guard.
a. Turn unit off and disconnect main power.
b. Disconnect water pressure switch tubing by loosening the two flare nuts. Install one-quarter inch flare
cap on water-cooled condenser inlet tube (replaces
tubing flare nut). De-scale tubing if necessary.
b. Loosen two square head set screws on fan. (Thread
sealer has been applied to set screws at installation.)
c. Disconnect wiring connector.
What You Will Need:
CAUTION
1. Oakite Aluminum Cleaner® 164, available as a powder in 20 kg (44 lb) pails and 205 kg (450 lb) drums.
Take necessary steps (place plywood over
coil or use sling on motor) to prevent motor
from falling into condenser coil.
2. Oakite Composition No. 32, available as a liquid in
cases, each containing 3.785 liters (4 U.S. gallon)
bottles and also in carboys of 52.6 kg (116 lbs) net.
d. Remove motor mounting hardware and replace the
motor. It is recommended that new locknuts be used
when replacing motor.
3. Fresh clean water.
4. Acid proof pump and containers or bottles with rubber
hose.
e. Connect the wiring connector.
6−7
T-340
NOTE
When Oakite Compound No. 32 is used for the
first time, the local Oakite Technical Service
representative should be called in for
suggestions in planning the procedure. The
representative will advise the reader on how to
do the work with a minimum dismantling of
equipment: how to estimate the time and
amount of compound required; how to prepare
the solution; how to control and conclude the
de-scaling operation by rinsing and neutralizing
equipment before putting it back into service.
The representative’s knowledge of metals,
types of scale, water conditions and de-scaling
techniques will be highly useful.
WARNING
Oakite No. 32 is an acid. Be sure that the
acid is slowly added to the water. DO NOT
PUT WATER INTO THE ACID - this will cause
spattering and excessive heat.
WARNING
Wear rubber gloves and wash the solution
from the skin immediately if accidental contact occurs. Do not allow the solution to
splash onto concrete.
5. Fill the tubes with this solution by filling from the bottom. See Figure 6−7.
Summary of Procedure:
7
1. Drain water from condenser tubing circuit.
6
2. Clean water tubes with Oakite Aluminum Cleaner)
164 to remove mud and slime.
4
3
3. Flush.
9
2
4. De-scale water tubes with Oakite No. 32 to remove
scale.
10
5. Flush.
1
6. Neutralize.
11
12
7. Flush.
1. Pump support
2. Tank
3. Suction
4. Pump
5. Priming Connection
(Centrifugal pump
50 gpm at 35’ head)
6. Globe valves
8. Put unit back in service under normal load and check
head (discharge) pressure.
Detailed Procedure:
1. Drain and flush the water circuit of the condenser
coil. If scale on the tube inner surfaces is accompanied by slime, a thorough cleaning is necessary
before de-scaling process can be accomplished.
7. Vent
8. Close vent pipe valve
when pump is running
9. Condenser
10. Remove water
regulating valve
11. Return
12. Fine mesh screen
Figure 6−7 Water-Cooled Condenser Cleaning,
Forced Circulation
NOTE
It is important to provide a vent at the top for
escaping gas.
2. To remove slime or mud, use Aluminum Cleaner®
164. Mixed 170 grams (6 ounces) per 3.785 liters (1
U.S. gallon) of water. Mix cleaner in one half the
volume of water, while stirring, and then add remaining water. Warm this solution and circulate through
the tubes until all slime and mud has been removed.
6. Allow the Oakite No. 32 solution to soak in the tube
coils for several hours, periodically pump-circulating
it with an acid-proof pump.
3. After cleaning, flush tubes thoroughly with fresh
clean water.
An alternate method may be used whereby a pail
(see Figure 6−8) filled with the solution and attached
to the coils by a hose can serve the same purpose by
filling and draining. The solution must contact the
scale at every point for thorough de-scaling. Air
pockets in the solution should be avoided by regularly opening the vent to release gas. Keep flames
away from the vent gases.
4. Prepare a 15% by volume solution for de-scaling, by
diluting Oakite Compound No. 32 with water. This is
accomplished by slowly adding 0.47 liter (1 U.S. pint)
of the acid (Oakite No. 32) to 2.8 liters (3 U.S. quarts)
of water.
T-340
8
5
6−8
7. The time required for de-scaling will vary, depending
upon the extent of the deposits. One way to determine when de-scaling has been completed is to
titrate the solution periodically, using titrating equipment provided free by the Oakite Technical Service
representative. As scale is being dissolved, titrate
readings will indicate that the Oakite No. 32 solution
is losing strength. When the reading remains
constant for a reasonable time, this is an indication
that scale has been dissolved.
What You Can Do For Further Help:
Contact the Engineering and Service Department of the
OAKITE PRODUCTS CO., 675 Central Avenue, New
Providence, NJ 07974 U.S.A. (or visit www.oakite.com)
for the name and address of the service representative
in your area.
6.13 FILTER DRIER
On units equipped with a water-cooled condenser, if the
sight glass appears to be flashing or bubbles are
constantly moving through the sight glass, the unit may
have a low refrigerant charge or the filter drier could be
partially plugged.
a. To check filter drier:
1. Test for a restricted or plugged filter drier by feeling
the liquid line inlet and outlet connections of the
drier cartridge. If the outlet side feels cooler than
the inlet side, then the filter drier should be
changed.
2. Check the moisture-liquid indicator if the indicator
shows a high level of moisture, the filter drier
should be replaced.
b. To replace filter drier:
1
5
2
4
1. Pump down the unit (refer to paragraph 6.4). Evacuate if unit is not equipped with service valves.
Then replace filter drier.
2. Evacuate the low side in accordance with paragraph 6.6.
3. After unit is in operation, inspect for moisture in
system and check charge.
3’ to 4’
3
1.Fill condenser with
cleaning solution. Do
not add solution more
rapidly than vent can
exhaust gases caused
by chemical action.
2.
3.
4.
5.
6.14 EVAPORATOR COIL & HEATER ASSEMBLY
Approximately 5’
Condenser
Vent pipe
1” pipe
The evaporator section, including the evaporator coil,
should be cleaned regularly. The preferred cleaning fluid
is fresh water or steam. Another recommended cleaner
is Oakite 202 or similar, following manufacturer’s
instructions.
The two drain pan hoses are routed behind the condenser fan motor and compressor. The drain pan line(s)
must be open to ensure adequate drainage.
Figure 6−8 Water-Cooled Condenser Cleaning Gravity Circulation
6.14.1 Evaporator Coil Replacement
a. Pump unit down. (Refer to paragraph 6.4) Evacuate if
unit is not equipped with service valves. Refer to
paragraph 6.6.1.
b. With power OFF and power plug removed, remove
the screws securing the panel covering the evaporator section (upper panel).
c. Disconnect the defrost heater wiring.
d. Remove the mounting hardware from the coil.
e. Unsolder the two coil connections, one at the distributor and the other at the coil header.
f. Disconnect the defrost temperature sensor (see
Figure 2−2) from the coil.
8. When de-scaling is complete, drain the solution and
flush thoroughly with water.
NOTE
If condenser cooling water is not being used as
drinking water or is not re-circulated in a closed or
tower system, neutralizing is not necessary.
9. Following the water flush, circulate a 56.7 gram (2
ounce) per 3.785 liter (1 U.S. gallon) solution of
Oakite Aluminum Cleaner® 164 thru the tubes to
neutralize. Drain this solution.
g. Remove middle coil support.
h. After defective coil is removed from unit, remove
defrost heaters and install on replacement coil.
i. Install coil assembly by reversing above steps.
10.Flush the tubes thoroughly with fresh water.
11. Put the unit back in service and operate under normal load. Check the head pressure. If normal, a thorough de-scaling has been achieved.
j. Leak check connections. Evacuate and add refrigerant charge.
6−9
T-340
6.14.2 Evaporator Heater Replacement
1
2
The heaters are wired directly back to the contactor and
if a heater failure occurs during a trip, the heater set
containing that heater may be disconnected at the
contactor.
The next Pre-trip (P1) will detect that a heater set has
been disconnected and indicate that the failed heater
should be replaced. To remove a heater, do the
following:
a. Before servicing unit, make sure the unit circuit breakers (CB-1 and CB-2) and the start-stop switch (ST)
are in the OFF position, and that the power plug is disconnected.
3
1.
2.
3.
b. Remove the upper back panel.
Figure 6−9 5+1 Heater Arrangement − Omega
Heater
c. Determine which heater(s) need replacing by checking resistance of each heater set. Refer to paragraph
2.3 for heater resistance values. Once the set containing the failed heater is determined, cut the splice
connection and retest to determine the actual failed
heater(s).
6.15 EVAPORATOR FAN AND MOTOR ASSEMBLY
The evaporator fans circulate air throughout the container by pulling air in the top of the unit. The air is forced
through the evaporator coil where it is either heated or
cooled and then discharged out the bottom of the refrigeration unit into the container. The fan motor bearings
are factory lubricated and do not require additional
grease.
d. Remove hold-down clamp securing heater(s) to coil.
e. Lift the bent end of the heater (with the opposite end
down and away from coil). Move heater to the side
enough to clear the heater end support and remove.
6.15.1 Replacing the Evaporator Fan Assembly
To replace a heater, do steps a through e in reverse.
WARNING
Optional 5+1 Heater Arrangement Heater Removal
and Replacement
Always turn OFF the unit circuit breakers
(CB-1 & CB-2) and disconnect main power
supply before working on moving parts.
Complete steps a. through e. noted above, then remove straight and Omega heaters:
a. Remove access panel (see Figure 2−2) by removing
mounting bolts and TIR locking device. Reach inside
of unit and remove the Ty-Rap securing the wire harness loop. Disconnect the connector by twisting to
unlock and pulling to separate.
b. Loosen four 1/4-20 clamp bolts that are located on the
underside of the fan deck at the sides of the fan
assembly. Slide the loosened clamps back from the
fan assembly.
c. Slide the fan assembly out from the unit and place on
a sturdy work surface.
a. To remove straight heater:
1. Locate holding clips positioned at the ends of the
heater element.
2. Rotate clips toward the center of the container unit.
3. Lift the heater slightly up and out to remove.
6.15.2 Disassemble the Evaporator Fan Assembly
b. To remove Omega heater (see Figure 6−9)
a. Attach a spanner wrench to the two 1/4-20 holes
located in the fan hub. Loosen the 5/8-18 shaft nut by
holding the spanner wrench stationary and turning
the 5/8-18 nut counter-clockwise (see Figure 6−10).
b. Remove the spanner wrench. Use a universal wheel
puller and remove the fan from the shaft. Remove the
washers and key.
c. Remove the four 1/4-20 x 3/4 long bolts that are
located under the fan that support the motor and stator housing. Remove the motor and plastic spacer.
1. Remove the two tube clamps located near the top
of the heater element.
2. Locate the holding clips positioned at the bottom of
the heater element and rotate slightly toward the
center of the container unit.
3. Carefully pull heater out to remove.
T-340
Omega Heater
Tube Clamps (2)
Holding Clips (2)
6−10
e. Install the evaporator fan assembly in reverse order
of removal. Torque the four 1/4-20 clamp bolts to
0.81 mkg (70 inch-pounds). Connect the wiring connector.
6.15.3 Assemble the Evaporator Fan Assembly
a. Assemble the motor and plastic spacer onto the stator.
NOTE
When removing the black nylon evaporator fan
blade, care must be taken to assure that the blade
is not damaged. In the past, it was a common practice to insert a screwdriver between the fan blades
to keep it from turning. This practice can no longer
be used, as the blade is made up of a material that
will be damaged. It is recommended that an impact
wrench be used when removing the blade. Do not
use the impact wrench when reinstalling, as galling
of the stainless steel shaft can occur.
f. Replace access the panel making sure that the panel
does not leak. Make sure that the TIR locking device
is lockwired.
6.16 EVAPORATOR SECTION CLEANING
Containers and Container units that are exposed to
certain fumigants may develop visible surface
corrosion. This corrosion will show up as a white powder
found on the inside of the container and on the reefer
unit evaporator stator and fan deck.
b. Apply Loctite to the 1/4-20 x 3/4 long bolts and torque
to 0.81 mkg (70 inch-pounds).
Analyses by Carrier Transicold environmental
specialists have identified the white powder as
consisting predominantly of aluminum oxide. Aluminum
oxide is a coarse crystalline deposit most likely the result
of surface corrosion on the aluminum parts within the
container. If left untreated over time, it may build up in
thickness and eventually flake as a light−weight white
powder.
c. Place one 5/8 flat washer on the shoulder of the fan
motor shaft. Insert the key in the keyway and lubricate
the fan motor shaft and threads with a graphite-oil
solution (such as Never-seez).
d. Install the fan onto the motor shaft. Place one 5/8 flat
washer with a 5/8-18 locknut onto the motor shaft and
torque to 40 foot-pounds.
The surface corrosion of aluminum is brought about by
exposure to chemicals such as sulfur dioxide and
possibly other fumigants that are commonly used for
fumigation and protection of some perishable cargo
such as grapes, for example. Fumigation is the process
by which a chemical is released into an enclosed area to
eliminate infestations of insects, termites, rodents,
weeds and soil−born disease.
3
2
2
4
1
Typically any aluminum oxide that becomes detached
from evaporator fan stators will be blown into the wet
evaporator coil where it will be caught and then flushed
out of the unit during routine defrost cycles.
5
However, it is still highly recommended that after
carrying cargo subject to fumigation procedures, that
the inside of the unit be thoroughly cleansed prior to
reuse.
6
Carrier Transicold has identified a fully biodegradable
and environmentally safe alkaline cleaning agent
(Tri−Pow’r® HD) for the unit. This will assist in helping to
remove the corrosive fumigation chemicals and
dislodging of the corrosive elements.
7
This cleaner is available from the Carrier Transicold
Performance Parts Group (PPG) and can be ordered
through any of the PPG locations; Part Number
NU4371−88.
8
1.
2.
3.
4.
Stator
5. Screw, 1/4
Flat washer, 5/8
6. Flat washer, 1/4
Locknut, 5/8-18
7. Mylar Protector
Impeller Fan
8. Evaporator Motor
Figure 6−10 Evaporator Fan Assembly
As a general safety precaution, before using this
product, refer to and retain the Material Safety Data
(MSDS) sheet. This document can be found at:
www.nucalgon.com/products/coil_cleaners_tripower.htm
6−11
T-340
Prior to Cleaning:
6.17.1 Replacing Electronic Expansion Valve and
Screen
− Always wear goggles, gloves and work boots.
a. Removing an EEV
1. Pump down the compressor (refer to paragraph 6.4)
and frontseat both suction and discharge valves.
2. Turn unit power off and remove power from the unit.
− Avoid contact with skin and clothing, and avoid
breathing mists.
3. Remove coil.
4. VALVE REMOVAL: The preferred method of removing the valve is to cut the connection between the
brazed section and the valve, using a small tube cutter. Remove valve.
Alternately, use a wet rag to keep valve cool. Heat inlet and outlet connections to valve body and remove
valve.
− When mixing, add water to the sprayer first, then the
cleaner.
− ALWAYS provide for proper ventilation when cleaning
indoor evaporator coils (rear doors must be open).
− Be aware of surroundings − food, plants, etc., and the
potential for human exposure.
5. Clean the valve stem with mild cleaner, if necessary.
b. Installing an EEV
− Always read directions and follow recommended
dilution ratios. More is not always better. Using
non−diluted cleaner is not recommended.
1. Reverse steps 1 through 4 above to install a new
valve. Install valve and screen with cone of screen
pointing into liquid line at inlet to the valve.
2. During installation, make sure the EEV coil is
snapped down fully, and the coil retention tab is properly seated in one of the valve body dimples. Also,
ensure that coil boot is properly fitted over valve
body. See Figure 6−11.
Cleaning Procedure:
a. Remove the upper evaporator access panel inside of
the unit.
b. Spray the surface with water before applying the
cleaning solution. This helps the cleaner work better.
Coil
Boot
c. Liberally apply the prepared cleaner solution (5 parts
water and 1 part cleaner).
Coil
d. Allow the cleaner to soak in for 5 to 7 minutes.
Electronic
Expansion
Valve
e. Assess area for rinsing. Follow all local regulations regarding disposal of waste water.
f. Thoroughly rinse the cleaner and surrounding area,
floor, etc. When rinsing where heavy foaming solution
is present, it is very important to take the time to thoroughly rinse the equipment and surroundings.
FLOW
DIRECTION
g. Always rinse the empty coil cleaner bottle, cap tightly
and dispose of properly.
Figure 6−11 Electronic Expansion Valve
6.17 ELECTRONIC EXPANSION VALVE
3. Replace filter drier.
4. Evacuate to 500 microns by placing vacuum pump
on liquid line and suction service valve.
5. Open liquid line service valve and check refrigerant
level.
6. Check superheat. (Refer to Section 2.2).
The electronic expansion valve (EEV) is an automatic
device which maintains required superheat of the refrigerant gas leaving the evaporator. The valve functions
are: (a) automatic response of refrigerant flow to match
the evaporator load and (b) prevention of liquid refrigerant entering the compressor. Unless the valve is defective, it seldom requires any maintenance.
T-340
7. Check unit operation by running Pre−trip (Refer to
Section 3.8).
6−12
6.18 ECONOMIZER SOLENOID VALVE
6.19 ECONOMIZER EXPANSION VALVE
1
The economizer expansion valve (see Figure 2−4) is an
automatic device that maintains constant superheat of
the refrigerant gas leaving at the point of bulb attachment, regardless of suction pressure.
2
Unless the valve is defective, it seldom requires maintenance other than periodic inspection to ensure that the
thermal bulb is tightly secured to the suction line and
wrapped with insulating compound.
3
4
6.19.1 Economizer Expansion Replacement
5
1.
2.
3.
4.
5.
Slotted Screw
Top Coil (small) O−ring
Solenoid Coil, Enclosing Tube and Body
Bottom Coil (large) O−ring
Brass Spacer
Figure 6−12 Coil View of Economizer Solenoid
Valve (ESV)
Inlet
a. Removing a Solenoid Valve Coil:
1. Turn unit power off and remove power from the unit.
Disconnect leads.
2. Remove top screw and o−ring. Remove coil and
save mounting hardware, seals and spacer for reuse. (See Figure 6−12). Refer to step d. for valve coil
replacement.
Outlet
b. Removing the Solenoid Valve:
1. Pump down the compressor (refer to paragraph
6.4) and frontseat both suction and discharge
valves.
Figure 6−13 Economizer Expansion Valve
2. VALVE REMOVAL: The preferred method of removing the solenoid valve is to cut the connection
between the brazed section and the valve, using a
small tube cutter. Remove valve.
a. Removing the Economizer Expansion Valve:
Alternately, heat inlet and outlet connections to
valve body and remove valve.
NOTE
The economizer expansion valve is a hermetic
valve, it does not have adjustable superheat
(See Figure 6−13).
3. Clean the valve stem with mild cleaner, if necessary.
c. Installing the Solenoid Valve:
1. Fit the new solenoid valve into position and braze.
Use a wet rag to keep valve cool whenever brazing.
1. Pump down the compressor (refer to paragraph 6.4)
and frontseat both suction and discharge valves.
Evacuate if unit is not equipped with service valves.
Refer to paragraph 6.6.1.
d. Installing the Solenoid Valve Coil:
1. Install the brass spacer on the valve stem.
2. Lubricate both o−rings with silicone provided in the
kit.
2. Turn unit power off and remove power from the unit.
3. Install bottom coil o−ring on the valve stem.
4. Install the solenoid coil on the valve stem.
3. Remove cushion clamps located on the inlet and outlet lines.
5. Place the top coil o−ring on the coil mounting screw
and secure the coil to the valve using a torque−
wrench. Torque the screw to 25 in−lbs.
4. Remove insulation (Presstite) from expansion valve
bulb.
6. Connect coil wires using butt−splices and heat−
shrink tubing.
5. Unstrap the bulb, located on the economizer line.
6−13
T-340
6. VALVE REMOVAL: The preferred method of removing the valve is to cut the connection between the
brazed section and the valve, using a small tube cutter. Remove valve.
2
1
Alternately, use a wet rag to keep valve cool. Heat inlet and outlet connections to valve body and remove
valve.
7. Clean the valve stem with mild cleaner, if necessary.
3
6
b. Installing the Economizer Expansion Valve:
1. The economizer expansion valve should be
wrapped in a soaked cloth for brazing.
2. Braze inlet connection to inlet line.
1. Sleeve
2. O−ring (hidden)
3. Screen Valve
Strainer
3. Braze outlet connection to outlet line.
4. Reinstall the cushion clamps on inlet and outlet
lines.
c. Replace filter drier, (Refer to Section 6.13).
4
5
4. Tube
5. Solenoid Valve
Body
6. Hex Nut, 1/2 OD
Figure 6−14 View of Digital Unloader Valve (DUV)
Assembly
d. Evacuate to 500 microns by placing vacuum pump on
liquid line and suction service valve.
e. Check economizer expansion valve superheat (see
Section 2.2).
7. Examine compressor and service valves. Ensure
that the o−ring is not stuck in the gland of the valve.
6.20 DIGITAL UNLOADER VALVE
8. Discard the o−ring on the o−ring face seal connection.
a. Removing the DUV:
b. Installing the DUV:
1. Pump down the compressor (refer to paragraph
6.4) and frontseat both suction and discharge
valves. In the event the DUV is stuck open and compressor cannot pump down, remove charge.
1. Lubricate the gland shoulder area and o−ring with
refrigerant oil.
2. Fit new valve in position and hand−tighten the
o−ring nut.
2. Turn unit power off and remove power from the unit.
3. Loosen bolt on top of the DUV and remove coil
assembly.
3. Use a wet rag to keep valve cool while brazing.
Braze DUV to service valve connection.
NOTE
There is a small spacer tube between the top of
the valve and the 12 VDC coil that needs to be reinstalled into the solenoid valve coil. When removing the coil, it may fall out when lifted from the
valve body. Take care that the spacer is not lost;
the valve will not function correctly without it.
4. Reinstall and tighten the brackets that secure the
valve body to the discharge line.
5. Torque o−ring face seal connections to 18 to 20 ft−
lbs.
6. Install the coil onto the valve body and tighten the attachment bolt.
4. Remove clamps holding the DUV to the discharge
line.
5. Loosen the nuts attaching the DUV to the top of the
compressor.
6. VALVE REMOVAL: The preferred method of removing the solenoid valve is to cut the connection
between the brazed section and the valve, using a
small tube cutter. Remove valve. (See
Figure 6−14).
NOTE
Confirm that the small spacer tube is inserted
into the coil prior to attaching it to the valve
body. The valve will not function correctly
without it.
7. Leak check and evacuate low side of unit as applicable. Refer to paragraph 6.6.1.
Alternately, use a wet rag to keep valve cool. Heat
outlet connection to valve body and remove valve.
T-340
8. Open service valves.
6−14
a. Press the CODE SELECT key then press an ARROW key until Cd41 is displayed in the left window.
The right window will display a controller communications code.
6.21 VALVE OVERRIDE CONTROLS
Controller function code Cd41 is a configurable code
that allows timed operation of the automatic valves for
troubleshooting. Test sequences are provided in
Table 6−1. Capacity mode (CAP) allows alignment of
the economizer solenoid valve in the standard and
economized operating configurations. DUV Capacity
Modulation, % Setting (PCnt) and Electronic Expansion
Valve (EEV) allows opening of the digital unloader valve
and electronic expansion valve, respectively, to various
percentages. If the unit is equipped with an LIV, the
Liquid Valve Setting allows the LIV to be automatically
controlled, or manually opened and closed.
The Override Timer (tIM) selection is also provided to
enter a time period of up to five minutes, during which
the override(s) are active. If the timer is active, valve
override selections will take place immediately. If the
timer is not active, changes will not take place for a few
seconds after the timer is started. When the timer times
out, the override function is automatically terminated
and the valves return to normal machinery control. To
operate the override:
b. Press the ENTER key. The left display will show a test
name alternating with the test setting or time remaining. Use an ARROW key to scroll to the desired test.
Press the ENTER key, SELCt will appear in the left
display.
c. Use an ARROW key to scroll to the desired setting,
and then press the ENTER key. Selections available
for each of the tests are provided in Table 6−1.
d. If the timer is not operating, follow the above procedure to display the timer. Use an ARROW key to scroll
to the desired time interval and press ENTER to start
the timer.
e. The above described sequence may be repeated
during the timer cycle to change to another override.
Table 6−1 Valve Override Control Displays
Left Display
Controller Communications Codes
(Right Display)
Setting Codes (Right Display)
Cd 41/SELCt
tIM
(Override Timer)
0 00 (0 minutes/0 Seconds)
In 30 second increments to
5 00 (5 minutes/ 0 seconds)
AUtO
(Normal Machinery Control)
0
3
6
10
25
50
100
AUtO
(Normal Machinery Control)
CLOSE (Closed)
0
3
6
10
25
50
100
AUtO
(Normal Control)
Std
UnLd
(Economizer = Closed)
ECOn
(Economizer = Open)
AUto
(Normal Control)
CLOSE (Closed)
OPEn (Open)
PCnt
(% Setting − DUV Capacity Modulation)
EEV
(% Setting − Electronic Expansion Valve)
CAP
(Capacity Mode)
LIV (If Equipped)
(Liquid Injection Valve Setting)
6−15
T-340
The guidelines and cautions provided herein should be
followed when handling the modules. These precautions and procedures should be implemented when
replacing a module, when doing any arc welding on the
unit, or when service to the refrigeration unit requires
handling and removal of a module.
6.22 AUTOTRANSFORMER
If the unit does not start, check the following:
a. Make sure the 460 VAC (yellow) power cable is
plugged into the receptacle (see Figure 6−15) and
locked in place.
a. Obtain a grounding wrist strap (Carrier Transicold
P/N 07-00304-00) and a static dissipation mat (Carrier Transicold P/N 07-00277-00). The wrist strap,
when properly grounded, will dissipate any potential
static buildup on the body. The dissipation mat will
provide a static-free work surface on which to place
and/or service the modules.
b. Make sure that circuit breakers CB-1 and CB-2 are in
the “ON” position. If the circuit breakers do not hold in,
check voltage supply.
c. There is no internal protector for this transformer
design, therefore, no checking of the internal protector is required.
b. Disconnect and secure power to the unit.
c. Place strap on wrist and attach the ground end to any
exposed unpainted metal area on the refrigeration
unit frame (bolts, screws, etc.).
d. Using a voltmeter, and with the primary supply circuit
ON, check the primary (input) voltage (460 VAC). Next,
check the secondary (output) voltage (230 VAC). The
transformer is defective if output voltage is not available.
d. Carefully remove the module. Do not touch any of the
electrical connections if possible. Place the module
on the static mat.
e. The strap should be worn during any service work on
a module, even when it is placed on the mat.
6.23.2 Controller Troubleshooting
2
A group of test points (TP, see Figure 6−16) are
provided on the controller for troubleshooting electrical
circuits (see schematic diagram, section 7). A
description of the test points follows:
3
1
NOTE
Use a digital voltmeter to measure AC voltage
between TP’s and ground (TP9), except for TP8.
TP 1 − Not used in this application.
TP 2 − Enables the user to check if the high pressure
switch (HPS) is open or closed.
1. Dual Voltage Modular Autotransformer
2. Circuit Breaker (CB−2) 230−Volt
3. 460 VAC Power Receptacle
TP 3 − Enables the user to check if the water pressure
switch (WP) contact is open or closed.
Figure 6−15 Autotransformer
TP 4 − Enables the user to check if the internal protector
for the condenser fan motor (IP-CM) is open or closed.
6.23 CONTROLLER
TP 5 − Enables the user to check if the internal protectors for the evaporator fan motors (IP-EM1 or IP-EM2)
are open or closed.
6.23.1 Handling Modules
CAUTION
TP 6 (IF EQUIPPED) − Enables the user to check if the
controller liquid injection valve relay (TQ) is open or
closed.
Do not remove wire harnesses from module
unless you are grounded to the unit frame
with a static safe wrist strap.
TP 7 − Enables the user to check if the controller economizer solenoid valve relay (TS) is open or closed.
TP 8 − Not used in this application.
CAUTION
TP 9 − The chassis (unit frame) ground connection.
Unplug all module connectors before
performing arc welding on any part of the
container.
T-340
TP 10 − Enables the user to check if the heat termination
thermostat (HTT) contact is open or closed.
6−16
1
2
6. The display will show the message “Pro SoFt”. This
message will last for up to one minute.
3
7. The display module will go blank briefly, then read
“Pro donE” when the software loading has completed. (If a problem occurs while loading the software: the display will blink the message “Pro FAIL” or
“bad 12V.” Turn start-stop switch OFF and remove
the card.)
8. Turn unit OFF, via start-stop switch (ST).
4
9. Remove the PCMCIA card from the programming/
software port and return the unit to normal operation
by placing the start-stop switch in the ON position.
10.Turn power on and wait about 15 seconds for the
new software to load into the controller memory. The
status LED will flash quickly and the display will remain blank as the controller loads the new software.
When complete, the controller will reset and power
up normally.
1.
2.
3.
4.
11. Wait for default display, setpoint on the left, and control temperature on the right.
Controller Software Programming Port
Mounting Screw
Controller
Test Points
12.Confirm software is correct using keypad code select 18 to view Cd18 XXXX.
13.Turn power off. Operational software is loaded.
Figure 6−16 Controller Section of the Control Box
b. Procedure for loading configuration software:
6.23.3 Controller Programming Procedure
1. Turn unit OFF using start-stop switch (ST).
2. Insert software/programming PCMCIA card containing the following (example) files into the programming/software port. (See Figure 6−16):
CAUTION
The unit must be OFF whenever a programming card is inserted or removed from the
controller programming port.
menuDDMM.ml3, this file allows the user to select
the file/program to upload into the controller.
cfYYMMDD.ml3, multi-configuration file.
3. Turn unit ON using start-stop switch (ST).
1. Turn unit OFF, via start-stop switch (ST).
4. The display module will display the message ruN
COnFG. (If a defective card is being used the display
will blink the message “bAd CArd.” Turn start-stop
switch OFF and remove the card.)
2. Insert software/programming PCMCIA card containing the following (example) files into the programming/software port. (See Figure 6−16):
menuDDMM.ml3, this file allows the user to select a
file/program to upload into the controller.
5. Press the ENTER key on the keypad.
6. The display module will go blank briefly and then display “551 00”, based on the operational software installed.
cfYYMMDD.ml3, multi-configuration file.
3. Turn unit ON, via start-stop switch (ST).
7. Press the UP or DOWN ARROW key to scroll
through the list to obtain the proper model dash number. (If a defective card is being used, the display will
blink the message “bAd CArd.” Turn start-stop
switch OFF and remove the card.)
If ruN COnFG is displayed, use procedure 6.23.3.1 If
Set UP is displayed, use procedure 6.23.3.2.
6.23.3.1 Programming Procedure for Software
Versions prior to 5328 and/or Cards Without
Updated Menu Option (menu0111.ml)
8. Press the ENTER key on the keypad.
a. Procedure for loading operational software:
9. When software loading has successfully completed,
the display will show the message “EEPrM donE.” (If
a problem occurs while loading the software, the display will blink the message “Pro FAIL” or “bad 12V.”
Turn start-stop switch OFF and remove the card.)
1. The display module will display the message ruN
COnFG. (If a defective card is being used the display
will blink the message “bAd CArd.” Turn start-stop
switch OFF and remove the card.)
10.Turn unit OFF using start-stop switch (ST).
2. Press the UP or DOWN arrow key until the display
reads, LOAd 53XX for Scroll.
11. Remove the PCMCIA card from the programming/
software port and return the unit to normal operation
by placing the start-stop switch in the ON position.
3. Press the ENTER key on the keypad.
4. The display will alternate to between PrESS EntR
and rEV XXXX.
12.Confirm the correct model configuration by using the
keypad to select Cd20. The model displayed should
match the unit serial number plate.
5. Press the ENTER key on the keypad.
6−17
T-340
b. Procedure for loading configuration software:
8. The display module will go blank briefly and then display “551 00”, based on the operational software
installed.
9. Press the UP or DOWN ARROW key to scroll
through the list to obtain the proper model dash number. (If a defective card is being used, the display will
blink the message “bAd CArd.” Turn start-stop
switch OFF and remove the card.)
10.Press the ENTER key on the keypad.
11. When software loading has successfully completed,
the display will show the message “EEPrM donE.” (If
a problem occurs while loading the software, the display will blink the message “Pro FAIL” or “bad 12V.”
Turn start-stop switch OFF and remove the card.)
12.Turn unit OFF using start-stop switch (ST).
13.Remove the PCMCIA card from the programming/
software port and return the unit to normal operation
by placing the start-stop switch in the ON position.
14.Confirm correct model configuration using the keypad to choose code 20 (CD20). The model displayed
should match the unit serial number plate.
c. Procedure for setting the date and time:
1. Press the UP or DOWN arrow key until display reads
Set TIM.
2. Press the ENTER key on the keypad.
3. The first value to be modified is the date in YYYY
MM−DD format. The values will be entered from right
to left. Press the UP or DOWN ARROW key to increase or decrease the values. The ENTER key will
enter the information for the current field and move to
the next value; the CODE SELECT key will allow
modification of the previous value.
4. Press the ENTER key on the keypad.
5. The next value to be modified is the time in HH MM
format. The values will be entered from right to left.
Press the UP or DOWN ARROW key to increase or
decrease the values. The ENTER key will enter the
information for the current field and move to the next
value; the CODE SELECT key will allow modification
of the previous value.
6. Press the ENTER key on the keypad. The date and
time will not be committed until start up procedures
are completed on the next power up.
1. Turn unit OFF using start-stop switch (ST).
d. Procedure for setting the container ID:
6.23.3.2 Programming Procedure for Software Versions 5350 and Greater & With Updated
Menu Option (menu0111.ml)
The updated menu option allows the operational software to be loaded, and time and container identification
to be set.
a. Procedure for loading operational software:
1. The display module will display the message Set UP.
2. Press the UP or DOWN arrow key until the display
reads, LOAd 53XX for Scroll.
3. Press the ENTER key on the keypad.
4. The display will alternate to between PrESS EntR
and rEV XXXX.
5. Press the ENTER key on the keypad.
6. The display will show the message “Pro SoFt”. This
message will last for up to one minute.
7. The display module will go blank briefly, then read
“Pro donE” when the software loading has loaded. (If
a problem occurs while loading the software: the display will blink the message “Pro FAIL” or “bad 12V.”
Turn start-stop switch OFF and remove the card.)
8. Turn unit OFF, via start-stop switch (ST).
9. Remove the PCMCIA card from the programming/
software port and return the unit to normal operation
by placing the start-stop switch in the ON position.
10.Turn power on and wait about 15 seconds for the
new software to load into the controller memory. The
status LED will flash quickly and the display will remain blank as the controller loads the new software.
When complete, the controller will reset and power
up normally.
11. Wait for default display, setpoint on the left, and control temperature on the right.
12.Confirm software is correct using keypad code select 18 to view Cd18 XXXX.
13.Turn power off. Operational software is loaded.
2. Insert software/programming PCMCIA card containing the following (example) files into the programming/software port. (See Figure 6−16):
NOTE
The characters will be preset to the container ID
already on the controller. If none exist, the default will be AAAA0000000.
menuDDMM.ml3, this file allows the user to select
the file/program to upload into the controller.
cfYYMMDD.ml3, multi-configuration file.
1. Press the UP or DOWN arrow key until display reads
Set ID.
2. Press the ENTER key on the keypad.
3. Values will be entered from right to left. Press the UP
or DOWN ARROW key to increase or decrease the
values. ENTER will enter the information for the current field and move to the next value; CODE
SELECT will allow modification of the previous
value.
4. When the last value is entered, press the ENTER
key to enter the information to the controller; the
CODE SELECT key will allow modification of the
previous value.
3. Turn unit ON using start-stop switch (ST).
4. Press the UP or DOWN arrow key until display reads
Set UP.
5. Press the ENTER key on the keypad.
6. Press the UP or DOWN arrow key until display reads
XXXX the message ruN COnFG. (If a defective card
is being used the display will blink the message “bAd
CArd.” Turn start-stop switch OFF and remove the
card.)
7. Press the ENTER key on the keypad.
T-340
6−18
d. Using Driver Bit, Carrier Transicold part number
07−00418−00, remove the 4 screws securing the display module to the control box. Disconnect the ribbon
cable and set the display module aside.
6.23.4 Removing and Installing a Controller
a. Removal:
1. Disconnect all front wire harness connectors and
move wiring out of way.
NOTE
The battery wires must face toward the right.
2. The lower controller mounting is slotted, loosen the
top mounting screw (see Figure 6−16) and lift up and
out.
e. Remove the old battery from the bracket and clean
bracket surface. Remove the protective backing from
the new battery and assemble to the bracket. Secure
battery by inserting the wire tie from the back of the
bracket around the battery, and back through the
bracket.
3. Disconnect the back connectors and remove
module.
4. When removing the replacement module from its
packaging , note how it is packaged. When returning
the old module for service, place it in the packaging
in the same manner as the replacement. The packaging has been designed to protect the module from
both physical and electrostatic discharge damage
during storage and transit.
f. Reconnect the ribbon cable to display and re−install
the display.
g. Route the battery wires from the battery along the display harness and connect the red battery wire and
one end of the red jumper to “KA14,” the other end of
the red jumper wire to “KA11,” and the black wire to
“KA13.”
b. Installation:
Install the module by reversing the removal steps.
Torque values for mounting screws (item 2, see
Figure 6−16) are 0.23 mkg (20 inch-pounds). Torque
value for the connectors is 0.12 mkg (10 inch-pounds).
h. Replace wire ties that were removed.
6.23.5 Battery Replacement
6.24 TEMPERATURE SENSOR SERVICE
Standard Battery Location (Standard Cells):
Service procedures for the return recorder, return temperature, supply recorder, supply temperature, ambient, defrost temperature, evaporator temperature, and
compressor discharge temperature sensors are provided in the following sub paragraphs.
a. Turn unit power OFF and disconnect power supply.
b. Slide bracket out and remove old batteries. (See
Figure 3−4, Item 8.)
6.24.1 Sensor Checkout Procedure
c. Install new batteries and slide bracket into control box
slot.
To verify that accuracy of a temperature sensor:
a. Remove the sensor and place in a 0C (32F)
ice-water bath. The ice-water bath is prepared by
filling an insulated container (of sufficient size to
completely immerse bulb) with ice cubes or chipped
ice, then filling voids between ice with water and
agitating until mixture reaches 0C (32F) measured
on a laboratory thermometer.
CAUTION
Use care when cutting wire ties to avoid
nicking or cutting wires.
b. Start unit and check sensor reading on the control
panel. The reading should be 0C (32F). If the reading is correct, reinstall sensor; if it is not, continue with
the following.
Standard Battery Location (Rechargeable Cells):
a. Turn unit power OFF and disconnect power supply.
b. Disconnect battery wire connector from control box.
c. Turn unit OFF and disconnect power supply.
c. Slide out and remove old battery and bracket. (See
Figure 3−4, Item 8.)
d. Refer to paragraph 6.23 and remove controller to gain
access to the sensor plugs.
d. Slide new battery pack and bracket into the control
box slot.
e. Using the plug connector marked “EC” that is connected to the back of the controller, locate the sensor
wires (RRS, RTS, SRS, STS, AMBS, DTS, or CPDS
as required). Follow those wires to the connector and
using the pins of the plug, measure the resistance.
Values are provided in Table 6−2 and Table 6−3.
e. Reconnect battery wire connector to control box and
replace wire ties that were removed.
Secure Battery Option (Rechargeable Cells Only):
a. Turn unit power OFF and disconnect power supply.
Due to the variations and inaccuracies in ohmmeters,
thermometers or other test equipment, a reading
within 2% of the chart value would indicate a good
sensor. If a sensor is defective, the resistance reading will usually be much higher or lower than the resistance values given.
b. Open control box door and remove both the high voltage shield and clear plastic rain shield (if installed).
c. Disconnect the battery wires from the “KA” plug positions 14, 13, 11.
6−19
T-340
Table 6−2 Sensor Resistance
5C
−40
−38.9
−37.8
−36.7
−35.6
−34.4
−33.3
−32.2
−31.1
−30
−28.9
−27.8
−26.7
−25.6
−24.4
−23.3
−22.2
−21.1
−20
−18.9
−17.8
−16.7
−15.6
−14.4
−13.3
−12.2
−11.1
−10.0
−8.9
T-340
°F
−40
−38
−36
−34
−32
−30
−28
−26
−24
−22
−20
−18
−16
−14
−12
−10
−8
−6
−4
−2
0
2
4
6
8
10
12
14
16
Ohms
336,500
312,600
290,600
270,300
251,500
234,200
218,200
203,400
189,700
177,000
165,200
154,300
144,200
134,800
126,100
118,100
110,500
103,600
97,070
91,030
85,400
80,160
75,270
70,720
66,460
62,500
58,790
55,330
52,090
Sensors AMBS, DTS, ETS, RRS, RTS, SRS, STS
5C
°F
Ohms
5C
°F
Ohms
−7.8
18
49,060
24.4
76
10,250
−6.7
20
46,230
25.6
78
9,760
−5.6
22
43,580
26.7
80
9,299
−4.4
24
41,100
27.8
82
8,862
−3.3
26
38,780
28.9
84
8,449
−2.2
28
36,600
30.0
86
8,057
−1.1
30
34,560
31.1
88
7,686
0
32
32,650
32.2
90
7,334
1.1
34
30,850
33.3
92
7,000
2.2
36
29,170
34.4
94
6,684
3.3
38
27,590
35.6
96
6,384
4.4
40
26,100
36.7
98
6,099
5.5
42
24,700
37.8
100
5,828
6.6
44
23,390
38.9
102
5,571
7.7
46
22,160
40.0
104
5,327
8.9
48
20,990
41.1
106
5,095
10
50
19,900
42.2
108
4,874
11.1
52
18,870
43.3
110
4,665
12.2
54
17,900
44.4
112
4,465
13.3
56
16,980
45.5
114
4,275
14.4
58
16,120
46.7
116
4,095
15.5
60
15,310
47.8
118
3,923
16.6
62
14,540
48.9
120
3,759
17.7
64
13,820
50.0
122
3,603
18.9
66
13,130
51.1
124
3,454
20.0
68
12,490
52.2
126
3,313
21.1
70
11,880
53.3
128
3,177
22.2
72
11,310
54.4
130
3,049
23.3
74
10,760
55.6
132
2,926
6−20
5C
56.7
57.8
58.9
60.0
61.1
62.2
63.3
64.4
65.6
68.3
71.1
73.9
76.7
79.4
82.2
85.0
87.8
90.6
93.3
96.1
98.9
101.7
104.4
107.2
110.0
112.8
115.6
118.3
121.1
°F
134
136
138
140
142
144
146
148
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
245
250
Ohms
2,809
2,697
2,590
2,488
2,390
2,297
2,208
2,124
2,042
1,855
1,687
1,537
1,402
1,281
1,171
1,072
983
902
829
762
702
647
598
553
511
473
438
406
378
Table 6−3 Sensor Resistance (CPDS)
5C
*40
*38
*36
*34
*32
*30
*28
*26
*24
*22
*20
*18
*16
*14
*12
*10
*8
*6
*4
*2
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
°F
*40
*36.4
*32.8
*29.2
*25.6
*22.0
*18.4
*14.8
*11.2
*7.6
*4.0
*0.4
3.2
6.8
10.4
14.0
17.6
21.2
24.8
28.4
32.0
35.6
39.2
42.8
46.4
50.0
53.6
57.2
60.8
64.4
68.0
71.6
75.2
78.8
82.4
83.0
89.6
93.2
96.8
Ohms
2,889,600
2,532,872
2,225,078
1,957,446
1,724,386
1,522,200
1,345,074
1,190,945
1,056,140
938,045
834,716
743,581
663,593
593,030
530,714
475,743
426,904
383,706
345,315
311,165
280,824
253,682
229,499
207,870
188,494
171,165
155,574
141,590
129,000
117,656
107,439
98,194
89,916
82,310
75,473
69,281
63,648
58,531
53,887
5C
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
°F
100.4
104.0
107.6
111.2
114.8
118.4
122.0
125.6
129.2
132.8
136.4
140.0
143.6
147.2
150.8
154.4
158.0
161.6
165.2
168.8
172.4
176.0
179.6
183.2
186.8
190.4
194.0
197.6
201.2
204.8
208.4
212.0
215.6
219.2
222.8
226.4
230.0
233.6
237.2
6−21
Ohms
49,656
45,812
42,294
39,078
36,145
33,445
30,985
28,724
26,651
27,750
23,005
21,396
19,909
18,550
17,294
16,133
15,067
14,078
13,158
12,306
11,524
10,793
10,122
9,494
8,918
8,376
7,869
7,404
6,972
6,571
6,197
5,848
5,529
5,233
4,953
4,692
4,446
4,204
3,977
5C
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150
152
154
156
158
160
162
164
166
168
170
172
174
176
178
180
182
184
186
188
190
°F
240.8
244.4
248.0
251.6
255.2
258.8
262.4
266.0
269.6
273.2
276.8
280.4
284.0
287.6
291.2
294.8
298.4
302.0
305.6
309.2
312.8
316.4
320.0
323.6
327.2
330.8
334.4
338.0
341.6
345.2
348.8
352.4
356.0
359.6
363.2
366.8
370.4
374.0
Ohms
3,759
3,550
3,354
3,173
3,004
2,850
2,711
2,580
2,454
2,335
2,223
2,119
2,021
1,928
1,839
1,753
1,670
1,591
1,508
1,430
1,362
1,302
1,247
1,193
1,142
1,096
1,054
1,014
975
938
902
867
834
798
764
733
706
697
T-340
g. If required, slide the cap and grommet assembly onto
the replacement sensor.
6.24.2 Sensor Replacement
a. Turn unit power OFF and disconnect power supply.
NOTE
Include white date code label when cutting out
and removing defective sensors. The label
could be required for warranty returns.
h. Slip crimp fittings over dressed wires (keeping wire
colors together). Make sure wires are pushed into
crimp fittings as far as possible and crimp with crimping tool.
i. Solder spliced wires with a 60% tin and 40% lead
Rosincore solder.
b. Cut cable. Slide the cap and grommet off a bulb type
sensor and save for reuse. Do not cut the grommet.
j. Slide heat shrink tubing over each splice so that ends
of tubing cover both ends of crimp as shown in
Figure 6−18.
c. Cut one wire of existing cable 40 mm (1-1/2 inches)
shorter than the other wire.
k. Heat tubing to shrink over splice. Make sure all seams
are sealed tightly against the wiring to prevent moisture seepage.
d. Cut replacement sensor wires (opposite colors) back
40 mm (1-1/2 inches). (See Figure 6−17.)
e. Strip back insulation on all wiring 6.3 mm (1/4 inch).
1
CAUTION
2
Do not allow moisture to enter wire splice
area as this may affect sensor resistance.
l. Slide large heat shrink tubing over both splices and
shrink.
3
m. Position sensor in unit as shown in Figure 6−18 and
re-check sensor resistance.
Mounting Stud Type
n. Reinstall sensor (refer to paragraph 6.24.3).
1
2
NOTE
The P5 Pre-Trip test must be run to inactivate
probe alarms (refer to paragraph 4.9).
3
6.24.3 Sensor Re-Installation
Bulb Type
1.
2.
3.
Sensors STS and SRS
Sensor
40 mm (1 1/2 in), 2 or 3 wires as required
6.3 mm (1/4 in).
To properly position a supply sensor, the sensor must be
fully inserted into the probe holder mounting clamp. See
Figure 6−19. Do not allow heat shrink covering to contact the probe holder. For proper placement of the
sensor, be sure to position the enlarged positioning section of the sensor against the the side of the mounting
clamp. This positioning will give the sensor the optimum
amount of exposure to the supply air stream, and will
provide accurate temperature readings to the controller.
Figure 6−17 Sensor Types
f. Slide a large piece of heat shrink tubing over the
cable, and place the two small pieces of heat shrink
tubing, one over each wire, before adding crimp fittings as shown in Figure 6−18.
Sensors RRS and RTS
2
1
Reinstall the return sensor as shown in Figure 6−20. For
proper placement of the return sensor, be sure to position the enlarged positioning section of the sensor
against the the side of the mounting clamp.
ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
3
1. Cable
2. Sensor (Typical)
3. Large Heat Shrink
Tubing (1)
Sensor DTS
The DTS sensor must have insulating material placed
completely over the sensor to ensure the coil metal temperature is sensed.
4
Sensors ETS1 and ETS2
4. Heat Shrink
Tubing, 2 or 3
as required
The ETS1 and ETS2 sensors are located in a tube holder under insulation, as illustrated in Figure 6−21. When
the combo sensor is removed and reinstalled, it must be
placed in a tube holder by applying thermal grease. Insulating material must completely cover the sensor to
ensure the correct temperature is sensed.
Figure 6−18 Sensor and Cable Splice
T-340
6−22
11
1
12
2
13
3
4
5
6
10
7
(2.5”)
9
1.
2.
3.
4.
5.
6.
7.
8
Supply Air Stream
Insulation
Back Panel
Supply Sensor
Mounting Clamp
Sensor Wires
Drip Loop
8.
9.
10.
11.
12.
13.
Gasket Mounting Plate
Gasketed Support Plate
Gasketed Cover
TIR Bolts
STS Probe
SRS Probe
Figure 6−19 Supply Sensor Positioning
1
4
1
2
3
1.50 in.
(38.1cm)
1. Mounting Clamp
2
1. Wire Tie
2. ETS1 and 2
2. Return Sensor
1.00 in.
(25.4cm)
3. ETS Tube Holder
4. Insulation
Figure 6−21 Evaporator Temperature Sensor
Positioning
Figure 6−20 Return Sensor Positioning
6−23
T-340
open). This can occur if the vent is loose or the panel is
defective. To confirm a defective panel, assure that the
wing nut is secure and then power cycle the unit. If the
alarm immediately reappears as active, the panel
should be replaced.
The alarm should immediately go inactive, check the
4-minute stability requirement. If the alarm reoccurs after the four minutes and the panel was known to have
been stable, then the sensor should be replaced.
Upper VPS:
Sensor, CPDS
To replace the Compressor Discharge Temperature
Sensor, see Figure 6−22:
a. Ensure the unit is disconnected from the power
source and that ST is in OFF position.
b. Remove the existing sensor. Clean all silicone sealer
and dielectric compound from the sensor well. Ensure well is clean and dry. The top of the compressor,
where the sensor seals, must also be clean and dry.
In order to replace the Upper VPS, the panel must be removed and replaced with another upper fresh air panel
equipped with VPS.
Upon installation, a new VPS assembly requires calibration as follows:
1. Rotate the vent to the 0 CMH/ CFM position.
SENSOR
SILICONE BEAD
2. Code select Cd45 will automatically display. Press
the Enter key and hold for five seconds.
3. After the enter key has been pressed the display will
read CAL (for calibration).
4. Press the ALT MODE key and hold for five seconds.
5. After the calibration has been completed, Cd45 will
display 0 CMH / CFM.
Lower VPS:
Calibration of the Lower VPS is only required when the
air makeup slide, motor or sensor has been repaired or
serviced.
The VPS is calibrated using the keypad:
SENSOR WELL
Figure 6−22 Compressor Discharge Temperature
Sensor
1. Remove the two nuts that secure the air makeup
panel slide to the unit.
c. Using the syringe supplied with the replacement
sensor, squeeze all of the dielectric compound into
the sensor well.
2. Rotate the gear clockwise until it stops.
3. Rotate the gear 1/4 turn counterclockwise.
4. Carefully reposition the slide onto the air makeup
panel, given that the gear is engaged with the rail and
has not moved.
d. Place a bead of the silicone sealer supplied with the
replacement sensor around the sensor sealing ring.
Insert sensor into the well with the leads parallel to the
suction fitting.
5. Position slide panel to the fully closed position.
6. Cd45 will automatically be shown on the left display.
e. Reconnect the sensor (see Figure 6−18) and run
Pre−trip P5.
7. Depress the ENTER key and hold for five seconds.
CAL for calibration is displayed.
6.25 VENT POSITION SENSOR (VPS)
8. Depress the ALT MODE key on the keypad and hold
for five seconds.
The vent position sensor (VPS) determines the position
of the fresh air vent in near real-time via the Cd55.
9. When calibration has been completed, Cd45 causes
0 CMH/CFM to be shown on the right display.
The fresh air vent position sensor alarm (AL50) will occur if the sensor reading is not stable for four minutes or
if the sensor is outside of its valid range (shorted or
T-340
10.Secure the air makeup panel slide to the unit with the
two nuts; stake threads.
6−24
6.26 eAutoFresh SERVICE
Stepper Drive (SD)
Stepper Motor (AF)
6.26.1 Servicing the eAutoFresh Air Filter
Removing the Air Sample Filter Element
The air sample filter element can be accessed in two
ways:
1. Through the eAutoFresh side evaporator access
panel (item 11, Figure 2−2).
Figure 6−23 Stepper Components
d. Set the SMA−12 pulse per second (PPS) to one PPS
and press button to open or close the valve. Each
LED should light sequentially until all four are lit. If an
LED fails to light, it indicates an open on that leg
caused by a poor connection or an open coil. Repair
or replace as required to achieve proper operation.
e. Set the SMA−12 step rate to 200 PPS. Press open or
close while watching the slide mechanism for movement, this is an indication that the motor is working.
2. Through the inside of the container by lowering the
upper evaporator panel.
a. By hand, unscrew and remove the filter cup from the
bottom of the air sample filter assembly.
b. Remove the filter element from the filter assembly.
c. Install the new air sample filter element by reversing
the above steps.
f. If the slide moves using the SMA−12, but fails to
move when connected in the unit (refer to “Checking
the Drive Module” in the section that follows.)
Checking the Drive Module:
6.26.2 Checking eAutoFresh Drive System
Checking the Auto Slide:
a. Turn unit OFF.
b. Disconnect the four pin connector to the Stepper Motor.
c. With a voltmeter set to read 24 volts AC, attach the
positive lead to the drive module outlet pin A (wire 1A)
of the four pin connector and the negative lead to the
B pin (wire 1B).
d. Turn ON unit, and watch the volt meter. After a short
delay, the reading should rise to approximately 12
volts.
a. To check with an ohmmeter, disconnect the four pin
connector to the stepper motor. With a reliable digital
ohmmeter, check the winding resistance. In normal
ambient, the motor should have 72 to 84 ohms measured on the red/green (a−b terminals) and on the
white/black (c−d terminals) leads. If an infinite or zero
reading occurs, check connections or replace the motor. If near normal or normal reading occurs, proceed
to the following sections to check out the controller.
b. To check with a SMA−12 portable stepper drive tester. The SMA−12 portable stepper drive tester (Carrier
Transicold P/N 07−00375−00) is a battery operated
stepper drive which will open and close the auto slide,
which allows a more thorough check of the motor.
e. Repeat for pins C and D (wires 2A and 2B).
f. If only one set of pins reads a voltage, check connections and retest.
g. If the retest reads out the same, the drive module or
controller is faulty.
h. If no voltage is present in any step, the output from the
controller to the drive module may be faulty. Check
the connections and wires from the controller to the
drive module.
i. To replace the drive module, disconnect all connectors, unscrew from mounting, and replace with a NEW
drive module in reverse order.
Checking the Slide Motor:
a. Turn unit OFF.
b. Disconnect the four pin connector from the Stepper
Drive to the Stepper Motor, (see Figure 6−23).
c. Attach the SMA−12 portable stepper drive tester to
the Stepper Motor.
6−25
T-340
There should be approximately five volts DC on sockets
“C” and “D” (S1 and S2) when measured as above. If not
the connections or controller is faulty. If any of these pins
are not consistent, the connections or the controller is
suspect. Check and replace as required.
6.26.3 Checking the Controller
a. Turn the unit OFF.
b. Disconnect the six pin connector to the stepper drive
from the controller.
c. With a voltmeter set to read 50 volts DC, attach the
positive lead to outlet pin A of the six pin connector,
and the negative lead to pin B or TP−9 of the controller.
6.26.4 Servicing the eAutoFresh Drive System
To replace the Drive Motor Assembly:
d. Turn ON the unit for 40 seconds, and watch the voltmeter. There should be approximately 24 to 32 VDC
shown on pin A.
e. There should be zero volts on pin B.
a. Remove the bolts that secure the eAutoFresh Panel
(3, Figure 6−25) to the front of the unit. Reach in, cut
tie wrap, (2) and disconnect the motor connector (1).
Bring panel to work area.
f. After a short delay, the reading should rise to approximately 24 to 32 VDC on pin E.
b. Remove four screws (8) fastening the grille (7).
g. Pins C and D will have zero to 5 volts transistor logic
(TTL) signals present, however, this can only be
checked with the connector assembled as this is an
open collector type circuit.
c. Remove six screws (9) fastening the rails (5 and 11),
the slide plate (10) and the gasket plate (6). Set components aside for reassembly.
Checking the outputs on A, B and E will verify that the
controller is supplying power to the drive module. To be
thorough, and if it is desired, the signals on pins C and D
can be checked as follows:
d. Remove the four screws (12) fastening the motor cup
(4) to the panel. Cut sealer on outside and inside of
motor cup assembly. Push out the motor cup assembly from the rear of the panel.
h. Install a jumper assembly (Carrier part number
07−00408−00) to connect the drive module and controller connectors as shown in Figure 6−24.
i. Connect the positive lead of the voltmeter to test connector socket C and negative lead to socket B, and
run as before by resetting unit.
e. Mount the replacement motor cup assembly in the
panel using original screws. Torque screws to 0.29
mkg (25 +/− 1 Inch pounds).
f. Reapply sealer to the inside and the outside of the
motor cup assembly.
j. Repeat for sockets D and B.
Controller
Connector (EC)
Drive Module
Connector (SD)
A
B
C
D
E
Test
Connector
g. Mount the upper & lower rails, slide plate and gasket
plate using original hardware. Apply thread sealant
and torque screws to 0.29 mkg (25 +/− 1 Inch
pounds).
h. Mount grille assembly using original hardware. Apply
thread sealant and torque screws to 0.29 mkg (25 +/−
1 Inch pounds).
A
B
C
D
E
i. Reconnect the motor connector.
j. Replace the bolts that secure the eAutoFresh Panel
to the front of the unit.
Jumper
k. Carry out functional test. Refer to section 4.4.3 step
c.
Figure 6−24 Jumper Assembly
T-340
6−26
1
2
5
3
6
7
8
4
12
1
1.
2.
3.
4.
5.
6.
Connector
Tie Wrap
eAutoFresh Panel
Cup, Motor
Rail, Top
Plate, Gasket
11
10
9
7. Grille
8. Grill Screws
9. Rail Screws
10. Plate, Slide
11. Rail, Bottom
12. Motor Cup Screws
Figure 6−25 Motor Cup Replacement
6−27
T-340
period is less than thirty days, the recorder will retrieve
the logged data from the DataCORDER for the power
off period and record it onto the chart. Thereafter, the
recorder will resume normal temperature recording.
6.27 ELECTRONIC PARTLOW TEMPERATURE
RECORDER
The microprocessor−based temperature recorder is
designed to interface with the DataCORDER to log
temperature with time. The electronic recorder will
automatically record the return air, supply air, or both,
based on the setting of temperature controller
configuration code CnF37, refer to Table 3−4. The
recorder reads and records data from the controller in
present time, under normal operating conditions.
If the optional DataCORDER battery pack is being used
and the charge is too low to enable recording during the
power off period of less than thirty days, the pen tip will
move to below the inner chart ring for the period when
NO data was recorded by the DataCORDER.
6.27.1 Replacing the Recorder
If the power has been OFF for more than thirty days, the
recorder will NOT re-synchronize (the chart will not
advance to present time), the pen tip will move to the
currently recorded temperature, and the recorder will
resume normal temperature recording.
a. Turn power to the unit OFF.
b. Open the recorder door (item 1, see Figure 6−26).
c.
If using the Electronic Partlow Recorder CTD part
number 12-00464-xx
Where xx= an even number (example: 12-00464-08)
Locate the connector below the recorder (item 6),
and squeeze the ears together to disconnect the
plug.
d. Remove the four mounting screws (item 8), and
remove the recorder.
The recorder will STOP when the power is OFF, and the
pen tip will remain at the last recorded temperature on
the chart. When power is applied, and the power off
e. Install the new recorder by reversing the above
steps.
1
3
2
4
5
10
9
8
7
6
1.
2.
3.
4.
5.
6.
7.
Recorder Door
Change Chart
Button
Recorder Box
Pen Tip
Stylus Arm
8.
9.
10.
Connector
Calibration Button
(Located underneath)
Mounting Screws,
#10-24 x 7/16 inches long
Hold Down Tab
Chart Retaining Nut
Figure 6−26 Electronic Partlow Temperature Recorder
T-340
6−28
6.27.2 Recalibrating the Temp Recorder to Zero
6.29 COMMUNICATIONS INTERFACE MODULE
INSTALLATION
For Electronic Partlow Recorder CTD part number
12-00464-xx
Where xx= an odd number (example: 12-00464-03)
NOTE
Use chart CTD: part number 09-00128-00 (F),
part number 09-00128-01 (C).
a. Press the “Calibration” button (item 7, Figure 6−26)
on the bottom of the recorder. The pen tip will drive fully down scale, then move upscale to the chart ring at
-29C (-20F), and stop.
b. If the tip of the pen (item 4) is on the -29C (-20F)
chart ring, the recorder is in calibration, proceed to
step c. If the tip of the pen is NOT on the -29C
(-20F) chart ring, the operator must loosen the two
screws on the bottom of the stylus arm to adjust the
pen tip manually to the -29C (-20F) chart ring.
Tighten the screws when adjustment is complete.
CB1
Communications
Interface Module
Figure 6−27 Communications Interface
Installation
Units that have been factory provisioned for installation
of a Communication Interface Module (CIM) have the
required wiring installed. If the unit is not factory provisioned, a provision wiring kit (Carrier Transicold part
number 76-00685-00) must be installed. Installation instructions are packaged with the kit.
c. Press the calibration button and the pen will position
itself to the correct temperature reading.
For Electronic Partlow Recorder CTD part number
12-00464-xx
Where xx= an even number (example: 12-00464-08)
To install the module:
NOTE
Use chart CTD part number 09-00128-00 (F),
part number 09-00128-01 (C).
WARNING
a. Press the “Calibration” button (item 7, Figure 6−26)
on the bottom of the recorder. The pen tip will drive fully down scale, then move upscale to the chart ring at
0C (32F), and stop.
Installation requires wiring to the main unit
circuit breaker, CB1. Make sure the power to
the unit is off and power plug disconnected
before beginning installation.
b. If the tip of the pen (item 4) is on the 0C (32F) chart
ring the recorder is in calibration, proceed to step c. If
the tip of the pen is NOT on the 0C (32F) chart ring,
the operator must loosen the two screws on the
bottom of the stylus arm to adjust the pen tip manually
to the 0C (32F) chart ring. Tighten the screws when
adjustment is complete.
a. CB1 is connected to the power system, see wiring
schematic. Ensure that the unit power is off AND
that the unit power plug is disconnected.
b. Open control box, (see Figure 6−27) and remove
low voltage shield. Open high voltage shield.
c.
c. Press the calibration button and the pen will position
itself to the correct temperature reading.
6.28 MAINTENANCE OF PAINTED SURFACES
The refrigeration unit is protected by a special paint
system against the corrosive atmosphere in which it
normally operates. However, should the paint system
be damaged, the base metal can corrode. In order to
protect the refrigeration unit from the highly corrosive
sea atmosphere, or if the protective paint system is
scratched or damaged, clean the area to bare metal
using a wire brush, emery paper or equivalent cleaning
method. Immediately following cleaning, apply paint to
the area, and allow to dry. Refer to the Parts List for
proper paint selection.
If using factory provisioned wiring, remove the circuit breaker panel, with circuit breaker, from the
control box. Locate, wires CB21/CIA3, CB22/CIA5
and CB23/CIA7 that have been tied back in the wire
harness. Remove the protective heat shrink from
the ends of the wires.
d. Refit the circuit breaker panel.
e. Fit the new CIM into the unit.
f.
Attach three wires CB21/CIA3, CB22/CIA5 and
CB23/CIA7 to the CIM at connection CIA.
g. Locate connectors CIA and CIB, remove plugs if required, and attach to the module.
h. Replace the low voltage shield.
6−29
T-340
Table 6−4 R-134a Temperature - Pressure Chart
Temperature
Vacuum
Temperature
Pressure
F
C
“/hg
cm/hg
kg/cm2
-40
-40
14.6
49.4
37.08
0.49
28
-2
24.5
168.9
1.72
1.69
-35
-37
12.3
41.6
31.25
0.42
30
-1
26.1
180.0
1.84
1.80
-30
-34
9.7
32.8
24.64
0.33
32
0
27.8
191.7
1.95
1.92
-25
-32
6.7
22.7
17.00
0.23
34
1
29.6
204.1
2.08
2.04
-20
-29
3.5
11.9
8.89
0.12
36
2
31.3
215.8
2.20
2.16
-18
-28
2.1
7.1
5.33
0.07
38
3
33.2
228.9
2.33
2.29
-16
-27
0.6
2.0
1.52
0.02
40
4
35.1
242.0
2.47
2.42
45
7
40.1
276.5
2.82
2.76
50
10
45.5
313.7
3.20
3.14
55
13
51.2
353.0
3.60
3.53
60
16
57.4
395.8
4.04
3.96
65
18
64.1
441.0
4.51
4.42
70
21
71.1
490.2
5.00
4.90
75
24
78.7
542.6
5.53
5.43
80
27
86.7
597.8
6.10
5.98
85
29
95.3
657.1
6.70
6.57
90
32
104.3
719.1
7.33
7.19
95
35
114.0
786.0
8.01
7.86
100
38
124.2
856.4
8.73
8.56
105
41
135.0
930.8
9.49
9.31
110
43
146.4
1009
10.29
10.09
115
46
158.4
1092
11.14
10.92
120
49
171.2
1180
12.04
11.80
125
52
184.6
1273
12.98
12.73
130
54
198.7
1370
13.97
13.70
135
57
213.6
1473
15.02
14.73
140
60
229.2
1580
16.11
15.80
145
63
245.6
1693
17.27
16.93
150
66
262.9
1813
18.48
18.13
155
68
281.1
1938
19.76
19.37
Temperature
bar
F
C
psig
kPa
kg/cm2
bar
Pressure
F
C
psig
kPa
kg/cm2
bar
-14
-26
0.4
1.1
0.03
0.03
-12
-24
1.2
8.3
0.08
0.08
-10
-23
2.0
13.8
0.14
0.14
-8
-22
2.9
20.0
0.20
0.20
-6
-21
3.7
25.5
0.26
0.26
-4
-20
4.6
31.7
0.32
0.32
-2
-19
5.6
36.6
0.39
0.39
0
-18
6.5
44.8
0.46
0.45
2
-17
7.6
52.4
0.53
0.52
4
-16
8.6
59.3
0.60
0.59
6
-14
9.7
66.9
0.68
0.67
8
-13
10.8
74.5
0.76
0.74
10
-12
12.0
82.7
0.84
0.83
12
-11
13.2
91.0
0.93
0.91
14
-10
14.5
100.0
1.02
1.00
16
-9
15.8
108.9
1.11
1.09
18
-8
17.1
117.9
1.20
1.18
20
-7
18.5
127.6
1.30
1.28
22
-6
19.9
137.2
1.40
1.37
24
-4
21.4
147.6
1.50
1.48
26
-3
22.9
157.9
1.61
1.58
T-340
6−30
Table 6−5 Recommended Bolt Torque Values
BOLT DIA. THREADS
TORQUE
FREE SPINNING
#4
40
5.2 in-lbs
#6
32
9.6 in-lbs
#8
32
20 in-lbs
#10
24
23 in-lbs
1/4
20
75 in-lbs
5/16
18
11 ft-lbs
3/8
16
20 ft-lbs
7/16
14
31 ft-lbs
1/2
13
43 ft-lbs
9/16
12
57 ft-lbs
5/8
11
92 ft-lbs
3/4
10
124 ft-lbs
NONFREE
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
Nm
0.6
1.1
2.0
2.5
8.4
15
28
42
59
78
127
171
SPINNING (LOCKNUTS ETC.)
20
82.5 in-lbs
9.3
18
145.2 in-lbs
16.4
16
22.0 ft-lbs
23
14
34.1 ft-lbs
47
13
47.3 ft-lbs
65
12
62.7 ft-lbs
86
11
101.2 ft-lbs
139
10
136.4 ft-lbs
188
6−31
T-340
SECTION 7
ELECTRICAL WIRING SCHEMATICS
7.1 INTRODUCTION
This section contains the Electrical Schematics and Wiring Diagrams. The diagrams are presented as follows:
Figure 7−1 provides the legend for use with Figure 7−2, the schematic diagram for standard refrigeration units.
Figure 7−2 provides the basic schematic diagram for standard refrigeration units.
Figure 7−3 provides the legend for use with Figure 7−4, the schematic diagram for units with available options
except Vent Positioning System, eAutoFresh and Emergency Bypass.
Figure 7−4 provides the basic schematic diagram for units with available options except Vent Positioning System,
eAutoFresh and Emergency Bypass.
Figure 7−5 provides the legend for use with Figure 7−6, the schematic diagram for units with eAutoFresh and/or
Emergency Bypass.
Figure 7−6 provides the basic schematic diagram for units with units with eAutoFresh and/or Emergency Bypass.
Figure 7−7 supplements Figure 7−4 and Figure 7−6 and provides schematic and wiring diagrams for Upper Vent
Position Sensor (VPS).
Figure 7−8 supplements Figure 7−4 and Figure 7−6 and provides schematic and wiring diagrams for Lower VPS.
NOTE
Options other than those mentioned below may be included in wiring diagrams.
Figure 7−9 provides the wiring diagram for standard refrigeration units with 3−phase condenser fan motors.
Figure 7−10 provides the wiring diagram for units with Single Phase condenser fan motors and/or optional 5+1 heater
arrangement.
Figure 7−11 provides the wiring diagram for units with eAutoFresh and/or Emergency Bypass installed.
7−1
T-340
LEGEND
SYMBOL DESCRIPTION
SYMBOL DESCRIPTION
AMBS
AMBIENT SENSOR (C−21)
HR
HEATER CONTACTOR (P−4, M−13)
C
CONTROLLER (J−19)
HS
HUMIDITY SENSOR (F−21)
CB1
CIRCUIT BREAKER − 460 VOLT (F−1)
HTT
HEAT TERMINATION THERMOSTAT (G−13)
CF
CONDENSER FAN CONTACTOR (M−11, P−6)
ICF
INTERROGATOR CONNECTOR FRONT (T−21)
CH
COMPRESSOR CONTACTOR (M−7, P−1)
ICR
INTERROGATOR CONNECTOR REAR (T−22)
CI
COMMUNICATIONS INTERFACE MODULE (OPTION)
(A−3)
IP
INTERNAL PROTECTOR (E−12, H−10, H−12)
PA
UNIT PHASE CONTACTOR (L−1, M−6)
CM
CONDENSER FAN MOTOR (H−10, T−6)
CP
COMPRESSOR MOTOR (T−1)
CPDS
DISCHARGE TEMPERATURE SENSOR (B−21)
CS
CURRENT SENSOR (J−2)
DHBL
DHBR
PB
UNIT PHASE CONTACTOR (L−3, M−3)
PR
USDA PROBE RECEPTACLE (E−21, L−22, M−22)
RM
REMOTE MONITORING RECEPTACLE (OPTION)
(L−6, M−6, L−11, M−11, L−14, M−14)
DEFROST HEATER − BOTTOM LEFT (R−5)
RRS
RETURN RECORDER SENSOR (C−21)
DEFROST HEATER − BOTTOM RIGHT (T−4)
RTS
RETURN TEMPERATURE SENSOR (B−21)
DHML
DEFROST HEATER − MIDDLE LEFT (R−4)
SPT
SUCTION PRESSURE TRANSDUCER (G−21)
DHMR
DEFROST HEATER − MIDDLE RIGHT (T−4)
SRS
SUPPLY RECORDER SENSOR (K−21)
DHTL
DEFROST HEATER − TOP LEFT (R−4)
ST
START − STOP SWITCH (G−4, G−5)
DHTR
DEFROST HEATER − TOP RIGHT (T−5)
STS
SUPPLY TEMPERATURE SENSOR (A−21)
DPT
DISCHARGE PRESSURE TRANSDUCER (J−21)
TC
CONTROLLER RELAY−COOLING (H−7)
DTS
DEFROST TEMPERATURE SENSOR (C−21)
TCP
DUV
DIGITAL UNLOADER VALVE (E−22)
CONTROLLER RELAY − COMPRESSOR PHASE
SEQUENCING (K−6, K−7)
EEV
ELECTRONIC EXPANSION VALVE (P−15)
TE
EF
EVAPORATOR FAN CONTACTOR−HIGH SPEED
(N−8, M−12)
CONTROLLER RELAY − HIGH SPEED EVAPORATOR
FANS (K−12)
TH
CONTROLLER RELAY − HEATING (K−13)
TN
CONTROLLER RELAY − CONDENSER FAN (K−10)
TP
TEST POINT (F−8, F−9, H−7, J−10, J−12, M−15)
TQ
CONTROLLER RELAY−LIQUID INJECTION (OPTION)
(E−9)
TR
TRANSFORMER (H−3)
TS
CONTROLLER RELAY − ECONOMIZER SOLENOID
VALVE (E−9)
TV
CONTROLLER RELAY − LOW SPEED EVAPORATOR
FANS (J−11)
WCR
WETTING CURRENT RESISTOR (H−10)
WP
WATER PRESSURE SWITCH (D−10)
EM
EVAPORATOR FAN MOTOR (D−15, F−12, T−7, T−10)
EPT
EVAPORATOR PRESSURE TRANSDUCER (G−21)
ES
EVAPORATOR FAN CONTACTOR−LOW SPEED
(M−11, P−7)
ETS
EVAPORATOR TEMPERATURE SENSOR
(D−16, D−21)
ESV
ECONOMIZER SOLENOID VALVE (K−9)
F
FUSE (C−6, D−6, D−18, E−18)
FLA
FULL LOAD AMPS
HPS
HIGH PRESSURE SWITCH (G−7)
Figure 7−1 LEGEND − Standard Unit Configuration
T-340
7−2
Based on Drawing 62−11271 Rev A
Figure 7−2 SCHEMATIC DIAGRAM − Standard Unit Configuration
7−3
T-340
LEGEND
SYMBOL DESCRIPTION
SYMBOL DESCRIPTION
AMBS
AMBIENT SENSOR (C−21)
HPS
HIGH PRESSURE SWITCH (G−7)
C
CONTROLLER (J−19)
HR
HEATER CONTACTOR (P−4, P−5, M−13)
CB1
CIRCUIT BREAKER − 460 VOLT (H−1)
HS
HUMIDITY SENSOR (OPTIONAL) (F−21)
CB2
OPTIONAL CIRCUIT BREAKER − DVM (OPTION)
(C−1) TERMINAL BLOCK WHEN CB2 NOT PRESENT
HTT
HEAT TERMINATION THERMOSTAT (G−13)
ICF
INTERROGATOR CONNECTOR FRONT (T−21)
ICR
INTERROGATOR CONNECTOR REAR (T−22)
CF
CONDENSER FAN CONTACTOR (M−7, M−8, P−1)
CH
COMPRESSOR CONTACTOR (M−7, M−8, P−1)
CI
COMMUNICATIONS INTERFACE MODULE (OPTION)
(A−3)
CL
COOL LIGHT (OPTION) (M−11)
CM
CONDENSER FAN MOTOR (H−10, T−7, T−9)
CP
COMPRESSOR MOTOR (T−1)
CPDS
DISCHARGE TEMPERATURE SENSOR (B−21)
CR
CHART (TEMPERATURE) RECORDER (OPTIONAL)
(A−15)
CS
CURRENT SENSOR (L−2)
DCH
DRAIN CUP HEATER (OPTIONAL) (T−6)
DHBL
DEFROST HEATER − BOTTOM LEFT (R−5)
DHBR
DEFROST HEATER − BOTTOM RIGHT (T−4, T−5)
DHML
DEFROST HEATER − MIDDLE LEFT (R−4, R−5)
DHMR
DEFROST HEATER − MIDDLE RIGHT (T−4, R−5)
DHT
DEFROST HEATER − TOP (OPTIONAL) (T−6)
DHTL
DEFROST HEATER − TOP LEFT (R−4)
DHTR
DEFROST HEATER − TOP RIGHT (T−5)
DL
DEFROST LIGHT (OPTION) (L−6)
DPT
DISCHARGE PRESSURE TRANSDUCER (K−21)
DTS
DEFROST TEMPERATURE SENSOR (C−21)
DUV
DIGITAL UNLOADER VALVE (E−22)
DVM
DUAL VOLTAGE MODULE (OPTIONAL) (D−1)
DVR
DUAL VOLTAGE RECEPTACLE (OPTIONAL) (E−2)
EEV
ELECTRONIC EXPANSION VALVE (R−14)
EF
EVAPORATOR FAN CONTACTOR−HIGH SPEED
(N−11, M−12)
EM
EVAPORATOR FAN MOTOR (D−12, H−12, T−10, T−13)
EPT
EVAPORATOR PRESSURE TRANSDUCER (F−21)
ES
EVAPORATOR FAN CONTACTOR−LOW SPEED
(M−11, P−10)
ETS
EVAPORATOR TEMPERATURE SENSOR (SUCTION)
(D−20)
ESV
ECONOMIZER SOLENOID VALVE (K−9)
F
FUSE (C−6, D−6, D−18, E−18)
FCR
FUSE, TRANSFRESH (H−5)
FLA
FULL LOAD AMPS
FT
FUSE, TRANSFRESH (H−5)
IP
INTERNAL PROTECTOR (E−12, H−10, H−12)
IRL
IN RANGE LIGHT (OPTION) (L−14)
LIV
LIQUID INJECTION SOLENOID VALVE (OPTION) (K−9)
PA
UNIT PHASE CONTACTOR (L−7, M−7, N−1)
PB
UNIT PHASE CONTACTOR (L−7, M−7, N−2)
PR
USDA PROBE RECEPTACLE (E−22, L−22, M−22)
RM
REMOTE MONITORING RECEPTACLE (OPTION)
(L−6, M−6, L−11, M−11, L−14, M−14)
RRS
RETURN RECORDER SENSOR (C−21)
RTS
RETURN TEMPERATURE SENSOR (B−21)
SPT
SUCTION PRESSURE TRANSDUCER (J−21)
SRS
SUPPLY RECORDER SENSOR (K−21)
ST
START − STOP SWITCH (K−4, K−5)
STS
SUPPLY TEMPERATURE SENSOR (A−21)
TC
CONTROLLER RELAY−COOLING (H−8)
TCC
TRANSFRESH COMMUNICATIONS CONNECTOR
(OPTION) (D−5)
TCP
CONTROLLER RELAY − COMPRESSOR PHASE
SEQUENCING (K−6, K−7)
TE
CONTROLLER RELAY − HIGH SPEED EVAPORATOR
FANS (K−12)
TFC
TRANSFRESH CONTROLLER (F6)
TH
CONTROLLER RELAY − HEATING (K−13)
TI
IN−RANGE RELAY (F−14)
TL
CONTROLLER RELAY − COOL LIGHT (K−11)
TN
CONTROLLER RELAY − CONDENSER FAN (K−10)
TP
TEST POINT (F−8, F−9, F−10, H−7, J−10, J−12, M−15)
TQ
CONTROLLER RELAY−LIQUID INJECTION (OPTION)
(E−9)
TR
TRANSFORMER (M−3)
TRANS
AUTO TRANSFORMER 230/460 (OPTION) (D−2)
TRC
TRANSFRESH REAR CONNECTOR (OPTION) (E−5)
TS
CONTROLLER RELAY − ECONOMIZER SOLENOID
VALVE (E−9)
TV
CONTROLLER RELAY − LOW SPEED EVAPORATOR
FANS (J−11)
WCR
WETTING CURRENT RESISTOR (OPTION) (H−10)
WP
WATER PRESSURE SWITCH (OPTION) (D−10)
Figure 7−3 LEGEND − Configuration Includes Available Options (Except Vent Positioning System,
eAutoFresh, Emergency Bypass Options)
T-340
7−4
OR
OR
see Figure 7−7
for VPS
Based on Drawings 62−66721 and 62−11271 Rev A
Figure 7−4 SCHEMATIC DIAGRAM − Configuration Includes Available Options (Except Vent Positioning
System, eAutoFresh, Emergency Bypass Options)
7−5
T-340
LEGEND
SYMBOL DESCRIPTION
SYMBOL DESCRIPTION
AF
EAUTOFRESH STEPPER MOTOR (OPTION) (J−18)
HPS
HIGH PRESSURE SWITCH (F−10)
AMBS
AMBIENT SENSOR (C−22)
HR
HEATER CONTACTOR (P−4, M−16)
BM
BYPASS MODULE (OPTION) (R−18)
HS
HUMIDITY SENSOR (OPTIONAL) (F−22)
C
CONTROLLER (J−19)
HTT
HEAT TERMINATION THERMOSTAT (F−16)
CB1
CIRCUIT BREAKER − 460 VOLT (F−1)
ICF
INTERROGATOR CONNECTOR FRONT (T−22)
CB2
OPTIONAL CIRCUIT BREAKER − DVM (OPTION)
(C−1) TERMINAL BLOCK WHEN CB2 NOT PRESENT
ICR
INTERROGATOR CONNECTOR REAR (T−23)
CF
CONDENSER FAN CONTACTOR (M−12, P−6)
CH
COMPRESSOR CONTACTOR (M−10, P−1)
CI
COMMUNICATIONS INTERFACE MODULE (OPTION)
(A−3)
CL
COOL LIGHT (OPTION) (L−11)
CM
CONDENSER FAN MOTOR (H−13, T−6)
CP
COMPRESSOR MOTOR (T−1)
COS
CO2 SENSOR (OPTION) (T−12)
CPDS
DISCHARGE TEMPERATURE SENSOR (B−22)
CR
CHART (TEMPERATURE) RECORDER (OPTIONAL)
(A−18)
CS
CURRENT SENSOR (M−2)
DHBL
DEFROST HEATER − BOTTOM LEFT (R−5)
DHBR
DEFROST HEATER − BOTTOM RIGHT (T−4)
DHML
DEFROST HEATER − MIDDLE LEFT (R−4)
DHMR
DEFROST HEATER − MIDDLE RIGHT (T−4)
DHTL
DEFROST HEATER − TOP LEFT (R−4)
DHTR
DEFROST HEATER − TOP RIGHT (T−5)
DL
DEFROST LIGHT (OPTION) (L−6)
DPT
DISCHARGE PRESSURE TRANSDUCER (J−21)
DTS
DEFROST TEMPERATURE SENSOR (C−22)
DUV
DIGITAL UNLOADER VALVE (E−22)
DVM
DUAL VOLTAGE MODULE (OPTIONAL) (D−1)
DVR
DUAL VOLTAGE RECEPTACLE (OPTIONAL) (E−7)
EB
EMERGENCY BYPASS SWITCH (E−7)
EEV
ELECTRONIC EXPANSION VALVE (T−14)
EF
EVAPORATOR FAN CONTACTOR−HIGH SPEED
(N−8, M−15)
EM
EVAPORATOR FAN MOTOR (D−15, G−15, T−8, T−10)
EPT
EVAPORATOR PRESSURE TRANSDUCER (H−23)
ES
EVAPORATOR FAN CONTACTOR−LOW SPEED
(M−14, P−7)
ETS
EVAPORATOR TEMPERATURE SENSOR (SUCTION)
(A−23, D−18)
ESV
ECONOMIZER SOLENOID VALVE (J−11)
F
FUSE (D−20, E−20, F−20)
FCR
FUSE, CHART RECORDER
FLA
FULL LOAD AMPS
FT
FUSE, TRANSFRESH
IP
INTERNAL PROTECTOR (E−15, G−13, G−15)
IRL
IN RANGE LIGHT (OPTION) (L−16)
LIV
LIQUID INJECTION SOLENOID VALVE (OPTION) (K−12)
MS
MODE SWITCH (H−9)
PA
UNIT PHASE CONTACTOR (M−1, M−9)
PB
UNIT PHASE CONTACTOR (M−10, N−3)
PR
USDA PROBE RECEPTACLE (K−23, L−23, M−23)
RM
REMOTE MONITORING RECEPTACLE (OPTION)
(L−6, M−6, L−11, M−11, L−14, M−14)
RRS
RETURN RECORDER SENSOR (B−22)
RTS
RETURN TEMPERATURE SENSOR (B−22)
SD
STEPPER MOTOR DRIVER (OPTION) (K−18)
SPT
SUCTION PRESSURE TRANSDUCER (G−22)
SRS
SUPPLY RECORDER SENSOR (K−23)
ST
START − STOP SWITCH (J−4, J−5)
STS
SUPPLY TEMPERATURE SENSOR (A−22)
TC
CONTROLLER RELAY−COOLING (H−10)
TCC
TRANSFRESH COMMUNICATIONS CONNECTOR
(OPTION) (D−5)
TCP
CONTROLLER RELAY − COMPRESSOR PHASE
SEQUENCING (J−9, J−10)
TE
CONTROLLER RELAY − HIGH SPEED EVAPORATOR
FANS (J−15)
TFC
TRANSFRESH CONTROLLER (OPTION) (F−5)
TH
CONTROLLER RELAY − HEATING (J−16)
TI
IN−RANGE RELAY (F−16)
TL
CONTROLLER RELAY − COOL LIGHT (J−14)
TN
CONTROLLER RELAY − CONDENSER FAN (J−13)
TP
TEST POINT (F−10, F−11, H−10, H−12, H−15, H−16,
M−17)
TQ
CONTROLLER RELAY−LIQUID INJECTION (OPTION)
(E−11)
TR
TRANSFORMER (L−3)
TRANS
AUTO TRANSFORMER 230/460 (OPTION) (D−2)
TRC
TRANSFRESH REAR CONNECTOR (OPTION) (E−5)
TS
CONTROLLER RELAY − ECONOMIZER SOLENOID
VALVE (E−11)
TV
CONTROLLER RELAY − LOW SPEED EVAPORATOR
FANS (J−14)
WCR
WETTING CURRENT RESISTOR (OPTION) (H−13)
WP
WATER PRESSURE SWITCH (OPTION) (E−13)
Figure 7−5 LEGEND − Configuration Includes eAutoFresh and Emergency Bypass Options
T-340
7−6
see Figure 7−4 for optional
heater and 3−ph condenser
fan motor arrangements
see Figure 7−7
for VPS
Based on Drawing 62−11418 Rev A
Figure 7−6 SCHEMATIC DIAGRAM − Configuration Includes eAutoFresh and Emergency Bypass Options
7−7
T-340
(SEE NOTE)
PTC
(SEE NOTE)
PTC
NOTE: DEPENDING ON CONFIGURATION:
− VPS 2 MAY BE CONNECTED TO L1 OR T1
− PTC MAY BE INSTALLED
Figure 7−7 SCHEMATIC AND WIRING DIAGRAM − Upper Vent Position Sensor (VPS) Option
T-340
7−8
Figure 7−8 SCHEMATIC AND WIRING DIAGRAM − Lower Vent Position Sensor (VPS) Option
7−9
T-340
Figure 7−9 UNIT WIRING DIAGRAM − Standard Unit Configuration with 3−Phase Condenser Fan Motors
(Sheet 1 of 2)
T-340
7−10
Based on Drawing 62−11271 Rev A
Figure 7−9 UNIT WIRING DIAGRAM − Standard Unit Configuration with 3−Phase Condenser Fan Motors
(Sheet 2 of 2)
7−11
T-340
Figure 7−10 UNIT WIRING DIAGRAM − Configuration Includes Single Phase Condenser Fan Motor and
Optional Heater Arrangement (Sheet 1 of 2)
T-340
7−12
Based on Drawing 62−66721
Figure 7−10 UNIT WIRING DIAGRAM − Configuration Includes Single Phase Condenser Fan Motor and
Optional Heater Arrangement (Sheet 2 of 2)
7−13
T-340
Figure 7−11 UNIT WIRING DIAGRAM − Configuration Includes eAutoFresh and Emergency Bypass
Options (Sheet 1 of 2)
T-340
7−14
Based on Drawing 62−11418 Rev A
Figure 7−11 UNIT WIRING DIAGRAM − Configuration Includes eAutoFresh and Emergency Bypass
Options (Sheet 2 of 2)
7−15
T-340
INDEX
A
Adjusting Fresh Air Makeup, 4−1
Air−Cooled Condenser Description, 2−4
Alarm Code, 3−29
Controller, 1−2, 3−3
CONTROLLER ALARM INDICATIONS, 3−29
Controller Alarms, 3−12
Controller Alarm Codes, 3−29
Controller Configuration Codes, 3−19
Alarm Indications, 3−29
CONTROLLER FUNCTION CODES, 3−20
Alarm Troubleshooting Sequence, 3−28
CONTROLLER PRE−TRIP TEST CODES, 3−37
Aluminum oxide, 6−11
Controller Service, 6−16
Automatic Defrost, 3−9
CONTROLLER SOFTWARE, 3−3
Autotransformer, 1−2
Autotransformer Service, 6−16
B
D
DataBANK Card, 3−17
DataCORDER, 3−13, 4−5
Back Panels, 1−2
DataCORDER Alarm Codes, 3−45
Battery, 1−1
DataCORDER Alarm Configuration, 3−16
Battery Replacement, 6−19
DataCORDER Alarms, 3−18
DataCORDER Communications, 3−16
C
Cable Restraint, 1−2
Cable, 230 Volt, 1−2
DataCORDER Configuration Software, 3−13
DataCORDER Function Codes, 3−43
DataCORDER Logging Interval, 3−14
DataCORDER Operational Software, 3−13
Cable, 460 Volt, 1−2
DataCORDER Power Up, 3−16
Communications Interface Module, 1−2, 3−17
DataCORDER Pre−Trip Codes, 3−44
Communications Interface Module Description, 2−6
DataCORDER Pre−Trip Data Recording, 3−16
Communications Interface Module Service, 6−29
DataCORDER Sampling Type, 3−16
Compressor, 1−1, 6−5
DataCORDER Sensor Configuration, 3−14
Compressor Removal and Replacement , 6−5
DataCORDER Software, 3−13
Compressor Section Description, 2−3
DataCORDER Standard Configurations, 3−16
Compressor−Cycle Perishable Cooling, 3−12
DataCORDER Thermistor Format, 3−14
Condenser Coil, 1−1
DataLINE, 3−17
Condenser Coil Service, 6−7
DataReader, 3−17
Condenser Fan Service, 6−7
Defrost, 3−9
Condenser Grille, 1−2
Defrost Initiation, 3−9
Condenser Pressure Control, 3−11
Defrost Interval, 3−10
Configuration Software (CnF Variables), 3−3
Defrost Related Settings, 3−10
Connecting Power, 4−1
Dehumidification, 1−1, 3−5
Connecting the Remote Monitoring Receptacle, 4−5
Dehumidification − Bulb Mode, 3−6
Connecting the Water−Cooled Condenser, 4−4
Digital Unloader Valve Service, 6−14
Control Box, 1−1
Display Alarm Codes, 3−12
Control Box Description, 2−6
Display Module, 3−2
Index−1
T-340
INDEX (Continued)
E
G
eAutoFresh, 1−2
General Unit Description, 2−1
eAutoFresh Modes of Operation, 4−3
Generator Protection, 3−11
eAutoFresh Operation, 4−3
Gutters, 1−2
eAutoFresh Pre−Trip Inspection, 4−3
eAutoFresh Service, 6−25
H
eAutoFresh Start−Up Procedure, 4−3
Economized Operation, Refrigeration Circuit, 2−10
Economizer Expansion Valve Service, 6−13
Economizer Solenoid Valve Service, 6−13
EEV Replacement, 6−13
Electrical Data, 2−8
Electronic Expansion Valve Description, 2−10
Handles, 1−2
Heat Lockout, 3−4, 3−7
Heater Service, 6−9
High Pressure Switch Service, 6−6
High Temperature, Low Pressure Protection, 3−11
Electronic Expansion Valve Service, 6−12
I
Emergency Bypass, 1−2
Emergency Bypass Operation, 4−8
EVACUATION AND DEHYDRATION, 6−3
Inspection, 4−1
Evaporator, 1−1
Interrogator, 1−1
Evaporator Coil Service, 6−9
Introduction, 1−1
Evaporator Fan and Motor Service, 6−10
ISO Trip Header, 3−18
Evaporator Fan Operation, 1−1, 3−11
Evaporator Section Cleaning, 6−11
K
Evaporator Section Description, 2−2
Keypad, 3−2
F
L
Failure Action, 3−11
Feature Descriptions, 1−1
Filter Drier Service, 6−9
Fresh Air Makeup Description, 2−1
Frozen “Heat” Mode, 3−8
Labels, 1−2
Lower Air (Fresh Air Make Up), 1−2
Lower Fresh Air Makeup Vent, 4−2
Frozen Economy Mode, 3−8
M
Frozen Idle Mode, 3−7
Frozen Mode − Temperature Control, 3−7
Frozen Mode Cooling − Sequence of Operation, 3−8
Manifold Gauge Set Service, 6−1
Frozen Steady State, 3−7
Microprocessor System Description, 3−1
Fumigation, 6−11
MODES OF OPERATION, 3−4
T-340
Index−2
INDEX (Continued)
O
S
Operational Software (Cd Function Codes), 3−4
Safety and Protective Devices, 2−9
Option Descriptions, 1−1
Sensor, Compressor Discharge Temperature, 6−24
P
SERVICE CONNECTIONS, 6−2
Standard Operation, Refrigeration Circuit, 2−10
Painted Surfaces Maintenance, 6−29
Start up − Compressor Bump Start, 3−4
Perishable Dehumidification, 3−5
Start up − Compressor Phase Sequence, 3−4
Perishable Economy, 3−6
Start−Up Inspection, 4−5
Perishable Heating, 3−4
Starting Instructions, 4−5
Perishable Idle, Air Circulation, 3−4
Perishable Mode − Trim Heat, 3−7
Perishable Mode Cooling − Sequence of Operation,
3−6
Stopping Instructions, 4−5
Surface corrosion, 6−11
System Pressure Regulation, 3−11
Perishable Mode Heating − Sequence of Operation,
3−7
T
Perishable Mode Temperature Control, 3−4
Perishable Pulldown, 3−4
Perishable Steady State, 3−4
Plate Set, 1−1
Temperature Readout, 1−1
Temperature Recorder, 1−2
Pre−Trip Diagnosis, 4−6
Temperature Recorder Service, 6−28
PRE−TRIP DIAGNOSTICS, 3−12
Temperature Recorder−Starting Instructions, 4−5
Pre−Trip Test Codes , 3−37
Temperature Sensor Service, 6−19
Pressure Readout, 1−1
Thermometer Port, 1−2
PROBE DIAGNOSTICS, 4−7
Torque Values, 6−31
Protective Modes of Operation, 3−11
Troubleshooting, 5−1
PUMP DOWN THE UNIT, 6−2
U
Q
QUEST − CCPC, 1−2, 3−12
Unit Configuration Identification, 1−1
Upper Air (Fresh Air Make Up), 1−2
R
REFRIGERANT LEAK CHECKING, 6−3
Refrigeration Circuit, 2−10
Upper Fresh Air Makeup Vent, 4−2
USDA, 1−1
USDA Cold Treatment, 3−17
Refrigeration System Data, 2−7
USDA Cold Treatment Procedure, 3−17
Refrigeration Unit Description − Front Section, 2−1
USDA Recording, 3−17
Remote Monitoring, 1−1
USDA/ Message Trip Comment, 3−17
Index−3
T-340
INDEX (Continued)
V
0
Valve Override Controls, 6−15
07−00176−11, 6−3
Vent Position Sensor, 4−3
07−00277−00, 6−16
VENT POSITION SENSOR (VPS), 6−24
07−00294−00, 6−1
07−00304−00, 6−16
W
Water Cooling, 1−2
09−00128−00, 6−29
09−00128−01, 6−29
Water−Cooled Condenser Description, 2−5
7
Water−Cooled Condenser Service, 6−7
Wiring Schematic, 7−1
T-340
76−00685−00, 6−29
Index−4
Carrier Transicold Division,
Carrier Corporation
P.O. Box 4805
Syracuse, N.Y. 13221 U.S A
A member of the United Technologies Corporation family. Stock symbol UTX
www.carrier.transicold.com