Carrier Container Refrigeration Unit Service manual

r
Container Refrigeration
OPERATION AND SERVICE
for
69NT40-541-300 TO 399
Container Refrigeration Units
T-318 Rev A
OPERATION AND SERVICE MANUAL
CONTAINER REFRIGERATION UNIT
Models
69NT40-541-300 to 399
TABLE OF CONTENTS
PARAGRAPH NUMBER
Page
GENERAL SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--1
FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--1
OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--1
MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--1
UNIT LABEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--1
SPECIFIC WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.2 CONFIGURATION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3 OPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.2 Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.3 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.5 Temperature Readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.6 Pressure Readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.7 USDA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.8 Interrogator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.9 Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.10 Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.11 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.12 Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.13 Autotransformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.3.14 Temperature Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.15 Gutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.16 Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.17 Thermometer Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.18 Water Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.19 Back Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.20 460 Volt Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.21 230 Volt Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.22 Cable Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.23 Upper Air (Fresh Air Make Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.24 Lower Air (Fresh Air Make Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.25 Arctic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.26 Power Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.27 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.28 Evaporator Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.29 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.30 Plate Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.31 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3.32 Condenser Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
i
T-318
TABLE OF CONTENTS - Continued
PARAGRAPH NUMBER
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--1
2.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
MICROPROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--1
3.1 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
3.2 CONTROLLER SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--3
3.2.1 Configuration Software (Configuration Variables) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--3
3.2.2 Operational Software (Function Codes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--3
3.3 MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--4
3.3.1 Temperature Control -- Perishable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--4
3.3.2 Evaporator Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--4
3.3.3 Defrost Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--4
3.3.4 Failure Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--4
3.3.5 Generator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--4
3.3.6 Condenser Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--4
3.3.7 Arctic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--4
3.3.8 Perishable Mode -- Conventional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--5
3.3.9 Perishable Mode -- Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--5
3.3.10 Perishable Mode -- Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--5
3.3.11 Perishable, Dehumidification -- Bulb Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--5
3.3.12 Temperature Control -- Frozen Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--6
3.3.13 Frozen Mode -- Conventional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--6
3.3.14 Frozen Mode -- Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--6
3.4 CONTROLLER ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--6
3.5 UNIT PRE-TRIP DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--7
3.6 DataCORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--7
3.6.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--7
3.6.2 DataCORDER Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--7
3.6.3 Sensor Configuration (dCF02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--8
3.6.4 Logging Interval (dCF03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--9
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TABLE OF CONTENTS - Continued
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3.6.5 Thermistor Format (dCF04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--9
3.6.6 Sampling Type (dCF05 & dCF06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--9
3.6.7 Alarm Configuration (dCF07 -- dCF10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--9
3.6.8 DataCORDER Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--9
3.6.9 Pre-Trip Data Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--11
3.6.10 DataCORDER Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--11
3.6.11 USDA Cold Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--11
3.6.12 USDA Cold Treatment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--11
3.6.13 DataCORDER Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--1
4.1 INSPECTION (Before Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--1
4.2 CONNECT POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--1
4.2.1 Connection To 380/460 VAC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--1
4.2.2 Connection to190/230 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 Fresh Air Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--2
4.4 CONNECT WATER-COOLED CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--2
4.4.1 Water-Cooled Condenser with Water Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--2
4.4.2 Water-Cooled Condenser with Condenser Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--3
4.5 CONNECT REMOTE MONITORING RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--3
4.6 STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--3
4.6.1 Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--3
4.6.2 Stopping the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--3
4.7 START-UP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--3
4.7.1 Physical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--3
4.7.2 Check Controller Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--3
4.7.3 Start Temperature Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--3
4.7.4 Complete Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--3
4.8 PRE-TRIP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--4
4.9 OBSERVE UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--5
4.9.1 Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--5
4.9.2 Probe Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--5
4.10 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--7
4.10.1 Sequence of Operation -- Perishable Mode Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--7
4.10.2 Sequence of Operation -- Perishable Mode Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--7
4.10.3 Sequence of Operation -- Frozen Mode Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--8
4.10.4 Sequence of Operation -- Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--8
4.11 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--9
4.11.1 Emergency Bypass Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--9
4.11.2 Emergency Defrost Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--9
4.12 ARCTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--10
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--1
5.1 UNIT WILL NOT START OR STARTS THEN STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--1
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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 (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--3
5.8 ABNORMAL NOISE OR VIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--3
5.9 CONTROLLER MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--3
5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--4
5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--4
5.12 AUTOTRANSFORMER MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--4
5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . .
5--4
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--1
6.1 SECTION LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--1
6.2 SERVICE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--1
6.3 MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--1
6.4 PUMPING THE UNIT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--2
6.5 REFRIGERANT LEAK CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--3
6.6 EVACUATION AND DEHYDRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--3
6.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--3
6.6.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--3
6.6.3 Procedure - Complete System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--3
6.6.4 Procedure - Partial System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--4
6.7 REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--4
6.7.1 Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--4
6.7.2 Adding Refrigerant to System (Full Charge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--4
6.7.3 Adding Refrigerant to System (Partial Charge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--4
6.8 COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--5
6.8.1 Removal and Replacement of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--5
6.8.2 Compressor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--6
6.8.3 Compressor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--8
6.8.4 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--8
6.8.5 Installing the Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--9
6.8.6 Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--9
6.9 HIGH PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--10
6.9.1 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--10
6.9.2 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--10
6.10 CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--10
6.11 CONDENSER FAN AND MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--10
6.12 WATER-COOLED CONDENSER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--11
6.13 FILTER-DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--12
6.14 THERMOSTATIC EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--12
6.14.1 Checking Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--13
6.14.2 Expansion Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--13
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6.15 EVAPORATOR COIL AND HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--14
6.15.1 Evaporator Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--14
6.15.2 Evaporator Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--14
6.16 EVAPORATOR FAN AND MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--15
6.16.1 Replacing the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--15
6.16.2 Disassemble the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--15
6.16.3 Assemble the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--15
6.17 EVAPORATOR FAN MOTOR CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--15
6.17.1 When To Check For A Defective Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--15
6.17.2 Removing the Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--16
6.17.3 Checking the Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--16
6.18 SUCTION MODULATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--16
6.18.1 Pre-check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--16
6.18.2 Checking the Stepper Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--17
6.18.3 Checking the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--17
6.18.4 Emergency Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--17
6.19 DPRV CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--17
6.20 AUTOTRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--18
6.21 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--18
6.21.1 Handling Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--18
6.21.2 Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--19
6.21.3 Controller Programming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--19
6.21.4 Removing and Installing the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--20
6.21.5 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--20
6.22 TEMPERATURE SENSOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--20
6.22.1 Sensor Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--20
6.22.2 Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--20
6.22.3 Sensor Re-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--21
6.23 VENT POSITION SENSOR (VPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--22
6.24 ELECTRONIC PARTLOW TEMPERATURE RECORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--23
6.24.1 Replacing the Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--23
6.24.2 Changing the Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--23
6.24.3 Adjusting the Recorder Stylus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--24
6.24.4 Rezeroing the Recording Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--24
6.24.5 Rezeroing the Recording Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--25
6.25 MAINTENANCE OF PAINTED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--25
6.26 COMPOSITE CONTROL BOX REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--25
6.27 COMMUNICATIONS INTERFACE MODULE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--28
6.28 POWER FACTOR CORRECTOR CAPACITORS (PFC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--28
ELECTRICAL WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7--1
7.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7--1
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Figure 2-1 Refrigeration Unit -- Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-2 Evaporator Section -- Units With Center Access Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-4 Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-5 Water-Cooled Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-6 Control Box Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-7 Refrigeration Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-1 Temperature Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-2 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-3 Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-4 Micro-Link 3 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-5 Standard Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-6 Data Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-1 Autotransformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-2 Make Up Air Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-3 Controller Operation -- Perishable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-4 Controller Operation -- Frozen Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-5 Perishable Mode Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-6 Perishable Mode Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-7 Frozen Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-8 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-1 Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-2 Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-3 R-134a Manifold Gauge/Hose Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-4 Refrigeration System Service Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-5 Compressor Service Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-6 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-7 Exploded View of Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-8 Bottom Plate Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-9 Oil Pump and Bearing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-10 Low Profile Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-11 Motor End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-12 Equalizing Tube and Lock Screw Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-13 Crankshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-14 Suction Valve & Positioning Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-15 Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-16 High Pressure Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-17 Water-Cooled Condenser Cleaning -- Forced Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-18 Water Cooled Condenser Cleaning - Gravity Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-19 Thermostatic Expansion Valve Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-20 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-21 Hermetic Thermostatic Expansion Valve Brazing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-22 Hermetic Thermostatic Expansion Valve Bulb Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-23 Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-24 Suction Modulation Valve (SMV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T-318
vi
Page
2--1
2--2
2--3
2--4
2--5
2--6
2--11
3--1
3--2
3--2
3--3
3--10
3--11
4--1
4--2
4--6
4--6
4--7
4--7
4--8
4--8
6--1
6--1
6--2
6--2
6--4
6--5
6--6
6--6
6--7
6--7
6--7
6--8
6--8
6--8
6--8
6--10
6--11
6--12
6--13
6--13
6--13
6--14
6--15
6--16
LIST OF ILLUSTRATIONS - Continued
FIGURE NUMBER
Page
Figure 6-25 DPRV Replacement Value Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--18
Figure 6-26 Controller Section of the Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--18
Figure 6-27 Sensor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--21
Figure 6-28 Sensor and Cable Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--21
Figure 6-29 Supply Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--22
Figure 6-30 Return Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--22
Figure 6-31 Electronic Partlow Temperature Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--24
Figure 6-32 Door Hinge Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--26
Figure 6-33 Insert Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--27
Figure 6-34 Communications Interface Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--28
Figure 6-35 R-134a Compressor Pressure and Motor Current Curves Versus Ambient Temperature . . . . .
6--32
Figure 6-35 R-134a Compressor Pressure and Motor Current Curves Versus Ambient Temperature . . . . .
6--33
Figure 7-1 Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7--2
Figure 7-2 SCHEMATIC DIAGRAM -- Units with Normal Evaporator Fan Capability . . . . . . . . . . . . . . . . . . . .
7--3
Figure 7-3 SCHEMATIC DIAGRAM -- Units with Single Evaporator Fan Capability . . . . . . . . . . . . . . . . . . . .
7--4
Figure 7-4 SCHEMATIC DIAGRAM -- TransFRESH and Vent Position Sensors (VPS) . . . . . . . . . . . . . . . . .
7--5
Figure 7-5 SCHEMATIC DIAGRAM -- Emergency Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7--6
Figure 7-6 SCHEMATIC DIAGRAM, WIRING DIAGRAM -- Electronic Partlow Recorder . . . . . . . . . . . . . . .
7--7
Figure 7-7 UNIT WIRING DIAGRAM -- Units with Normal Evaporator Fan Capability . . . . . . . . . . . . . . . . . .
7--8
Figure 7-8 UNIT WIRING DIAGRAM -- Units with Single Evaporator Fan Capability . . . . . . . . . . . . . . . . . . .
7--10
LIST OF TABLES
TABLE NUMBER
Page
Table 2-1 Safety and Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--9
Table 3-1 Keypad Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--2
Table 3-2 DataCORDER Configuration Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--8
Table 3-3 DataCORDER Standard Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--9
Table 3-4 Controller Configuration Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--13
Table 3-5 Controller Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--14
Table 3-6 Controller Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--18
Table 3-7 Controller Pre-Trip Test Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--21
Table 3-8 DataCORDER Function Code Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--25
Table 3-9 DataCORDER Pre-Trip Result Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--26
Table 3-10 DataCORDER Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--27
Table 6-1 Sensor Temperature/Resistance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--20
Table 6-2 Crack, Chip & Hole Repair Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--26
Table 6-3 Insert Repair Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--26
Table 6-4 Drill Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--26
Table 6-5 Recommended Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--29
Table 6-6 Wear Limits For Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--29
Table 6-7 Compressor Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--30
Table 6-8 R-134a Temperature - Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--31
vii
T-318
SAFETY SUMMARY
GENERAL SAFETY NOTICES
The following general safety notices supplement the 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.
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, start-stop switches are turned off, and power supply
is disconnected.
Always work in pairs. Never work on the equipment alone.
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, and 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
both 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).
UNIT LABEL IDENTIFICATION
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 -- Indicates an immediate hazard that WILL result in severe personal injury or death.
WARNING -- Warns against hazards or unsafe conditions which COULD result in severe personal injury or death.
CAUTION -- Warns against potentially hazardous or unsafe practices that could result in minor personal injury, product
or property damage.
Safety--1
T-318
SPECIFIC WARNING AND CAUTION STATEMENTS
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
WARNING
Make sure power to the unit is OFF and
power plug disconnected before replacing
the compressor.
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 use a nitrogen cylinder without a
pressure regulator. Do not use oxygen in or
near a refrigeration system as an explosion
may occur.
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
Do not open the condenser fan grille before
turning power OFF and disconnecting
power plug.
WARNING
WARNING
Do not open condenser fan grille before
turning power OFF and disconnecting
power plug.
Make sure the power plugs are clean and
dry before connecting to any power receptacle.
WARNING
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.
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.
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.
WARNING
Never use air for leak testing. It has been determined that pressurized mixtures of refrigerant and air can undergo combustion
when exposed to an ignition source.
WARNING
Always turn OFF the unit circuit breakers
(CB-1 & CB-2) and disconnect main power
supply before working on moving parts.
WARNING
WARNING
Never use air for leak testing. It has been
determined that pressurized, air-rich mixtures of refrigerants and air can undergo
combustion when exposed to an ignition
source.
T-318
Make sure power to the unit is OFF and
power plug disconnected before servicing
capacitor(s).
Safety--2
WARNING
CAUTION
With power OFF discharge the capacitor
before disconnecting the circuit wiring.
Pre-trip inspection should not be performed with critical temperature cargoes in
the container.
CAUTION
WARNING
The unit power plug must be disconnected
to remove power from circuit breaker CB1
When Pre-Trip key is pressed, dehumidification and bulb mode will be deactivated.
At the completion of Pre-Trip activity, dehumidification and bulb mode must be reactivated.
WARNING
CAUTION
When condenser water flow is below 11 lpm
(3 gpm) or when water-cooler is not in use,
the CFS switch MUST be set to position “I”
or the unit will not operate properly.
Make sure power to the unit is OFF and
power plug disconnected before removing
capacitor(s).
CAUTION
WARNING
Pre-trip inspection should not be performed with critical temperature cargoes in
the container.
Before removing the capacitors, the
terminals must be checked for voltage with
a multimeter. The discharge resistors
installed on the unit (capacitors) should
bring the voltage to a safe level in a minute.
However, there may be a broken resistor
that retains voltage for a longer period.
Therefore, it is highly recommended to wait
15 minutes and to check for voltage.
CAUTION
When Pre-Trip key is pressed, dehumidification and bulb mode will be deactivated.
At the completion of Pre-Trip activity, dehumidification and bulb mode must be reactivated.
CAUTION
CAUTION
Do not remove wire harnesses from controller unless you are grounded to the unit
frame with a static safe wrist strap.
When a failure occurs during automatic
testing, the unit will suspend operation
awaiting operator intervention.
CAUTION
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!
Unplug all controller wire harness connectors before performing arc welding on any
part of the container.
Safety--3
T-318
CAUTION
CAUTION
Ensure that the thrust washer does not fall
off dowel pins while installing oil pump.
The unit will remain in the full cooling mode
as long as the emergency bypass switch is
in the BYPASS position and the MODE
SWITCH is in the FULL COOL position. If
the cargo may be damaged by low temperatures, the operator must monitor container
temperature and manually cycle operation
as required to maintain temperature within
required limits.
CAUTION
The set screw on the crankshaft must be
removed for this type of oil pump. (See
Figure 6-9.)
CAUTION
CAUTION
Use only Carrier Transicold approved
Polyol Ester Oil (POE) -- Castrol-Icematic
SW20 compressor oil with R-134a. Buy in
quantities of one quart or smaller. When
using this hygroscopic oil, immediately
reseal. Do not leave container of oil open or
contamination will occur.
The unit will remain in the DEFROST mode
as long as the emergency defrost switch is
in the DEFROST position. To prevent cargo
damage, the operator must monitor container temperature and manually cycle operation as required to maintain temperature
within required limits.
CAUTION
CAUTION
Take necessary steps (place plywood over
coil or use sling on motor) to prevent motor
from falling into condenser coil.
To prevent trapping liquid refrigerant in the
manifold gauge set, be sure set is brought
to suction pressure before disconnecting.
CAUTION
DO NOT disassemble piston from NEW suction modulating valve powerhead assembly. Doing so may result in damage to piston.
WARNING
Before disassembly of any external compressor component, make sure to relieve
possible internal pressure by loosening the
bolts and tapping the component with a
soft hammer to break the seal.
CAUTION
Do not remove wire harnesses from controller unless you are grounded to the unit
frame with a static safe wrist strap.
CAUTION
Removing the compressor motor press-fit
stator in the field is not recommended. The
rotor and stator are a matched pair and
should not be separated.
CAUTION
Unplug all controller connectors before
performing arc welding on any part of the
container.
CAUTION
CAUTION
The copper tube that connects to the oil
suction strainer extends out the bottom
with the bottom plate removed. Take precautions to avoid bending or breaking it
while changing crankcase positions.
T-318
The unit must be OFF whenever a programming card is inserted or removed from the
controller programming port.
Safety--4
CAUTION
CAUTION
Do not allow moisture to enter wire splice
area as this may affect the sensor resistance.
DO NOT move the stylus arm up and down
on the chart face. This will result in damage
to the stylus motor gear.
CAUTION
Do not allow the recorder stylus to snap
back down. The stylus arm base is
spring-loaded, and damage may occur to
the chart or the stylus force may be altered.
Safety--5
T-318
SECTION 1
INTRODUCTION
1.1 INTRODUCTION
1.3.4 Display Module
The Carrier Transicold model 69NT40-541-300/399
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 may be fitted with a backlit Liquid Crystal
Display (LCD) or a Light Emitting Diode (LED) Display.
1.3.5 Temperature Readout
The unit may be fitted with suction and discharge
temperature sensors. The sensor readings may be
viewed on the controller display.
They are one piece, self-contained, all-electric units,
which includes cooling and heating systems to provide
precise temperature control.
1.3.6 Pressure Readout
The units are suppled 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.
The unit may be fitted with suction and discharge
pressure gauges, or suction and discharge transducers
or no pressure readout. The transducer readings may
be viewed on the controller display.
The base unit operates on nominal 380/460 volt, 3
phase, 50/60 hertz power. An optional autotransformer
may be fitted to allow operation on nominal 190/230 , 3
phase, 50/60 hertz power. Power for the control system
is provided by a transformer, which steps the supply
power down to 18 and 24 volts, single phase.
1.3.7 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.
The controller is a Carrier Transicold Micro-Link 3
microprocessor.
The
controller
will
operate
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 a mechanical or electronic temperature recorder.
1.3.8 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 accessible from the front of the container and
the other mounted inside the container (with the USDA
receptacles).
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.
1.3.9 Remote Monitoring
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
1.2 CONFIGURATION IDENTIFICATION
Unit identification information is provided on a plate
located near the compressor. 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
provides information on specific optional equipment,
factory provision to allow for field installation of optional
equipment and differences in detailed parts.
1.3.10 Communications.
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.
Configuration identification for the models covered
herein may be obtained on the Container Products
Group Information Center by authorized Carrier
Transicold Service Centers.
1.3.11 Compressor
1.3 OPTION DESCRIPTION
Various options may be factory or field equipped to the
base unit. These options are listed in the tables and
described in the following subparagraphs.
The unit is fitted with a single speed reciprocating
compressor.
1.3.1 Battery
The unit is fitted with a 3--row coil using 7mm tubing.
The refrigeration controller may be fitted with standard
replaceable batteries or a rechargeable battery pack.
1.3.13 Autotransformer
1.3.12 Condenser Coil
An autotransformer may be provided to allow operation
on 190/230, 3 phase, 50/60 hertz 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.
1.3.2 Dehumidification
The unit may be fitted with a humidity sensor. This
sensor allows setting of a humidity set point in the
controller. In the dehumidification mode the controller
will operate to reduce internal container moisture level.
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.
1.3.3 Control Box
Units are equipped with a composite material box and
may be fitted with a lockable door.
1--1
T-318
1.3.14 Temperature Recorder
1.3.25 Arctic Mode
The units may be fitted with an electronic temperature
recording device.
To improve operation in cold ambients, the unit may be
fitted with a crankcase heater. The crankcase heater is
operated any time the unit is under power and the
compressor is not running. The purpose of the heater is
to warm the compressor oil and boil off any liquid
refrigerant that may be present in the crankcase.
1.3.15 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.
1.3.26 Power Correction
The unit may be fitted with a set of power factor
correction capacitors to assist in correction of
imbalance in current draw by the compressor.
1.3.16 Handles
The unit may be equipped with handles to facilitate
access to stacked containers. These handles may
include fixed handles (located at the sides of the unit)
and/or a hinged handle at the center (attached to the
condenser coil cover).
1.3.27 Evaporator
The evaporator section is equipped with a hermetic
thermal expansion valve and a heat exchanger. The unit
may have six heaters.
1.3.17 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.
1.3.28 Evaporator Fan Operation
Two evaporator fan motor operation systems are
available. On units with Normal Evaporator Fan
Operation, opening of an evaporator fan internal
protector will shut down the unit. On units equipped with
Single Evaporator Fan Capability, additional relays are
installed to allow the unit to continue to operate on a
single fan.
1.3.18 Water Cooling
The refrigeration system may be fitted with a
water-cooled condenser. The condenser is constructed
using copper-nickel tube for seawater 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 can be deactivated by either a water
pressure switch or condenser fan switch. Depending on
the unit’s configuration and the compressor discharge
temperature, the condenser fan may also be activated
during water-cooled condenser operation.
1.3.29 Labels
Operating instruction and function code listing labels will
differ depending on the options installed. For example,
additional operating instructions are required to
describe start-up of a unit equipped with an
autotransformer. Where the labels are available with
additional languages, they are listed in the parts list.
1.3.19 Back Panels
1.3.30 Plate Set
Back panel designs that may be fitted include panels of
aluminum and stainless steel. Panels may have access
doors and/or hinge mounting.
Each unit is equipped with a tethered set of wiring
schematic and wiring diagram plates. The plate sets are
ordered using a seven-digit base part number and a
two-digit dash number.
1.3.20 460 Volt Cable
1.3.31 Controller
Various power cable and plug designs are available for
the main 460 volt supply. The plug options tailor the
cables to each customers requirements.
Two different controllers are available:
1. Remanufactured -- Controller is the equivalent of a
new OEM controller and is supplied with a 12 month
warranty.
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.
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.
1.3.21 230 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
customers requirements.
1.3.22 Cable Restraint
Various designs are available for storage of the power
cables. These options are variations of the compressor
section front cover.
1.3.32 Condenser Grille
1.3.23 Upper Air (Fresh Air Make Up)
Two styles of condenser grilles are available -- direct
bolted grilles and hinged grilles.
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.
1.3.33 Emergency Bypass
The unit may be equipped with switches to allow
emergency bypass of the controller. The EMERGENCY
BYPASS switch functions to bypass the controller in the
event of controller failure. The EMERGENCY
DEFROST switch functions to bypass all controls and
place the unit in the defrost mode.
1.3.24 Lower Air (Fresh Air Make Up)
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.
T-318
1--2
SECTION 2
DESCRIPTION
2.1 GENERAL DESCRIPTION
parts identification number can be found on the serial
plate to the left of the compressor.
2.1.1 Refrigeration Unit -- Front Section
2.1.2 Fresh Air Makeup Vent
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
The function of the upper or lower makeup air vent is to
provide ventilation for commodities that require fresh air
circulation.
13
1
12
11
10
2
9
3
8
7
6
5
4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Access Panel (Evaporator Fan #1)/Thermostatic
Expansion Valve / HTT)
Fork Lift Pockets
Control Box
Compressor
Unit Serial Number, Model Number, and
Parts Identification Number (PID) Plate
Condenser Fan
TransFRESH Communications Connector
11.
12.
13.
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
Access Panel (Evaporator Fan #2)/ Humidity
Sensor / Return Temperature Sensor
Figure 2-1 Refrigeration Unit -- Front Section
2--1
T-318
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.
2.1.3 Evaporator Section
The evaporator section (Figure 2-2) contains the return
temperature sensor, humidity sensor, thermostatic
expansion valve, dual-speed evaporator fans (EM1 and
EM2), evaporator coil and heaters, defrost temperature
sensor, heat termination thermostat, and heat
exchanger.
The evaporator components are accessible by
removing the upper rear panel (as shown in Figure 2-2).
6
3
5
4
2
1
7
16
8
14
13
12
11
10
9
15
1.
2.
3.
4.
5.
6.
7.
8.
TXV Bulb
(under Insulation)
Evaporator Fan Motor #1
9.
Heat Exchanger
Return Recorder Sensor (RRS) / Return
10. Interrogator Connector (Rear)
Temperature Sensor (RTS)
11. USDA Probe Receptacle PR2
Humidity Sensor
12. USDA Probe Receptacle PR1
Evaporator Fan Motor #2
13. USDA Probe Receptacle PR3
Defrost Temperature Sensor
14. Cargo Probe Receptacle PR4
Heater Termination Thermostat
15. Evaporator Coil Heaters
Evaporator Coil
16. TXV Bulb Routing
Hermetic Thermostatic Expansion Valve
Figure 2-2 Evaporator Section -- Units With Center Access Panel
T-318
2--2
discharge pressure regulating valve, discharge
temperature sensor, and discharge/suction pressure
transducers.
The supply temperature sensor, supply recorder
sensor, and ambient sensor are located at the right side
of the compressor.
2.1.4 Compressor Section
The compressor section includes the compressor (with
high pressure switch), power cable storage
compartment, and autotransformer.
This section also contains the suction modulating valve,
1
5
6
2
7
8
11
10
3
9
4
12
13
22
21
16
14
17
20
19
1.
2.
3.
4.
5.
6.
7.
8
9.
10.
11.
15
18
12. Suction Temperature Sensor
Autotransformer
Power Cables and Plug
13. Quench Valve Temperature Bulb
14. Quench Valve
Compressor Sight Glass View Port
15. Access Valve
Compressor Guard
Supply Temperature Sensor
16. Suction Modulating Valve
17. Suction Service Valve
Supply Recorder Sensor
18. Compressor Crankcase Heater
Ambient Sensor
Supply Air Thermometer Port
19. Compressor Motor
20. Suction Pressure Transducer
Discharge Service Valve
21. High Pressure Switch
Discharge Temperature Sensor
Discharge Pressure Regulating Valve
22. Discharge Pressure Transducer
Figure 2-3 Compressor Section
2--3
T-318
line valve, filter-drier, condenser pressure transducer,
and fusible plug.
The condenser fan pulls air in through the bottom of the
coil and discharges it horizontally out through the
condenser fan grille.
2.1.5 Air-cooled Condenser Section
The air-cooled condenser section (Figure 2-4) consists
of the condenser fan, condenser coil, receiver with sight
glass/moisture indicator, quench valve, manual liquid
6
7
5
2
3
4
1
8
9
15
10
11
12
13
14
1.
2.
3.
4.
5.
6.
7.
8.
Grille and Venturi Assembly
Condenser Fan
Key
Condenser Fan Motor
Condenser Coil Cover
Condenser Coil
Condenser Motor Mounting Bracket
Receiver
9.
10.
11.
12.
13.
14.
15.
Sight Glass
Fusible Plug (Rupture Disc -- Alternate)
Condenser Pressure Transducer
Sight Glass/Moisture Indicator
Filter-Drier
Liquid Line Service Valve
Quench Valve
Figure 2-4 Condenser Section
T-318
2--4
quench expansion valve, rupture disc, condenser
pressure transducer, filter-drier, water couplings, and
water pressure switch. The water-cooled condenser
replaces the standard unit receiver.
2.1.6 Water-Cooled Condenser Section
The water-cooled condenser section (Figure 2-5)
consists of a water-cooled condenser, sight glass,
3
4
5
6
7
8
2
1
9
11
1.
2.
3.
4.
5.
6.
10
Sight Glass
7. Liquid Line Service Valve
Water-Cooled Condenser
8. Moisture/Liquid Indicator
Rupture Disc
9. Coupling (Water In)
Condenser Pressure Transducer
10. Self Draining Coupling (Water Out)
Quench Valve
11. Water Pressure Switch
Filter-Drier
Figure 2-5 Water-Cooled Condenser Section
2--5
T-318
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, keypad, display module, current sensor module,
controller module and the communications interface
module.
1
21
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
2.1.8 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 master system technical manual
for further information.
2
20
19
18
17
16
3
15
14
13
12
4
5
6
11
10
9
Compressor Contactor
12. Controller Battery Pack
Heater Contactor
13. Interrogator Connector (Box Location)
Display Module
14. Control Transformer
Communications Interface Module
15. Evaporator Fan Contactor - E1
Controller/DataCORDER Module (Controller)
16. Evaporator Fan Contactor - S1
Key Pad
17. Evaporator Fan Contactor - S2 or EF
Emergency Defrost Light
18. Evaporator Fan Contactor - E2 or ES
Start-Stop Switch
19. Condenser Fan Contactor
Remote Monitoring Receptacle
20. Circuit Breaker -- 460V
Manual Defrost Switch
21. Current Sensor Module
Condenser Fan Switch
Figure 2-6 Control Box Section
T-318
2--6
8 7
2.2 REFRIGERATION SYSTEM DATA
a. Compressor/Motor
Assembly
Number of Cylinders
Model
CFM
Weight (Dry)
Approved Oil
Oil Charge degrees
Oil Sight Glass
b. Expansion Valve Superheat
c. Heater Termination Thermostat
d. High Pressure Switch
Verify at -18 degrees
C
(0 degrees F) container box temperature
Opens
Closes
Cutout
Cut-In
Unit Configuration
e. Refrigerant Charge
Water-Cooled
Condenser
Receiver
6
06DR
41
118 kg (260 lb)
Castrol Icematic
3.6 liters (7.6 U.S. pints)
The oil level range, with the compressor off,
should be between the bottom and one-eighth
level of the sight glass.
4.5 to 6.7 C (8 to 12 F)
54 (+/-) C = 130 (+/-) F
38 (+/- 4) C = 100 (+/- 7) F
25 (+/- 1.0) kg/cm@ = 350 (+/- 10) psig
18 (+/- 0.7) kg/cm@ = 250 (+/- 10) psig
Charge Requirements -- R-134a
3 row condenser
5.2 kg (11.5 lbs)
4.9 kg (10.8 lbs)
NOTE
When replacing the following components (f.), (g.) and (h.), refer to the installation instructions included with the
replacement part for additional information.
Melting point
99 C = (210 F)
f. Fusible Plug*
Torque*
6.2 to 6.9 mkg (45 to 50 ft-lbs)
g. Sight Glass/Moisture Indicator Torque
8.9 to 9.7 mkg (65 to 70 ft-lbs)
Bursts at
35 +/- 5% kg/cm@ = (500 +/- 5% psig)
h. Rupture Disc
Torque
1.4 to 2 mkg (10 to 15 ft-lbs)
(P/N 14-00215-03)
The condenser fan will start if the condenser
pressure is greater than 14.06 kg/cm@ (200
Condenser Fan Starts psig) OR the condenser fan is OFF for more
than 60 seconds.
i. Condenser Pressure
Transducer
The condenser fan will stop if the condenser
pressure is less than 9.14 kg/cm@ (130 psig)
Condenser Fan Stops AND the condenser fan remains ON for at least
30 seconds.
Refer to unit model number plate.
0.5 +/- 0.2 kg/cm@
3-row condenser (7 +/- 3 psig)
j. Unit Weight
k. Water Pressure Switch
Cut-In
Cutout
l. Discharge Pressure
Regulating Valve
1.6 +/- 0.4 kg/cm@ (22 +/- 5 psig)
Factory Setting
32.7 +/- 2.5 kg/cm@ (72+/- 5.5 psig)
* Rupture Disc, part number 14 -00215 -04 may be installed as an alternate for the receiver mounted fusible plug.
2--7
T-318
2.3 ELECTRICAL DATA
CB-1 Trips at
CB-2 (50 amp) Trips at
a. Circuit Breaker
CB-2 (70 amp) Trips at
b. Compressor
Full Load Amps (FLA)
Motor
c. Condenser Fan
Motor
d. Evaporator Coil
Heaters
e. Evaporator Fan
Motor(s)
f. Fuses
Full Load Amps
Horsepower
Rotations Per Minute
Voltage and Frequency
Bearing Lubrication
Rotation
Number of Heaters
Rating
Resistance (cold)
Type
Full Load Amps
High Speed
Full Load Amps
Low Speed
Nominal Horsepower
High Speed
Nominal Horsepower
Low Speed
Rotations Per Minute
High Speed
Rotations Per Minute
Low Speed
Voltage and Frequency
Voltage & Frequency using power autotransformer
Bearing Lubrication
Rotation
Control Circuit
Controller/DataCORDER
Emergency Defrost
Drain Line Heater
Humidity Power
Transformer
29 amps
62.5 amps
87.5 amps
17.6 amps @ 460 VAC
(with current limiting set at 21 amps)
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 @ 20 C (68 F)
Sheath
380 VAC/50 hz
460 VAC/60 hz
1.6
2.0
0.8
1.0
0.70
0.84
0.09
0.11
2850 rpm
3450 rpm
1425 rpm
1750 rpm
360 -- 460 VAC +/- 1.25 hz
400 -- 500 VAC +/- 1.5 hz
180 -- 230 VAC +/- 1.25hz
200 -- 250 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)
5 amps (FED)
5 amps (FDH)
5 amps (FH)
g. Compressor Crankcase Heater
T-318
180 watts @ 460 VAC
2--8
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
h. 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
i. Controller
Setpoint Range
-30 to +30 C ( -22 to +86 F)
2.4 SAFETY AND PROTECTIVE DEVICES
Unit components are protected from damage by safety and protective devices listed in the following table. These
devices monitor the unit operating conditions and open a set of electrical contacts when an unsafe condition occurs.
Table 2-1 Safety and Protective Devices
UNSAFE CONDITION
Excessive current draw
Excessive current draw in the
control circuit
SAFETY DEVICE
DEVICE SETTING
Circuit Breaker (CB-1) -- 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)
Fuse (F3A & F3B)
7.5 amp rating
Excessive current draw by the
Fuse (F1 & F2)
controller
5 amp rating
Excessive current draw by the
Fuse (FED)
emergency defrost circuit
5 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
Fusible Plug -- Used on the Receiver
99 C = (210 F)
Rupture Disc -- Used on the Water-Cooled
Condenser
35 kg/cm@ = (500 psig)
High Pressure Switch (HPS)
Opens at 25 kg/cm@
(350 psig)
2--9
T-318
2.5 REFRIGERATION CIRCUIT
Starting at the compressor (see Figure 2-7, upper
schematic), the suction gas is compressed to a higher
pressure and temperature.
The gas flows through the discharge service valve into
the pressure regulating valve. During periods of low
ambient operation, the discharge pressure regulating
valve modulates the flow of refrigerant to maintain a pre
-set minimum discharge pressure. Refrigerant gas then
moves 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.
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
excess refrigerant.
The liquid refrigerant continues through the liquid line
service valve, the filter-drier (which keeps refrigerant
clean and dry), and a heat exchanger (that increases
subcooling of the liquid) to the thermostatic expansion
valve. As the liquid refrigerant passes through the
variable orifice of the expansion valve, some of it
vaporizes into a gas (flash gas). Heat is 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 modulating valve to the compressor.
The thermostatic expansion valve is activated by the
bulb strapped to the suction line near the evaporator
T-318
outlet. The valve maintains a constant superheat at the
coil outlet regardless of load conditions.
During periods of low load, the suction modulating valve
decreases flow of refrigerant to the compressor. This
action balances the compressor capacity with the load
and prevents operation with low coil temperatures. In
this mode of operation, the quench valve will open as
required to provide sufficient liquid refrigerant flow into
the suction line for cooling of the compressor motor. The
quench valve senses refrigerant condition entering the
compressor and modulates the flow to prevent entrance
of liquid into the compressor.
The refrigeration system is also fitted with a condenser
pressure transducer, which feeds information to the
controller. When operating on the air-cooled condenser,
the controller programming will operate the condenser
fan so as to attempt to maintain discharge pressures
above 130 psig in low ambients. At ambients below 27
degrees C (80 degrees F), the condenser fan will cycle
on and off depending on condenser pressure and
operating times.
1 The condenser fan will start if the condenser pressure is greater than 200 psig OR the condenser fan
has been OFF for more than 60 seconds.
2 The condenser fan will stop if the condenser pressure is less than 130 psig AND the condenser fan
has been running for at least 30 seconds.
At ambients above 27 C (80 F), condenser pressure
control is disabled and the condenser fan runs
continuously.
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
be automatically started. When operating a system
fitted with a condenser fan switch, the condenser fan will
be off when the switch is placed in the “O” position. The
condenser fan will be on when the switch is placed in the
“I” position.
2--10
EVAPORATOR
TXV
TXV BULB
CONDENSER
HEAT EXCHANGER
DISCHARGE PRESSURE
REGULATING VALVE
PRESSURE
TRANSDUCER
SERVICE VALVE
MODULATING VALVE
QUENCH VALVE
PRESSURE TRANSDUCER
FUSIBLE PLUG
Suction
Liquid
Discharge
FILTER DRIER
SIGHT GLASS
SERVICE VALVE
RECEIVER
Circuit with Receiver
EVAPORATOR
TXV
TXV BULB
CONDENSER
HEAT EXCHANGER
DISCHARGE PRESSURE
REGULATING VALVE
FUSIBLE PLUG
MODULATING VALVE
SERVICE VALVE
SIGHT GLASS
PRESSURE
TRANSDUCER
WATER-COOLED
CONDENSER
Suction
Liquid
Discharge
SERVICE VALVE
QUENCH VALVE
FILTER DRIER
Circuit with Water-Cooled Condenser
Figure 2-7 Refrigeration Circuit Schematic
2--11
T-318
SECTION 3
MICROPROCESSOR
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 3.6.
3.1 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM
The temperature control Micro-Link 3 microprocessor
system (see Figure 3-1) consists of a keypad, display
module,
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. The
DataCORDER software functions to record unit
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.
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
OPERATIONAL
SOFTWARE
CONFIGURATION
VARIABLE
(dCF## read only)
FUNCTION
CODE (dC)
DATA
STORAGE
MEMORY
ALARMS
(AL>68)
TO
DISPLAY
(Scrollback)
TO
DISPLAY
Computer Device
With DataLine
Software
DATABANK CARD
Figure 3-1 Temperature Control System
3--1
T-318
Table 3-1 Keypad Function
3.1.1 Keypad
The keypad (Figure 3-2) is mounted on the right-hand
side of the control box. The keypad consists of 11 push
button switches that act as the user’s interface with the
controller. Descriptions of the switch functions are
provided in Table 3-1.
KEY
Code Select Accesses function codes.
Pre-Trip
Alarm List
CODE
SELECT
PRE
TRIP
ALARM
LIST
MANUAL
DEFROST/
INTERVAL
FUNCTION
Manual
Defrost/
Interval
Enter
Arrow Up
ENTER
Displays the pre-trip selection menu.
Discontinues pre-trip in progress.
Displays alarm list and clears the
alarm queue.
Displays selected defrost mode. Depressing and holding the Defrost interval key for five seconds will 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
Change or scroll a selection upward
Pre-trip advance or test interruption.
Change or scroll a selection downArrow Down ward. Pre-trip repeat backward
Return/
Supply
RETURN
SUPPLY
_C
_F
BATTERY
POWER
ALT.
MODE
Figure 3-2 Keypad
COOL
HEAT DEFROST IN RANGE ALARM
SETPOINT/Code
Battery
Power
Initiate battery backup mode to allow
set point and function code selection
if AC power is not connected.
ALT. Mode
This key is pressed to switch the
functions from the 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 the perishable range
will be the SUPPLY air probe and the controlling
probe in the frozen range will be the RETURN
air probe.
Figure 3-3 Display Module
3.1.2 Display Module
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. This LED
will flash if dehumidification or humidification is enabled.
7. Alarm -- Red LED: Energized when there is an active
or an inactive shutdown alarm in the alarm queue.
The display module (Figure 3-3) consists of five digital
displays and seven indicator lights. The indicator lights
include:
1. Cool -- White LED: Energized when the refrigerant
compressor is energized.
2. Heat -- Orange LED: Energized to indicate heater operation in the heat or defrost mode.
3. Defrost -- Orange LED: Energized when the unit is in
the defrost mode.
4. In-Range -- Green LED: Energized when the controlled temperature probe is within specified tolerance
of set point.
T-318
DegreesC/Degrees F
Displays alternate English/Metric
scale (momentary display). When set
to degrees Fahrenheit, 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 degrees Celsius, pressure readings are in bars. “b” appears after the value to indicate bars.
SUPPLY RETURN
AIR TEMPERATURE/Data
Displays non-controlling probe temperature (momentary display).
3--2
1
1.
2.
3.
4.
2
Mounting Screw
Micro-Link 3
Controller
Connectors
Test Points
3.1.3 Controller
3
3
4
5
3
6
7
3
8
3
5.
6.
Fuses
Control Circuit Power Connection
(Location: In back of controller)
7. Software Programming Port
8. Battery Pack
Figure 3-4 Micro-Link 3 Controller
c. Provide ability to read, and if applicable, modify the
configuration software variables, operating software
function codes, and alarm code indications.
CAUTION
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.
Do not remove wire harnesses from controller unless you are grounded to the unit
frame with a static safe wrist strap.
e. Provide battery-powered ability to access or change
selected codes and set points without AC power connected
CAUTION
Unplug all controller 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.
3.2.1 Configuration Software (Configuration Variables)
NOTE
Do not attempt to service the controller. Breaking the seal will void the warranty.
The 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 the
original software has been lost 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 (page 3--13). A change to the factory-installed
configuration software is achieved via a configuration
card.
NOTE
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.
The Micro-Link 3 controller is a single module
microprocessor as shown in Figure 3-4. It is fitted with
test points, harness connectors and a software card
programming port.
3.2.2 Operational Software (Function Codes)
3.2 CONTROLLER SOFTWARE
The controller software is a custom designed program
that is subdivided into the configuration software and the
operational software. The controller software performs
the following functions:
a. Control supply or return air temperature to required
limits, provide modulated refrigeration control, electric heat control and defrost. Defrost is performed to
clear buildup of frost and ice from the coil to ensure
continuous conditioned air delivery to the load.
b. Provide default independent readouts of set point and
supply or return air temperatures.
The operational software is the actual operation
programming of the controller, which activates or
deactivates components in accordance with current unit
operation conditions and operator selected modes of
operation.
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 (page 3--14)
3--3
T-318
To access the function codes, perform the following:
below the frozen setpoint and then adjust to 24 hours
thereafter.
All defrost interval times reflect the number of
compressor runtime hours since the last defrost de-ice
cycle. The minimum defrost interval under the
automatic setting is three hours, while the maximum is
24. In frozen mode, the amount of wall-clock time
necessary to accumulate a given amount of 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 not accumulated in
any mode until the defrost termination sensor reads less
than 10 degrees C (50 degrees F).
3.3.4 Failure Action
Function code Cd29 may be operator set to allow
continued operation in the event the control sensors are
reading out of range. The factory default is full system
shutdown (refer to Table 3-5, page 3--14).
3.3.5 Generator Protection
Function codes Cd31 and Cd32 may be operator set to
control start-up sequence of multiple units and
operating current draw. The factory default allows on
demand starting of units and full current draw (refer to
Table 3-5, page 3--14).
3.3.6 Condenser Pressure Control
When configuration variable CnF14 is set to “In,” the
condenser pressure control logic is activated to
maintain discharge pressures above 130 psig in low
temperature ambients. The logic turns the condenser
fan on or off in accordance with the condenser pressure
transducer reading (refer to Table 3-4, page 3--13.) The
function is enabled when the following conditions are
met:
1. The ambient sensor reading is less than or equal to
27 C (80 F), and
2. Voltage/Frequency ratio is less than or equal to 8.38.
When the above conditions are met, either pressures or
timers may dictate a change of state from OFF to ON or
ON to OFF. If the condenser fan is OFF, it will be
energized if saturated condensing pressure is greater
than 200 psig OR if the condenser fan has been OFF for
a variable time period of up to 60 seconds depending on
the ambient temperature. As the ambient temperature
increases, the amount of time that the condenser fan is
energized will correspondingly increase towards the
maximum.
If the condenser fan is ON, it will de-energize only if the
saturated condensing pressure is less than 130 psig
and the condenser fan has been running for a minimum
of thirty seconds depending on the ambient
temperature.
3.3.7 Arctic Mode
With arctic mode enabled (configuration variable CnF29
set to “In”), there will be a 30-minute time delay at
startup if the ambient is colder than -10.0 C (14 F). When
the START/STOP switch is placed in the “I” (ON)
position, the controller will energize the compressor
crankcase heater. Operation of the heater will warm the
oil and boil off any liquid refrigerant that may be present
in the crankcase.
If Pre-Trip is initiated during the 30 minute time period,
Pre-Trip will be allowed to run normally. Once Pre-Trip is
over, the controller will revert to its normal control mode
logic (refer to Table 3-4, page 3--13).
a. Press the CODE SELECT key, then press an arrow
key until the left window displays the desired code
number.
b. The right window will display the value of this item for
five seconds before returning to the normal display
mode.
c. If a longer time is desired, press the ENTER key to extend the time to 30 seconds.
3.3 MODES OF OPERATION
The operational software responds to various inputs.
These inputs come from the temperature and pressure
sensors, the temperature set point, the settings of the
the configuration variables, and the function code
assignments. The action taken by the operational
software will change if any one of the inputs changes.
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.
3.3.1 Temperature Control -- Perishable Mode
With configuration variable CnF26 (Heat Lockout
Temperature) set to -10 C, the perishable mode of
operation is active with set points above -10 C (+14 F).
With the variable set to -5 C, the perishable mode is
active above -5 C (+23 F). Refer to Table 3-4, page
3--13.
When in the perishable mode, the controller maintains
the supply air temperature at set point, the SUPPLY
indicator light will be illuminated on the display module,
and the default reading on the display window will be the
supply temperature sensor reading.
When the supply air temperature enters the in-range
temperature tolerance (as selected at function code
Cd30), the in-range light will energize.
3.3.2 Evaporator Fan Operation
Opening of an evaporator fan internal protector will shut
down a unit with Normal Evaporator Fan Operation.
(CnF32 set to 2EFO). On units equipped with Single
Evaporator Fan Capability (CnF32 set to 1EFO),
additional relays are installed to allow the unit to
continue to operate on a single fan (refer to Table 3-4,
page 3--13).
3.3.3 Defrost Interval
Controller function code Cd27 sets two modes for
defrost initiation -- either user-selected timed intervals or
automatic control. The user-selected values are 3, 6, 9,
12, or 24 hours and the factory default for the timed
interval is 12 hours (some units may be configured to
allow defrost to be disabled altogether; in this case a
user-selected value of OFF will be available). Refer to
Table 3-5.
In perishable mode, perishable-pulldown mode, or
frozen-pulldown 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.
Once setpoint has been reached in frozen operation, the
automatic selection will set the time interval to 12 hours
for the first two defrosts once the return probe is reading
T-318
3--4
controller will activate the heat relay to begin
dehumidification.
1. The humidity sensor reading is above the set point.
2. The supply air temperature is less than 0.25 degrees
C above set point.
3. The heater debounce timer (three minutes) has
timed out.
4. Heater termination thermostat (HTT) is closed.
If the above conditions remain true for at least one hour,
the evaporator fans will switch from high to low speed
operation. The evaporator fan speed will switch every
hour thereafter as long as all conditions are met (see
Bulb Mode section for different evaporator fan speed
options). If any condition except for 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.
In the dehumidification mode, power is applied to the
defrost and drain pan heaters. This added heat load
causes the controller to open the suction modulating
valve to match the increased heat load while still holding
the supply air temperature very close to the set point.
Opening the modulating valve reduces the temperature
of the evaporator coil surface, which increases the rate
at which water is condensed from the passing air.
Removing water from the air reduces the relative
humidity. When the relative humidity sensed is 2%
below the 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 the mode 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.
Two timers are activated in the dehumidification mode
to prevent rapid cycling and consequent contactor wear.
They are:
S Heater debounce timer (three minutes)
S Out-of-range timer (five 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 is satisfied.
The out-of-range timer is started to maintain heater
operation during a temporary out-of-range condition. If
the 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 the
temperature exceeds the in-range tolerance value set
by function code Cd30.
3.3.11 Perishable, Dehumidification -- Bulb Mode
Bulb mode is an extension of the dehumidification
mode, which allows changes to the evaporator fan
speed and/or defrost termination set points.
Bulb mode is active when configuration code Cd35 is set
to “Bulb.” Once the bulb mode is activated, the user may
then change the dehumidification mode 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 function code Cd36 from its
default of “alt” to “Lo” or “Hi” as desired. If low speed
evaporator fan operation is selected, the user has the
3.3.8 Perishable Mode -- Conventional
The unit is capable of maintaining supply air
temperature to within +/- 0.25
degrees C
(+/- 0.5 degrees F) of set point. Supply air temperature
is controlled by positioning of the suction modulation
valve (SMV), cycling of the compressor, and cycling of
the heaters.
When pulling down from a temperature that is more than
5 degrees C (9 degrees F) above set point, the SMV will
open to reduce the pulldown time. However, pressure
and current limit functions may restrict the valve if either
exceeds the preset value.
The operational software is designed so the SMV will
begin to close as the set point is reached. The SMV will
continue to close and restrict refrigerant flow until the
capacity of the unit and the load are balanced.
If the temperature drops below the set point, the
compressor will remain running for a few minutes. This
is to accommodate any initial undershoot which might
occur. After this time has expired and the temperature is
0.2 degrees C (0.4 degrees F) or greater below the set
point, the compressor will be turned OFF.
If the temperature drops to 0.5 degrees C
(0.9 degrees F) below set point, the heaters will be
energized. The heaters will de-energize when the
temperature rises to 0.2 degrees C (0.4 degrees F)
below the set point. The compressor will not restart until
the temperature rises to 0.2 degrees C (0.4 degrees F)
above the set point and three minutes have elapsed
since the last compressor turn off.
3.3.9 Perishable Mode -- Economy
The economy mode is an extension of the conventional
mode and is applicable to units with two speed
evaporator fan motors. The mode is activated when the
setting of function code Cd34 is “ON.“ Economy mode is
provided for power saving purposes. Economy mode
could be utilized in the transportation of temperature
tolerant cargo or non-respiration items that do not
require high airflow for removing respiration heat. There
is no active display indicator that economy mode has
been activated. To check for economy mode, perform a
manual display of code Cd34.
In order to achieve economy mode, a perishable set
point must be selected prior to activation. When
economy mode is active, the evaporator fans will be
controlled as follows:
At the start of each cooling or heating cycle, the
evaporator fans will be run in high speed for three
minutes. They will then be switched to low speed any
time the supply air temperature is within +/- 0.25
degrees C (0.45 degrees F) of the set point and the
return air temperature is less than or equal to the supply
air temperature + 3 degrees C (5.4 degrees F). 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.
3.3.10 Perishable Mode -- Dehumidification
The dehumidification mode is provided to reduce the
humidity levels inside the container. The mode is
activated when a humidity value is set at at function
code Cd33. The display module SUPPLY LED will flash
ON and OFF every second to indicate that the
dehumidification mode is active. Once the mode is
active and the following conditions are satisfied, the
3--5
T-318
additional capability of selecting dehumidification set
points from 60 to 95% (instead of the normal 65 to 95%).
NOTE
On start up of the unit, SMV will reset to a known
open position. This is accomplished by assuming the valve was fully open, driving it fully
closed, resetting the percentage open to zero,
then opening to a known 21% staging position.
In addition, if bulb mode is active, function code Cd37
may be set to override the previous defrost termination
thermostat settings (refer to paragraph 4.10.4) The
temperature at which the defrost termination thermostat
will be considered “open” may be changed [in 0.1
degrees C (0.2 degrees F) increments] to any value
between 25.6 C (78 F) and 4 C (39.2 F). The
temperature at which the defrost termination thermostat
is considered closed for interval timer start or demand
defrost is 10 C (50 F) for “open” values from 25.6 C down
to a 10 C setting. For “open” values lower than 10 C, the
“closed” values will decrease to the same value as the
“open” setting.
To prevent rapid cycling of the compressor, a three
minute compressor off time must be satisfied before the
compressor will restart. Under a condition of rapidly
changing return air temperature, the time delay may
allow the return air temperature to rise slightly above set
point temperature before the compressor can restart.
3.3.14 Frozen Mode -- Economy
In order to activate economy frozen mode operation, a
frozen set point temperature must be selected. The
economy mode is active when function code Cd34 is set
to “ON.” When economy mode frozen 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
-2 degrees C. 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 set
point + 0.2 degrees C, the unit will restart the
refrigeration system and continue to cool until the
previously mentioned off-cycle temperature criteria are
met. If the control temperature is less than the set point
+ 0.2 degrees C, the unit will turn off the evaporator fans
and restart another 60 minute off-cycle.
Bulb mode is terminated when:
1. Bulb mode code Cd35 is set to “Nor.”
2. Dehumidification code Cd33 is set to “Off.”
3. The user changes the set point to one
that is in the frozen range.
When bulb mode is disabled by any of the above, the
evaporator fan operation for dehumidification reverts to
“alt” and the DTS termination setting resets to the value
determined by controller configuration variable CnF41.
3.3.12 Temperature Control -- Frozen Mode
With configuration variable CnF26 set to -10 C, the
frozen mode of operation is active with set points at or
below -10 C (+14 F). With the variable set to -5 C, the
frozen mode is active at or below -5 C (+23 F).
3.4 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, page 3--18.
When in the frozen mode, the controller maintains the
return air temperature at set point, the RETURN
indicator light will be illuminated on the display module,
and the default reading on the display window will be the
return air probe reading.
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.
When the return air temperature enters the in-range
temperature tolerance as selected at function code
Cd30, the in-range light will energize.
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.
3.3.13 Frozen Mode -- Conventional
Frozen range cargoes are not sensitive to minor
temperature changes. The method of temperature
control employed in this range takes advantage of this
fact to greatly improve the energy efficiency of the unit.
Temperature control in the frozen range is
accomplished by cycling the compressor on and off as
the load demand requires. The unit will operate in the
conventional frozen mode when the controller set point
is at or below the frozen range and function code CD34
is set to “OFF.”
An alarm is indicated by flashing an alarm code on the
display panel, and for some alarms, by the alarm light
illuminating.
When an Alarm Occurs:
a. The red alarm light will illuminate for “20 series”
alarms.
If the return air temperature in the container drops 0.2
degrees C (0.4 degrees F) below the set point, the
compressor is cycled off. When the temperature is
greater than 0.2 degrees C (0.4 degrees F) above the
set point and the three minute time delay has been met,
the compressor will restart. The unit will always operate
at full capacity and the suction modulation valve will
open as allowed by current and pressure limiting.
T-318
b. If a detectable problem is found to exist, its alarm
code will be alternately displayed with the set point on
the left display.
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.
3--6
To Display Alarm Codes:
A detailed description of the pre-trip tests and test codes
is provided in Table 3-9, page 3--21. Detailed operating
instructions are provided in paragraph 4.8.
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.
3.6 DataCORDER
3.6.1 Description
The Carrier Transicold “DataCORDER” software is
integrated into the controller and serves to eliminate the
temperature recorder and paper chart. The
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 Data Reader to download data. A personal
computer with Carrier Transicold Data View software
may also be used to download data and configure
settings. The DataCORDER consists of:
S Configuration Software
S Operational Software
S Data Storage Memory
S Battery Low (Battery Pack)
S Real--Time Clock (with internal battery backup)
S Six thermistor inputs
S Interrogation Connections
S Power Supply (battery pack)
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.
c. The left display will show “AL##,” where ## is the
alarm number sequentially in the queue.
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 (refer to Table 3-6, page 3--18).
e. “END” is displayed to indicate the end of the alarm list
if any alarms are active.
f. “CLEAr” is displayed if all alarms are inactive. The
alarm queue may than be cleared by pressing the ENTER key. The alarm list will clear and “ -- -- -- -- -- ” will
be displayed.
NOTE
AL26 is active when all of the sensors are not responding. Check the connector at the back of the
controller, if it is loose or unplugged, reconnect it.
Then run a pretrip test (P5) to clear AL26.
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:
S Container ID Change
S Software Upgrades
S Alarm Activity
S Battery Low (Battery Pack)
S Data Retrieval
S Defrost Start and End
S Dehumidification Start and End
S Power Loss (w/wo battery pack)
S Power Up (w/wo battery pack)
S Remote Probe Temperatures in the Container
(USDA cold treatment and cargo probe recording)
S Return Air Temperature
S Set Point Change
S Supply Air Temperature
S Real Time Clock Battery (Internal Battery)
Replacement
S Real--Time Clock Modification
S Trip Start
S ISO Trip Header (When entered via Interrogation
program)
S Economy Mode Start and End
S “Auto 2” Pre-Trip Start and End
S Bulb Mode Start
S Bulb Mode changes
S Bulb Mode End
S USDA Trip Comment
S Humidification Start and End
S USDA Probe Calibration
3.6.2 DataCORDER Software
The DataCORDER Software is subdivided into the
configuration software, operational software and the
Data Memory.
3.5 UNIT PRE-TRIP DIAGNOSTICS
Pre-trip diagnostics is an independent controller
function that will suspend normal refrigeration controller
activities and provide preprogrammed test routines.
The test routines include Auto Mode testing, which
automatically preforms a pre programmed sequenced
of tests or Manual Mode testing, which allows the
operator to select and run any of the individual tests.
CAUTION
Pre-trip inspection should not be performed with critical temperature cargoes in
the container.
CAUTION
When Pre-Trip key is pressed, dehumidification and bulb mode will be deactivated.
At the completion of Pre-Trip activity, dehumidification and bulb mode must be reactivated.
Testing 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).
At the end of a pre-trip test, the message “P,” “rSLts”
(pretest results) will be displayed. Pressing the ENTER
key will allow the user to see the results for all subtests.
The results will be displayed as “PASS” or “FAIL” for all
the tests run to completion.
3--7
T-318
3. If a longer time is desired, press the ENTER key to extend the 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 the
same configuration card as the unit control module
software. Changes to the software may be made made
using the Data View integration device. A listing of the
configuration variables is provided in Table 3-2.
Descriptions of DataCORDER operation for each
variable setting are provided in the following
paragraphs.
a. Operational Software
The operational software reads and interprets inputs for
use by the configuration software. The inputs are
labeled Function Codes. There are 35 functions (see
Table 3-10, page 3--25), 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 & 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.
Table 3-2 DataCORDER Configuration Variables
CONFIGURATION NO.
dCF01
dCF02
dCF03
dCF04
dCF05
dCF06
dCF07
dCF08
dCF09
dCF10
TITLE
(Future Use)
Sensor Configuration
Logging Interval (Minutes)
Thermistor Format
Thermistor Sampling Type
Controlled Atmosphere/Humidity Sampling Type
Alarm Configuration USDA Sensor 1
Alarm Configuration USDA Sensor 2
Alarm Configuration USDA Sensor 3
Alarm Configuration Cargo Sensor
OPTION
---2,5,6,9,54,64,94
15,30,60,120
Low, Normal
A,b,C
A,b
Auto, On, Off
Auto, On, Off
Auto, On, Off
Auto, On, Off
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.
1. Control mode
2. Control temperature
3. Frequency
4. Humidity
5. Phase A current
6. Phase B current
7. Phase C current
8. Main voltage
9. Suction modulation valve percentage
10. Discrete outputs (See Note )
11. Discrete inputs (See Note )
12. Ambient sensor
13. Compressor suction sensor
14. Compressor discharge sensor
15. Return temperature sensor
16. Supply temperature sensor
17 Defrost temperature sensor
18. Discharge pressure transducer
19. Suction pressure transducer
20. Condenser pressure transducer
3.6.3 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 six thermistor inputs (supply, return, USDA #1, #2,
#3, and cargo probe) and the humidity sensor input will
be generated by the DataCORDER. An example of a
report using a standard configuration is shown in
Figure 3-5.
NOTE
The DataCORDER software uses the supply
and return recorder sensors. The temperature
control software uses the supply and return
temperature sensors.
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
T-318
DEFAULT
---2
60
Short
A
A
A
A
A
A
Note: Bitmapped -- require special handling if used
3--8
If a probe alarm is configured to OFF, then the alarm for
this probe is always disabled.
Table 3-3 DataCORDER Standard Configurations
Standard
Config.
2 sensors
(dCF02=2)
5 sensors
(dCF02=5)
6 sensors
(dCF02=6)
9 sensors
(dCF02=9)
Description
If a probe alarm is configured to ON, then the associated
alarm is always enabled.
2 thermistor inputs(supply & return)
If the probes are configured to AUTO, they act as a
group. This function is designed to assist users who
keep their 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, then all of the
alarms are enabled and the remaining probes that are
not installed will give active alarm indications.
2 thermistor inputs(supply & return)
3 USDA thermistor inputs
2 thermistor inputs(supply & return)
3 USDA thermistor inputs
1 humidity input
Not Applicable
The DataCORDER will record the initiation of a pre-trip
test (refer to paragraph 3.5) and the results of each of
the tests included in pre-trip. The data is time-stamped
and may be extracted via the Data Retrieval program.
Refer to Table 3-11, page 3--26 for a description of the
data stored in the DataCORDER for each
corresponding pre-trip test.
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)
3.6.8
2 thermistor inputs(supply & return)
3 USDA thermistor inputs
10 sensors
humidity input
(dCF02=94) 1
1 cargo probe (thermistor input)
3 CA inputs (NOT APPLICABLE)
DataCORDER Power-Up
The DataCORDER may be powered up in any one of
four ways:
1. Normal AC power: The DataCORDER is powered
up when the unit is turned on via the stop-start switch.
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.
3.6.4 Logging Interval (dCF03)
The user may configure four 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.
3.6.5 Thermistor Format (dCF04)
The user may configure the format in which the
thermistor readings are recorded. The low resolution is
a 1 byte format and the normal resolution is a 2 byte
format. The low resolution requires less memory and
records temperature in 0.25 degrees C (0.45 degrees F)
increments when in perishable mode or 0.5 degrees C
(0.9 degrees F) increments when in the frozen mode.
The normal resolution records temperature in 0.01
degrees C (0.02 degrees F) increments for the entire
range.
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.
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.
3.6.6 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, the supply and
return temperature readings are averaged and the three
USDA probe readings are snapshot.
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, the
battery pack needs replacement.
3.6.7 Alarm Configuration (dCF07 -- dCF10)
The USDA and cargo probe alarms may be configured
to OFF, ON or AUTO.
3--9
T-318
Raw Data Report for ABC1234567
May 31, 2003 to Jun 04, 2003
System Configuration at the Time of Interrogation:
Interrogated On Sept 05, 2003
Extracted by DataLine Rev 1.0.0
Controller Software: 5120
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, 2001
Setpoint: 1.66, Container :
Serial : 04189552
9 Sensors Logged at 15 Minute Interval
Sensor
Format
Resolution
Figure 3-5 Standard Configuration Report
T-318
3--10
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.
3.6.9 Pre-Trip Data Recording
The DataCORDER will record the initiation of a pre-trip
test (refer to paragraph 3.5) and the results of each of
the tests included in pre-trip. The data is time-stamped
and may be extracted via the Data Retrieval program.
Refer to Table 3-11 for a description of the data stored in
the DataCORDER for each corresponding pre-trip test.
b. 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. With a remote monitoring unit 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.
3.6.10 DataCORDER Communications
Data retrieval from the DataCORDER can be
accomplished by using one of the following;
DataReader, DataLine/DataView or a communications
interface module.
NOTE
A DataReader, DataLine/DataView, 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:
1.
3.6.11 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 2.2 C (36 F)
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 setpoint and record minute changes
in product temperature within the DataCORDER
memory, thus meeting USDA criteria. Information on
USDA is provided in the following subparagraphs
Bad cable or connection between
DataCORDER and data retrieval device.
2. PC communication port(s) unavailable or
misassigned.
3. Chart Recorder Fuse (FCR) blown.
a. DataReader
The Carrier Transicold Data Reader (see Figure 3-6) is
a simple to operate hand held device designed to extract
data from the DataCORDER and then upload it to a
personal computer. The Data Reader has the ability to
store multiple data files. Refer to Data Retrieval manual
62-10629 for a more detailed explanation of the
DataReader.
a. USDA Recording
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 three-pin
receptacles are for the probes and fifth, five-pin,
receptacle is the rear connection for the 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.
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.
b. USDA/ Message Trip Comment
A special feature is incorporated which allows the user
to enter a USDA (or other) message at the head of a
data report. The maximum message length is 78
characters. Only one message will be recorded per day.
3.6.12 USDA Cold Treatment Procedure
The following is a summary of the steps required to
initiate a USDA Cold Treatment:
a. Calibrate the three USDA probes by ice bathing the
probes and performing the calibration function with
the DataReader or a personal computer. 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.
DataReader
Figure 3-6 Data Reader
b.
DataBANKTM
Card
DataBANKTM
The
card is a PCMCIA card that
interfaces with the controller through the programming
slot and can download data at a much faster rate when
compared to the PC or DataReader. Files downloaded
to the DataBANK card files are accessible through an
Omni PC Card Drive. The files can then be viewed using
the DataLine software.
c DataLine
The DataLINE software for a personal computer is
supplied on both floppy disks and CD. This software
allows interrogation, configuration variable assignment,
3--11
T-318
b. Pre-cool the container to the treatment temperature
or below.
c. Install the DataCORDER module battery pack (if not
already installed).
d. Place the three probes. The probes are placed into
the pulp of the fruit (at the locations defined in the following table) as the product is loaded.
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 conor three feet from the end of the
Sensor 2 tainers,
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 containor three feet from the end of the load
Sensor 3 ers
for 20--foot containers. This probe
should be placed in a carton at a side
wall at one-half the height of the load.
e. To initiate USDA Recording, connect the personal
computer and perform the configuration as follows:
1. Fill in ISO header information
2. Add a trip comment if desired
3. Configure for five probes (s, r, P1, P2, P3)
4. Configure for one--hour logging interval
5. Set the sensor configuration at USDA
6. Configure for two byte memory storage format
7. Do a trip start
3.6.13 DataCORDER Alarms
Sensor 1
Alarm display is an independent DataCORDER
function. If an operating parameter is outside of the
expected range or a component does not return the
T-318
correct signals back 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 3-12, page 3--27. Refer to paragraph
3.6.7 for configuration information.
To display alarm codes:
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.
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:
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.
5. Upon clearing of the Alarm Queue, the Alarm light will
be turned off.
3--12
Table 3-4 Controller Configuration Variables
CONFIGURATION
NUMBER
TITLE
DEFAULT
OPTION
CnF01
Bypass Valve Enable
In
Out
CnF02
Evaporator Fan Speed
dS (Dual)
SS (Single)
CnF03
Control Sensors
FOUr
duAL
CnF04
Dehumidification Mode
On
OFF
CnF05
Reserved for future use
---------n/a
CnF06
Condenser Fan Speed Select
OFF (Single)
On (Variable)
CnF07
Unit Selection, 20FT/ 40FT/45FT
40ft
20ft,45
CnF08
Single Phase/Three Phase Motor
1Ph
3Ph
CnF09
Refrigerant Selection
r134a
r12, r22, bLEnd
CnF10
Two Speed Compressor Logic
Out (Single)
In (Dual)
CnF11
Defrost “Off” Selection
noOFF
OFF
CnF12
TXV/Solenoid Quench Valve
Out (TXV)
In (Solenoid)
CnF13
Unloader
Out
In
CnF14
Condenser Pressure Control (CPC)
In
Out
CnF15
Discharge Temperature Sensor
Out
In
CnF16
DataCORDER Present
On (Yes)
OFF (No)
CnF17
Discharge Pressure Sensor
Out (No)
In (Yes)
CnF18
Heater
Old (Low Watt)
nEW (High Watt)
CnF19
Controlled Atmosphere
Out (No)
In (Yes)
CnF20
Suction Pressure Sensor
Out (No)
In (Yes)
CnF21
Autotransformer
Out
In
CnF22
Economy Mode Option
OFF
Standard, Full
CnF23
Defrost Interval Timer Save Option
noSAv
SAv
CnF24
Advanced Pre-Trip Enhanced Test Series Option
Auto
Auto2, Auto 3
CnF25
Pre-Trip Test Points/Results Recording Option
rSLtS
dAtA
CnF26
Heat Lockout Change Option
Set to -10 C
Set to -5 C
CnF27
Suction Temperature Display Option
Out
In
CnF28
Bulb Mode Option
NOr
bULb
CnF29
Arctic Mode
Out
In
CnF30
Compressor Size
41 CFM
37 CFM
CnF31
Probe Check Option
Standard
SPEC
CnF32
Single Evaporator Fan Option
2EF0
1EF0
CnF33
Snap Freeze Option
OFF
SnAP
CnF34
Degree Celsius Lockout Option
bOth
F
CnF35
Humidification Mode
OFF
On
CnF36
SMV Type
1 (standard)
2, 3 (stepper)
CnF37
Electronic Temperature Recorder
rEtUR
SUPPL, bOth
CnF38
Quench Bypass Valve
Out
In
CnF39
Expanded Current Limit Range
Out
In
CnF40
Demand Defrost
Out
In
CnF41
Lower DTT Setting
Out
In
CnF42
Auto Pre-trip Start
Out
In
CnF47
Fresh Air Vent Position Sensor
OFF
UPP, LOW
CnF48
CFS Override
OFF
On
CnF49
Datacorder Configuration Restore
OFF
On
CnF50
Enhanced Bulb Mode Selection
OFF
Bulb, dEHUM
CnF51
Timed Defrost Disable
0
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--13
T-318
Table 3-5 Controller Function Codes (Sheet 1 of 4)
Code
No.
TITLE
DESCRIPTION
Note: If the function is not applicable, the display will read “-- -- -- -- -- ”
Display Only Functions
Suction Modulation
Cd01 Valve Opening (%)
Displays the SMV percent open. The right display reads 100% when the valve is
fully open and 0% when the valve is fully closed. The valve will usually be at 21%
on start up of the unit except in very high ambient temperatures.
Cd02 Quench Valve
Displays state of the solenoid quench valve, open or closed.
Cd03 Not Applicable
Not used
Cd04 Line Current,
Phase A
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.
Cd05 Line Current,
Phase B
Cd06 Line Current,
Phase C
Cd07 Main Power Voltage
The main supply voltage is displayed.
Main Power FreCd08 quency
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 TemperaCd09 ture
The ambient sensor reading is displayed.
Compressor Suction
Cd10 Temperature
Compressor suction temperature sensor reading is displayed.
Compressor DisCd11 charge Temperature
Compressor discharge temperature sensor reading is displayed.
Compressor Suction
Cd12 Pressure
Compressor suction pressure transducer reading is displayed.
Cd13 Condenser Pressure Condenser pressure transducer reading is displayed.
Compressor DisCd14 charge Pressure
Compressor discharge pressure transducer reading is displayed.
UnloaderValve(On-Cd15 Off)
Not used in this application
Compressor Motor
Cd16 Hour Meter
Records total hours of compressor run time. Total hours are recorded in increments of 10 hours (i.e., 3000 hours is displayed as 300).
Relative Humidity
Cd17 (%)
Humidity sensor reading is displayed. This code displays the relative humidity, as
a percent value.
Cd18 Software Revision #
The software revision number is displayed.
Cd19 Battery Check
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.
Cd20 Config/Model #
This code indicates the dash number of the model for which the Controller is
configured (i.e., if the unit is a 69NT40-541-100, the display will show “41100”).
Humidity Water
Cd21 Pump/Atomizer
Status
This code displays the status of the humidity water pump (-- -- -- -- -- , forward,
reverse or off). If not configured, the mode is permanently deactivated and will
display “-- -- -- -- -- .”
Cd22 Compressor Speed
The status of the compressor is displayed (high, low or off).
Cd23 Evaporator Fan
Displays the current evaporator fan state (high, low or off).
T-318
3--14
Table 3-5 Controller Function Codes (Sheet 2 of 4)
Code
No.
TITLE
Controlled
Cd24 Atmosphere State
Compressor Run
Cd25 Time Remaining Until Defrost
Defrost Temperature
Cd26 Sensor Reading
DESCRIPTION
Not used in this application
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 sensor reading is displayed.
Configurable Functions
NOTE
Function codes Cd27 through Cd37 are user-selectable functions. The operator can change the value of
these functions to meet the operational needs of the container.
There are two modes for defrost initiation, either user-selected timed intervals or
automatic control. The user-selected values are (OFF), 3, 6, 9, 12, or 24 hours
while the factory default is 12 hours. 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 a defrost, the time will not begin counting down until the defrost temperature sensor (DTS) reading falls below set point. If the reading of DTS rises above
set point any time during the timer count down, the interval is reset and the
countdown begins over. If DTS fails, alarm code AL60 is activated and control
switches over to the the return temperature sensor. The controller will act in the
Defrost Interval
Cd27 (Hours or Automatic) same manner as with the DTS except the return temperature sensor reading will
be used.
Defrost Interval Timer Value (Configuration variable CnF23): If the software is
configured to “SAv” (save) for this option, 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.
NOTE
The defrost interval timer counts only during compressor run time.
Temperature Units
Cd28 (Degrees C or Degrees F)
This code determines the temperature units (C or F) which 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.
NOTE
This function code will display “--- --- --- --- ---“ if Configuration Variable CnF34 is
set to degrees 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 (stepper motor SMV at maximum allowed opening)
B -- Partial Cooling (stepper motor SMV 11% open)
C -- Evaporator Fan Only
D -- Full System Shutdown -- Factory Default
Cd30 In-Range Tolerance
The in-range tolerance will determine the band of temperatures around the set
point which will be designated as in-range. If the control temperature is in-range,
the in-range light will be illuminated. 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
3--15
T-318
Table 3-5 Controller Function Codes (Sheet 3 of 4)
Code
No.
TITLE
Stagger Start Offset
Cd31 Time (Seconds)
DESCRIPTION
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
Perishable Mode
Dehumidification/HuCd33 midification Control
(% RH)
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. This is
accomplished by reducing the SMV position until current draw is reduced to the
set point. When desirable, the limit can be lowered. Note, however, that capacity
is also reduced. The five values for 460 VAC operation are:
15, 17, 19, 21 (Factory Default), 23
Relative humidity set point is available only on units configured for dehumidification. When the mode is activated, the control probe LED flashes on and off every
second to alert the user. If not configured, the mode is permanently deactivated
and “-- -- -- -- -- ” will display. The value can be set to “OFF.” “TEST,” or a range of
65 to 95% relative humidity in increments of 1%. [If bulb mode is active (code
Cd35) and “Lo” speed evaporator motors are selected (code Cd36) then set point
ranges from 60 to 95%.] When “TEST” is selected or test set point is entered, the
heat LED should illuminate, indicating that dehumidification mode is activated.
After a period of five minutes in the “TEST” mode has elapsed, the previously
selected mode is reinstated.
Economy Mode
Cd34 (On--Off)
NOTE
If humidification (CnF35) is enabled, then humidification will be enabled and
dehumidification locked out at set points of 75% and above. At set points below 75%, dehumidification will be enabled and dehumidification locked out.
Economy mode is a user selectable mode of operation provided for power saving
purposes.
Current Limit
Cd32 (Amperes)
Cd35 Bulb Mode
Evaporator Speed
Cd36 Select
Defrost Termination
Cd37 Temperature Setting
(Bulb Mode)
T-318
Bulb mode is a user selectable mode of operation that is an extension of dehumidification control (Cd33). If dehumidification is set to “Off,” code Cd35 will
display “Nor” and the user will be unable to change it. After a dehumidification set
point has been selected and entered for code Cd33, the user may then change
code Cd35 to “bulb.” After bulb has been selected and entered, the user may then
utilize function codes Cd36 and Cd37 to make the desired changes.
This code is enabled only if in the dehumidification mode (code 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
display 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 code, as with function code Cd36, is used in conjunction with bulb mode and
dehumidification. If bulb mode is active, this code allows the user to change the
defrost termination thermostat settings. If bulb mode is deactivated, the DTS
setting returns to the default.
3--16
Table 3-5 Controller Function Codes (Sheet 4 of 4)
Code
No.
TITLE
DESCRIPTION
Secondary Supply
Cd38 Temperature Sensor
Code Cd38 will display the current secondary supply temperature sensor reading
for units configured for four probes. If the unit is configured with a DataCORDER,
Cd38 will display “-- -- -- -- -- .” If the DataCORDER suffers a failure, (AL55) Cd38
will display the supply recorder sensor reading.
Secondary Return
Cd39 Temperature Sensor
Code Cd39 will display the current secondary return temperature sensor reading
for units configured for four probes. If the unit is configured with a DataCORDER,
Cd39 will display “-- -- -- -- -- .” If the DataCORDER suffers a failure, (AL55) Cd39
will display the return recorder sensor reading.
Container IdentificaCd40 tion Number
Code 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
Cd42 Not Applicable
Scroll Units Only
Code 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).
Cd43 AutoFresh Mode
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 “--------”
Code Cd44 will display CO2 and O2 concentrations and limits. If the unit is not
configured for AutoFresh or a CO2 sensor is not installed, CD44 will display
Cd44 AutoFresh Values
“--------”
Code Cd45 will display whenever the control detects movement via the sensor
Vent Position Sensor unless alarm 50 is active. The code will display for 30 seconds, then time out and
Cd45 (VPS)
return to the normal display mode. If the Temperature unit is degrees F, the VPS
units will be CFM and in degrees C the VPS units shall be CMH.
Cd46 Not Used
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.
Dehumidification/Cd48 Bulb Mode
Parameter Selection
Days Since Last
Cd49 Successful Pre-trip
Code CD48 is used to determine limits (between 60%-95%) for dehumidification
and/or bulb mode (CNF28) when active.
Code CD49 will display the number of days since the last successful Auto1,
Auto2 or Auto3 pre-trip sequence.
3--17
T-318
Table 3-6 Controller Alarm Indications (Sheet 1 of 3)
Code
No.
TITLE
DESCRIPTION
Evaporator Motor 1
AL11 IP Trip
Alarm 11 is applicable to units with Single Evaporator Fan Capability (CnF32 set
to 1EFO) only. The alarm is triggered if the evaporator fan motor #1 internal
protector opens. If the alarm is active, probe check is deactivated.
Evaporator Motor 2
AL12 IP Trip
Alarm 12 is applicable to units with Single Evaporator Fan Capability (CnF32 set
to 1EFO) only. The alarm is triggered if the evaporator fan motor #2 internal
protector opens. If the alarm is active, probe check is deactivated.
Control Circuit Fuse
AL20 Open (24 vac)
Alarm 20 is triggered by control power fuse (F3A, F3B) opening and will cause
the software shutdown of all control units. This alarm will remain active until the
fuse is replaced.
Micro Circuit Fuse
AL21 Open (18 vac)
Alarm 21 is triggered by one of the fuses (F1/F2) being opened on 18 volts AC
power supply to the Controller. The suction modulation valve (SMV) will be
opened and current limiting is halted. Temperature control will be maintained by
cycling the compressor.
Evaporator Fan MoAL22 tor Safety
Alarm 22 responds to the evaporator motor internal protectors. On units with
Normal Evaporator Fan Operation (CnF32 set to 2EFO) the alarm is triggered by
opening of either internal protector. It will disable all control units until the motor
protector resets. On units with Single Evaporator Fan Capability (CnF32 set to
1EFO), the alarm is triggered by opening of both internal protectors. It will disable
all control units until a motor protector resets.
Compressor Motor
AL24 Safety
Alarm 24 is triggered by the opening of the compressor motor internal protector.
This alarm will disable all control units except for the evaporator fans and will
remain active until the motor protector resets. This alarm triggers the failure
action code set by Function Code Cd29.
Condenser Fan MoAL25 tor Safety
Alarm 25 is triggered by the opening of the condenser motor internal protector
and will disable all control units except for the evaporator fans. This alarm will
remain active until the motor protector resets. This alarm is deactivated if the unit
is operating on water cooled condensing.
All Supply and Return temperature
AL26 Control Sensors
Failure
Alarm 26 is triggered if the Controller determines that all of the control sensors
are out-of-range. This can occur for box temperatures outside the range of -50 C
to +70 C (-58 F to +158 F). This alarm triggers the failure action code set by
Function Code Cd29.
Probe Circuit CalAL27 ibration Failure
The Controller has a built-in Analog to Digital (A-D) converter, used to convert
analog readings (i.e. temperature sensors, current sensors, etc.) to digital readings. The Controller continuously performs calibration tests on the A-D converter.
If the A-D converter fails to calibrate for 30 consecutive seconds, this alarm is
activated.This alarm will be inactivated as soon as the A-D converter calibrates.
Fresh Air Position
AL50 Sensor (VPS)
Alarm 50 is activated whenever the sensor is outside the valid range. There is a
five minute adjustment period where the user can change the vent position
without generating an alarm event. The sensor requires five minutes of no movement to confirm stability. If the vent position changes at any point beyond the five
minute adjustment period, the sensor will generate an alarm event. The alarm is
triggered off when the unit power cycles and the sensor is within valid range.
AL51 Alarm List Failure
During start-up diagnostics, the EEPROM is examined to determine validity of its
contents. This is done by testing the set point and the alarm list. If the contents
are invalid, Alarm 51 is activated. During control processing, any operation
involving alarm list activity that results in an error will cause Alarm 51 to be
activated. Alarm 51 is a “display only” alarm and is not written into the alarm list.
Pressing the ENTER key when “CLEAr” is displayed will result in an attempt to
clear the alarm list. If that action is successful (all alarms are inactive), Alarm 51
will be reset.
AL52 Alarm List Full
Alarm 52 is activated whenever the alarm list is determined to be full; at start-up
or after recording an alarm in the list. Alarm 52 is displayed, but is not recorded in
the alarm list. This alarm can be reset by clearing the alarm list. This can be done
only if all alarms written in the list are inactive.
AL53 Battery Pack Failure
Alarm 53 is caused by the battery pack charge being too low to provide sufficient
power for battery-backed recording. Renew replaceable batteries. 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 to deactivate the alarm
T-318
3--18
Table 3-7 Controller Alarm Indications (Sheet 2 of 3)
Code
No.
TITLE
DESCRIPTION
Alarm 54 is activated by an invalid primary supply temperature sensor reading
that is sensed outside the range of -50 to +70 C (-58 F to +158 F) or if the probe
check logic has determined there is a fault with this sensor. If Alarm 54 is activated and the primary supply is the control sensor, the secondary supply sensor
Primary Supply Tem- will be used for control if the unit is so equipped. If the unit does not have a
AL54 perature Sensor
secondary supply temperature sensor, and AL54 is activated, the primary return
Failure (STS)
sensor reading, minus 2 C will be used for control.
NOTE
The P5 Pre-Trip test must be run to inactivate the alarm
Alarm 56 is activated by an invalid primary return temperature sensor reading
that is outside the range of -50 to +70 C (-58 F to +158 F). If Alarm 56 is activated and the primary return is the control sensor, the secondary return sensor
Primary Return Tem- will be used for control if the unit is so equipped. If the unit is not equipped with a
secondary return temperature sensor or it fails, the primary supply sensor will be
AL56 perature Sensor
used for control.
Failure (RTS)
Ambient TemperaAL57 ture Sensor Failure
NOTE
The P5 Pre-Trip test must be run to inactivate the alarm.
Alarm 57 is triggered by an ambient temperature reading outside the valid range
from -50 to +70 C (-58 F to +158 F).
Alarm 58 is triggered when the compressor high discharge pressure safety switch
remains open for at least one minute. This alarm will remain active until the
pressure switch resets, at which time the compressor will restart.
Alarm 59 is triggered by the opening of the heat termination thermostat and will
Heat Termination
result in the disabling of the heater. This alarm will remain active until the thermoAL59 Thermostat
stat resets.
Alarm 60 is an indication of a probable failure of the defrost temperature sensor
(DTS). It is triggered by the opening of the heat termination thermostat (HTT) or
the failure of the DTS to go above set point within two hours of defrost initiation.
Defrost Temperature After one-half hour with a frozen range set point, or one-half hour of continuous
AL60 Sensor Failure
compressor run time, if the return air falls below 7 C (45 F), the Controller checks
to ensure the DTS reading has dropped to 10 C or below. If not, a DTS failure
alarm is given and the defrost mode is operated using the return temperature
sensor. The defrost mode will be terminated after one hour by the Controller.
Alarm 61 is triggered by detection of improper amperage resulting from heater
activation or deactivation. Each phase of the power source is checked for proper
AL61 Heaters Failure
amperage.This alarm is a display alarm with no resulting failure action, and will
be reset by a proper amp draw of the heater.
Compressor High
AL58 Pressure Safety
Compressor Circuit
AL62 Failure
AL63 Current Over Limit
Discharge TemperaAL64 ture Over Limit
Discharge Pressure
AL65 Transducer Failure
Alarm 62 is triggered by improper current draw increase (or decrease) resulting
from compressor turn on (or off). The compressor is expected to draw a minimum of 2 amps; failure to do so will activate the alarm.This is a display alarm
with no associated failure action and will be reset by a proper amp draw of the
compressor.
Alarm 63 is triggered by the current limiting system. If the compressor is ON and
current limiting procedures cannot maintain a current level below the user selected limit, the current limit alarm is activated.This alarm is a display alarm and
is inactivated by power cycling the unit, changing the current limit via the code
select Cd32, or if the suction modulation valve (SMV) is open beyond the controller desired point.
Alarm 64 is triggered if the discharge temperature sensed is greater than 135 C
(275 F) for three continuous minutes, if it exceeds 149 C (300 F), or if the sensor
is out of range. This is a display alarm and has no associated failure action.
Alarm 65 is triggered by a compressor discharge transducer reading outside the
valid range of 73.20 cm Hg (30 in Hg) to 32.34 Kg/cm2 (460 psig). This is a
display alarm and has no associated failure action.
3--19
T-318
Table 3-8 Controller Alarm Indications (Sheet 3 of 3)
Code
No.
TITLE
DESCRIPTION
Suction Pressure
AL66 Transducer Failure
Alarm 66 is triggered by a suction pressure transducer reading outside the valid
range of 73.20 cm Hg (30 in Hg) to 32.34 Kg/cm2 (460 psig). This is a display
alarm and has no associated failure action.
Humidity Sensor
AL67 Failure
Alarm 67 is triggered by a humidity sensor reading outside the valid range of 0%
to 100% relative humidity. If alarm AL67 is triggered when the dehumidification
mode is activated, then the dehumidification mode will be deactivated.
reading outside the
Condenser Pressure Alarm 68 is triggered by a condenser pressure transducer
valid range of 73.20 cm Hg (30 in Hg) to 32.34 Kg/cm2 (460 psig). This is a
AL68 Transducer Failure
display alarm and has no associated failure action.
Suction Temperature Alarm 69 is triggered by a suction temperature sensor reading outside the valid
range of -60 C (-76 F) to 150 C (302 F). This is a display alarm and has no
AL69 Sensor Failure
associated failure action.
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.
ERR
#
Internal
Microprocessor
Failure
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.
ERR
#
Internal
Microprocessor
Failure
ERROR
DESCRIPTION
Indicates that the controller working memory has
failed.
ERR 0 -- RAM failure
EER 1 -failure
EER 2 -time-out
EER 3 -EER 4 --
Program Memory
Indicates a problem with the controller program.
ERR
#
Internal
Microprocessor
Failure
The controller program has entered a mode whereby
the controller program has stopped executing.
N/A
N/A
N/A
N/A
The Controller’s Analog to Digital (A-D) converter
EER 5 -- A-D failure
has failed.
EER 6 -- IO Board failure
Internal program/update failure.
EER 7 -- Controller failure Internal version/firmware incompatible.
EER 8--DataCorder failure Internal DataCorder memory failure.
EER -- 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 EER code using Morse code as shown below.
E R R 0 to 9ERR0 = . .--. .--. ---------ERR1 = . .--. .--. . -------ERR2 = . .--. .--. . . -----ERR3 = . .--. .--. . . . ---ERR4 = . .--. .--. . . . . -ERR5 = . .--. .--. . . . . .
ERR6 = . .--. .--. -- . . . .
ERR7 = . .--. .--. ---- . . .
ERR8 = . .--. .--. ------ . .
ERR9 = . .--. .--. -------- .
Entr
StPt
Enter Setpoint
(Press Arrow &
Enter)
The controller is prompting the operator to enter a set point.
LO
Low Main Voltage
(Function Codes
Cd27-38 disabled
and NO alarm
stored.)
This message will be alternately displayed with the set point whenever the supply
voltage is less than 75% of its proper value.
T-318
Watchdog
3--20
Table 3-9 Controller Pre-Trip Test Codes (Sheet 1 of 4)
Code
No.
TITLE
DESCRIPTION
NOTE
“Auto” or “Auto1” menu includes the: P, P1, P2, P3, P4, P5, P6 and rSLts. “Auto2” menu
includes P, P1, P2, P3, P4, P5, P6, P7, P8, P9, P10 and rSLts.“Auto3 menu includes P, P1, P2,
P3, P4, P5, P6, P7, P8 and rSLts
P
Pre-Trip Initiated
All lights and display segments will be energized for five seconds at the start of
the pre-trip. Since the unit cannot recognize lights and display failures, there are
no test codes or results associated with this phase of pre-trip.
P1-0
Heaters Turned On
Setup: Heater must start in the OFF condition, and then be turned on. A current
draw test is done after 15 seconds.
Pass/Fail Criteria: Passes if current draw change is within the range specified.
P1-1
Heaters Turned Off
Setup: Heater must start in the ON condition, and then be turned off. A current
draw test is done after 10 seconds.
Pass/Fail Criteria: Passes if current draw change is within the range specified.
P2-0
Condenser Fan On
Requirements: Water pressure switch (WP) input must be closed.
Setup: Condenser fan is turned ON, a current draw test is done after 15 seconds.
Pass/Fail Criteria: Passes if current draw change is within the range specified.
P2-1
Condenser Fan Off
Setup: Condenser fan is turned OFF, a current draw test is done after 10 seconds.
Pass/Fail Criteria: Passes if current draw change is within the range specified.
Requirements: The unit must be equipped with a low speed evaporator fan, as
determined by the Evaporator Fan speed select configuration variable.
P3
Low Speed Evaporator Fans
NOTE
If the unit is configured for single evaporator fan operation, Pre-Trip tests
P3-0, P3-1, P4-0 and P4-1 will fail immediately if Controller alarm codes
AL11 or AL12 are active at the start of testing.
P3-0
Setup: The high speed evaporator fans will be turned on for 10 seconds, then off
Low Speed Evapo- for two seconds, then the low speed evaporator fans are turned on. A current
rator Fan Motors On draw test is done after 60 seconds.
Pass/Fail Criteria: Passes if change in current draw is within the range specified. Fails if AL11 or AL12 activates during test.
P3-1
Setup: The low speed Evaporator Fan is turned off, a current draw test is done
Low Speed Evapo- after 10 seconds.
rator Fan Motors Off Pass/Fail Criteria: Passes if change in current draw is within the range specified. Fails if AL11 or AL12 activates during test.
P4-0
Setup: The high speed Evaporator Fan is turned on, a current draw test is done
High Speed Evapo- after 60 seconds.
rator Fan Motors On Pass/Fail Criteria: Passes if change in current draw is within the range specified. Fails if AL11 or AL12 activates during test.
P4-1
Setup: The high speed Evaporator Fan is turned off, a current draw test is done
High Speed Evapo- after 10 seconds.
rator Fan Motors Off Pass/Fail Criteria: Passes if change in current draw is within the range specified. Fails if AL11 or AL12 activates during test.
P5-0
Supply/Return Probe
Test
Setup: The High Speed Evaporator Fan is turned on and run for eight minutes,
with all other outputs de-energized.
Pass/Fail Criteria: A temperature comparison is made between the return and
supply probes.
NOTE
If this test fails, “P5-0” and “FAIL” will be displayed. If both Probe tests (this
test and the PRIMARY/ SECONDARY) pass, the display will read “P5”
“PASS.”
3--21
T-318
Table 3-9 Controller Pre-Trip Test Codes (Sheet 2 of 4)
Code
No.
TITLE
DESCRIPTION
Requirements: For units equipped with secondary supply probe only.
Pass/Fail Criteria: The temperature difference between primary and secondary
probe (supply) is compared.
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 ’P 5’ ’PASS’.
Requirements: For units equipped with secondary return probe only.
Pass/Fail Criteria: The temperature difference between primary and secondary
probe (return) is compared.
NOTES
P5-2
Return Probe Test
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.
P-6
P6-0
Compressor On
P6-H & P6L
P6-2
Suction Modulation
Valve (Open and
Closed)
P6-3
Quench Valve Test
P6-4
P6-5
Not Applicable
Not Applicable
Not Applicable
Setup: A current draw test is performed before the compressor is started. The
compressor is started. SMV is opened and another current draw test is performed.
Pass/Fail Criteria: Passes if the change in compressor current draw is within the
specified range.
Not Applicable
Setup: The compressor and fans continue to run from the previous test. The
quench valve (if configured) will operate as in normal control mode. The SMV is
closed to 0% open, current and condenser pressure readings are taken. The
SMV is opened to 50% with continuous current and condenser pressure readings taken to establish maximum values. The SMV is returned to 0% open and
final readings are taken.
Pass/Fail Criteria: Passes if the calculated difference in current at the 50%
open position are above a specified value before and after opening of the SMV,
OR the calculated difference in condenser pressure at the 50% open position are
above a specified value before and after opening of the SMV
Setup: The compressor suction temperature is measured with the Quench valve
closed. The Quench valve is energized and the suction temperature drop is
checked.
Pass/Fail Criteria: Passes if suction temperature is within the valid range.
Not Used
Not Used
NOTE
P7-0 & P8 are included with the “Auto2 & Auto 3” only. P9-0 through P10 are included with “Auto2” only
P7-0
T-318
High Pressure
Switch Closed
Setup: When the unit is running, the condenser fan is de-energized, and a 15
minute timer is started. The right display shows discharge pressure if the unit is
equipped with a discharge pressure transducer (DPT). If no DPT is installed, the
condenser pressure transducer (CPT) reading will be displayed.
Pass/Fail Criteria: The test fails if high pressure switch fails to open in 15
minutes.
3--22
Table 3-9 Temperature Controller Pre-Trip Test Codes (Sheet 3 of 4)
Code
No.
TITLE
DESCRIPTION
Note, this test is skipped if the unit does NOT have:
A compressor discharge sensor (CPDS).
A discharge pressure transducer (DPT).
Condenser pressure transducer (CPT).
In addition, this test is skipped if:
The sensed ambient temperature is less than 7 C (45 F).
The return air temperature is less than -17.8 C (0 F).
P7-0
High Pressure
Switch Closed
(Continued)
The water pressure switch (WP) is open, indicating that the unit is operating
with a water-cooled condenser.
Pass/Fail Criteria: Under conditions of the above NOTE; the test immediately
fails if the following inputs are sensed to be invalid:
Compressor discharge sensor (CPDS).
Discharge pressure transducer (DPT).
Condenser pressure transducer (CPT).
OR, if any one of the following inputs are sensed to be invalid:
Return temperature sensor (RTS).
Ambient sensor (AMBS).
In addition, the test will fail if:
The high pressure switch (HPS) fails to open within 15 minutes.
The discharge temperature exceeds 138 C (280 F).
The discharge temperature is less than or equal to ambient temperature
plus 5 C (9 F).
P7-1
High Pressure
Switch Open
P8-0
Perishable Mode
Heat Test
P8-1
Perishable Mode
Pull Down Test
The condenser pressure transducer (CPT) or discharge pressure transducer (DPT) pressure exceeds 27.42 kg/cm2 (390 psig).
Requirements: Test P7-0 must pass for this test to execute. Setup: The condenser fan is started and a 60 second timer is started.
Pass/Fail Criteria: Passes the test if the high pressure switch (HPS) closes
within the 60 second time limit, otherwise, it fails.
Setup: If the container temperature is below 15.6 C (60 F), the set point is
changed to 15.6 C, and a 60 minute timer is started. The left display will read
“P8-0.” The control will then heat the container until 15.6 C is reached. If the
container temperature is above 15.6 C at the start of the test, then the test
proceeds immediately to test P8-1 and the left display will change to “P8-1.”
Pass/Fail Criteria: The test fails if the 180 minute timer expires before the
control temperature reaches set point. The display will read “P8-0,” “FAIL.”
Requirements: Control temperature must be at least 15.6 C (60 F).
Setup: 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.
Pass/Fail Criteria: The test passes if the container temperature reaches set
point before the 180 minute timer expires.
3--23
T-318
Table 3-9 Controller Pre-Trip Test Codes (Sheet 4 of 4)
Code
No.
P8-2
P9-0
P10-0
P10-1
P10-2
T-318
TITLE
DESCRIPTION
Requirements: Test P8-1 must pass for this test to execute.
Setup: The left display will read “P8-2,” and the right display will show the supply
air temperature. A 60 minute timer is started. The unit will be required to maintain the 0 C temperature to within + or - 0.5 degrees C (0.9 degrees F) of set
point until a DataCORDER recording is executed. The recorder supply probe
temperature running total (and its associated readings counter) will be zeroed
out for the remainder of the recording period at the start of this test, so that the
Perishable Mode
Maintain Tempera- actual value recorded in the DataCORDER will be an average of only this test’s
results. Once a recording interval is complete, the average recorder supply
ture Test
temperature will be recorded in the DataCORDER, as well as stored in memory
for use in applying the test pass/fail criteria.
Pass/Fail Criteria: If the recorded temperature is within +/- 0.5 degrees C. of
set point from test start to DataCORDER recording, the test passes. If the
average temperature is outside of the tolerance range at the recording, the test
fails.
Setup: 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.
Once the DTT is considered closed, the unit simulates defrost by running the
Defrost Test
heaters for up to two hours, or until the DTT is considered open.
Pass/Fail Criteria: The 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).
Setup: After completion of the defrost test, the testing proceeds directly to test
P10-1 if the container temperature is above 7 C (45 F). If the container temperature is below 7 C, a 180 minute timer will be started, the set point will be set to 7
Frozen Mode
C and the control will be placed in normal heat. The left display will read “P10-0”
Setup Test
and the unit will continue in operation until the temperature is raised to set point.
Pass/Fail Criteria: If the temperature does not reach set point (less -0.3 C or
6.7 F) before the timer times out display will read “P100,” “FAIL.” The test will not
auto-repeat.
Setup: When the container temperature is greater than or equal to the 7.2 C
(45 F) set point which was set in the frozen mode heat test, the left display will
“P10-1” and the right display will show the return air temperature. The set
Frozen Mode (Pull read
point
will then be changed to -17.7 C (0 F). The unit will then have a maximum
Down) Test
of three hours to pull the container temperature down to the -17.7 C set point.
Pass/Fail Criteria: If this occurs within the three hour time limit, the test passes.
If pulldown is not completed within the three hour time, the test fails.
Setup: After the unit has successfully completed frozen pulldown test, the left
display will read “P10-2” and the right display will show return air temperature.
The unit will then be required to maintain -17.7 C (0 F) temperature within
+/- 0.5 degrees C (0.9 degrees F) of set point until a DataCORDER recording is
executed. The recorder return probe temperature running total (and its associatFrozen Mode Main- ed counter) will be zeroed for the remainder of the recording period at the start of
tain Temperature
this test, so that the actual recorded value will be an average of only this test’s
results. Once the recording interval is complete, the average return temperature
Test
will be recorded in the DataCORDER, and stored in memory for use in applying
the test pass/fail criteria.
Pass/Fail Criteria: If the recorded temperature is within +/- 0.5 degrees C of set
point from test start to DataCORDER recording, the test passes. If temperature
is outside of the tolerance range at the DataCORDER recording, the test fails.
3--24
Table 3-10 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
dC26,27
S/N, Left 4, Right 4
dC28
Minimum Days Left
dC29
Days Stored
dC30
dC31
dC32
dC33
dC34
dC35
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)
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
Date of last Trip start goes without power for seven continuous days or longer, a trip start will
automatically be generated on the next AC power up.
Shows the current status of the optional battery pack.
PASS: Battery pack is fully charged.
Battery Test
FAIL: Battery pack voltage is low.
Time: Hour, Minute
Current time on the real-time clock (RTC) in the DataCORDER.
Date: Month, Day
Current date (month and day) on the RTC in the DataCORDER.
Date: Year
Current year on the RTC in the DataCORDER.
Cargo Probe 4
Current calibration value for the Cargo Probe. This value is an input via the
Calibration
interrogation program.
3--25
T-318
Table 3-11 DataCORDER Pre-Trip Result Records
Test
No.
1-0
1-1
Heater On
Heater Off
2-0
Condenser Fan On
2-1
6-4
6-5
Condenser Fan Off
Low Speed Evaporator Fan
On
Low Speed Evaporator Fan
Off
High Speed Evaporator Fan
On
High Speed Evaporator Fan
Off
Supply/Return Probe Test
Secondary Supply Probe Test
Secondary Return Probe Test
Compressor On
Not Applicable
Suction Modulation Valve
Open and Closed
Not Applicable
Not Applicable
7-0
High Pressure Switch Closed
7-1
High Pressure Switch Open
8-0
8-1
Perishable Heat
Perishable Pull Down
8-2
Perishable Maintain
9-0
Defrost Test
10-0
10-1
Frozen Mode Set-up
Frozen Mode Pull Down
10-2
Frozen Mode Maintain
3-0
3-1
4-0
4-1
5-0
5-1
5-2
6-0
6-1
6-2
T-318
TITLE
DATA
Pass/Fail/Skip Result, Change in current for Phase A, B and C
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
Pass/Fail/Skip Result, Water pressure switch (WPS) -- Open/Closed,
Change in currents for Phase A, B and C
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
Pass/Fail/Skip Result, STS, RTS, SRS and RRS
Pass/Fail/Skip Result
Pass/Fail/Skip Result
Pass/Fail/Skip Result, Change in currents for Phase A, B and C
Not Used
Pass/Fail/Skip Result, Is current or pressure limit in effect (Y,N)
Not Used
Not Used
Pass/Fail/Skip Result, AMBS, DPT or CPT (if equipped)
Input values that component opens
Pass/Fail/Skip Result, STS, DPT or CPT (if equipped)
Input values that component closes
Pass/Fail/Skip Result, STS, time it takes to heat to 16 C (60 F)
Pass/Fail/Skip Result, STS, time it takes to pull down to 0 C (32 F)
Pass/Fail/Skip Result, Averaged DataCORDER supply temperature
(SRS) over last recording interval.
Pass/Fail/Skip Result, DTS reading at end of test, line voltage, line
frequency, time in defrost.
Pass/Fail/Skip Result, STS, time unit is in heat.
Pass/Fail/Skip Result, STS, time to pull down unit to -17.8 C (0 F).
Pass/Fail/Skip Result, Averaged DataCORDER return temperature
(RRS) over last recording interval.
3--26
Table 3-12 DataCORDER Alarm Indications
To Access: Press ALT. MODE key
Code No.
TITLE
DESCRIPTION
The supply recorder sensor reading is outside of the range of -50 C to
70 C (-58 F to +158 F) or, the probe check logic has determined there
Recorder Supply Tem- is a fault with this sensor.
dAL70
perature Out of Range
NOTE
The P5 Pre-Trip test must be run to inactivate the alarm.
The return recorder sensor reading is outside of the range of -50 C to
70 C (-58 F to +158 F) or, the probe check logic has determined there is a
Recorder Return Tem- fault with this sensor.
dAL71
perature Out of Range
NOTE
The P5 Pre-Trip test must be run to inactivate the alarm.
USDA Temperatures
The USDA probe temperature reading is sensed outside of -50 to 70 C
dAL72-74 1, 2, 3 Out of Range
(-58 to 158 F) range.
dAL75
Cargo Probe 4 Out of
Range
The cargo probe temperature reading is outside of -50 to 70 C (-58 to 158
F) 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 8 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.
dAL87
RTC Failure
An invalid date or time has been detected. This situation may be corrected
by changing the Real Time Clock (RTC) to a valid value using DataLINE.
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--27
T-318
SECTION 4
OPERATION
power source. Place circuit breaker (CB-1) in position
“I” (ON). Close and secure control box door.
4.1 INSPECTION (Before Starting)
WARNING
4.2.2 Connection to190/230 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 hertz power to the unit
when the 230 VAC power cable is connected to a
190/230 VAC, 3-phase power source.
Beware of unannounced starting of the
evaporator and condenser fans. The unit
may cycle the fans and compressor unexpectedly as control requirements dictate.
a. If container is empty, 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. Make permanent or temporary repairs.
3. Visually check evaporator fan motor mounting bolts
for proper securement (refer to paragraph 6.16).
4. Check for dirt or grease on evaporator fan or fan
deck and clean if necessary.
5. Check evaporator coil for cleanliness or obstructions. Wash with fresh water.
6. Check defrost drain pans and drain lines for obstructions and clear if necessary. Wash with fresh water.
7. Check panels on refrigeration unit for loose bolts and
condition of panels. Make sure T.I.R. devices are in
place on access panels.
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.
e. Check oil level in compressor sight glass.
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 “O”
(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 CB2 to
position “I” (ON). Close and secure control box door.
3
2
1
4.2 CONNECT POWER
WARNING
1. Dual Voltage Modular Autotransformer
2. Circuit Breaker (CB-2) 230V
3. 460 VAC Power Receptacle
Do not attempt to remove power plug(s) before turning OFF start-stop switch (ST), unit
circuit breaker(s) and external power
source.
Figure 4-1 Autotransformer
4.3 ADJUST FRESH AIR MAKEUP VENT
WARNING
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.
Make sure the power plugs are clean and
dry before connecting to any power receptacle.
Air exchange depends on static pressure differential,
which will vary depending on the container and how the
container is loaded.
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 “O” (OFF).
2. Plug the 460 VAC (yellow) cable into a de-energized
380/460 VAC, 3-phase power source. Energize the
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.
4--1
T-318
bar, with 15 mm (0.6 inch) H2O external static above
free blow.
4.3.1 Upper Fresh Air Makeup Vent
Two slots and a stop are designed into the disc for air
flow adjustments. The first slot allows for a 0 to 30% air
flow and 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. To
clear the gap between the slots, loosen the wing nut until
the disc clears the stop. Figure 4-2 gives air exchange
values for an empty container. Higher values can be
expected for a fully loaded container.
d. Air Sampling for Carbon Dioxide (CO2) Level
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 hose to the
sampling port.
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.
69NT40 FRESH AIR MAKEUP
AIR
FLOW
(CMH)
240
4.3.3 Fresh Air Position Sensor
ZERO EXTERNAL STATIC 50HZ
The VPS allows the user to determine position of the
fresh air vent via function code 45. This function code is
accessible via the code select key.
T-BAR
1-!/2”
T-BAR
210
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 Function Code 45 will display the Fresh Air
Vent Position.
2-%/8”
180
T-BAR
3”
150
Data Recording of the Sensor Position -- The position of
the vent will be recorded in the DataCorder whenever
the unit is running under AC power and any of the
following:
S Trip start
S On every power cycle
S Midnight
S Manual change greater than 5 CMH (3 CFM) and
remains in that position for four minutes
120
90
60
30
0
0 10 20 30 40 50 60 70 80 90 100
PERCENT OPEN
NOTE
The user has four minutes to make necessary
adjustments to the vent setting. This time 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 in stable
for the next four minutes. If vent position
changes are detected during the four minutes
stability period, an alarm will be generated. This
provides the user with the ability to change the
vent setting without generating multiple events
in the DataCorder.
For 60Hz operation multiply curves by 1.2
Figure 4-2 Make Up Air Flow Chart
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.
b. Reduced Flow for Fresh Air Makeup
On some models, the air slide is supplied with two
adjustable air control disks. 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 60Hz
power and 2 1/2 inch T bar and with 15mm (.6 inch) H2O
external static above free blow. Loosen the hex nut and
adjust each disk to the required air flow and tighten hex
nut.
4.4 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.
4.4.1 Water-Cooled Condenser with Water Pressure Switch
NOTE
The main air slide is in the fully closed position
during reduced air flow operation.
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).
c. Adjustment
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 until the water pressure
switch closes.
The air slide is supplied with two adjustable air control
discs. The fresh air makeup can be adjusted for 15, 35,
50, and 75 cubic meters per hour (CFM). The air flow
has been established at 60 Hz power, and a 2-1/2 inch T
T--318
4--2
NOTE
If controller configuration variable CNF48 is activated the condenser fan motor will activate if
the HPS opens twice in less than seven minutes. Power cycling the unit resets the counter.
4.6 STARTING AND STOPPING INSTRUCTIONS
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.
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 or if the controller configuration variable CNF48 is activated, the condenser fan
motor will activate if the HPS opens twice in less than
seven minutes. Power cycling the unit resets the
count.
4.6.1 Starting the Unit
1. With power properly applied, the fresh air damper set,
and if required, the water-cooled condenser connected (refer to paragraphs 4.2, 4.3, & 4.4), place the
START-STOP switch to “I” (ON).
4.4.2 Water-Cooled Condenser with Condenser
Fan Switch
2. Continue with Start Up Inspection (refer to paragraph
4.7).
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).
4.6.2 Stopping the Unit
To stop the unit, place the START-STOP switch in
position “O” (OFF).
b. Maintain a flow rate of 11 to 26 lpm (3 to 7 gpm).
c. Set the condenser fan switch to position “O.” This will
de-energize the condenser fan relay. The condenser
fan motor will stop until the CFS switch is set to position “I.”
4.7 START-UP INSPECTION
4.7.1 Physical Inspection
a. Check rotation of condenser and evaporator fans.
NOTE
If controller configuration variable CNF48 is activated, the condenser fan motor will activate if
temperature at the compressor discharge temperature sensor (CPDS) exceeds 115.5 C
(240 F). The fan will cycle off when the temperature drops to 90.5 C (150 F). If the CPDS sensor is faulty, the logic will not operate.
b. Check compressor oil level (refer to paragraph 6.8.6).
4.7.2 Check Controller Function Codes
Check and, if required, reset controller Function Codes
(Cd27 through Cd39) in accordance with desired
operating parameters (refer to paragraph 3.2.2).
4.7.3 Start Temperature Recorder
a. Open recorder door and wind mechanical clock or
check battery of electronic recorder. Be sure key is returned to storage clip of mechanical recorder.
CAUTION
b. Lift stylus (pen) by pulling the marking tip outward until the stylus arm snaps into its retracted position.
When condenser water flow is below 11 lpm
(3 gpm) or when water-cooler is not in use,
the CFS switch MUST be set to position “I”
or the unit will not operate properly.
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 door.
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.
DataCORDER
4.5 CONNECT REMOTE MONITORING
RECEPTACLE
b. Enter a “Trip Start.” To enter a “Trip Start,” do the following:
If remote monitoring is required, connect remote
monitor plug at unit receptacle (see item 9, Figure 2-6).
When the remote monitor plug is connected to the
remote monitoring receptacle, the following remote
circuits are energized:
1. Depress the ALT MODE key and scroll to Code
dC30.
CIRCUIT
Sockets B to A
Sockets C to A
Sockets D to A
a. Check, and if required, set the DataCORDER Configuration in accordance with desired recording parameter (refer to paragraph 3.6.3).
2. Depress and hold the ENTER key for five seconds.
3. The “Trip Start” event will be entered in the DataCORDER.
FUNCTION
Energizes remote cool light
Energizes remote defrost light
Energizes remote in-range light
4.7.4 Complete Inspection
Allow unit to run for five minutes to stabilize conditions
and perform a pre-trip diagnosis in accordance with the
following paragraph.
4--3
T-318
3. Pre-trip diagnosis may also be initiated via
4.8 PRE-TRIP DIAGNOSIS
communications. The operation is the
same as for the key pad initiation described
below except that should a test fail, the
pre-trip mode will automatically terminate.
When initiated via communications, a test
may not be interrupted with an arrow key,
but the pre-trip mode can be terminated
with the PRE-TRIP key.
CAUTION
Pre-trip inspection should not be performed with critical temperature cargoes in
the container.
a. Press the PRE-TRIP key. This accesses a test selection menu.
b. TO RUN AN AUTOMATIC TEST: Scroll through the
selections by pressing the UP ARROW or DOWN
ARROW keys to display AUTO, AUTO 2 or AUTO 3
as desired and then press the ENTER key.
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, where the #’s indicate the test number and
sub-test. The right display will show a countdown time
in minutes and seconds, indicating how much time
there is left remaining in the test.
CAUTION
When Pre-Trip key is pressed, dehumidification and bulb mode will be deactivated.
At the completion of Pre-Trip activity, 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
three automatic tests (depending on software revision
installed). 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. The
contents of the menus are as follows:
PRE-TRIP SELECTION MENU
Auto or Auto 1 Auto 2
Auto 3
P1, P2, P3, P4,
P5, P6, rSLts
P, P1, P2, P3,
P4, P5, P6, P7,
P8, rSLts
P, P1, P2, P3,
P4, P5, P6, P7,
P8, P9, P10,
rSLts
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. 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 until the user manually enters a command.
A detailed description of the pre-trip test codes is listed
in Table 3-9, page 3--21. 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.
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!
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.
When an Auto test runs to completion without a failure, the unit will exit the pre-trip mode and return to normal control operation. If configuration variable CnF42
is set to IN, a datacorder trip start will be entered. If
CnF42 is set to OUT, the trip start will not be entered.
However, dehumidification and bulb mode must be
reactivated manually if required.
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.
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
To start a pre-trip test, do the following:
NOTE
1. Prior to starting tests, verify that unit
voltage (Function Code Cd 07) is within
tolerance and unit amperage draw
(Function Codes Cd04, Cd05, Cd06) is
within expected limits. Otherwise, tests
may fail incorrectly.
2. All alarms must be rectified and cleared
before starting tests.
T--318
4--4
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.
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. Throughout the duration of any pre-trip test except
the P-7 high pressure switch tests, the current and
pressure limiting processes are active .
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). 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.
a. Probe Diagnostic Logic -- Standard
4.9 OBSERVE UNIT OPERATION
4.9.1 Crankcase Heater
When the crankcase heater is installed, it will be
operational whenever the compressor is off and there is
power to the unit. The heater is connected to a set of
normally closed auxiliary contacts on the compressor
contactor.
4.9.2 Probe Check
If the DataCORDER is off or in alarm mode, the
controller will revert to a four probe configuration, which
includes the DataCORDER supply and return air probes
as the secondary controller probes. The controller
continuously performs probe diagnosis testing, which
compares the four probes. If the probe diagnosis result
indicates a probe problem exists, the controller will
perform a probe check to identify the probe(s) in error.
S
At every power up
S
At the end of every defrost
S
After every diagnostic check that does not fall outside of the limits as outlined above.
If the probe check option (controller configuration code
CnF31) is configured for standard, the criteria used for
comparison between the primary and secondary
control probes is:
1 degrees C (1.8 degrees F) for perishable set points
or 2 degrees C (3.6 degrees F) for frozen set points.
If 25 or more of 30 readings taken within a 30 minute
period are outside of the limit, then a defrost is initiated and a probe check is performed.
In this configuration, a probe check will be run as a part
of every normal (time initiated) defrost.
b. Probe Diagnostic Logic -- Special
If the probe check option is configured for special, the
above criteria are applicable. A defrost with probe check
will be initiated if 25 of 30 readings or 10 consecutive
readings are outside of the limits
In this configuration, a probe check will not be run as a
part of a normal defrost, but only as a part of a defrost
initiated due to a diagnostic reading outside of the limits.
c. The 30 minute timer will be reset at each of the following conditions:
d. Probe Check:
A defrost cycle probe check is accomplished by
energizing just the evaporator motors for eight minutes
at the end of the normal defrost. At the end of the eight
minute period, the probes will be compared to a set of
predetermined limits. The defrost indicator will remain
on throughout this period.
Any probe(s) determined to be outside the limits will
cause the appropriate alarm code(s) to be displayed to
identify the probe(s) that needs to be replaced. The P5
Pre-Trip test must be run to inactivate alarms.
4--5
T-318
FALLING
TEMPERATURE
+2.5 C (4.5 F)
RISING
TEMPERATURE
+1.5 C (2.7 F)
MODULATING
COOLING
+1 C (1.8 F)
AIR CIRCULATION
+0.5 C (0.9 F)
+.20 C
SET POINT
-0.20 C
-0.5 C (0.9 F)
MODULATING
COOLING
AIR CIRCULATION
-1 C (1.8 F)
HEATING
-1.5 C (2.7 F)
HEATING
Figure 4-3 Controller Operation -- Perishable Mode
FALLING
TEMPERATURE
RISING
TEMPERATURE
+1.5 C (2.7 F)
COOLING
+1 C (1.8 F)
COOLING
+0.5 C (0.9 F)
+.20 C
SET POINT
-0.20 C
-0.5 C (0.9 F)
AIR
CIRCULATION
ONLY
-1 C (1.8 F)
AIR
CIRCULATION
ONLY
-1.5 C (2.7 F)
Figure 4-4 Controller Operation -- Frozen Mode
T--318
4--6
from the supply air and multiplying the result by the
time reading. The result is negative number.
4.10 SEQUENCE OF OPERATION
General operation sequences for cooling, heating, and
defrost are provided in the following subparagraphs.
Schematic representation of controller action are
provided in Figure 4-3 and Figure 4-4. Refer to Section
3 for detailed descriptions of special events and timers
that are incorporated by the controller in specific modes
of operation.
e. When the calculation reaches -250, contacts TC and
TN are opened to de-energize compressor and condenser fan motors. The cool light is also de-energized.
f. The evaporator fan motors continue to run to circulate
air throughout the container. The in-range light remains illuminated as long as the supply air is within
tolerance of set point.
4.10.1 Sequence of Operation -- Perishable Mode
Cooling
g. When the supply air temperature increases to 0.2 degrees C (0.4 degrees F) above set point and the three
minute off time has elapsed, relays TC and TN are energizes to restart the compressor and condenser fan
motors. The cool light is also illuminated.
NOTE
In the conventional Perishable Mode of
Operation, the evaporator motors run in high
speed. In the economy Perishable Mode, the
fan speed is varied.
4.10.2 Sequence of Operation -Perishable Mode Heating
NOTE
In low temperature ambients, the condenser
fan will be cycled by the controller to maintain
proper condensing pressure.
NOTE
The unit will heat only when in the Perishable
Mode, relay TH is electronically locked out
when in the Frozen Mode.
a. With supply air temperature above set point and decreasing, the unit will be cooling with the condenser
fan motor (CF), compressor motor (CH), evaporator
fan motors (EF) energized, and the COOL light illuminated (see Figure 4-5).
ENERGIZED
DE--ENERGIZED
FOR FULL DIAGRAM AND
LEGEND, SEE SECTION 7
a. If the air temperature decreases 0.5 degrees C (0.9
degrees F) below set point, the system enters the
heating mode (see Figure 4-3). The controller closes
contacts TH (see Figure 4-6) to allow power flow
through the heat termination thermostat (HTT) to energize the heaters (HR). The HEAT light is also illuminated. The evaporator fans continue to run to circulate air throughout the container.
CONTROL TRANSFORMER
b. When the temperature rises to 0.2 degrees C (0.4 degrees F) below set point, contact TH opens to de-energize the heaters. The HEAT light is also de-energized. The evaporator fans continue to run to
circulate air throughout the container.
POWER TO
CONTROLLER
SIGNAL TO
CONTROLLER
c. A safety heater termination thermostat (HTT), attached to an evaporator coil support, will open the
heating circuit if overheating occurs.
ENERGIZED
DE-ENERGIZED
FOR FULL DIAGRAM AND
LEGEND, SEE SECTION 7
CONTROL TRANSFORMER
POWER TO
CONTROLLER
SIGNAL TO
CONTROLLER
SIGNAL TO
CONTROLLER
NOTE: HIGH SPEED EVAPORATOR FAN SHOWN. FOR LOW SPEED
CONTACT TE IS DE-ENERGIZED AND CONTACT TV IS ENERGIZED
Figure 4-5 Perishable Mode Cooling
b. When the air temperature decreases to a predetermined tolerance above set point, the in-range light is
illuminated.
c. As the air temperature continues to fall, modulating
cooling starts at approximately 2.5 degrees C (4.5
degrees F) above set point (see Figure 4-3).
SIGNAL TO
CONTROLLER
d. The controller monitors the supply air. Once the supply air falls below set point and 0% SMV position is
reached, the controller periodically records the supply air temperature, set point, and time. A calculation
is then performed by subtracting the set point reading
Figure 4-6 Perishable Mode Heating
4--7
T-318
Defrost may be requested by any one of the following
methods:
The manual defrost function (also manual defrost switch
function if equipped) is initiated and ended by the user
using the keypad or manual defrost switch (if equipped).
4.10.3 Sequence of Operation -- Frozen Mode Cooling
NOTES
1. In the Frozen Mode of operation the
evaporator motors run in low speed.
NOTE
The Manual Defrost / Interval key can be used
to initiate a manual defrost. Minimum Software
release version #5126 is required in order for to
use this function
2. In low temperature ambients, the
condenser fan will be cycled by the
controller to maintain proper condensing
pressure.
a. With supply air temperature above set point and decreasing, the unit will be cooling with the condenser
fan motor (CF), compressor motor (CH), evaporator
fan motors (ES) energized and the COOL light illuminated (see Figure 4-7).
Manual Defrost/Interval Key Operation:
1 Depressing and holding the Defrost Interval key for
five seconds will initiate defrost. If the defrost interval
key is released in less than five seconds, defrost interval (code 27) shall be displayed.
2. The user sends a defrost request by communications.
3. The defrost interval timer (controller function code
Cd27) reaches the defrost interval set by the user.
4. The controller probe diagnostic logic determines that
a probe check is necessary based on the temperature values currently reported by the supply and return probes.
5. The controller Demand Defrost configuration variable (CnF40) is set to “In” and the unit has been in
pull down operation for over 2.5 hours without reaching set point.
b.When the air temperature decreases to a predetermined tolerance above set point, the in-range light is
illuminated.
ENERGIZED
DE-ENERGIZED
FOR FULL DIAGRAM AND
LEGEND, SEE SECTION 7
CONTROL TRANSFORMER
POWER TO
CONTROLLER
SIGNAL TO
CONTROLLER
ENERGIZED
DE-ENERGIZED
FOR FULL DIAGRAM AND
LEGEND, SEE SECTION 7
CONTROL TRANSFORMER
POWER TO
CONTROLLER
SIGNAL TO
CONTROLLER
SIGNAL TO
CONTROLLER
Figure 4-7 Frozen Mode
c. Contacts TC and TN are opened to de-energize the
compressor and condenser fan motors when the return air temperature decreases to 0.2 degrees C
(0.4 degrees F) below set point. The cool light is also
de-energized.
SIGNAL TO
CONTROLLER
d. The evaporator fan motors continue to run to circulate
air throughout the container. The in-range light remains illuminated as long as the return air is within tolerance of set point.
Figure 4-8 Defrost
The processing of a defrost request is controlled by the
defrost termination thermostat. The defrost termination
thermostat is not a physical component. It is a software
point that acts as a thermostat, allowing defrost when it
is considered “closed” and preventing or terminating
defrost when it is considered “open.” The actual
temperatures used to make the “open” or “closed”
determinations are dependent on the type of defrost
request made and the operator setting of configuration
variable CnF41. Configuration variable CnF41may be
factory set at the default value of 25.6 C (78 F) or a lower
value of 18 C (64 F).
e. When the return air temperature increases to
0.2 degrees C (0.4 degrees F) above set point and
the three minute off time has elapsed, relays TC and
TN are energizes to restart the compressor and condenser fan motors. The cool light is also illuminated.
4.10.4 Sequence of Operation -- Defrost
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.
T--318
SIGNAL TO
CONTROLLER
4--8
To operate the fans only, the MODE switch must be in
the FANS ONLY position and the EMERGENCY
BYPASS Switch must be in the ON position.
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.
When a request for defrost is made by the use of the
Manual Defrost Switch or Communications, the unit will
enter defrost when the reading at the defrost
temperature sensor is at or below the CnF41 setting.
Defrost will terminate when the defrost sensor
temperature reading rises above the CnF41 setting.
When a request for defrost is made by probe check, the
unit will enter defrost when the defrost temperature
sensor reading is at or below 25.6 C (78 F). The unit will
terminate defrost when the Defrost Temperature
Sensor reading rises above 25.6 C (78 F)
CAUTION
The unit will remain in the full cooling mode
as long as the emergency bypass switch is
in the BYPASS position and the MODE
SWITCH is in the FULL COOL position. If
the cargo may be damaged by low temperatures, the operator must monitor container
temperature and manually cycle operation
as required to maintain temperature within
required limits.
When a request for defrost is made by demand defrost,
the unit will enter defrost when the reading at the defrost
temperature sensor is at or below 18 C (64.4 F). Defrost
will terminate when the defrost sensor temperature
reading rises above the CnF41 setting.
When a defrost has terminated, the defrost interval
timer will begin counting when the reading at the defrost
temperature sensor is at or below 10 C (50 F). Once the
timer has counted the required time, the unit will enter
defrost if the Defrost Temperature Sensor is at or below
25.6 C (78 F). Defrost will terminate when the defrost
sensor temperature reading rises above the CnF41
setting.
In the ON position the EBS will be enabled. With the
MODE SWITCH in the FULL COOL MODE. The
following will occur simultaneously:
1. The EBS switch will enable EBS input.
2. The phase detection circuit will detect the phase
rotation and close to provide power to the compressor contactor.
3. The condenser fan contact will close to energize the
condenser contactor and provide power to the condenser fan motor.
4. The evaporator fan contact will close to energize the
high speed evaporator contactor and provide power
to the evaporator fan motor.
5. The EBS electronic module will open the SMV to
100%.
When the unit enters defrost, the controller opens
contacts TC, TN, and TE (or TV) to de-energize the
compressor, condenser fan and evaporator fans (see
Figure 4-8). The COOL light is also de-energized.
The controller then closes TH to supply power to the
heaters. The defrost light is illuminated.
When the defrost temperature sensor reading rises to
the applicable defrost termination thermostat “opening”
point, the de-icing operation is terminated.
If defrost does not terminate correctly and temperature
reaches the set point of the heat termination thermostat
(HTT), the thermostat will open to de-energize the
heaters. If termination does not occur within two hours,
the controller will terminate defrost. An alarm will be
given of a possible DTS failure.
To return the unit to normal operation, place the EBS
switch in the NORMAL OPERATION position. When
emergency operation is no longer required, re-install the
wire tie at the switch mounting.
If probe check (controller function code CnF31) is
configured to special, the unit will proceed to the next
operation (snap freeze or terminate defrost). If the code
is configured to standard, the unit will perform a probe
check. The purpose of the probe check is to detect
malfunctions or drift in the sensed temperature that is
too small to be detected by the normal sensor out of
range tests. The system will run for eight minutes in this
condition. At the end of the eight minutes, probe alarms
will be set or cleared based on the conditions seen.
4.11.2 Emergency Defrost Operation
To place the unit in the emergency defrost mode of
operation, cut the wire tie installed at the switch
mounting (see Figure 2-6) and place the switch in the
EMERGENCY DEFROST position.
NOTE
1. If the unit is in the emergency bypass
cooling mode, the emergency defrost
switch will override this mode and place the
unit in defrost.
4.11 EMERGENCY OPERATION
Operation by the refrigeration controller may be
overridden by use of the EMERGENCY BYPASS or by
use of the EMERGENCY DEFROST switch. The
EMERGENCY BYPASS switch functions to bypass the
controller in the event of controller failure, The
EMERGENCY DEFROST switch functions to bypass
the controller and place the unit in the defrost mode.
2. The IN-RANGE LIGHT is de-energized
when in the emergency defrost mode.
The switch is a normally open four-pole switch, which is
placed in the EMERGENCY DEFROST position to:
a. De-energize the compressor, condenser fan and
evaporator fan contactors.
b. Illuminate the EMERGENCY DEFROST LIGHT.
c. Energize the heater contactor.
d. Illuminate the DEFROST LIGHT.
4.11.1 Emergency Bypass Operation
To place the unit in the emergency bypass mode, cut the
wire tie installed at the switch mounting and place the
EMERGENCY BYPASS switch in the ON position. This
will in turn activate the Emergency Bypass System
(EBS) control module.
4--9
T-318
4.12 ARCTIC MODE
With arctic mode enabled, if the ambient is colder than
-10.0 degrees C there is a 30 minute time delay at
startup for any of the components in the system, except
for the controller and the compressor crankcase heater
(CCH), which should be active at this point. In arctic
mode, the CCH is energized for 30 minutes to warm the
oil in the compressor and boil off any liquid refrigerant
that may be present in the crankcase.
If Pre-Trip is initiated during the 30 minute time period,
Pre-Trip will be allowed to run normally. Once Pre-Trip is
over, the controller will revert to its normal control mode
logic.
If ambient is warmer than -10.0 C, the system will run its
normal startup logic.
Arctic mode is configurable by using the configuration
variable #29, refer to Table 3-4.
CAUTION
The unit will remain in the DEFROST mode
as long as the emergency defrost switch is
in the DEFROST position. To prevent cargo
damage, the operator must monitor container temperature and manually cycle operation as required to maintain temperature
within required limits.
To return the unit to normal operation, place the switch in
the NORMAL OPERATION position. When emergency
defrost is no longer required, re-install the wire tie at the
switch mounting.
T--318
4--10
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
Fuses (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
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
6.16
6.11
6.8
5.7
Replace
Check
Check
6.8
6.8
5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING
Container
Refrigeration System
Hot load (Failure to Pre--cool)
Defective box insulation or air leak
Shortage of refrigerant
Evaporator coil covered with ice
Evaporator coil plugged with debris
Evaporator fan(s) rotating backwards
Defective evaporator fan motor/capacitor
Air bypass around evaporator coil
Controller set too low
Compressor service valves or liquid line shutoff valve partially closed
Dirty condenser
Compressor worn
Current limit (function code Cd32) set to wrong value
Suction modulation valve malfunction
5--1
Normal
Repair
6.7.1
5.6
6.15
6.15/6.16
6.17
Check
Reset
Open valves
completely
6.10
6.8
3.3.5
6.18
T-318
CONDITION
POSSIBLE CAUSE
REMEDY/
REFERENCE
SECTION
5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING
Compressor
Refrigeration System
Compressor valves defective
Abnormal pressures
Controller malfunction
Evaporator fan or motor defective
Suction modulation valve malfunction
Condenser Pressure Transducer defective
Shortage of refrigerant
6.8
5.7
5.9
6.16
6.18
Check
6.7.1
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 switch 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
6.16
Check
6.15
6.15
Replace
6.15/6.16
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
6.15
5.6 UNIT WILL NOT DEFROST PROPERLY
Defrost timer malfunction (Cd27)
Loose terminal connections
Defective wiring
Defrost temperature sensor defective or heat termination
thermostat open
Table 3-5
Tighten/
Replace
Will not initiate defrost
manually
Heater contactor or coil defective
Manual defrost switch defective
Defrost temperature sensor open
Replace
Replace
4.10.4
Initiates but relay (DR) drops
out
Low line voltage
2.3
Initiates but does not defrost
Heater contactor or coil defective
Heater(s) burned out
Replace
6.15
Will not initiate defrost
automatically
T-318
5--2
Replace
CONDITION
POSSIBLE CAUSE
REMEDY/
REFERENCE
SECTION
5.6 UNIT WILL NOT DEFROST PROPERLY --Continued
Frequent defrost
Wet load
Normal
5.7 ABNORMAL PRESSURES (COOLING)
Condenser coil dirty
Condenser fan rotating backwards
Condenser fan inoperative
Refrigerant overcharge or noncondensibles
High discharge pressure
Discharge pressure regulator valve defective
Discharge service valve partially closed
Suction modulation valve malfunction
Suction service valve partially closed
Filter-drier partially plugged
Low refrigerant charge
Expansion valve defective
No evaporator air flow or restricted air flow
Low suction pressure
Excessive frost on evaporator coil
Evaporator fan(s) rotating backwards
Discharge pressure regulator valve defective
Suction modulation valve malfunction
Heat exchanger defective
Suction and discharge pressures tend to equalize when unit Compressor valves defective
is operating
Compressor cycling/stopped
6.10
6.11
6.11
6.7.1
Replace
Open
6.18
Open
6.13
6.7.1
6.14
6.15
5.6
6.16.3
Replace
6.18
Replace
6.8
Check
5.8 ABNORMAL NOISE OR VIBRATIONS
Compressor
Condenser or Evaporator Fan
Loose mounting bolts
Worn bearings
Worn or broken valves
Liquid slugging
Insufficient oil
Bent, loose or striking venturi
Worn motor bearings
Bent motor shaft
Tighten
6.8
6.8
6.14
6.8.6
Check
6.11/6.16
6.11/6.16
5.9 CONTROLLER MALFUNCTION
Will not control
Defective Sensor
Defective wiring
Fuse (F1, F2) blown
Stepper motor suction modulation valve circuit malfunction
5--3
6.22
Check
Replace
6.18
T-318
CONDITION
POSSIBLE CAUSE
REMEDY/
REFERENCE
SECTION
5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW
Evaporator coil blocked
No or partial evaporator air flow
Frost on coil
Dirty coil
Evaporator fan motor internal protector open
Evaporator fan motor(s) defective
Evaporator fan(s) loose or defective
Evaporator fan contactor defective
5.6
6.15
6.16
6.16
6.16
Replace
5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION
Low suction pressure with high
superheat
High suction pressure with low
superheat
Liquid slugging in compressor
Fluctuating suction pressure
Low refrigerant charge
External equalizer line plugged
Wax, oil or dirt plugging valve or orifice ice formation at
valve seat
Superheat too high
Power assembly failure
Loss of element/bulb charge
Broken capillary
Foreign material in valve
Superheat setting too low
External equalizer line plugged ice holding valve open
Foreign material in valve
Pin and seat of expansion valve eroded or held open by
foreign material
Improper bulb location or installation
Low superheat setting
6.7.1
Open
6.14
6.7.1
6.14
6.14
Open
6.14
6.14
5.12 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
6.20
Check
4.2.2
5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH
High discharge pressure
Condenser fan starts and stops
T-318
Dirty coil
Noncondensibles
Water pressure switch malfunction
Water supply interruption
5--4
6.12
Check
Check
SECTION 6
SERVICE
NOTE
To avoid damage to the earth’s ozone layer, 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., refer to EPA section 608.
WARNING
Never use air for leak testing. It has been
determined that pressurized mixtures of
refrigerant and air can undergo combustion
when exposed to an ignition source.
A
6.1 SECTION LAYOUT
B
OPENED (Backseated )
HAND VALVE
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.
C
CLOSED (Frontseated)
HAND VALVE
A. Connection to Low Side of System
B. Connection to either :
Refrigerant Cylinder or
Oil Container
C. Connection to High Side of System
6.2 SERVICE VALVES
The compressor suction, compressor discharge, and
liquid line service valves (see Figure 6-1) are provided
with a double seat and a gauge connection, which
enable servicing of the compressor and refrigerant
lines. Turning the valve stem clockwise (all the way
forward) will frontseat the valve to close off the suction,
discharge or liquid line and open the gauge port to the
compressor or low side. Turning the stem
counterclockwise (all the way out) will backseat the
valve to open the connections and close off the port
Figure 6-2 Manifold Gauge Set
6.3 MANIFOLD GAUGE SET
The manifold gauge set (see Figure 6-2) is used to
determine system operating pressure, add refrigerant
charge, and to equalize or evacuate the system.
When the suction pressure hand valve is frontseated
(turned all the way in), the suction (low) pressure can be
checked. When the discharge pressure hand valve is
frontseated, the discharge (high) pressure can be
checked. When both valves are open (turned
counter-clockwise all the way out), high pressure vapor
will flow into the low side. When the suction pressure
valve is open and the discharge pressure valve shut, the
system can be charged. Oil can also be added to the
system.
A R-134a manifold gauge/hose set with self-sealing
hoses (see Figure 6-3) is required for service of the
models covered within this manual. The manifold
gauge/hose set is available from Carrier Transicold.
(Carrier Transicold P/N 07-00294-00, which includes
items 1 through 6, Figure 6-3). To perform service using
the manifold gauge/hose set, do the following:
a. Preparing Manifold Gauge/Hose Set For Use
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. Back seat (turn counterclockwise) both field service
couplings (see Figure 6-3) and midseat both hand
valves.
2. Connect the yellow hose to a vacuum pump and
refrigerant 134a cylinder.
3. Evacuate to 10 inches of vacuum and then charge
with R-134a to a slightly positive pressure of 0.1
kg/cm@ (1.0 psig).
With the valve stem midway between frontseat and
backseat, the lines are open to both the connections and
the gauge connection.
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
3
1
VALVE
FRONTSEATED
(Clockwise)
DISCHARGE
PRESSURE
GAUGE
SUCTION
PRESSURE
GAUGE
5
4
VALVE
BACKSEATED
(Counterclockwise)
1. Suction, Discharge or 3. Stem Cap
Liquid Line
4. Valve stem
Connection
5. Compressor Or Filter
2. Service Port
Drier Inlet Connection
Figure 6-1 Service Valve
6--1
T--318
4. Front seat both manifold gauge set valves and disconnect from cylinder. The gauge set is now ready
for use.
1
3
2
4
1
To Low Side
Service Port
To High Side
Service Port
13
2
3
Blue
5
7-BLUE
8-YELLOW
9-RED
S D
3 - Red
11
6
12
4
6
Blue Knob
2
5
Red Knob
1. Discharge Service
7.
Valve
8.
2. Compressor
9.
3. Suction Service Valve 10.
4. Receiver or Water
Cooled Condenser
11.
5. Liquid Service Valve 12.
6. Vacuum Pump
13.
1. Manifold Gauge Set
2. Hose Fitting (0.5-16 Acme)
3. Refrigeration and/or Evacuation Hose
(SAE J2196/R-134a)
4. Hose Fitting w/O-ring (M14 x 1.5)
5. High Side Field Service Coupling
6. Low Side Field Service Coupling
Low Side Hose
Center Hose
High Side Hose
Electronic Vacuum
Gauge
Manifold Gauge Set
Refrigerant Cylinder
Reclaimer
Figure 6-4 Refrigeration System Service
Connections
Figure 6-3 R-134a Manifold Gauge/Hose Set
b. Connecting Manifold Gauge/Hose Set
CAUTION
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. 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. To connect the manifold gauge/hose set, do
the following:
To prevent trapping liquid refrigerant in the
manifold gauge set, be sure set is brought
to suction pressure before disconnecting.
c. Removing the Manifold Gauge Set
1. While the compressor is still ON, backseat the high
side service valve.
2. Midseat both hand valves on the manifold gauge set
and allow the pressure in the manifold gauge set to
be drawn down to suction pressure. This returns any
liquid that may be in the high side hose to the system.
3. Backseat the suction service valve. Backseat both
field service couplings and frontseat both manifold
set valves. Remove the couplings from the service
ports.
4. Install both service valve stem caps and service port
caps (finger-tight only).
1. Remove service valve stem caps and check to make
sure they are backseated. Remove service port caps
(See Figure 6-1).
2. Connect the high side field service coupling (see
Figure 6-3) to the discharge or liquid line valve service valve port.
3. Turn the high side field service coupling knob (red)
clockwise, which will open the high side of the system to the gauge set.
6.4 PUMPING THE UNIT DOWN
4. Connect the low side field service coupling to the
suction service valve port.
To service the filter-drier, moisture-liquid indicator,
expansion valve, suction modulation valve, quench
valve, or evaporator coil, pump the refrigerant into the
high side as follows:
a. Attach manifold gauge set to compressor service
valves (refer to paragraph 6.3).
b. Start the unit and run in a cooling mode for 10 to 15
minutes. Frontseat the liquid line service valve. Place
5. Turn the low side field service coupling knob (blue)
clockwise, which will open the low side of the system
to the gauge set.
6. To read system pressures, slightly midseat the high
side and suction service valves.
T--318
10
3 - Yellow 4
6--2
start-stop switch in the OFF position when the suction
reaches a positive pressure of 0.1 kg/cm@ (1.0 psig).
6.6 EVACUATION AND DEHYDRATION
6.6.1 General
c. Frontseat the suction service valve. The refrigerant
will be trapped between the compressor suction service valve and the liquid line valve.
Moisture is the deadly enemy of 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.
6.6.2 Preparation
a. Evacuate and dehydrate only after pressure leak test
(refer to paragraph 6.5).
b. Essential tools to properly evacuate and dehydrate
any system include a vacuum pump (8 m3/hr = 5 cfm
volume displacement) and an electronic vacuum
gauge. The pump is available from Carrier Transicold
(P/N 07-00176-11).
c. If possible, keep the ambient temperature above
15.6 C (60 F) to speed evaporation of moisture. If the
ambient temperature is lower than 15.6 C (60 F), ice
might form before moisture removal is complete.
Heat lamps or alternate sources of heat may be used
to raise the system temperature.
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.
6.6.3 Procedure - Complete System
a. Remove all refrigerant using a refrigerant recovery
system.
b. The recommended method to evacuate and dehydrate the system is to connect three evacuation
hoses (see Figure 6-5) to the vacuum pump and
refrigeration unit. Be sure the service hoses are
suited for evacuation purposes.
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.
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.
f. Break the vacuum with clean dry refrigerant 134a
gas. Raise system pressure to approximately 0.2 kg/cm@ (2 psig), monitoring it with the compound gauge.
g. Remove refrigerant using a refrigerant recovery system.
h. Repeat steps e.and f. one time.
d. Before opening up any part of the system, a slight
positive pressure should be indicated on the pressure
gauge. If a vacuum is indicated, emit refrigerant by
cracking the liquid line valve momentarily to build up a
slight positive pressure.
e. 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. After repairs have been made, be sure to perform a
refrigerant leak check (refer to paragraph 6.5), and
evacuate and dehydrate the low side (refer to paragraph 6.6).
g. Check refrigerant charge (refer to paragraph 6.7).
6.5 REFRIGERANT LEAK CHECKING
WARNING
Never use air for leak testing. It has been
determined that pressurized, air-rich mixtures of refrigerants and air can undergo
combustion when exposed to an ignition
source.
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.
b. If the system is without refrigerant, charge the system
with refrigerant 134a to build up pressure between 2.1
to 3.5 kg/cm@ (30 to 50 psig). Remove refrigerant cylinder and leak-check all connections.
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.
c. If required, remove refrigerant using a refrigerant
recovery system and repair any leaks.
d. Evacuate and dehydrate the unit (refer to paragraph
6.6).
e. Charge unit per paragraph 6.7.
6--3
T--318
2
4
3
6.7 REFRIGERANT CHARGE
5
6.7.1 Checking the Refrigerant Charge
NOTE
To avoid damage to the earth’s ozone layer, 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., refer to EPA section 608.
6
1
S D
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
1.7 C (35 F) or -17.8 C (0 F). Set the controller set
point to -25 C (-13 F) to ensure that the suction modulation valve is at maximum allowed open position.
c. Partially block the condenser coil inlet air. Increase
the area blocked until the compressor discharge
pressure is raised to approximately 12 kg/cm@ (175
psig).
d. On units equipped with a receiver, the level should be
between the glasses. On units equipped with awater-cooled 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).
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.
9
7
10
1. Reclaimer
6.
2. Discharge Service
7.
Valve
8.
3. Compressor
4. Suction Service Valve 9.
5. Receiver or Water
10.
Cooled Condenser
8
Liquid Service Valve
Vacuum Pump
Electronic Vacuum
Gauge
Manifold Gauge Set
Refrigerant Cylinder
Figure 6-5 Compressor Service Connections
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. Continue to paragraph 6.7.
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 (refer
to section paragraph 6.7.3).
6.6.4 Procedure - Partial System
a. If the refrigerant charge has been removed from the
compressor for service, evacuate only the compressor by connecting the evacuation set-up at the compressor service valves. Follow evacuation procedures of the preceding paragraph except leave
compressor service valves frontseated until evacuation is completed.
d. Backseat manual liquid line valve (to close off gauge
port). Close liquid valve on cylinder.
e. Start unit in cooling mode. Run 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.
b. If refrigerant charge has been removed from the low
side only, evacuate the low side by connecting the
evacuation set-up at the compressor service valves
and liquid service valve except leave the service
valves frontseated until evacuation is completed.
c. 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.
T--318
6--4
e. Partially frontseat (turn clockwise) the suction service
valve and slowly add charge until the refrigerant
appears at the proper level.
1
2
3
16
6.8 COMPRESSOR
15
WARNING
14
Make sure power to the unit is OFF and
power plug disconnected before replacing
the compressor.
4
13
5
12
NOTES
11
10
1. The compressor should not operate in a
vacuum greater than 500 mm/hg (20
inches/hg).
6
9
8
7
1. Discharge Valve
Flange
2. High Side Pressure
Connection
3. Low Side Pressure
Connection
4. Suction Valve Flange
5. Motor End Cover
6. Serial/Model No. Plate
7. Crankcase Heater
2. The service replacement compressor is
sold without shutoff valves (but with valve
pads), and without terminal box and cover.
Customer should retain the original
terminal box, cover, and high pressure
switch for use on replacement compressor.
3. Check oil level in service replacement
compressor (refer to paragraph 6.8.6).
4. A compressor terminal wiring kit must be
ordered as a separate item when ordering
replacement compressor. Appropriate
installation instructions are included with
kit.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Bottom Plate
Sight Glass
Oil Drain Plug
Oil Charging Valve
Bearing Head
Oil Pump
Oil Fill Plug
Cylinder Head
Valve Plate
Figure 6-6 Compressor
h. Remove compressor mounting bolts from mounting
plate and install mounting plate on replacement compressor.
5. Refer to Table 6-6 and Table 6-7 for
applicable compressor wear limits and
torque values.
i. Install replacement compressor terminal wiring kit,
following instructions included with kit.
6. Refer to Figure 6-35 for charts on
compressor pressure, temperature and
motor current curves.
k. Install compressor and mounting plate in unit.
j. Install high pressure switch on compressor.
l. Connect junction box(es) to compressor and connect
all wiring per wiring diagram. Install junction box
cover(s).
6.8.1 Removal and Replacement of Compressor
m. Install new gaskets on service valves.
a. Remove the protective guard from lower section of
the unit.
n. Install mounting bolts in service valves and torque to
2.77 to 4.15 mkg (20-30 ft/lb).
b. Pump down low side (refer to paragraph 6.4) or frontseat compressor service valves and remove refrigerant from compressor using a refrigerant recovery
system.
o. Attach two hoses (with hand valves near vacuum
pump) to the suction and discharge service valves.
Dehydrate and evacuate compressor to 500 microns
(75.9 cm Hg vacuum = 29.90 inches Hg vacuum).
Turn off valves on both hoses to pump.
c. Locate the compressor junction box. Tag and disconnect wiring from compressor terminals and remove
compressor junction box.
p. Fully backseat (open) both suction and discharge
service valves.
d. Loosen service valve mounting bolts, break seal, and
then remove bolts.
q. Remove vacuum pump lines.
r. Start unit and check refrigerant charge (refer to paragraph 6.7).
e. Remove compressor plate mounting bolts.
f. Remove compressor and mounting plate. Refer to
paragraph 2.2 for weight of compressor.
s. Check moisture-liquid indicator for wetness. Change
filter-drier if necessary (refer to paragraph 6.13).
g. Remove high pressure switch (HPS) from compressor and check operation of switch (refer to paragraph
6.9.2).
t. Check compressor oil level per paragraph 6.8.6. Add
oil if necessary.
6--5
T--318
6.8.2 Compressor Disassembly
2
3
WARNING
1
Before disassembly of any external compressor component make sure to relieve
possible internal pressure by loosening the
bolts and tapping the component with a
soft hammer to break the seal.
5
4
1. Oil Pressure Relief
Valve
2. Oil Return Check
Valve
CAUTION
Removing the compressor motor press-fit
stator in the field is not recommended. The
rotor and stator are a matched pair and
should not be separated.
Figure 6-8 Bottom Plate Removed
b. Loosen cylinder head cap screws. If the cylinder head
is stuck, tap the center of the cylinder head with a
wooden or lead mallet. Do not strike the side of the
cylinder head. Be careful not to drop the head or damage the gasket sealing surface. Remove cylinder
head bolts and gasket (see Figure 6-7).
When disassembling compressor, matchmark parts so
they may be replaced in their same relative positions
(see Figure 6-6). Refer to Table 6-6 and Table 6-7 for
compressor wear limits and bolt torque values.
c. Remove valve stops and valves. After they have been
removed, free the valve plate from the cylinder deck
by using the outside discharge valve hold-down cap
screw as a jack screw through the tapped hole of the
valve plate. Remove the valve plate gasket.
a. Place the compressor in a position where it will be
convenient to drain the oil. Remove the oil fill plug
(see Figure 6-6) to vent the crankcase. Loosen the
drain plug in bottom plate and allow the oil to drain out
slowly. Remove the plug slowly to relieve any crankcase pressure. Some units have a plug in the bottom
center of the crankcase, which may be removed for
draining the motor end more quickly.
1
2
3
4
5
3. Oil Suction Tube
4. Cap screw
5. Connecting Rod and
Cap Assembly
d. Turn the compressor on its side and remove the bottom plate oil suction screen and screen hold down
plate. Inspect the screen for holes or an accumulation
of dirt. The screen can be cleaned with a suitable solvent.
e. Match mark each connecting rod cap (see Figure 6-8)
and connecting rod for correct reassembly. Remove
the bolts and connecting rod caps. Push the piston
rods up as far as they will go without having the piston
rings extend above the cylinders.
7
CAUTION
JACK HERE
The copper tube, which connects to the oil
suction strainer extends out the bottom
with the bottom plate removed. Take precautions to avoid bending or breaking it
while changing crankcase positions.
6
1. Cylinder Head Gasket
2. Discharge Valve
Screw & Lockwasher
3. Discharge Valve Stop
4.
5.
6.
7.
Discharge Valve
Valve Plate
Valve Plate Assembly
Valve Plate Gasket
f. If necessary, remove the oil return check valve (see
Figure 6-8). Inspect it for proper operation (flow in
one direction only). Replace the assembly with a new
unit if check valve operation is impaired.
g. To remove the oil pump (see Figure 6-9) remove eight
cap screws, oil pump bearing head assembly, gasket,
and thrust washer.
Figure 6-7 Exploded View of Valve Plate
T--318
6--6
h. Be very careful not to damage the motor windings
when removing the motor end cover (see
Figure 6-11), as the cover fits over the winding coils.
Loosen the cap screws, break the seal, and then remove all cap screws except one in the top of the
cover. While holding the cover in place, remove the
remaining cap screw. Do not allow the cover to drop
from its own weight. To prevent striking the winding,
remove the cover horizontally and in line with the
motor axis.
Set screw must be removed.
1
6
5
4
1. Oil Pump & Bearing
Head
2. Thrust Washer
4
2
3
7
5
3
3. Oil Pickup Tube
4. Oil Inlet Port
5. Oil Pump Inlet
2
1
Figure 6-9 Oil Pump and Bearing Head
NOTE
If the oil pump was not operating properly, the
entire oil pump & bearing head assembly must
be replaced. Individual parts are not available. If
the pump requires inspection or cleaning, disassemble and reassemble by referring to
Figure 6-10. Clean all parts and coat all moving
parts with compressor oil before proceeding
with reassembly.
1. Strainer Screws and
Washers
2. Suction Strainer
3. Motor End Cover
Gasket
1
2
3
4
5
7
11
8
1.
2.
3.
4.
5.
6.
Cap screws
Cover
Reversing Assembly
Pinion
Gear
Drive
Motor End Cover
Valve Gasket
Suction Service Valve
Valve Cap screw
Figure 6-11 Motor End Cover
i. Remove the refrigerant suction strainer. If it is
removed with ease, it may be cleaned with solvent
and replaced. If the strainer is broken, corroded or
clogged with dirt that is not easily removed, replace
the strainer. Install new gaskets upon reassembly.
j. Block the compressor crankshaft so that it cannot
turn. Use a screwdriver to bend back the tabs on the
lockwasher, and remove the equalizer tube and lock
screw assembly (see Figure 6-12). The slingers at
the end of the tube draw vapor from the crankcase.
Remove the rotor using a jack bolt. Insert a brass plug
into the rotor hole to prevent damage to the end of the
crankshaft.
k. If the piston rings extend beyond the cylinder tops, the
pistons can be pulled through the bottom plate opening after the piston rings are compressed. A piston
ring compresser will facilitate removal. Each piston
pin is locked in place by lock rings, which are snapped
into grooves in the piston wall (see Figure 6-13).
l. Since the stator cannot be replaced in the field, the
terminal plate assembly need not be disturbed unless
a leak exists and the plate assembly needs to be replaced. If no terminal plate repair is required, proceed
with reassembly.
12
6
4.
5.
6.
7.
10
9
7. O-Ring
8. Oil Pump & Bearing
9. Set Screw
10. Relief Valve
11. Pin
12. Gasket
Figure 6-10 Low Profile Oil Pump
6--7
T--318
1
2
1
3
2
3
1. Equalizer Tube and
Lock Screw Assembly
2. Lockwasher
3. Counterweight Motor End
1. Suction Valve
2. Suction Valve
Positioning Spring
Figure 6-12 Equalizing Tube and Lock Screw
Assembly
6
9
Figure 6-14 Suction Valve & Positioning Springs
5
7
3. Valve Plate Dowel
Pin
Suction valves are positioned by dowel pins (see Figure
Figure 6-14). Do not omit the suction valve positioning
springs. Place the springs so that the ends bear against
the cylinder deck (middle bowed away from cylinder
deck). Use new gaskets when reinstalling valve plates
and cylinder heads.
8
4
b. Compression Rings
3
The compression ring is chamfered on the inside
circumference. This ring is installed with the chamfer
toward the top. Stagger the ring end gaps so they are
not aligned.
2
10
1
1.
2.
3.
4.
5.
Cap screw
Cap
Crankshaft
Thrust Washer
Rotor Drive Key
6.
7.
8.
9.
10.
Connecting Rod
Compression Ring
Piston
Pin
Retainer
Figure 6-13 Crankshaft Assembly
6.8.3 Compressor Reassembly
Clean all compressor parts, using a suitable solvent with
proper precautions. Coat all moving parts with the
proper compressor oil before assembly. Refer to
Table 6-7 for applicable compressor torque values.
6.8.4 Preparation
a. Suction and Discharge Valves
If the valve seats look damaged or worn, replace valve
plate assembly. Always use new valves because it is
difficult to reinstall used valves so that they will seat as
before removal. Any valve wear will cause leakage.
T--318
Figure 6-15 Piston Ring
The gap between the ends of the piston rings can be
checked with a feeler gauge by inserting the ring into the
piston bore approximately one inch below the top of the
bore. Square the ring in the bore by pushing it slightly
with a piston. The maximum and minimum allowable
ring gaps are 0.33 and 0.127 mm (0.013 and 0.005 inch)
respectively.
6--8
6.8.5 Installing the Components
a. Push pistons from the inside of the crankcase through
the cylinders, being careful not to break the rings.
Place rods so that the chamfered side will be against
radius of crankpins. Install the crankshaft and thrust
washer through the pump end of the compressor. Ensure thrust washer is fitted on locating pin. Do not
damage main bearings. Bring rods in position against
crank bearings.
b. Install the pump end thrust washer on the two dowel
pins located on the bearing head (see Figure 6-9).
CAUTION
Ensure that thrust washer does not fall off
dowel pins while installing oil pump.
CAUTION
The set screw on the crankshaft must be
removed for this type of oil pump (see
Figure 6-9).
c. Install the bearing head assembly with a new gasket
on the compressor crankshaft. Carefully push oil
pump on by hand, ensuring that the thrust washer remains on the dowel pins. The tang on the end of the
drive engages the slot in the crankshaft, and the oil inlet port on the pump is aligned with the oil pickup tube
in the crankcase. The pump should mounted flush
with the crankcase, and should be oriented with the oil
pick up tube and oil inlet port aligned as shown in
Figure 6-9.
d. Align the gasket and install the eight cap screws in the
mounting flange. Refer to Table 6-7 for applicable
torque values.
e. Install matching connecting rod caps Be sure rod is
not bound and crankshaft will turn correctly as each
set of rod bolts is torqued.
f. Be sure key fits properly when installng rotor on shaft.
Screw on equalizer tube and lock screw assembly
with lock washer and bend over tabs of lock washer.
Assemble suction strainer to motor and cover, and
bolt cover to crankcase. Assemble valve plates and
gaskets. Assemble cylinder heads and gaskets. Turn
the shaft by hand to see that it moves freely.
g. Install the oil suction screen, the oil suction screen
hold down plate, and the bottom plate.
6.8.6 Compressor Oil Level
CAUTION
Use only Carrier Transicold approved
Polyol Ester Oil (POE) -- Castrol-Icematic
SW20 compressor oil with R-134a. Buy in
quantities of one quart or smaller. When
using this hygroscopic oil, immediately
reseal. Do not leave container of oil open or
contamination will occur.
6--9
a. Checking the Oil Level in the Compressor
1. Operate the unit in cooling mode for at least 20 minutes.
2. Check the front oil sight glass on the compressor to
ensure that no foaming of the oil is present after 20
minutes of operation. If the oil is foaming excessively
after 20 minutes of operation, check the refrigerant
system for flood-back of liquid refrigerant. Correct
this situation before performing step 3.
3. Turn unit off to check the oil level. The correct oil level
range should be between the bottom to one-eighth
level of the sight glass. If the level is above one-eighth, oil must be removed from the compressor. To
remove oil from the compressor, follow step d in this
section. If the level is below the bottom of the sight
glass, add oil to the compressor following step b
below.
b. Adding Oil with Compressor in System
1. The recommended method is to add oil using an oil
pump at the oil fill valve (see item 11, Figure 6-6).
2. In an emergency where an oil pump is not available,
oil may be drawn into the compressor through the
suction service valve.
Connect the suction connection of the gauge manifold to the compressor suction service valve port,
and immerse the common connection of the gauge
manifold in an open container of refrigeration oil.
Extreme care must be taken to ensure the manifold
common connection remains immersed in oil at all
times. Otherwise air and moisture will be drawn into
the compressor. Crack the suction service valve and
gauge valve to vent a small amount of refrigerant
through the common connection and the oil to purge
the lines of air. Close the gauge manifold valve.
With the unit running, frontseat the suction service
valve and induce a vacuum in the compressor crankcase. SLOWLY crack the suction gauge manifold
valve and oil will flow through the suction service
valve into the compressor. Add oil as necessary.
c. Adding Oil to Service Replacement Compressor
Service replacement compressors are shipped without
oil. If oil is present in the crankcase, it must be tested to
ensure it is the correct oil and that the moisture level is
acceptable.
When adding oil to a service replacement compressor
add three liters (6.3 pints) using an oil pump at the oil fill
valve (see item 11, Figure 6-6). This quantity is
recommended to allow for return of any oil that may be in
the refrigerant system. Install compressor and check oil
level after it is placed in operation (refer to paragraph
6.8.6).
d. Removing Oil from the Compressor
1. If the oil level is above one-eighth sight glass, oil
must be removed from the compressor.
2. Close (frontseat) suction service valve and pump
unit down to 1.2 to 1.3 kg/cm@ (2 to 4 psig). Frontseat
discharge service valve and removeremaining refrigerant.
3. Loosen the oil drain plug on the bottom plate of the
compressor and drain the proper amount of oil from
the compressor to obtain the correct level. Backseat
the suction and discharge service valves.
4. Repeat step a to ensure proper oil level.
T--318
6.9 HIGH PRESSURE SWITCH
6.10 CONDENSER COIL
6.9.1 Replacing High Pressure Switch
The condenser 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:
a. Turn unit start-stop switch OFF. Frontseat both suction and discharge service valves to isolate compressor. Remove the refrigerant from the compressor.
b. Disconnect wiring from defective switch. The high
pressure switch is located on the center head and is
removed by turning counterclockwise (see
Figure 2-3).
WARNING
Do not open the condenser fan grille before
turning power OFF and disconnecting
power plug.
c. Install a new high pressure switch after verifying
switch settings (refer to paragraph 6.9.2).
a. Using a refrigerant reclaim system, remove the refrigerant charge.
b. Remove the condenser coil guard.
c. Unsolder discharge line and remove the line to the
receiver or water-cooled condenser.
d. Remove coil mounting hardware and remove the coil.
e. Install replacement coil and solder connections.
f. Leak-check the coil connections per paragraph paragraph 6.5. Evacuate the unit per paragraph 6.6 then
charge the unit with refrigerant per paragraph 6.7.
d. Evacuate and dehydrate the compressor per paragraph 6.6.
6.9.2 Checking High Pressure Switch
WARNING
Do not use a nitrogen cylinder without a
pressure regulator. Do not use oxygen in or
near a refrigeration system as an explosion
may occur.
6.11 CONDENSER FAN AND MOTOR ASSEMBLY
NOTE
The high pressure switch is non-adjustable.
WARNING
a. Remove switch as outlined in paragraph 6.9.1
Do not open condenser fan grille before
turning power OFF and disconnecting
power plug.
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.
The condenser fan rotates counter-clockwise (viewed
from front of unit), pulls air through the the condenser
coil and discharges horizontally through the front of the
unit. To replace motor assembly:
a. Open condenser fan screen guard.
b. Loosen two square head set screws on fan (thread
sealer has been applied to set screws at installation).
Disconnect wiring from motor junction box.
c. Connect hose to a cylinder of dry nitrogen (see
Figure 6-16).
d. Set nitrogen pressure regulator at 26.4 kg/cm@ (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/cm@ (350 psig). If a
light is used, light will go out. If an ohmmeter is used,
the meter will indicate open circuit.
CAUTION
Take necessary steps (place plywood over
coil or use sling on motor) to prevent motor
from falling into condenser coil.
g. Slowly open bleed-off valve to decrease the pressure. The switch should close at 18 kg/cm@ (250
psig).
1
4
5
2
3
6
c. Remove motor mounting hardware and replace the
motor. It is recommended that new locknuts be used
when replacing motor. Connect wiring per wiring diagram.
d. 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 projects 3.2 to 6.4 mm (3/16”
1. Cylinder Valve
and Gauge
2. Pressure Regulator
3. Nitrogen Cylinder
4. Pressure Gauge
(0 to 36 kg/cm@ =
0 to 400 psig)
5. Bleed-Off Valve
6. 1/4 inch Connection
¦1/16”) back from edge of the venturi. Spin fan by
hand to check clearance.
e. Close and secure condenser fan screen guard.
f. Apply power to unit and check fan rotation. If fan motor
rotates backward, reverse wire numbers 5 and 8.
Figure 6-16 High Pressure Switch Testing
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6--10
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.
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.
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.
To find the approximate condensing temperature, with
the unit running in the cooling mode, install a gauge 0 to
36.2 kg/cm@ (0 to 500 psig) on the compressor
discharge service valve.
Example: Discharge pressure is 10.3 kg/cm@ (146.4
psig). Referring to Table 6-8 (R-134a pressure/
temperature chart), the 10.3 kg/cm@ (146.4 psig) value
converts to 43 C (110 F).
If the water-cooled condenser is dirty, it may be cleaned
and de-scaled by the following procedure:
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.
What You Will Need:
1. Oakite composition No. 22, available as a powder in
68 kg (150 lb) and 136 kg (300 lb) containers.
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.
3. Fresh clean water.
4. Acid proof pump and containers or bottles with rubber hose.
e. Neutralize.
f. Flush.
g. 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.
2. To remove slime or mud, use Oakite composition No.
22. Mixed 170 grams (6 ounces) per 3.785 liters (1
U.S. gallon) of water. Warm this solution and circulate through the tubes until all slime and mud has
been removed.
3. After cleaning, flush tubes thoroughly with fresh
clean water.
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.
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. PUT WATER INTO
THE ACID -- this will cause spattering and
excessive heat.
5. Fill the tubes with this solution by filling from the bottom. See Figure 6-17. Important: be sure to provide
a vent at the top for escaping gas.
NOTE
When Oakite compound No. 32 is being used
for the first time, the local Oakite Technical Service representative should be called in for assistance in planning the procedure. They will
advise the reader on how to do the work with a
minimum dismantling of equipment, estimate
the time and amount of compound required,
preparation, how to control and conclude the
de-scaling operation by rinsing and neutralizing
equipment before putting it back into service.
Centrifugal pump
30 GPM at 35’ head
Priming
connection
Pump
Vent
Globe
valves
Close vent pipe
valve when pump
is running.
Suction
Condenser
Tank
Remove water
regulating valve
Return
Summary of Procedure:
a. Drain water from condenser tubing circuit. Clean
water tubes with Oakite No. 22 to remove mud and
slime.
b. Flush.
c. De-scale water tubes with Oakite No. 32 to remove
scale.
d. Flush.
Pump
support
Fine mesh
screen
Figure 6-17 Water-Cooled Condenser Cleaning -Forced Circulation
6--11
T--318
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.
NOTE
If the 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.
An alternate method may be used whereby a pail (see
Figure 6-18) 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.
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.
For Additional Help:
Contact the Engineering and Service Department of
Chemetall Oakite, 675 Central Avenue, New
Providence, NJ 07974 for the name and address of the
service representative in your area, or visit the
company’s Web site (www.oakite.com).
Fill condenser with cleaning solution. Do not add
solution more rapidly than
vent can exhaust gases
caused by chemical
action.
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 when the
suction modulation valve is fully open, 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. Pump down the unit (refer to paragraph 6.4 and
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.
1” Pipe
5’ Approximate
Vent
pipe
3’ to 4’
Condenser
Figure 6-18 Water Cooled Condenser Cleaning Gravity Circulation
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.
6.14 THERMOSTATIC EXPANSION VALVE
The thermostatic expansion valve (see Figure 2-2) is an
automatic device that maintains constant superheat of
the refrigerant gas leaving the evaporator, regardless of
suction pressure.
The valve functions are:
1. Automatic control of the refrigerant flow to match the
evaporator load.
2. Prevention of liquid refrigerant entering the compressor.
Unless the valve is defective, it seldom requires
maintenance other than periodic inspection to ensure
that the thermal bulb is tightly secured and properly
insulated. See Figure 6-19.
8. When de-scaling is complete, drain the solution and
flush thoroughly with water.
9. Following the water flush, circulate a 56.7 gram (2
ounce) per 3.785 liter (1 U.S. gallon) solution of
Oakite No. 22 thru the tubes to neutralize. Drain this
solution.
NOTE
TXV Bulb Clamp is soldered to the suction line.
10.Flush the tubes thoroughly with fresh water.
T--318
6--12
1
the evaporator outlet test pressures at the suction
modulation valve.
g. Subtract the saturation temperatures determined in
step f from the temperatures measured in step e. The
difference is the superheat of the suction gas. Determine the average superheat It should be 4.5 to 6.7 C
(8 to 12 F).
3
2
6.14.2 Expansion Valve Replacement
a. Removing the Expansion Valve
NOTES
5
1. The TXV is a hermetic valve and does not
have
adjustable
superheat
(See
Figure 6-20).
4
1. Suction Line
2. Thumbscrew
3. TXV Bulb Clamp
4. TXV Bulb
5. Foam Insulation
2. All connections on the hermetic TXV are
bi-metallic, copper on the inside and
stainless on the outside.
Figure 6-19 Thermostatic Expansion Valve Bulb
3. All joints on the hermetic TXV (inlet, outlet
and equalizer lines) are brazed.
6.14.1 Checking Superheat
4. Bi-metallic connections heat up very quickly.
NOTE
Proper superheat measurement should be
completed at -18 C (0 F) container box temperature where possible.
6
a. Open the upper right (EFM#1) access panel (see
Figure 2-1) to expose the expansion valve.
1
b. Attach a temperature sensor near the expansion
valve bulb and insulate. Make sure the suction line is
clean and that firm contact is made with the sensor.
c. Connect an accurate gauge to the service port directly upstream of the suction modulating valve
d. Set the temperature set point to -18 C (0 F) and run
unit until conditions stabilize.
e. The readings may cycle from a high to a low reading.
Take readings of temperature and pressure every
three to five minutes for a total of 5 or 6 readings
f. From the temperature/pressure chart (Table 6-8), determine the saturation temperature corresponding to
2
5
3
4
1.
2.
3.
4.
5.
6.
Hermetic Thermostatic Expansion Valve
Non-adjustable Superheat Stem
Equalizer Connection
Inlet Connection
Outlet Connection
Hermetic Expansion Valve Bulb
Figure 6-20 Thermostatic Expansion Valve
Braze Rod
(’Sil-Phos” = 5.5% Silver, 6% Phosphorus)
Copper Tube
(Apply heat for
10-15 seconds)
Bi-metallic Tube Connection
(Apply heat for 2-5 seconds)
Use of a wet cloth is not necessary due to rapid heat dissipation
of the bi-metallic connections
Figure 6-21 Hermetic Thermostatic Expansion Valve Brazing Procedure
6--13
T--318
1. Pump down the unit per paragraph 6.4.
6.15 EVAPORATOR COIL AND HEATER
ASSEMBLY
2. If TXV replacement is to be performed from the front
of the unit, open the upper right (EFM#1) access
panel (see Figure 2-1) and remove the evaporator
fan motor.
The evaporator section, including the 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 drain pan hose is routed behind the condenser fan
motor and compressor. The drain pan line must be open
to ensure adequate drainage.
3. Remove cushion clamp that secures the valve body
to the bracket.
4. Unbraze the equalizer connection (1/4”), the outlet
connection (5/8”), and then the inlet connection
(3/8”). See Figure 6-21. Be careful to protect the insulation on the heaters and their wires.
6.15.1 Evaporator Coil Replacement
a. Pump unit down (refer to paragraph 6.4).
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. Disconnect the defrost temperature sensor (see Figure Figure 2-2) from the coil.
e. Remove middle coil support.
f. Remove the mounting hardware from the coil.
g. Unsolder the two coil connections, one at the distributor and the other at the coil header.
h. After defective coil is removed from unit, remove
defrost heaters and install on replacement coil.
i. Install coil assembly by reversing above steps.
j. Leak check connections per paragraph 6.5. Evacuate
the unit per paragraph 6.6, and add refrigerant charge
per paragraph 6.7.
6.15.2 Evaporator Heater Replacement
The heaters are wired directly back to the contactor. If a
heater failure occurs during a trip, the heater set
containing that heater may be disconnected at the
contactor.
The next pre-trip will detect that a heater set has been
disconnected and indicate that the failed heater should
be replaced. To replace a heater, do the following:
a. Before servicing unit, make sure the unit circuit breakers (CB-1 & CB-2) and the start-stop switch (ST) are
in the OFF position, and that the power plug is disconnected.
b. Remove the upper back panel.
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).
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.
5. If TXV replacement is being performed from the front
of the unit, remove the access panel for the bulb.
6. Open the insulation flap. Flap is secured with Velcro
(Item 3, Figure 6-22).
7. Loosen the thumb screw and slide the bulb, out by
pulling it towards the front of the unit.
3
4
2
5
6
1
1.
2.
3.
4.
5.
6.
Hermetic Expansion Valve Bulb
Insulation
Insulation Flap
Velcro strip
Bulb Clamp
Thumb Screw
Figure 6-22 Hermetic Thermostatic Expansion
Valve Bulb Location
b. Installing the Expansion Valve
1. Braze inlet connection to inlet line (see Figure 6-21).
2. Braze outlet connection to outlet line.
3. Braze the equalizer connection to the equalizer line.
4. Reinstall the cushion clamp.
5. Thread the thermal bulb through the opening above
the evaporator coil (see Figure 2-2), and slide it under the strap and secure the thumb screw. Close the
insulation flap. Reinstall bulb access panel.
6. Check superheat (refer to step 6.14.1).
T--318
6--14
6.16 EVAPORATOR FAN AND MOTOR ASSEMBLY
If fan spins backward, then motor wiring or motor is
defective.
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.
f. Replace access panel making sure that panel does
not leak. Make sure that the T.I.R. locking device is
lockwired.
5
4
6.16.1 Replacing the Evaporator Fan Assembly
6
3
WARNING
5
2
1
Always turn OFF the unit circuit breakers
(CB-1 & CB-2) and disconnect main power
supply before working on moving parts.
a. Remove access panel (see Figure 2-2) by removing
mounting bolts and T.I.R. locking device. Reach
inside of unit and remove the Ty-Rap securing the
wire harness loop. Unplug the connector by twisting
to unlock and pulling to separate.
7
8
b. Loosen four 1/4-20 clamp bolts that are located on the
underside of the fan deck at the sides of the of the fan
assembly. Slide the loosened clamps back from the
fan assembly.
9
c. Slide the fan assembly out from the unit and place on
a sturdy work surface.
6.16.2 Disassemble the Evaporator Fan Assembly
1.
2.
3.
4.
5.
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 6-23).
b. Remove the spanner wrench. Use a universal wheel
puller and remove the fan from the shaft. Remove the
washers and key.
Stator
Flat washer, 1/4
Bolt, 1/4-20 x 3/4
Locknut, 5/8-18
Flat washer, 5/8
6.
7.
8.
9.
Impeller Fan
Key
Mylar Protector
Evaporator Motor
Figure 6-23 Evaporator Fan Assembly
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.
6.16.3 Assemble the Evaporator Fan Assembly
a. Assemble the motor and plastic spacer onto the stator.
b. Apply loctite to the 1/4-20 x 3/4 long bolts and torque
to 0.81 mkg (70 inch-pounds).
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).
6.17 EVAPORATOR FAN MOTOR CAPACITOR
Units are equipped with single permanent-split
capacitor fan motors.
6.17.1 When To Check For A Defective Capacitor
a. Fan motor will not change speed. For example: in the
conventional perishable mode, the motors should run
in high speed. In the economy perishable mode they
should switch speeds and in the frozen mode, the motors should run in low speed.
NOTE
The evaporator fan motors will always start in
high speed.
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.
b. Motor running in wrong direction (after checking for
correct wiring application).
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) Apply power momentarily to
check for proper fan rotation (refer to paragraph 2.3).
c. Motor will not start and IP-EMs are not open.
6--15
T--318
6.17.2 Removing the Capacitor
WARNING
Make sure power to the unit is OFF and
power plug disconnected before servicing
capacitor(s).
2-1/8 inch Nut
WARNING
Figure 6-24 Suction Modulation Valve (SMV)
6.18.1 Pre-check Procedure
With power OFF discharge the capacitor
before disconnecting the circuit wiring.
a. Check unit for abnormal operation.
b. Check charge. If refrigerant is low repair as required
and again check operation.
Capacitors must be discharged properly before testing.
To discharge the capacitor, first turn the unit power OFF
and disconnect the unit power plug. Then place a
20,000 ohm, 2 watt resistor across the terminals of the
capacitor for approximately 30 seconds.
c. If sufficient capacity cannot be maintained or unit is
tripping excessively on high pressure switch (HPS) in
high ambients, check coils and clean if required.
d. If capacity or control cannot be maintained, turn unit
OFF, then back ON. This will reset the valve in the
event the controller lost communication with the
valve, and may correct the problem.
The capacitors are located on the motor and may be
removed by two methods:
1 If container is empty, open upper rear panel of the
unit.
NOTE
Carefully listen to the valve. During reset, the
valve will make a ratcheting noise that may be
heard or felt as it is attempting to close. If this
can be heard or felt, it indicates that the controller and drive module are attempting to close the
valve, and may serve as a quick indication that
the drive module is in working order.
2 If container is full, turn the unit power OFF and disconnect power plug. Remove the evaporator fan
motor access panel (see Figure 2-1). For removal of
the evaporator fan assembly, refer to section 6.16.
6.17.3 Checking the Capacitor
If the capacitor is suspected of malfunction, you may
choose to simply replace it. Direct replacement requires
a capacitor of the same value. Two methods for
checking capacitor function are:
e. During the first few minutes of unit operation, compressor reliability enhancement logic (CREL) may be
in effect. This places the valve at a 21% staging position and is sufficient to drive the temperature of the
supply probe down several degrees during this interval.
1. Volt-ohmmeter set on RX 10,000 ohms.
Connect ohmmeter leads across the capacitor
terminals and observe the meter needle. If the capacitor
is good, the needle will make a rapid swing toward zero
resistance and then gradually swing back toward a very
high resistance reading.
f. After the CREL time-out has been met, the valve will
start responding to the control logic and open or close
relative to the demand. Scrutinize the unit operation
for a few minutes. While in pulldown, the unit will open
the SMV to a maximum discharge pressure of 325
psig in high ambient conditions, or as much as the
current setting and control logic will allow. The current
level should be high. A lower discharge pressure will
be seen in lower ambient temperatures. Once the unit
has reached set point, the SMV will go into control
mode. Both the discharge/suction pressures, and
current draw will go significantly lower. Once below
set point, the suction pressure should go into a vacuum within several minutes. Should the operation differ as mentioned, the SMV, controller, or wiring, may
be faulty.
If the capacitor has failed open, the ohmmeter needle
will not move when the meter probes touch the
terminals. If the capacitor is shorted, the needle will
swing to zero resistance position and stay there.
2. Capacitor analyzer:
The function of the analyzer is to read the microfarad
value of a capacitor and to detect insulation breakdown
under load conditions. The important advantages of an
analyzer are its ability to locate capacitors that have
either failed to hold their microfarad ratings or those that
are breaking down internally during operation. It is also
useful in identifying capacitors when their microfarad
rating marks have become unreadable.
g. Check for correct wire location at the stepper motor
plug and the environmental connector (EC). Make
sure that the wires terminate in accordance with the
wire markings (addresses).
6.18 SUCTION MODULATION VALVE
On start up of the unit, the valve will reset to a known
open position. This is accomplished by assuming the
valve was fully open, driving it fully closed, resetting the
percentage open to zero, then opening to a known 21%
staging position.
T--318
h. Attach a manifold gauge set (refer to paragraph 6.3).
If the unit is operating in the perishable mode, proceed to step i. If the unit is operating in the frozen
mode, proceed to step j.
6--16
i. Perishable operation: If the operation of the unit is in
question, place the set point to approximately 6 C
(11 F) less than the current box temperature, so the
unit goes into pulldown. Run the unit for approximately one minute. Record readings on gauges and current draw. The current draw and pressures should go
up. Place set point 0.5 degrees C (0.9 degrees F)
above current box temperature to fully modulate
valve, and run for approximately one minute.
NOTE
The unit may shut off for a short time. Wait until
the unit self starts and sufficient time has
elapsed to cause the valve to fully modulate.
Record new gauge readings and current draw. The
suction pressure should go into a vacuum and the
current draw should have gone down. If little or no
change to the suction pressure or current draw occurs, this is an indication of a malfunctioning SMV.
pressure will go into a vacuum. This is an indication
that the valve is moving.
4. If no change in suction pressure is detected, check
for resistance (refer to step 6.18.2), and check connections for proper continuity and retest. If the valve
is functioning, and all connections and motor resistance are good, check the drive module (refer to step
6.18.3).
5. If the valve is determined to be faulty after completing the above steps, perform a low side pump down.
Remove valve powerhead assembly, and replace
with a NEW valve powerhead assembly, torque nut
to 35 ft-lb, evacuate low side, and open all service
valves.
CAUTION
j. Frozen operation: In frozen mode the valve tends to
stay open as much as possible. Again, this is dependent upon current limit setting and control logic. Turn
the unit OFF and ON, as in the perishable mode, and
watch the gauges. The valve will run at 21% open if
CREL logic is active, and will open to maximum allowable after this. Depending on ambient conditions,
there should be an increase in suction pressure and
current draw as the valve opens. However, at times,
this may be difficult to fully determine.
k. If the unit still does not operate properly, stop unit and
proceed to the following step to check out the SMV
system.
6.18.2 Checking the Stepper Valve
a. Checking with ohmmeter
Disconnect the 4-pin connector to the stepper SMV.
With a reliable digital ohmmeter, check the winding
resistance. In normal ambient, the valve 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 and replace
the motor. If near normal or normal reading occurs,
proceed to step 6.18.3 to check out the controller.
b. Checking with 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 that will open and close the SMV, allowing
a more thorough check of the motor.
To check operation:
1. Stop the unit, disconnect the 4-pin connector from
the stepper module to the valve (see Figure 6-24)
and attach the SMA-12 stepper drive to the connector going to the valve.
2. Set the SMA-12 pulse per second (PPS) to one PPS
and either open or close valve. Each LED should
light sequentially until all four are lit. Any LED failing
to light indicates an open on that leg, which indicates
a poor connection or an open coil. Repair or replace
as required to achieve proper operation.
DO NOT disassemble piston from NEW suction modulating valve powerhead assembly. Doing so may result in damage to piston.
6.18.3 Checking the Controller
a. Turn unit OFF.
b. With voltmeter set to read 20 volts DC, attach the positive lead to MC1 of the 4-pin connector and the negative lead to the TP9. Turn ON unit and watch the volt
meter. After a short delay, the reading should remain
unchanged at 0 volts. If 5 VDC, check jumper wire
form MC1 to MC8 is in place; if not, install and retest.
6.18.4 Emergency Repair Procedures
In the event that the SMV system has a failure and
replacement components are not readily available, the
system can be bypassed by removing the valve piston.
To remove the piston, do the following:
a. Perform a low side pump down (refer to paragraph
6.4).
b. Remove SMV powerhead by loosening the 2-1/8
inch diameter nut (see Figure 6-24) to relieve any
pressure and then sliding the powerhead out.
c. Remove the piston by loosening the Allen screw and
removing the piston and screw.
d. Install the powerhead assembly (without the piston)
and torque to 35 to 40 foot-lbs.
e. Open all valves.
f. Start the unit.
g. Adjust the suction service valve so that the approximate temperature OR current limit is maintained.
For perishable loads, it is recommended that the adjustment be made so that the available capacity is
slightly larger than the load. The unit will cycle OFF
and ON.
h. Once repair parts become available, repair as required.
6.19 DPRV CHECK PROCEDURE
The discharge pressure regulating valve (DPRV) is
designed to maintain a minimal level of pressure within
the compressor. Refer to paragraph 2.2 for valve
setting.
The following procedure can be used to perform a
functional check:
a. Install a high pressure gauge at the discharge service
valve.
3. Restart unit, set the step rate to 200 PPS on SMA-12
for the valve, and close stepper valve while watching
the suction gauge. Within one minute the suction
6--17
T--318
b. Install another high pressure gauge at the liquid line
service valve.
6.21 CONTROLLER
6.21.1 Handling Controller
c. Run unit with -18 C (0 F) set point.
CAUTION
d. After five minutes, read both gauges and subtract the
liquid line pressure from the discharge pressure. This
is the actual differential pressure.
Do not remove wire harnesses from controller unless you are grounded to the unit
frame with a static safe wrist strap.
e. Using the ambient temperature and the chart below,
determine the replacement differential pressure.
Replacement Differential
Pressure (psi)
CAUTION
Unplug all controller connectors before
performing arc welding on any part of the
container.
70
60
REPLACE DPRV
50
The guidelines and cautions provided herein should be
followed when handling the Controller/DataCORDER
module. These precautions and procedures should be
implemented when replacing the module, when doing
any arc welding on the unit, or when service to the
refrigeration unit requires handling and removal of the
controller.
40
30
20
DO NOT REPLACE DPRV
10
1
0
30
40
50
60
70
80
90
100
110
2
3
4
120
Ambient Temperature (F)
Figure 6-25 DPRV Replacement Value Chart
NOTE
1. This test should not be run below -1.1 C
(30 F) or above 49 C (120 F). If the actual
differential pressure is close to the
replacement differential pressure, it is
recommended that the readings be taken
several times at two minutes intervals.
2. If valve cap is found to be leaking it may be
replaced using cap & O-ring (Carrier Part
Number 40-50024-00).
6.20 AUTOTRANSFORMER
If the unit does not start, check the following:
1.
Controller Software 3. Controller
Programming Port
2. Mounting Screw
4. Test Points
Figure 6-26 Controller Section of the Control Box
a. Obtain a grounding wrist strap (Carrier Transicold PN
07-00304-00) and a static dissipation mat (Carrier
Transicold PN 07-00304-00). The wrist strap, when
properly grounded, will dissipate any potential buildup on the body. The dissipation mat will provide a static-free work surface on which to place and/or service
the controller.
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. Carefully remove the controller. Do not touch any of
the electrical connections if possible. Place the module on the static mat.
a. Make sure the 460 VAC (yellow) power cable is
plugged into the receptacle (item 3, Figure 4-1) and
locked in place.
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.
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.
T--318
6--18
e. The strap should be worn during any service work on
the controller, even when it is placed on the mat.
2. Insert software/programming PCMCIA card containing the following (example) files into the programming/software port (see Figure 6-26):
6.21.2 Controller Troubleshooting
menuDDMM.ml3 -- This file allows the user to select
a file/program to upload into the controller.
A group of test points (TP) (see Figure 6-26) are
provided on the controller for troubleshooting electrical
circuits (see schematic diagram, section 7). A
description of the test points follows:
cfYYMMDD.ml3 -- Multi-configuration file.
3. Turn unit ON 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.
NOTE
Use a digital voltmeter to measure AC voltage
between TPs and ground (TP9), except for
TP8.
5. Press the UP or DOWN arrow key until display
reads, LOAd 54XX for Recip (even numbers).
TP2
6. Press the ENTER key on the keypad. The display
will alternate to between PrESS EntR and rEV
XXXX.
This test point enables the user to check if the internal
protector for the compressor motor (IP-CP) or high
pressure switch is open.
7. Press the ENTER key on the keypad.
TP3
8. The display will show the message “Pro SoFt”. This
message will last for up to one minute.
This test point enables the user to check if the water
pressure switch (WP) contact is open or closed.
9. Press the ENTER key on the keypad.
TP 4
10.The display module will go blank briefly, then read
“Pro donE” when the software is 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.
This test point enables the user to check if the internal
protector for the condenser fan motor (IP-CM) is open or
closed.
TP 5
11. Turn unit OFF via start-stop switch (ST).
This test point enables the user to check if the internal
protectors for the evaporator fan motors (IP-EM1 or
IP-EM2) are open or closed.
12.Remove the PCMIA card from the programming/software port and return the unit to normal operation
by placing the start-stop switch in the ON position.
TP 6
13.Turn power on and wait 15 second. The status LED
will flash quickly and there will be no display. The
controller is loading the new software into memory.
This takes about 15 seconds.
This test point enables the user to check if the controller
water tank heater relay (TQ) is open or closed.
TP 7
When complete the controller will reset and power up
normally.
This test point is not used in this application.
TP 8
14 Wait for default display -- setpoint on the left and control temperature on the right.
This test point is not applicable to the units covered
herein.
TP 9
15.Confirm software is correct using keypad code select 18 to view Cd18 XXXX.
This test point is the chassis (unit frame) ground
connection.
16.Turn power off. Operational software is loaded.
b. Procedure for loading configuration software:
TP 10
1. Turn unit OFF using start-stop switch (ST).
This test point enables the user to check if the heat
termination thermostat (HTT) contact is open or closed.
2. Insert software/programming PCMCIA card containing the following (example) files into the programming/software port (see Figure 6-26):
6.21.3 Controller Programming Procedure
To load new software into the module, the programming
card is inserted into the programming/software port.
menuDDMM.ml3 -- This file allows the user to select
the file/program to upload into the controller.
cfYYMMDD.ml3 -- Multi-configuration file.
CAUTION
recp54XX.ml3 -- Controller software program for
recip units.
The unit must be OFF whenever a programming card is inserted or removed from the
controller programming port.
3. Turn unit ON using start-stop switch (ST).
a. Procedure for loading operational software
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.
1. Turn unit OFF via start-stop switch (ST).
5. Press the ENTER key on the keypad.
6--19
T--318
6. The display module will go blank briefly and then display “541 00.” Based on the operational software
installed.
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.)
8. Press the ENTER key on the keypad.
9. When the 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.)
10.Turn unit OFF using start-stop switch (ST).
11. Remove the PCMIA card from the programming/software port and return the unit to normal operation
by placing the start-stop switch in the ON position.
12.Confirm correct model configuration using the keypad to choose code select 20 (CD20). The model
displayed should match the unit serial number plate.
6.21.4 Removing and Installing the Controller
a. Removal:
1. Disconnect all front wire harness connectors and
move wiring out of way.
2 The lower controller mounting is slotted. Loosen the
top mounting screw (see Figure 6-26) and lift up and
out.
3 Disconnect the two back connectors (EC) and remove module.
4 When removing the replacement controller from its
packaging, note how it is packaged. When returning
the old controller for service, place it in the packaging
in the same manner as the replacement. The packaging has been designed to protect the controller
from both physical and electrostatic discharge damage during storage and transit.
b.Installation:
Install the module by reversing the removal steps.
Torque values for mounting screws (item 2, see
Figure 6-26) are 0.23 mkg (20 inch-pounds). Torque
value for the connectors is 0.12 mkg (10 inch-pounds).
6.21.5 Battery Replacement
If required, use tool 07-00418-00.
6.22 TEMPERATURE SENSOR SERVICE
Procedures for service of the Return Recorder, Return
Temperature, Supply Recorder, Supply Temperature,
Ambient, Defrost Temperature, Compressor Discharge
and Compressor Suction temperature sensors are
provided in the following sub paragraphs.
T--318
6--20
6.22.1 Sensor Checkout Procedure
To check a sensor reading, do the following:
a. Remove the sensor and place in a 0 degrees C (32
degrees F) 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 0 degrees C (32
degrees F) measured on a laboratory thermometer.
b. Start unit and check sensor reading on the control
panel. The reading should be 0 degrees C (32 degrees F). If the reading is correct, reinstall sensor; if it
is not, continue with the following:
c. Turn unit OFF and disconnect power supply.
d. Refer to paragraph 6.21 and remove controller to gain
access to the sensor plugs.
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, CPDS
OR CPSS as required). Follow those wires to the connector and using the pins of the plug, measure the
resistance. Values are provided in Table 6-1.
Table 6-1 Sensor Temperature/Resistance Chart
Temperature
Centigrade
0
25
Temperature
Fahrenheit
Resistance
(Ohms)
RRS, RTS, SRS and STS:
32
32,650 +/-- 91
77
10,000 +/-- 50
AMBS and DTS
0
32
25
77
32,650 + 1720
- 1620
10,000 + 450
- 430
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.
6.22.2 Sensor Replacement
a. Turn unit power OFF and disconnect power supply.
b. For two wire sensors, cut cable 5 cm (2 inches) from
shoulder of defective sensor and discard the defective sensor only. For 3-wire sensors, cut at 23 cm (9
inches). Slide the cap and grommet off well mounted
sensor and save for possible reuse. Do not cut the
grommet.
c. If required, prepare the replacement sensor by cutting sensor wire(s) back 40 mm (1-1/2 inch). For
3-wire sensors, the black wire should be cut at the
middle length and the red/white wire cut to the shorter
length (See Figure 6-27).
Sensor
j. Slide heat shrink tubing over splice so that ends of
tubing cover both ends of crimp as shown in
Figure 6-28.
40 mm (1 1/2 inch)
k. Heat tubing to shrink over splice. Make sure all seams
are sealed tightly against the wiring to prevent moisture seepage.
6.3 mm (1/4 inch)
l. Slide large heat shrink tubing over both splices and
shrink.
Mounting Stud Type
40 mm (1-1/2 inches)
6.3 mm (1/4 inch)
CAUTION
Do not allow moisture to enter wire splice
area as this may affect the sensor resistance.
Sensor
Bulb Type
m. Reinstall sensor, refer to paragraph 6.22.3.
Figure 6-27 Sensor Types
NOTE
The P5 Pre-Trip test must be run to inactivate
probe alarms (refer to paragraph 4.8).
d. Prepare the cables by cutting wires to the opposite of
the sensor (See Figure 6-28).
When installing a single wire color two wire sensor,
cut one wire of existing two wire cable 40 mm (1-1/2
inch) shorter than the other wire.
6.22.3 Sensor Re-Installation
When replacing two single sensors with a combination (3-wire) sensor, the black wires of the cables
should be cut to the same length and the red wire of
one cable cut to the shorter length.
a. Sensors STS/SRS
e. Strip back insulation on all wiring 6.3 mm (1/4 inch).
To properly position a supply sensor, the sensor must be
fully inserted into the probe holder. This positioning will
give the sensor the optimum amount of exposure to the
supply air stream, and will allow the Controller to
operate correctly. Insufficient probe insertion into the
probe holder will result in poor temperature control due
to the lack of air flow over the sensor.
f. Slide a large piece of heat shrink tubing over the
cable, and place small pieces of heat shrink tubing,
one over each wire, before adding crimp fittings as
shown in Figure 6-28.
It is also necessary to ensure that the probe tip does not
contact the evaporator back panel. The design
minimum clearance of 6 mm (1/4 inch) should be
maintained (see Figure 6-29).
g. If required, slide the cap and grommet assembly onto
the replacement sensor. If the replacement sensor is
of a larger diameter than the original, a different grommet may be required.
b. Sensor RTS/RRS
When replacing a original 3-wire sensor, cut the black
wire to the middle length and the red wire to the shorter length.
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.
Reinstall the return sensor as shown in Figure 6-30. For
proper placement of the return sensor, be sure to
position the seal section of the sensor against the the
side of the mounting clamp.
c. Sensor DTS
The DTS sensor must have insulating material placed
completely over the sensor to insure the coil metal
temperature is sensed.
REPLACEMENT 2 WIRE TO
2 WIRE OR 3 WIRE TO 3 WIRE
RED
BLACK
RED/WHITE
REPLACEMENT FOR DUAL SINGLE
SENSOR CONFIGURATION
Sensor (Typical)
Cable
Large Heat Shrink
Tubing
Heat Shrink
Tubing
Figure 6-28 Sensor and Cable Splice
6--21
T--318
Sensor
Wires
Upon installation, a new VPS assembly requires
calibration as follows:
1. Rotate the vent to the 0 CMH/ CFM position.
Cap and Grommet
Assembly
2. Code select 45 will automatically be displayed.
Press the
Enter key and hold for five seconds.
Evaporator
Back Panel
3. After the enter key has been pressed, the display will
read CAL (for calibration).
Probe
Holder
4. Press the ALT MODE key and hold for five seconds.
5. After the calibration has been completed, Code 45
will display 0 CMH / CFM.
Supply
Air
Stream
Lower VPS:
1. Remove Condenser fan guard.
2. If unit is equipped with Partlow recorder, remove four
Partlow box assembly mounting bolts and pull Partlow box assembly away from unit.
Supply Sensor
If unit is not equipped with Partlow remove left hand
access panel to obtain clearance behind fresh air
make-up assembly.
6 mm
(1/4 inch)
3. Remove the two nuts and two washers that hold the
slide assembly on. These threads are staked the
nuts will be cutting threads during removal.
Figure 6-29 Supply Sensor Positioning
4. Remove slide assembly.
5. The VPS bracket may be riveted in place. If that’s the
case, drill out rivet heads.
Evaporator Grille
Combination
Sensor (Mount in
Either Clamp)
If bracket is bolted, remove bolts, washers, and nuts.
6. Note position of wire ties and wire routing for new
sensor installation.
7. Remove sensor and bracket assembly from the
backside of fresh air make-up.
Seal
8. Insert new sensor assembly through clearance hole
where the old sensor was removed and route wire
harness as noted in step 7.
Mounting
Clamp
9. Mount bracket to unit using bolts, washers, and nuts.
Figure 6-30 Return Sensor Positioning
10.Wire tie wire harness in locations noted in step 7.
6.23 VENT POSITION SENSOR (VPS)
11. Calibrate sensor:
a.Use a multi-meter set to 200k ohms. Connect lead
to VPS connector.
The vent position sensor (VPS) determines the position
of the fresh air vent in near real-time via the function
code 55.
b.Turn the gear wheel on the motor all the way to the
right (clockwise) until it stops.
The fresh air VPS alarm (AL50) will occur if the sensor
reading is not stable for five minutes or if the sensor is
outside of its valid range (shorted or 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.
c.Adjust the gear wheel counter clockwise until the
meter reads 6.5k ohms (approximately).
d. Install the VPS slide door so that the door is flush
against the bottom rail, the motor gear and the door
teeth are meshed, and the gear wheel does not move
from the set position.
The alarm should immediately go inactive. Check the
four-minute stability requirement. If the alarm reoccurs
after the four minutes and the panel was known to have
been stable, then the panel should be replaced.
12.Position slide assembly back on to studs and re-install two washers and two nuts that secure slide
assembly.
If the alarm immediately reappears as active, the panel
should be replaced.
Upper VPS:
13.Stake then ends of the two studs on panel assembly
with wire cutters so that nuts will not be easily removed.
In order to replace the VPS, the panel must be removed
and replaced with another upper fresh air panel
equipped with VPS.
15.Reinstall condenser fan guard.
T--318
14.Reinstall Partlow box assembly if equipped, or access panel.
6--22
c. Locate the connector below the recorder, and
squeeze the ears together to disconnect the plug
(item 6).
d. Remove the four mounting screws (item 8) and remove the recorder.
e. Install the new recorder by reversing the above steps.
6.24.2Changing the Chart
6.24 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.
NOTE
To prevent recorder corrosion, it is important to
assure the door is securely closed at all times
after completing the chart change.
If using the Electronic Partlow Recorder CTD P/N
12-00464-xx
Where xx= an odd number (example: 12-00464-03 )
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
period is less than thirty days; the pen tip will move to 25
degrees C (77 degrees F), the chart will advance to
present time, and the pen tip will move to the currently
recorded temperature.
a. Lift the stylus (item 5, Figure 6-31) by grasping the
arm near the base, and pulling the arm away from the
chart until it snaps into its retracted position.
b. Remove the chart retaining nut (item 10), remove the
used chart, and record today’s date on the old chart.
c. Press the “Change Chart” button (item 2).
NOTE
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.
Failure to press the change chart button when
changing a chart with the power OFF may result
in the chart advancing when power is applied.
d. Install a new chart. Make sure the chart center hole is
placed over the center hub and the chart edges are
behind the four hold down tabs (item 9).
e. Mark today’s date, container number, and other required information on the new chart and install under
hold down tabs.
f. Replace the chart nut loosely. Rotate the chart until
the correct day is aligned with the “start arrow” and
hand tighten the chart nut.
g. Gently lower the stylus arm until the pen tip (item 4)
comes in contact with the chart.
If using the Electronic Partlow Recorder CTD P/N
12-00464-xx
Where xx= an even number (example: 12-00464-06)
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
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.
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.
CAUTION
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.
Do not allow the recorder stylus to snap
back down. The stylus arm base is spring
loaded, and damage may occur to the chart,
or the stylus force may be altered.
6.24.1Replacing the Recorder
DO NOT move the stylus arm up and down
on the chart face. This will result in damage
to the stylus motor gear.
a. Turn power to the unit OFF.
b. Open the recorder door (see Figure 6-31, item 1).
6--23
T--318
3
2
1
4
5
10
9
8
7
6
1.
2.
3.
4.
5.
Recorder Door
Change Chart Button
Recorder Box
Pen Tip
Stylus Arm
6.
7.
8.
9.
10.
Connector
Calibration Button (Located underneath)
Mounting Screws, #10-24 x 7/16 inches long
Hold Down Tab
Chart Retaining Nut
Figure 6-31 Electronic Partlow Temperature Recorder
6.24.3Adjusting the Recorder Stylus
6.24.4Rezeroing the Recording Thermometer
Proper stylus force upon the chart paper is important.
Factory adjustment is 113 to 127 grams (4 to 4.5
ounces). To measure the force, use a spring type gauge
and attach it under the stylus as close as possible to the
pen tip (item 4). Exert pull on the gauge perpendicular to
the chart surface. The measured force should be noted
just as the pen tip leaves the surface.
For Electronic Partlow Recorder CTD P/N
12-00464-xx
Where xx= an even number (example: 12-00464-06)
NOTE
Use chart CTD P/N 09-00128-00 (degrees F)
P/N 09-00128-01 (degrees C).
a. Press the “Calibration” button (item 7, Figure 6-31)
on the bottom of the recorder. The pen tip will drive
fully down scale, then move upscale to the chart ring
at 0 degrees C (32 degrees F), and stop.
NOTE
The two coil springs near the base of the stylus
are NOT involved in establishing chart contact
force. They serve only to hold the stylus in its
retracted position.
b. If the tip of the pen (item 4) is on the 0 C (32 F) chart
ring the recorder is in calibration, proceed to step c.
If the tip of the pen is NOT on the 0 C (32 F) chart
ring, the operator must loosen the two screws on the
bottom of the stylus arm to adjust the pen tip
manually to the 0 C (32 F) chart ring. Tighten the
screws when adjustment is complete.
Correct adjustment is made by carefully bending the
portion of the stylus arm between the bend near the pen
tip and the first bend towards the stylus arm base. If the
force is too low, the stylus trace will be light and difficult
to read. If the force is too great, wrinkling or tearing of the
paper chart may occur.
T--318
c.
6--24
Press the calibration button and the pen will position
itself to the correct temperature reading.
b. Cut the fiberglass cloth to allow a 25mm (1 inch) overlap around the area to be repaired.
c. Stretch and position the cloth over the area to be repaired and secure it with masking tape.
d. Make up sufficient epoxy glue to cover the cloth by
mixing equal parts of resin and hardener. Saturate the
cloth with the epoxy glue, spreading evenly.
e. Remove the tape and overlap the edge of the cloth
approximately 6 to 12 mm (1/4” to 1/2”) with glue.
f. Epoxy will dry in 45-60 minutes. When completely
cured (12 hours), use sandpaper to smooth edges of
the patch.
6.26.3 Chips And Holes
Chips and holes in the control box are repaired using a
piece of aluminum or stainless steel to cover the
damaged area. The material can be cut to suit and
riveted in place. An adhesive sealant must be used to
make the repair watertight. The adhesive sealant
(Sikaflex 221) is included in Crack Repair Kit Carrier
Transicold part number 76-00724-00SV (see
Table 6-2). Do not use an acetone based silicone
sealant, which can be identified by a vinegar-like odor.
a. To make up the patch, cut a piece of aluminum or
stainless steel so that it will overlap the damaged area
by at least 40 mm (1 1/2”) on all sides.
b. Choose rivet locations and drill the rivet holes in the
corresponding locations on the control box and patch
piece.
c. Apply the adhesive sealant around the damaged area
to form a seal between the control box and the patch
piece.
d. Rivet the patch piece in place.
e. File smooth any rough edges (including rivets) that
may come into contact with wires.
6.26.4 Inserts
The threaded brass inserts that are molded into the
control box will need to be replaced if the threads
become stripped or if the insert becomes loose. The
inserts and epoxy are contained in repair kit, Carrier
Transicold part number 76-50084-00 (see Table 6-3).
There are 6 different inserts used in the control box.
Refer to Figure 6-33 for the locations of the various
inserts.
6.24.5Rezeroing the Recording Thermometer
For Electronic Partlow Recorder CTD P/N
12-00464-xx
Where xx= an odd number (example: 12-00464-03 )
NOTE
Use chart CTD P/N 09-00128-00 (degrees F)
P/N 09-00128-01 (degrees C).
a. Press the “Calibration” button (item 7, Figure 6-31)
on the bottom of the recorder. The pen tip will drive fully down scale, then move upscale to the chart ring at
-29 C (-20 F), and stop.
b. If the tip of the pen (item 4) is on the -29 C (-20 F) chart
ring the recorder is in calibration, proceed to step c. If
the tip of the pen is NOT on the -29 C
(-20 F) chart
ring, the operator must loosen the two screws on the
bottom of the stylus arm to adjust the pen tip manually
to the -29 degrees C (-20 degrees F) chart ring. Tighten the screws when adjustment is complete.
c. Press the calibration button and the pen will position
itself to the correct temperature reading.
6.25 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 area to bare metal using a
wire brush, emery paper, or equivalent cleaning
method. Immediately following cleaning, spray or brush
on zinc-rich primer. After the primer has dried, spray or
brush on finish coat of paint to match original unit color.
6.26 COMPOSITE CONTROL BOX REPAIRS
6.26.1 Introduction
This procedure provides instructions for repair of the
Carrier Transicold composite control box. Damage to
the control box may be in the form of a chip or hole, a
crack, a damaged thread insert or damage to the door
hinge inserts. Generally, the object of the repair must be
to ensure sufficient strength is restored to the damaged
area and the repair must keep the box water tight.
Information on repair kits and repair procedures for each
type of damage is provided in the following paragraphs.
Ambient temperature must be above 7 degrees C (45
degrees F) for proper curing of epoxy repairs.
NOTE
An epoxy application gun is also needed,
Carrier Transicold part number 07-00391-00.
6.26.2 Cracks
The damaged insert must be removed from the control
box. Table 6-4 identifies the drill size and drill depth to be
used for each insert. A stop ring should be used on the
drill bit to limit the depth.
a. Center the drill bit on the insert and drill to the prescribed depth.
b. Remove the chips from the drilled hole.
Cracks in the control box are repaired using a fiberglass
patch over the damaged area. Materials required are
included in the Fiberglass Patch Kit supplied with Crack
Repair Kit, Carrier Transicold part number
76-00724-00SV (see Table 6-2).
a. The surface must be clean and dry. Roughen the surface with sandpaper to ensure a good bond.
6--25
T--318
c. Mix the two component epoxy and fill the hole halfway
to the top with epoxy.
d. Press the insert in until it is flush with the surface.
e. Wipe away any excess epoxy. The part is ready for
service after the bond material has hardened and is
tack free (approximately 20 minutes).
6.26.5 Door Hinge Inserts
If the door hinges have been pulled from the control box,
drill and reinstall the hinge as shown in Figure 6-32 and
described in the following steps:
Materials needed:
1. Cut two square pieces of 3 mm thick (1/8 inch) aluminum or stainless steel approximately 40 mm (1 5/8”)
square. These squares will serve as backing plates.
2. Two nuts, bolts (10-24 x 1”) and washers for each insert that needs repair.
a. Drill a 1/4” hole in the center of each square backing
plate.
b. Pass the bolts through the bolts holes in the door
hinge, then through the control box at the location
where the hinge insert pulled out.
Figure 6-32 Door Hinge Repair
c. From inside the control box, slide the backing plates
over the bolts and secure in place with the washers
and nuts.
Table 6-2 Crack, Chip & Hole Repair Kit
ITEM
1
2
3
4
DESCRIPTION
PART NUMBER
Crack Repair Kit -- Includes
. . . Fiberglass Patch Kit (Loctite FK-98 or 80265)
. . . Sikaflex 221 Adhesive Sealant (Sikaflex 232-361)
. . . Instruction Sheet
76-00724-00SV
76-00724-00Z
02-00067-02Z
98-02339-00
Qty
1
10
10
10
Table 6-3 Insert Repair Kit
ITEM
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
PART NUMBER
Insert Repair Kit -- Includes
. . . Insert - 17.53 x 9.91 mm (..690 x .390 in) 1/4-20 Threads
. . . Insert - 15.88 x 6.35 mm (.625 x .250 in) 10-24 Threads
. . . Insert - 25.15 x 7.54 mm (.990 x .297 in) 10-24 Threads
. . . Insert - 10.16 x 9.53 mm (.400 x .375 in) 10-24 Threads
. . . Insert - 12.7 x 9.91 mm (.5 x .390 in) 1/4-20 Threads
. . . Insert - 9.53 x 6.76 mm (.375 x .266 in) 10-24 Threads
. . . Durabond Epoxy E20-HP (Loctite 29314)
. . . Static Mixing Tube (Loctite 983440)
. . . Instruction Sheet
76-50084-00
34-06231-01
34-06231-03
34-06231-04
34-06231-05
34-06231-06
34-06231-07
02-0082-00
07-00390-00
98-02338-00
Qty
1
10
10
10
10
10
10
1
1
1
Note: Insert repair procedures require use of an Application Gun, Carrier part number 07-00391-00 (Loctite 983435).
Table 6-4 Drill Information
Item
1
2
3
4
5
6
T--318
Insert part number
34- 06231- 01
34- 06231- 03
34- 06231- 04
34- 06231- 05
34- 06231- 06
34- 06231- 07
Drill size and depth
10.3 mm x 17.8 mm deep (.404 in. x .700 in. deep)
6.8 mm x 16.3 mm deep (.266 in. x .640 in. deep)
7.9 mm x 25.4 mm deep (.3125 in. x 1.0 in. deep)
6.9 mm (.270 in.) Drill completely through.
10.3 mm (.404 in.) Drill completely through.
6.8 mm (.266 in.) Drill completely through.
6--26
Figure 6-33 Insert Location
6--27
T--318
07
03
03
04
05
06
INSERT PART NUMBERS 34-06231-## WHERE THE ## IS AS INDICATED
05
07
01
03
03
03
04
03
6.27 COMMUNICATIONS INTERFACE MODULE
INSTALLATION
6.28 POWER FACTOR CORRECTOR
CAPACITORS (PFC)
The power factor corrector capacitors are of the
permanent-split capacitor type. There are a total of
three capacitors with discharge resistors enclosed in a
single case.
a. When to check for a defective capacitor
The capacitors assist in correcting current draw by the
compressor. If one or more of the capacitors is faulty,
there will be an imbalance in current. In addition, the
power consumption of the unit will increase.
b. Removing the capacitor
WARNING
CB1
Communications
interface Module
Make sure power to the unit is OFF and
power plug disconnected before removing
capacitor(s).
Figure 6-34 Communications Interface Installation
WARNING
Units with communication interface module provision
have the required wiring installed. The provision wiring
kit (part number 76-00685-00), includes three
pre-addressed wires installed between the circuit
breaker and communication interface module locations.
These wires are to be connected to the module and
circuit breaker to allow the module to communicate over
the power system. To install the module, do the
following:
Before removing the capacitors the
terminals must be checked for voltage with
a multimeter. The discharge resistors
installed on the unit (capacitors) should
bring the voltage to a safe level in a minute.
However, there may be a broken resistor
that retains voltage for a longer period, it is
highly recommended to wait 15 minutes
and to check for voltage.
WARNING
If the capacitors require discharging, first, turn the unit
power OFF and disconnect the unit power plug. Then,
place a 20,000 ohm, 2 watt resistor across the terminals
of the capacitor for approximately 30 seconds.
1. The capacitors are located on the unit sidewall
above the evaporator fan deck and may be removed
by two methods:
The unit power plug must be disconnected
to remove power from circuit breaker CB1
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 6-34 and remove low
voltage shield. Open high voltage shield.
c. Remove the circuit breaker panel, with circuit breaker, from the control box.
d. 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.
If container is empty -- Open upper rear panel of
the unit. The capacitors will be on the right and
may be serviced after checking discharge.
S
If container is full -- Remove the upper fresh air
makeup vent.
c. Checking the capacitor
If the capacitor is suspected of malfunction, you may
choose to simply replace it. Direct replacement requires
a capacitor of the same value. Two methods for
checking capacitor function are:
1. Volt-ohmmeter set on RX 10,000 ohms.
e. Attach the three wires as addressed to the LOAD side
of the circuit breaker.
f. Refit the circuit breaker panel.
Connect ohmmeter leads across the capacitor
terminals and observe the meter needle. If the capacitor
is good, the needle will make a rapid swing toward zero
resistance and then gradually swing back toward a very
high resistance reading. The reading should read about
330,000 ohms (for a good capacitor) due to the
discharge resistors.
g. Fit the new RMU into the unit.
h. Remove plugs CIA, CIB and CID from the wiring harness and attach to the module.
i. Replace the low voltage shield.
T--318
S
6--28
If the capacitor has failed open, the ohmmeter needle
will not move when the meter probes touch the
terminals. If the capacitor is shorted, the needle will
swing to zero resistance position and stay there.
Table 6-5 Recommended Bolt Torque Values
TORQUE
BOLT DIA. THREADS
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
2. Capacitor analyzer:
The function of the analyzer is to read the microfarad
value of a capacitor and to detect insulation breakdown
under load conditions. The important advantages of a
analyzer are its ability to locate capacitors that have
failed to hold their microfarad ratings, or those that are
breaking down internally during operation. It is also
useful in identifying capacitors when their microfarad
rating marks have become unreadable.
N.m
.6
1.0
2.25
2.6
8.4
1.52
2.76
4.28
5.94
7.88
12.72
17.14
NONFREE SPINNING (LOCKNUTS ETC.)
1/4
20
82.5 in-lbs
9.3
5/16
18
145.2 in-lbs
16.4
3/8
16
22.0 ft-lbs
30
7/16
14
34.1 ft-lbs
46
1/2
13
47.3 ft-lbs
64
9/16
12
62.7 ft-lbs
85
5/8
11
101.2 ft-lbs
137
3/4
10
136.4 ft-lbs
168
Table 6-6 Wear Limits For Compressors
PART NAME
MAIN BEARING
Main Bearing Diameter
Main Bearing Journal Diameter
PUMP END
Main Bearing Diameter
Main Bearing Journal Diameter
CONNECTING ROD
Piston Pin Bearing
CRANKPIN DIAMETER
Throw
THRUST WASHER (Thickness)
CYLINDERS
Bore
Piston (Diameter)
Piston Pin (Diameter)
Piston Ring Gap
Piston Ring Side Clearance
FACTORY MAXIMUM
inches
mm
1.6268
41.3207
FACTORY MINIMUM
inches
1.6233
1.3760
1.3768
41.2318
34.9504
1.3735
34.8869
0.6878
1.3735
1.070
0.1520
17.4701
34.8869
27.1780
03.8608
34.9707
1.072
0.154
27.2288
3.9116
2.0010
50.8254
0.013
0.002
mm
00.3302
00.0508
6--29
1.9860
0.6873
0.0050
0.0010
50.4444
17.4574
00.1270
00.0254
MAXIMUM WEAR
BEFORE REPAIR
inches
mm
.0020
.0020
0.0508
0.0508
.0020
.0020
.0020
.0010
.0025
0.0508
0.0508
0.0508
0.0254
0.0635
.0250
0.6350
.0020
.0020
.0010
.0250
.0020
0.0508
0.0508
0.0254
0.6350
0.0508
T--318
Table 6-7 Compressor Torque Values
TORQUE RANGE
SIZE
DIAMETER
(inches)
1/16
1/8
1/4
1/4
THREADS
PER INCH
27 (pipe)
20 (pipe)
20 (pipe)
20
1/4
28
5/16
18
3/8
16
7/16
5/8
5/8
#10
1-1/2
14
11
18
32
18 NEF
USAGE
ft-lb
N.m
8 - 12
6 -- 10
20 -- 25
10 -- 12
12 -- 15
12 -- 16
6 -- 10
12 -- 16
11 -- 16
8 -- 13
27 -- 34
13 -- 16
16 -- 20
16 -- 22
8 -- 13
16 -- 22
16 -- 20
2 -- 27
20 -- 30
27 -- 41
40 -- 50
55 -- 70
55
25
60
4
35
76 -- 83
34 -- 41
83 -- 103
5 -- 8
48 -- 62
------
60
30
75
6
45
NEF -- National Extra Fine
T--318
6--30
Pipe Plug -- Crankshaft
Oil Return Check Valve -- Crankcase
Pipe Plug -- Gauge Connection
Connecting Rod cap screw
Baffle Plate -- Crankcase
Side Shield
Oil Pump Drive Segment
Unloader Valve
Cover Plate -- Plate End
Bearing Head
Terminal Block Cap Screws
Suction Valve
Discharge Valve
Pump End Bearing Head
Bottom Plate -- Crankcase Compressor Foot
Cylinder Head
Motor End Cover -- Crankcase
Crankshaft
Oil Bypass Plug -- Crankcase
Oil Pump Drive Segment
Oil Level Sight Glass
Table 6-8 R-134a Temperature - Pressure Chart
Temperature
Vacuum
F
C
“/hg
-40
-40
14.6
49.4
.35
.37
12.3
-30
-34
-25
Pressure
bar
F
C
psig
kPa
kg/cm@
bar
37.08
0.49
28
-2
24.5
168.9
1.72
1.69
41.6
31.25
0.42
30
-1
26.1
180.0
1.84
1.80
9.7
32.8
24.64
0.33
32
0
27.8
191.7
1.95
1.92
-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
cm/hg kg/cm@
Temperature
Pressure
F
C
psig
kPa
kg/cm@
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
6--31
T--318
Note: Curves to be used as troubleshooting guide only for model series 69NT40 with
fresh air makeup vent closed, unit powered on 460 VAC/60Hz and SMV 100% open.
(Bar) psig
(22.0) 320
(20.7) 300
(19.3) 280
(17.9) 260
35 F (1.7 C)
Box
(16.6) 240
(15.2) 220
(13.8) 200
(12.4) 180
(11.0) 160
(9.7) 140
(8.3) 120
(6.9) 100
(5.5)
80
60
(15.6)
70
(21.1)
80
(26.7)
90
(32.2)
100
(37.8)
110
(43.3)
120
( Degrees F)
( Degrees C)
Ambient Air Temperature
(Bar) psig
(22.0) 320
(20.7) 300
(19.3) 280
(17.9) 260
(16.6) 240
(15.2) 220
(13.8) 200
(12.4) 180
(11.0) 160
(9.7) 140
0 F (-17.8 C)
Box
(8.3) 120
(6.9) 100
(5.5)
80
60
(15.6)
70
(21.1)
80
(26.7)
90
(32.2)
100
(37.8)
Ambient Air Temperature
110
(43.3)
120 ( Degrees F)
(48.9) ( Degrees C)
Compressor Discharge Pressure Versus Ambient Air Temperature at Stable Box Temperature
Figure 6-35 R-134a Compressor Pressure and Motor Current Curves Versus Ambient Temperature
(Sheet 1 of 2)
T--318
6--32
(Bar)
(.97)
psig
14
(.83)
12
(.69)
10
(.55)
8
(.41)
6
(.28)
4
(.14)
2
(0)
0
(-.14)
--2
(-.28)
--4
(-.41)
--6
60
(15.6)
35 F (1.7 C) Box
0 F (-17.8 C) Box
70
(21.1)
80
(26.7)
90
(32.2)
100
(37.8)
110
(43.3)
120 (Degrees F)
(48.9) (Degrees C)
Ambient Air Temperature
Compressor Suction Pressure Versus Ambient Air Temperature at Stable Box Temperature
17
16
15
35 F (1.7 C) Box
14
13
12
11
0 F (-17.8 C) Box
10
9
8
60
(15.6)
70
80
90
100
(21.1)
(26.7)
(32.2)
(37.8)
110
(43.3)
(Degrees F)
(Degrees
C)
(48.9)
120
Ambient Air Temperature
Compressor-Motor Current Versus Ambient Air Temperature At Stable Box Temperature
Figure 6-35 R-134a Compressor Pressure and Motor Current Curves Versus Ambient Temperature
(Sheet 2 of 2)
6--33
T--318
SECTION 7
ELECTRICAL WIRING SCHEMATIC
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 all figures.
Figure 7-2 provides the schematic diagram for units with normal evaporator fan operation capability.
Figure 7-3 provides the schematic diagram for units with single evaporator fan operation capability.
Figure 7-4 supplements the other schematic diagrams and provides schematics for Upper and Lower VPS and
Transfresh.
Figure 7-5 supplements the other schematic diagrams and provides schematics Emergency Bypass.
Figure 7-6 provides the Schematic and Wiring Diagrams for the Electronic Partlow Recorder
Figure 7-7 provides the wiring diagram for units with normal evaporator fan operation capability.
Figure 7-8 provides the wiring diagram for units equipped with single evaporator fan operation capability.
Sequence of operation descriptions for the various modes of operation are provided in paragraph 4.10.
7--1
T-318
LEGEND
SYMBOL DESCRIPTION (Normal Schematic Location)
(Single Evap. Fan Schematic Location)
SYMBOL DESCRIPTION (Normal Schematic Location)
(Single Evap. Fan Schematic Location)
AMBS
BM
CB1
AMBIENT SENSOR (D--19) [D--23]
BYPASS MODULE (Figure 7-5)
CIRCUIT BREAKER -- 460 VOLT (J--1) [J--1]
HPS
HR
HS
HIGH PRESSURE SWITCH (J--7) [H--8]
HEATER CONTACTOR (M--13, P--3) [M--14, N--6]
HUMIDITY SENSOR (G--19) [G--23]
CB2
CIRCUIT BREAKER -- AUTO TRANSFORMER (D--1)
[C--1]
CRANKCASE HEATER (T--4) [T--4]
CONDENSER FAN CONTACTOR (M--9, P--8) [M--9, P--8]
CONDENSER FAN SWITCH (E--9) [F--10]
HTT
IC
HEAT TERMINATION THERMOSTAT (H--12) [G--14]
INTERROGATOR CONNECTOR [FRONT/REAR]
(T--19, T--20) [T--23, T--24]
INTERNAL PROTECTOR (E--8, E--10, H--9, H10)
[E--8, G--8, M--11, M--13]
CCH
CF
CFS
CH
CI
CL
CM
CP
CPT
CPDS
CPSS
CR
COMPRESSOR CONTACTOR (M--7, P--1, P3)
[M--8, N--1, N--3]
COMMUNICATIONS INTERFACE MODULE (A--3) [A--3]
COOL LIGHT (M--11) [G--13]
CONDENSER FAN MOTOR (T--8) [T--8]
CS
DHBL
DHBR
DHML
COMPRESSOR MOTOR (T--2) [T--1]
CONDENSER PRESSURE TRANSDUCER (H--19) [H--23]
COMPRESSOR DISCHARGE SENSOR (B--18) [B--23]
COMPRESSOR SUCTION SENSOR (E--18)[D--23]
CHART RECORDER [TEMPERATURE RECORDER]
(Figure 7-6)
CURRENT SENSOR (M--2) [M--2]
DEFROST HEATER -- BOTTOM LEFT (R--7)[R--7]
DEFROST HEATER -- BOTTOM RIGHT (T--6) [T--6]
DEFROST HEATER -- MIDDLE LEFT (R--6) [R--6]
DHMR
DHTL
DHTR
DL
DEFROST HEATER -- MIDDLE RIGHT (T--6) [T--6]
DEFROST HEATER -- TOP LEFT (R--6) [R--6]
DEFROST HEATER -- TOP RIGHT (T--7) [R--7]
DEFROST LIGHT (M--12) [L--15]
DPT
DTS
DVM
DVR
E1
F
DISCHARGE PRESSURE TRANSDUCER (K--19) [K--23]
DEFROST TEMPERATURE SENSOR (D--18)[D--23]
DUAL VOLTAGE MODULE (E--1) [D--1]
DUAL VOLTAGE RECEPTACLE (F--2) [E--2]
EVAPORATOR FAN CONTACTOR #1 [HIGH]
(P--8, H--11, J--11) [P--8, H--11, J--11]
EVAPORATOR FAN CONTACTOR #2 [HIGH]
(J--11, K--11, P--10) [J--11, K--11, P--10]
EMERGENCY BYPASS SWITCH (Figure 7-6)
EVAPORATOR FAN CONTACTOR [HIGH]
(M--10, P--10, P12) [M--10, P--10, P12]
EVAPORATOR FAN MOTOR (T--10, T--12) [T--10, T--12]
EVAPORATOR FAN CONTACTOR [LOW]
(M--11, R--10, R--11) [M--11, R--10, R--11]
FUSE (D--7, R--4) [C--6, R--4]
FCR
FED
FH
FT
HM
FUSE -- CHART RECORDER (Figure 7-6)
FUSE -- EMERGENCY DEFROST (E--5)
FUSE -- HUMIDITY (Figure 7-4)
FUSE -- TransFRESH (Figure 7-4)
HOUR METER (H--6)
E2
EB
EF
EM
ES
IP
IRL
MDS
PE
PFC
IN RANGE LIGHT (M--13) [L--15]
MANUAL DEFROST SWITCH (H--13) [F--16]
PRIMARY EARTH (J--3) [J--2]
PFC POWER FACTOR CORRECTOR CAPACITOR
(R--3) [R--3]
PR
PROBE RECEPTACLE [USDA]
(F--18, M--19, N--19, P--19) [E--23, L--24, M--24, N--24]
REMOTE MONITORING RECEPTACLE
(M--11, M--12, M--13) [G--13, L--15, L--16]
RETURN RECORDER SENSOR (C--18) [C--23]
RM
RRS
RTS
S1
S2
RETURN TEMPERATURE SENSOR (C--18) [C--23]
EVAPORATOR FAN CONTACTOR #1 [LOW]
(Figure 7-3)
EVAPORATOR FAN CONTACTOR #2 [LOW]
(Figure 7-3)
SMV
SPT
SRS
ST
SUCTION MODULATING VALVE (R--14) [R--17]
SUCTION PRESSURE TRANSDUCER (J--19) [J--23]
SUPPLY RECORDER SENSOR (L--19) [L--23]
START -- STOP SWITCH (L--5) [J--4]
STS
TBU
TC
TCC
SUPPLY TEMPERATURE SENSOR (C--18) [B--23]
TRANSFORMER BRIDGING UNIT
CONTROLLER RELAY -- COOLING (K--8) [J--8]
TransFRESH COMMUNICATIONS
CONNECTOR (Figure 7-4)
TE
CONTROLLER RELAY -- HIGH SPEED EVAP. FANS
(K--10) [J--10]
CONTROLLER RELAY -- DEFROST (F--12) [F--15]
TransFRESH CONTROLLER (Figure 7-4)
CONTROLLER RELAY -- HEATING (K--12) [J--12]
TF
TFC
TH
TI
TN
TP
TR
TRANS
TRC
TV
CONTROLLER RELAY -- IN RANGE (G--13) [G--15]
CONTROLLER RELAY -- CONDENSER FAN (K--9) [J--9]
TEST POINT (F--9,J--7, J--9, J--10, J--12, N--14)
[G--10, E--11, J--8, J--14, K--8, M--17]
TRANSFORMER (M--3) [L--2]
WCR
AUTO TRANSFORMER 230/460 (D--3) [C--3]
TransFRESH REAR CONNECTOR (Figure 7-4)
CONTROLLER RELAY -- LOW SPEED EVAP. FANS
(K--11) [J--11]
WETTING CURRENT RELAY (H--9) [J--10]
WP
WATER PRESSURE SWITCH (D--9) [E--10]
Figure 7-1 LEGEND
T--318
7--2
FCCH
FCCH
6 Heater
Figure 7-2 SCHEMATIC DIAGRAM -- Units with Normal Evaporator Fan Capability
7--3
T-318
FCCH
FCCH
Figure 7-3 SCHEMATIC DIAGRAM -- Units with Single Evaporator Fan Capability
T--318
7--4
ST
SEE FIGURE
7--2 or 7--3
TR
SEE FIGURE
7--2 or 7--3
TO KB7
TransFRESH Controller
Lower Air Exchange VPS
Upper Air Exchange VPS
Figure 7-4 SCHEMATIC DIAGRAM -- TransFRESH and Vent Position Sensors (VPS)
7--5
T-318
To ST10
To TRX2
To QC1
To QC1
To MC6
To QC1
CONTROLLER
Figure 7-5 SCHEMATIC DIAGRAM -- Emergency Bypass
T--318
7--6
NOTE: STANDARD CONTROLLER JUMPERS: MA3 TO MA7 AND MA9 TO MA11
(SEE Figure 7-2 ) ARE REMOVED IN THIS APPLICATION
CR5
CR4
CR3
CR6
CR8
CR2
NOTE: STANDARD CONTROLLER JUMPERS: MA3 TO MA7 AND MA9 TO MA11
(SEE Figure 7-2) ARE REMOVED IN THIS APPLICATION
Figure 7-6 SCHEMATIC DIAGRAM, WIRING DIAGRAM -- Electronic Partlow Recorder
7--7
T-318
UPPER VPS
KB7
[DF11]
CFL1
CFL3
TRC2 TRC1
31
11
12
CH11
[CFS--2]
CH31
FCCH
FCCH
32
WIRES TO TR X2:
DF--(TFC), P--(TFC),
BMA2,CIB1, GRD,
CHA2, RMA, KA12,
EFA2, HRA2 & CR8
ECG1
[EB8]
FCCH
FCCH
LOWER VPS
(ICF MAY BE IN
CONTROL BOX)
Figure 7-7 UNIT WIRING DIAGRAM -- Units with Normal Evaporator Fan Capability (Sheet 1 of 2)
T--318
7--8
[UVPS1]
[UVPS2]
SMVD
[BM2B]
SMVC
[BM1B]
SMVB
[BM2A]
SMVA
[BM1A]
KA1
NOTE: RM MAY
BE OUTSIDE
BOX
KB7
[HPRB]
RMB
CFS
UVPS3
KA6
TFC1
[RMC]
CFA1
RMD
KB7
NOTE: WHEN EB, ED, BM OR CFS IS/ARE INSTALLED, WIRE DESTINATIONS CHANGE FROM THE STANDARD.
ADDRESSES FOR THE CHANGED DESTINATIONS ARE SHOWN IN BRACKETS “[XXX]”.
FOR UNITS WITHOUT ELECTRONIC CR ONLY, FOR CR WIRING, SEE Figure 7-6
Figure 7-7 UNIT WIRING DIAGRAM Units with Normal Evaporator Fan Capability (Sheet 2 of 2)
7--9
T-318
UPPER VPS
KB7
[DF11]
CFL3
CFL1
TRC2 TRC1
31
11
12
FCCH
CH11
CH31
FCCH
32
WIRES TO TR X2:
DF--(TFC),
P--(TFC),
BMA2,CIB1,
GRD, CHA2,
RMA, KA12,
EFA2, HRA2
& CR8
ECG1
[EB8]
FCCH
FCCH
(ICF MAY BE IN
CONTROL BOX)
LOWER VPS
Figure 7-8 UNIT WIRING DIAGRAM -- Units with Single Evaporator Fan Capability (Sheet 1 of 2)
T--318
7--10
[UVPS1]
[UVPS2]
KA1
NOTE: RM MAY
BE OUTSIDE
BOX
KB7
[HPRB]
SMVD
[BM2B]
SMVC
[BM1B]
SMVB
[BM2A]
SMVA
[BM1A]
RMB
CFS
KA6
CFA1
TFC1
[RMC]
RMD
KB7
Figure 7-8 UNIT WIRING DIAGRAM -- Units with Single Evaporator Fan Capability (Sheet 2 of 2)
7--11
T-318
INDEX
A
Air Cooled Condenser Section, 2--4
Alarm, 3--6, 3--9, 3--12, 3--18, 3--27
Arctic Mode, 3--4
Evacuation, 6--3
Evaporator, 6--14
Evaporator Fan, 1--2, 3--4, 6--15
Evaporator Section, 2--2
Expansion Valve, 6--12
B
Bulb Mode, 3--5
F
Failure Action, 3--4
Filter--Drier, 6--12
C
Capacitors, 6--15
Checking Superheat, 6--13
Communications Interface Module, 3--11, 6--28
Composite Control Box, 6--25
Fresh Air Makeup, 2--1, 4--1
Frozen Mode, 4--8
Frozen Mode -- Conventional, 3--6
Frozen Mode -- Economy, 3--6
Function Code, 3--14, 3--15, 3--25
Compressor, 6--5
G
Compressor Section, 2--3
Condenser Coil, 6--10
General Description, 2--1
Condenser Pressure Control, 3--4
Generator Protection, 3--4
Configuration Software, 3--3, 3--8
H
Configuration Variables, 3--13
Controller, 3--3, 6--17, 6--18
Controller Software, 3--3
Crankcase Heater, 4--5
D
Heat Lockout, 3--4
Heater, 6--14
Heating Mode, 4--7
High Pressure Switch, 6--10
I
DataBANK Card , 3--11
DataCORDER, 3--7, 3--9, 4--3
DataCORDER Software, 3--7
DataReader, 3--11
Inspection, 4--1, 4--3
Introduction, 1--1
Defrost Interval, 3--4
K
Defrost Mode, 4--8
Display Module, 3--2
Key Pad, 3--2
DPRV Check Procedure, 6--17
E
L
Leak Checking, 6--3
Emergency Bypass, 4--9
Logging Interval, 3--9
Emergency Defrost, 4--9
Lower Air, 1--2
Index--1
T-318
INDEX -- Continued
M
S
Manifold Gauge Set, 6--1
Safety and Protective Devices, 2--9
Microporcessor System, 3--1
Sensor Configuration, 3--8
Modes of Operation, 3--4
Sequence of Operation, 4--7
Motor Current, 6--32
Service Valves, 6--1
O
Oil Level, 6--9
Starting, 4--3
Stopping, 4--3
Suction Modulating Valve, 6--16
Operational Software, 3--3, 3--8
P
T
Temperature Control, 3--4, 3--6
Painted Surfaces, 6--25
Temperature Recorder, 4--3, 6--23
Perishable Mode, 4--7
Temperature Sensor, 6--20
Perishable Mode -- Conventional, 3--5
Thermistor Format, 3--9
Perishable Mode -- Dehumidification, 3--5
Torque Values, 6--29, 6--30
Perishable Mode -- Economy, 3--5
U
Power, 4--1
Pre--Trip, 3--7, 3--11, 3--21, 3--26, 4--4
Probe Check, 4--5
Pumping Down, 6--2
Upper Air, 1--2
USDA, 3--11
W
R
Refrigerant Charge, 6--4
Water Cooled Condenser, 6--11
Refrigeration Circuit, 2--10
Water--Cooled Condenser Section, 2--5
Refrigeration System Data, 2--7
Wear Limits, 6--29
Refrigeration Unit -- Front Section, 2--1
Wiring Schematic, 7--1
T-318
Index--2
Carrier Transicold Division,
Carrier Corporation
Container Products Group
P.O. Box 4805
Syracuse, N.Y. 13221 U.S A
www.carrier.transicold.com
A member of the United Technologies Corporation family. Stock symbol UTX
©2007 Carrier Corporation D Printed in U. S. A. 05/07