Carrier VECTOR 1800 MT Trailer Refrigeration Unit OPERATION & SERVICE MANUAL
VECTOR 1800 MT is a trailer refrigeration unit designed for multi-temperature applications. It features a powerful engine and compressor, allowing for efficient cooling and heating. The unit includes a microprocessor with a user-friendly keypad for easy control and monitoring. It has multiple compartments and offers various temperature control modes, including cool, pulse cool, heat, and defrost. The unit also features ProductShield, providing temperature range lock and protection for your valuable cargo. It includes several safety features and sensors for added security and peace of mind.
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Trailer Refrigeration
EVAPORATOR
CONDENSER
TXV
TXV BULB
RECEIVER
OPERATION & SERVICE
MANUAL for
VECTOR 1800 MT
Trailer
Multi--Temp
Refrigeration Units
62--11039 Rev B Change 09/11
OPERATION & SERVICE
MANUAL for
VECTOR 1800 MT
Trailer
Multi--Temp
Refrigeration Units
TABLE OF CONTENTS
PARAGRAPH NUMBER
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
SPECIFIC WARNING AND CAUTION STATEMENTS
1.3
SAFETY DECALS
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UNIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
CONDENSING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1 Condenser Coil
2.3.2 Engine
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2.3.3 Compressor
2.3.4 Filter Drier
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2.3.5 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.6 Transducers and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4
COMPARTMENT 1 EVAPORATOR SECTION
2.4.1 Electronic Expansion Valve (EVXV)
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2.4.2 Heat Exchanger
2.4.3 Evaporator Coil
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2.4.4 Transducers and Sensors
2.5
REMOTE EVAPORATOR(S)
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2.6
SYSTEM OPERATING CONTROLS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.1 Multiple Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2 Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.3 Microprocessor Component Description And Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7
ELECTRONIC MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1 Overload Ground Fault Module (OGF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.2 Phase Reversal Module (PRM)
2.8
OPTIONS
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2.8.1 Light Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.2 Door Switch(es) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.3 Out of Range Alarm
2.8.4 Remote Control Panel
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2.9
ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10 ENGINE AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11 COMPRESSOR DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12 REFRIGERATION SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.13 ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.14 COMPONENT RESISTANCE & CURRENT DRAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.15 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.16 REFRIGERANT CIRCUIT DURING COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.17 REFRIGERANT CIRCUIT -- HEATING AND DEFROSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--10
2--10
2--10
2--10
2--10
2--11
2--11
2--11
2--11
2--12
2--18
2--18
2--18
2--7
2--9
2--9
2--10
2--2
2--7
2--7
2--7
Page
1-1
1-1
1-1
1-5
2-1
2--1
2--18
2--18
2--19
2--19
2--20
2--20
2--21
2--21
2--22
2--23
2--23
2--24
2--24 i
62--11039
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
RS “ON” AND ALL COMPARTMENT SWITCHES “OFF” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
STARTING UNIT -- ENGINE/ROAD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 STARTING UNIT -- ELECTRIC STANDBY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Unit Startup -- Engine/Road and Electric Standby
3.5
PRETRIP
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3.6
CHANGING SETPOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 START--STOP OPERATION -- ENGINE/ROAD AND ELECTRIC STANDBY . . . . . . . . . . . . . . . . . .
3.8
CONTINUOUS RUN OPERATION
3.9
SLEEP MODE ON
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3.10 SLEEP MODE OFF
3.11 MANUAL DEFROST
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3.11.1 Manual Defrost
3.12 TRIP START
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3.13 VIEW ACTIVE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.14 VIEW INACTIVE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.15 UNIT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.16 VIEW HOURMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.17 FUNCTIONAL CHANGE (PARAMETERS)
3.18 LANGUAGE SELECTION
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3.19 STOPPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.20 DATA RECORDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.20.1 Microprocessor Information
3.20.2 Data Recording
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3.20.3 Sensor & Event Data
3.20.4 Data Downloading
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3.20.5 Data Recorder Power--Up
3.21 OPTIONS
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3.21.1 IntelliSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.21.2 Remote Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--31
3--31
3--31
3--32
3--32
3--33
3--33
3--36
3--17
3--18
3--19
3--23
3--24
3--29
3--30
3--31
3--9
3--10
3--11
3--12
3--13
3--15
3--15
3--16
Page
3-1
3--1
3--2
3--3
3--5
3--6
62--11039 ii
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
TEMPERATURE CONTROL
4.1
SYSTEM START--UP
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4.2
START--STOP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
CONTINUOUS RUN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4
TEMPERATURE CONTROL
4.4.1 COOL MODE
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4.4.2 PULSE COOL MODE
4.4.3 PRIORITY MODES
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4.4.4 SUPPLY AIR LIMIT CONTROL
4.4.5 HEAT MODE
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4.4.6 NULL MODE
4.4.7 UNLOADERS
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4.4.8 SPEED CONTROL
4.4.9 DEFAULT MODE
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4.4.10DEFROST OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5
Temperature Range Lock 1 & 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6
ProductShieldt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.2 Temperature Ranges
4.7
OUTPUT OVERRIDES
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4.7.1 Speed Control Solenoid (SCS) Overrides
4.7.2 Unloader Control Overrides
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4.7.3 Suction Pressure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--7
4--7
4--8
4--8
4--5
4--5
4--6
4--7
Page
4-1
4--1
4--2
4--4
4--4
4--4
4--8
4--10
4--12
4--12
4--13
4--16
4--16
4--17
4--19 iii
62--11039
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
TECHNICIAN INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
PC MODE/DOWNLOAD PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2
MICROPROCESSOR CONFIGURATION AND TECHNICIAN TEST MODES . . . . . . . . . . . . . . . .
5.2.1 Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Component Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
DOWNLOADING DATA WITH THE PC CARD
5.4
INSTALLING NEW SOFTWARE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 Using The Program PC Card
5.4.2 Using MicroProgrammer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3 Troubleshooting Software Loading Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5
SETTING PM (PREVENTATIVE MAINTENANCE) HOURMETERS . . . . . . . . . . . . . . . . . . . . . . . . .
5.6
ADVANCE MICROPROCESSOR REPLACEMENT & CONFIGURATION SETUP . . . . . . . . . . . . .
5.6.1 Microprocessor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.2 Microprocessor Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.3 Configurations Via Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.4 Functional Parameters Via Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.5 DataRecorder Via ReeferManager PC Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.6 Engine And Switch--on Hour Meters Via ReeferManager PC Program
5.6.7 Configuration/IntelliSet Card
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.8 Microprocessor Final Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MESSAGECENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
MessageCenter Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALARM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1
7.2
INTRODUCTION TO ALARM TROUBLESHOOTING
NOTES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7.3 DRIVER/OPERATOR ALARMS
1
2
3
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LOW FUEL LEVEL WARNING
LOW ENGINE OIL LEVEL
LOW COOLANT LEVEL
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7.4 SHUTDOWN ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 LOW ENGINE OIL PRESSURE
12
13 HIGH DISCHARGE PRESSURE
14 ELECTRICAL CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIGH COOLANT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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15 BATTERY VOLTAGE TOO HIGH
16 BATTERY VOLTAGE TOO LOW
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 HIGH COMP DISCHARGE TEMP
18 LOW REFRIGERANT PRESSURE
19 LOW FUEL SHUTDOWN.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 MAXIMUM COMPRESSOR ALARMS
21 TECHNICIAN RESET REQUIRED
22 LOW SUCTION SUPERHEAT
23 A/C CURRENT OVER LIMIT
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 A/C CURRENT OVER LIMIT
27 HIGH SUCTION PRESSURE
28
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
7-1
7-1
7--2
7--3
7---3
7---4
7---5
7---12
7---13
7---14
7---14
7---15
7---15
7---16
7---17
7---19
7---20
7--6
7---6
7---7
7---8
7---9
7---10
7---11
5--20
5--20
5--21
5--21
5--21
5--22
5--22
5--15
5--16
5--16
5--17
5--17
5--18
5--19
5--19
Page
5-1
5--1
5--2
5--3
5--12
5--14
62--11039 iv
Change 09/11
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
7.5 START UP/ENGINE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 FAILED TO RUN MINIMUM TIME
31 FAILED TO START --- AUTO MODE
34 ENGINE FAILED TO STOP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 CHECK STARTER CIRCUIT
36
37 CHECK LOW SPEED RPM
38
39
40
CHECK HIGH SPEED RPM
CHECK ENGINE RPM
CHECK GLOW PLUGS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK COOLANT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 ENGINE STALLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6 WARNING / STATUS ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51 ALTERNATOR NOT CHARGING
53 BOX TEMP OUT---OF---RANGE
54 DEFROST NOT COMPLETE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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55 CHECK DEFROST AIR SWITCH
59
60
62
63
DATALOGGER NOT RECORDING
DATALOGGER TIME WRONG
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C2 BOX TEMP OUT---OF---RANGE
C3 BOX TEMP OUT---OF---RANGE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7.7 ELECTRICAL ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71 BAD F2 OR F3 FUSE
73
75
76
77
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NO POWER---CHECK POWER CORD
COMP MOTOR OVERLOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER MOTOR OVERHEATED
EVAP MOTOR OVERHEATED
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83 CHECK REMOTE DEFROST LIGHT
84 CHECK REMOTE ALARM LIGHT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85 CHECK UL1 CIRCUIT
86 CHECK UL2 CIRCUIT
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89 CHECK REMOTE AUTO LIGHT
91 CHECK HTCON1 RELAY COIL
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92 CHECK HTCON2 RELAY COIL
93 CHECK START UP BUZZER
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94 CHECK COMP CONTACTOR 1
95 CHECK CDCON RELAY COIL
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96 CHECK GENCONR RELAY COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
98 CHECK HIGH TEMP THERMOSTAT
99 CHECK STANDBY CONTACTOR
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100 OVERLOAD / GROUND FAULT
101 C2 EVAP MOTOR OVERHEATED
102
103
104
C3 EVAP MOTOR OVERHEATED
CHECK 2HTCON1 RELAY COIL
CHECK 2HTCON2 RELAY COIL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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105 CHECK 3HTCON1 RELAY COIL
106 CHECK 3HTCON2 RELAY COIL
107 CHECK 2LSV CIRCUIT
108 CHECK 3LSV CIRCUIT
109 CHECK 1EVCON RELAY COIL
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110 CHECK 2EVCON RELAY COIL
111 CHECK 3EVCON RELAY COIL
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Page
7--21
7---21
7---22
7---233
7---24
7---25
7---26
7---27
7---28
7---29
7---30
7--32
7---32
7---33
7---34
7---35
7---36
7---37
7---38
7---40
7--42
7---42
7---43
7---44
7---45
7---46
7---46
7---47
7---47
7---48
7---48
7---49
7---49
7---50
7---50
7---51
7---51
7---57
7---57
7---58
7---58
7---59
7---59
7---60
7---52
7---52
7---53
7---54
7---55
7---56
7---56 v
62--11039
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
7.8 SENSOR ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
121 CHECK AMBIENT AIR SENSOR
122 CHECK RETURN AIR SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
123 CHECK SUPPLY AIR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
124 CHECK DEFROST TERM 1 SENSOR
125
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK COMP DISCHARGE SENSOR (CDT) . . . . . . . . . . . . . . . . . . . . . .
126 CHECK FUEL SENSOR CIRCUIT
127
128
129
130
CHECK SUCTION TEMP SENSOR (CST)
LOW A/C AMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK ENG COOLANT SENSOR
CHECK ENGINE RPM SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
131 CHECK EVAP TEMP SENSOR
134
136
CHEK REMOTE TEMP SENSOR 2
C2 CHK SUPPLY AIR SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
133 CHEEK REMOTE TEMP SENSOR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
137 C2 CHECK RETURN AIR SENSOR
138 C3 CHECK RETURN AIR SENSOR
139 C2 CHECK DEFROST SENSOR
140 C3 CHECK DEFROST SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9 PRETRIP ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P141 PRE---TRIP STOPPED BY USER
P144 CHECK UL1 CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P145 CHECK SPEED SOL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P146 C2 CHECK HEATER 1 CIRCUIT
P147 C2 CHECK HEATER 2 CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P151 CHECK GLOW PLUG CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P152 CHECK FUEL SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P153 CHECK RETURN AIR SENSOR
P154 CHECK SUPPLY AIR SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P155 CHECK COOLANT TEMP SENSOR
P156 CHECK BATTERY VOLTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P157 CHECK BATTERY CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P158 CHECK AMBIENT AIR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P159 CHECK DEFROST TERM 1 SENSOR
P160 CHECK DISCHARGE TEMP SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
161 CHECK SUCTION TEMP SENSOR (CST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P163 C3 CHECK HEATER 1 CIRCUIT
P164 CHECK UL2 CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P166 C2 CHK SUPPLY AIR SENSOR
P167 C3 CHECK HEATER 2 CIRCUIT
P168 C2 CHECK LSV VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P171 CHECK EVAP & DISC PRESS
P174 CHECK LOW SPEED RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P175 CHECK HIGH SPEED RPM
P176 C3 CHECK LSV VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P177 CHECK EVAP SUPERHEAT
P178 CHECK UL1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P180 CHECK SUCTION MOD VALVE
P184 C2 CHECK EVAP FAN MOTOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P185 C3 CHECK EVAP FAN MOTOR
P186 CHECK EVAP OUTLET TEMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
7--61
7---67
7---67
7---68
7---68
7---69
7---69
7---70
7---70
7---61
7---61
7---62
7---62
7---63
7---63
7---64
7---64
7---65
7---66
7---91
7---92
7---93
7---94
7---94
7---95
7---96
7---97
7---99
7---101
7---81
7---81
7---82
7---82
7---83
7---84
7---86
7---87
7---88
7---90
7--71
7---71
7---71
7---72
7---73
7---75
7---77
7---78
7---79
7---79
7---80
7---80
62--11039 vi
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
7.9 PRETRIP ALARMS (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P187 CHECK HEATER 1 CIRCUIT
P188 CHECK HEATER 2 CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P189 CHECK EVAPORATOR FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P190 CHECK CONDENSER FAN MOTOR
P191 CHECK UL2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P199 C2 CHECK RETURN AIR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P206 CHECK CONDENSER FAN CIRCUIT
P207 CHK COMPRESSOR CONTACT CIRC
P208 CHK GENERATOR CONT CIRC
P209 CHECK STANDBY CONT CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P210 C3 CHECK RETURN AIR SENSOR
P211 CHECK DEFROST SENSOR (2DTT)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P212 C3 CHECK DEFROST SENSOR (3DTT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.10 MAINTENANCE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
223 ENGINE MAINTENANCE DUE
225
226
GENERAL MAINTENANCE DUE
SERVICE SOON---PM #1 DUE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
224 STANDBY MAINTENANCE DUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
227 SERVICE SOON---PM #2 DUE
228 SERVICE SOON---PM #3 DUE
229 SERVICE SOON---PM #4 DUE
230 SERVICE SOON---PM #5 DUE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.11 MICROPROCESSOR ALARMS
232 SETPOINT ERROR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
233 MODEL # ERROR
234
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT SERIAL # ERROR
235 CONTROL SERIAL # ERROR
236 TRAILER ID # ERROR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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237 FUNCTION PARAMETERS ERROR
238 CONFIGURATIONS 1 ERROR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
239
240
CONFIGURATIONS 2 ERROR
HOUR METER ERROR
241 ALARM STATUS ERROR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
242 DIS PRESS CALIBRATE ERROR
243 SUCTION/EVAP CALIBRATE ERROR
245 MICRO SW REV ERROR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
246 EEPROM WRITE FAILURE
247 CONFIGURATIONS 3 ERROR
248 CONFIGURATION MODE / HP2 ERROR
249 MICROPROCESSOR ERROR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Page
7--122
7---122
7---122
7---123
7---123
7---124
7---124
7---125
7---125
7---126
7---126
7---127
7---127
7---128
7---128
7---129
7---129
7---130
7--118
7---118
7---118
7---119
7---119
7---120
7---120
7---121
7---121
7--71
7---102
7---104
7---106
7---108
7---109
7---110
7---111
7---113
7---114
7---115
7---116
7---117
7---117 vii
62--11039
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2
PRETRIP INSPECTION
8.3
PRIMING FUEL SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.1 Mechanical Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4
SERVICING FUEL PUMP
8.4.1 Mechanical Pump
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.2 Electrical Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6
ENGINE SERVICE AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.1 Engine RPM Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.3 Testing The RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.4 Lube Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.5 Servicing The Speed Control Solenoid And Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.6 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.7 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.8 Servicing Glow Plugs
8.6.9 Water Pump V--Belt
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7
EVAPORATOR HEATERS
8.7.1 Description
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.2 Replacing Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.3 Compartment One Evaporator Blower and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.4 Condenser Fan And Motor Assemblies
8.8
BATTERY CHARGER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.2 Checking Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9
GENERATOR
8.9.1 Description
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9.2 Preventive Maintenance and Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9.3 Generator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9.4 Generator Assembly Procedure
8.10 REMOTE COMPARTMENT LSVs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.1CHECKING OPERATION OF C2 LSV AND C3 LSV AND EVXV
8.11 PUMPING UNIT DOWN OR REMOVING REFRIGERANT CHARGE
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
8.11.1 Pumping Down The Low Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.2 Removing The Refrigerant Charge: Use Micro “EVAC MODE” . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12 REFRIGERANT LEAK CHECKING: Use Micro “EVAC MODE”
8.13 EVACUATION AND CHARGING: Use Micro “EVAC MODE”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13.3 Procedure For Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13.4 Adding Refrigerant To System (Full Charge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.14
ADDING REFRIGERANT TO SYSTEM (PARTIAL CHARGE) . . . . . . . . . . . . . . . . . . . . . . . . . . .
8--18
8--19
8--19
8--20
8--20
8--20
8--20
8--20
8--22
8--22
8--12
8--12
8--13
8--13
8--13
8--14
8--16
8--18
8--10
8--10
8--11
8--11
8--11
8--11
8--12
8--12
8--7
8--7
8--8
8--8
8--9
8--9
8--9
Page
8-1
8--1
8--3
8--4
8--4
8--5
8--5
8--5
8--5
8--7
62--11039 viii
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
8.15 COMPRESSOR -- MODEL 06D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.15.1 Removal and Replacement of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.15.2 Compressor Disassembly
8.15.3 Compressor Reassembly
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8.15.4 Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.16 COMPRESSOR UNLOADER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17 CHECKING AND REPLACING FILTER-DRIER
8.18 ELECTRONIC EXPANSION VALVE
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8.18.1 Replacing Expansion Valve & Screen
8.18.2 EVXV coil
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8.19 THERMOSTATIC EXPANSION VALVES (REMOTE COMPARTMENTS)
8.19.1 Replacing Expansion Valve & Screen
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8.19.2 To Measure Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.20 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCH (HPS) . . . . . . . . . . . . . . . . .
8.20.1 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.20.2 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.21 DISCHARGE PRESSURE TRANSDUCER (CDP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.21.1 Calibrating Compressor Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.21.2 Testing Compressor Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.21.3 Replacing Compressor Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.22 COMPRESSOR SUCTION PRESSURE TRANSDUCER (CSP AND EVOP)
8.22.1 Calibrating Compressor Suction Pressure Transducer
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8.22.2 Testing Compressor Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.22.3 Replacing Compressor Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.23 REPLACING RECEIVER SIGHT GLASS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.24 COMPRESSOR SUCTION MODULATION VALVE (CSMV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.24.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.24.2 CSMV Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.24.3 Replacing The SMV Power Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.25 CHECKING DEFROST OR HEATING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.25.1 Defrost Air Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.25.2 Electronic Defrost Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.26 CHECKING CALIBRATION OF DEFROST AIR SWITCH
8.27 EVAPORATOR COIL
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8.27.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.27.2 Coil Replacement -- Compartment 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.28 CONDENSER COIL
8.28.1 Coil Cleaning
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8.28.2 Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.29 CONTROLLER SENSOR CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8--33
8--34
8--34
8--34
8--34
8--35
8--36
8--36
8--30
8--31
8--31
8--32
8--32
8--33
8--33
8--33
8--36
8--37
8--37
8--37
8--37
8--37
8--38
8--38
8--38
8--38
8--28
8--28
8--28
8--29
8--29
8--29
8--30
8--30
Page
8--23
8--23
8--24
8--24
8--25
8--26 ix
62--11039
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
MICROPROCESSOR AND UNIT TROUBLESHOOTING
9.1 MICROPROCESSOR TROUBLESHOOTING
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DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.2 Engine Starts Then Stops
9.1.3 Engine Will Not Shut Off
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9.1.4 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.5 Malfunction In The Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.6 Miscellaneous Engine Troubleshooting
9.2
BATTERY CHARGER
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9.3
ALTERNATING CURRENT GENERATOR
9.4
REFRIGERATION
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9.4.1 Unit Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.3 Unit Operates Long Or Continuously In Cooling
9.4.4 Unit Will Not Heat Or Has Insufficient Heating
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9.4.5 Unit Will Not Terminate Heating
9.4.6 Defrost Cycle Malfunction
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9.4.7 Abnormal Pressure
9.4.8 Abnormal Noise
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9.4.9 Control System Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.10 No Evaporator Air Flow Or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.11 Expansion Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.12 Solenoid Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9--8
9--8
9--8
9--9
9--6
9--6
9--7
9--7
9--9
9--9
10-2
9--5
9--6
9--6
9--6
9--2
9--2
9--3
9--4
Page
9-1
9--1
9--1
9--1
9--2
9--2
62--11039 x
LIST OF ILLUSTRATIONS
FIGURE NUMBER
Figure 2-1 Front View
Figure 2-2. Front View
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Figure 2-3 Evaporator Section -- Grille Removed
Figure 2-4 Control Box
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Figure 2-5 Compressor Cylinder Head Unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-6 Compressor Cylinder Head Loaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-7 Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-8 Display And Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-9 OGF Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-10 PRM Phase Reversal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-11 Refrigerant Circuit All Compartments Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-12 Refrigerant Circuit -- Compartment One Cooling, Compartments 2 & 3 Heating . . . . . . . . . . . .
Figure 2-13 Refrigerant Circuit -- Compartments One And Two Cooling, Compartment 3 Heating . . . . . . .
Figure 2-14 Refrigerant Circuit -- Compartments One And Three Cooling, Compartment 2 Heating
Figure 2-15 Refrigerant Circuit -- All Compartments Heating
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Figure 4--1 Auto Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4--2 Continuous Run Frozen Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4--3 Start/Stop Frozen Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4--4 Continuous Run Perishable Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4--5 Start/Stop Perishable Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4--6 Evaporator Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4--7 Refrigeration System Suction Pressures Unloading (Heat and Defrost Only) . . . . . . . . . . . . . .
Figure 8--1 Priming Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--2 Mechanical Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--3 Electric Fuel Pump (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--4 Fuel Level Sensor Wiring
Figure 8--5 Fuel System Diagram
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Figure 8--6 Lube Oil Flow Diagram
Figure 8--7 Speed Control Solenoid
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Figure 8--8 Engine Crankcase Breather
Figure 8--9 Water Pump V--Belt
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Figure 8--10 Evaporator fan bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--11 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--12 Generator Removal
Figure 8--13 Generator Removal
Figure 8--14 Generator Removal
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Figure 8--15 Generator Removal
Figure 8--16 Generator Removal
Figure 8--17 Generator Removal
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Figure 8--18 Generator Removal
Figure 8--19 Generator Assy
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Figure 8--20 Bolt Hole Pattern For Bell Housing and Crankshaft
Figure 8--21 Vacuum Pump Connection
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Figure 8--22 Compressor -- model 06D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--23 Exploded view of valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--18
4--19
8--4
8--5
8--5
8--6
8--8
8--8
8--9
2--28
2--29
4--1
4--14
4--14
4--15
4--15
2--9
2--13
2--15
2--18
2--18
2--25
2--26
2--27
Page
2--3
2--4
2--5
2--6
2--8
8--14
8--15
8--15
8--16
8--16
8--17
8--21
8--23
8--24
8--9
8--10
8--12
8--12
8--14
8--14
8--14 xi
62--11039
LIST OF ILLUSTRATIONS (Continued)
FIGURE NUMBER
Figure 8--24 Suction valve & positioning springs
Figure 8--25 Compressor oil pump end view
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--26 Oil Level in Sight Glass
Figure 8--27 Unloader solenoid valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--28 Solenoid Coil Replacement
Figure 8--29 Electronic expansion valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--30 Electronic expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--31 Thermostatic Expansion Valve Bulb and Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--32 Typical Setup for Testing High Pressure Switch
Figure 8--33 Pressure Transducer Values
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--34 Suction modulation valve (CSMV)
Figure 8--35 CSMV Coil (Bi--Polar Design)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8--36 Defrost Air Switch Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8--29
8--30
8--31
8--31
8--34
8--35
8--37
Page
8--24
8--25
8--26
8--27
8--27
8--28
LIST OF TABLES
TABLE NUMBER
Table 2-1 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-2 Compartment Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-3 Additional Support Manuals
Table 2-4 Field Effect Transistors
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-5 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-6 Compressor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-7 Component Resistance & Current Draw
Table 3-1 Unit Data
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3-2 Functional Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-1 Glow Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-2 Battery Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 8-1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 8-2 Blower wheels identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 8-3 Compressor Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 8-4 Suction and discharge Pressure Transducer Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 8-5 Compressor Discharge Pressure Transducer
Table 8-6 Compressor Suction Pressure Transducer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 8-7 CSMV Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 8-8 Sensor Resistance (ATT, 1RAT, 2RAT, 3RAT, 1SAT, ENCT, EVOT, CST, 1DTT, 2DTT) . . . . . . .
Table 8-9 Sensor Resistance (CDT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 8-10 Temperature Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--23
3--20
3--25
4--2
4--2
8--1
8--11
Page
2--1
2--1
2--2
2--14
2--20
2--21
8--26
8--31
8--32
8--33
8--34
8--38
8--39
8--41
62--11039 xii
SECTION 1
SAFETY PRECAUTIONS
Engine Coolant
1.1 SAFETY PRECAUTIONS
Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind. During normal operation, all moving parts are fully enclosed to help prevent injury. During all pre-trip inspections, daily inspections, and problem troubleshooting, you may be exposed to moving parts. Please stay clear of all moving parts when the unit is in operation and when the unit main power switch is in the START/RUN position.
The engine is equipped with a pressurized cooling system. Under normal operating conditions, the coolant in the engine and radiator is under high pressure and is very hot. Contact with hot coolant can cause severe burns. Do not remove the cap from a hot radiator. If the cap must be removed, do so very slowly in order to release the pressure without spray.
CAUTION
Under no circumstances should anyone attempt to repair the Logic or Display Boards.
Should a problem develop with these component, contact your nearest Carrier Transicold dealer for replacement.
Refrigerants
The refrigerant contained in the refrigeration system of your unit can cause frostbite, severe burns, or blindness when in direct contact with the skin or eyes. For this reason, and because of legislation regarding the handling of refrigerants during system service, we recommend that whenever your unit requires service of the refrigeration system you contact your nearest
Carrier Transicold authorized repair facility for service.
CAUTION
Under no circumstances should a technician electrically probe the processor at any point, other than the connector terminals where the harness attaches. Microprocessor components operate at different voltage levels and at extremely low current levels. Improper use of voltmeters, jumper wires, continuity testers, etc. could permanently damage the processor.
Battery
This unit is equipped with a lead-acid type battery. The battery normally vents small amounts of flammable hydrogen gas. Do not smoke when checking the battery.
A battery explosion can cause serious physical harm and/or blindness.
1.2 SPECIFIC WARNING AND CAUTION
STATEMENTS
CAUTION
Most electronic components are susceptible to damage caused by electrical static discharge (ESD). In certain cases, the human body can have enough static electricity to cause resultant damage to the components by touch. This is especially true of the integrated circuits found on the truck/trailer microprocessor.
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 -- warns against an immediate hazard which
WILL result in severe personal injury or death.
WARNING -- warns against hazards or unsafe conditions which COULD result in severe personal injury or death.
Auto-Start
Your refrigeration unit is equipped with Auto-Start in both Start--Stop and Continuous Run modes. The unit may start at any time when the Start/Run--Off Switch
(SROS) is in the Start/Run position. A buzzer will sound for 5 seconds before the unit is started. When performing any check of the refrigeration unit (e.g., checking the belts, checking the oil), make certain that the SROS is in the OFF position.
CAUTION -- warns against potential hazard or unsafe practice which could result in minor personal injury, or product or property damage.
The statements listed below are specifically applicable to this 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.
1--1 62-11039
WARNING
Be aware of HIGH VOLTAGE supplied by the generator as the unit may start automatically. Before servicing the unit, make sure the START/RUN--OFF switch is in the OFF position. Also disconnect the negative battery cable.
MAGNETIC FIELD INSIDE!
NEVER dis--assemble the generator: HIGH
WARNING
Under no circumstances should ether or any other starting aids be used to start engine.
WARNING
When performing service and/or maintenance procedures, make certain the unit is disconnected from the power source and that the RS is in OFF position so that it is impossible for the unit to start up automatically during the maintenance operation.
WARNING
Make sure the power plug is clean and dry before connecting to any electrical outlet/receptacle.
WARNING
Do not connect to any electrical outlet without checking that it meets the
460/3/60 and 30 Amp electrical requirements.
WARNING
Always place RS in the OFF position and turn off the high voltage power supply before disconnecting the high voltage power plug from the unit.
WARNING
Do not place the Start/Run--OFF Switch
(RS) in the Start/Run position or the unit will start.
WARNING
Do Not Allow Jumper Wire To Touch Any
Ground.
WARNING
Voltage will be applied to high voltage components (i.e. the fan motor contactor) and those components will operate (i.e. the fan blades will turn) when those components are energized and the unit is in standby operation and using component test mode.
WARNING
Carefully protect eyes from solvent.
WARNING
Do not direct water or steam into the generator openings. Do not allow any soap and water solutions to enter the generator.
WARNING
High voltage (dielectric) testing must not be performed to the machine without first observing NEMA rules. The insulation of this generator winding may be safely checked by using a megohm meter. A high reading indicates good insulation.
62-11039 1--2
WARNING
Relieve internal pressure of replacement compressor by slightly loosening the bolts of both service valve flanges/blank valve pads and then lightly tapping the center of the valve flanges/pads with a soft mallet to break the seal.
WARNING
Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is approximately 159.9 Bars (2350 PSIG). Do not use oxygen in or near a refrigerant system as an explosion may occur.
(See
Figure 8--32)
WARNING
The Compressor Discharge Pressure
Transducer does not have a Schrader valve in the connecting fitting. Any discharge pressure remaining in the compressor will be released when removing the CDP.
WARNING
Carrier Transicold does not recommend allowing the compressor to pull less than 0
Bar/PSIG at any time.
CAUTION
Service Mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating.
CAUTION
The display and MessageCenter may behave differently during the software loading process, depending on the version of software currently in the controller. DO NOT IN-
TERRUPT THE SOFTWARE INSTALLATION
PROCESS ONCE IT HAS STARTED.
CAUTION
It is important that communications between the Micro and the computer are not disturbed during the software loading process. If using a laptop computer, turn all energy saving features off. Turn off any screen saver, or any hard drive time out settings.
CAUTION
Be certain that the clock you are using is accurate. Also, some customers are located in different time zones from the repair location. If you know the repair location time zone, enter that time. If you don’t, enter your current time.
CAUTION
Use only Carrier Transicold approved Polyol Ester Oil (POE). Buy quantities of one quart or less. When using this hygroscopic oil, immediately reseal. Do not leave container of oil open or contamination will occur.
CAUTION
Unit uses R404A and POE oil. The use of inert gas brazing procedures is mandatory for all Carrier Transicold refrigeration units; otherwise compressor failure will occur.
For more information Refer to Technical
Procedure 98-50553-00 Inert Gas Brazing
1--3 62-11039
CAUTION
Use only ethylene glycol anti-freeze (with inhibitors) in system as glycol by itself will damage the cooling system. Always add pre-mixed 50/50 anti-freeze and water to radiator/engine. Never exceed more than a
60% concentration of anti-freeze. Use a low silicate anti-freeze meeting GM specifications GM 6038M for standard life coolant or use Texaco Havoline extended life coolant or any other extended life coolant which is
Dexcool approved and has 5/150 (5 years/150,000 miles) on the label.
CAUTION
When changing oil filters, the new filters should be primed (partially filled) with clean oil if possible. If the filters are not primed, the engine may operate for a period with no oil supplied to the bearings.
CAUTION
The mica shim must be used during disassembly of the generator from the engine.
Never attempt to remove the rotor from the stator. Leave the shim in place until the generator is re installed on the engine.
CAUTION
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 compressor.
CAUTION
Do not vapor charge R404a systems. Only liquid charging through the receiver outlet
(King) valve is acceptable.
CAUTION
The +5.0 VDC (terminal B) is common between the Compressor Discharge Pressure
Transducer, the Compressor Suction Pressure Transducer, and the RPM sensor. If this circuit is shorted to ground (due to one of the mentioned components being defective, or a worn wire) the MessageCenter will show:
Suction Pressure: --29.9inHg (--1 Bar)
Discharge Pressure: 0 Bar/PSIG
Engine RPM: 0.
62-11039 1--4
1.3 SAFETY DECALS
1--5 62-11039
62--03957--01 High Voltage
62--03958--00 Heat Warning
62-11039
62--60280--00 Standby Safety
1--6
9
SECTION 2
UNIT DESCRIPTION
2.1 INTRODUCTION
WARNING
This manual contains operating data, electrical data and service instructions for the Vector 1800MT refrigeration system.
Be aware of HIGH VOLTAGE supplied by the generator as the unit may start automatically. Before servicing the unit, make sure the START/RUN--OFF switch is in the OFF position. Also disconnect the negative battery cable.
MAGNETIC FIELD INSIDE!
NEVER dis--assemble the generator: HIGH
Additional support manuals are listed in Table 2-3.
The model/serial number plate is located inside the unit on the frame as shown in Figure 2-2.
Table 2-1. Model Chart
Models
NDP33GN6HBV2
NDP33GN6HBV3
Description
2 Comp.
3 Comp.
R-404A
LB KG
19
19
8.3
8.3
Compressor
06D 41cfm
Engine
V2203--DI--E2B
Engine Speed
High Low
1850 1450
Description
2 Comp.
3 Comp.
5
6
7
13
14
15
16
Table 2-2. Compartment Configurations
Available Configurations
1
2
3
4
Compartment No.
2
3
2
3
2
3
2
3
2
3
3
2
3
2
2
2
2
2
Description of Configuration
2200 Single Disch.
2200 Dual Discharge
1100 Single Disch.
1100 Dual Disch.
1100 Single Disch
1100 Dual Discharge
1100 Dual Discharge
1100 Single Discharge
2200 Single Discharge
1100 Single Discharge
2200 Dual Discharge
1100 Dual Discharge
2200 Dual Discharge
1100 Single Discharge
2200 Single Discharge
1100 Dual Discharge
2--1 62-11039
Manual Number
62--11038
62--11040
62--11041
62--11095
62--10865
Table 2-3. Additional Support Manuals
Equipment Covered
Vector 1800MT & 06D Compressor
Vector 1800MT
Vector 1800M
CT4-134DI-E2B Engine
CT4-134DI-E2B Engine
2.2 GENERAL DESCRIPTION
The VECTOR 1800MT unit is a hybrid diesel/electric, fully charged, pre-wired, refrigeration/heating
“nosemount” unit used in conjunction with one or two remote evaporators. The unit is used on insulated trailers to maintain cargo temperatures within very close limits.
Electrical power is supplied to the unit from a power plug or by the diesel engine / A-C generator which is driven
Type of Manual
Service Parts List
Operator’s Manual
Easy To Run
Parts List
Workshop Manual by the engine. The generator provides nominal
480V/3Ø/60Hz power when the engine is in high speed and nominal 300V/3Ø/45Hz in low speed .
The control system is a microprocessor controller. Once the controller is set at the desired temperature, the system automatically selects cooling and heating cycles as necessary to maintain the desired temperature within very close limits.
62-11039 2--2
1
19
9
18
17
15
14
16
2
3
4
5
1. Fuel filter
2. Model/Serial number nameplate
3. Battery
4. Battery charger
5. Generator
6. Engine RPM (ENRPM)
7. Lube oil filter
8. Oil drain
9. Starter motor
10. Lube oil fill & dipstick
6
7
8
9
10
11
12
13
11. Engine oil pressure switch (ENOPS)
12. Download Port
13. Display and Keypad
14. Fuel solenoid (FS)
15. Speed control solenoid (SCS)
16. Control box
17. Engine coolant temperature (ENCT)
18. Air cleaner
19. Coolant bottle
Figure 2-1. Front View
2--3 62-11039
1
7
6
5
4
3
10
11
9
8
2
17
16
13
14
15
12
1. Condenser/Radiator
2. Defrost air switch (DAS)
3. Receiver and sight glasses
4. Shutoff (King) valve
5. Compressor suction modulation valve (CSMV)
6. Filter drier
7. Compressor suction temperature (CST)
8. Discharge pressure transducer (CDP), High pressure switch (HP1)
9. Discharge service valve
10. Front unloader solenoid valve
11. Compressor, Compressor discharge temperature (CDT), Rear unloader solenoid, Compressor electrical box (Located on rear of compressor)
12. Suction service valve
13. Compressor sight glass
14. Suction pressure transducer (CSP)
15. Power Supply Receptacle (PSR)
16. Condenser fan and motor
17. Muffler
Figure 2-2. Front View
62-11039 2--4
13
14
2
15
12
11
1
9
2
4
3
10
8
9
7
6
5
1. Evaporator fans and motors
2. Nozzle cover
3. Defrost termination thermostat sensor (1DTT)
4. Evaporator Coil
5. Drain pan heater
6. Heat Exchanger
7. Remote suction and liquid lines
8. Evaporator outlet pressure sensor (EVOP
9. Return air thermistor sensor (1RAT)
10. Electronic expansion valve (EVXV)
11. Evaporator outlet temperature sensor (EVOT)
12. Electric heaters
13. Remote evaporator liquid line connection
14. Remote evaporator suction line connection
15. Supply air temperature sensor (1SAT)
Figure 2-3. Evaporator Section -- Grille Removed
2--5 62-11039
12
13
16
14
15
11
1 2
3
4
5
8
6
7
29
26
25
24
28
27
9
23
22
21
18
17
19 20
10
INSIDE LEFT SIDE OF BOX
1. Compartment 2 evaporator contactor (2EVCON)
2. Compartment 2 heater contactor 1 (2HTCON1)
3. Compartment 2 heater contactor 2 (2HTCON2)
4. Compartment 3 heater contactor 1 (3HTCON1)
5. Compartment 3 heater contactor 2 (3HTCON2)
6. Generator contactor (GENCON)
7. Compressor contactor (CCON)
8. Condenser motor contactor (CDCON)
9. Compartment 1 evaporator contactor (1EVCON)
10. Microprocessor
11. Compartment 1 heater contactor 2 (HTCON2)
12. (OGF)
13. Transformer
14. Power source contactor (PSCON)
15. Power source contactor 2 (PSCON2)
Figure 2-4. Control Box
16. Compartment 3 evaporator contactor (3EVCON)
17. Compartment 1 heater contactor 2 (HTCON2)
18. Compartment 1 heater contactor 1 (HTCON1)
19. Microprocessor power fuse (F6)
20. Contactor power fuse (F9)
21. Run control relay (RCR)
22. Power supply contactor relay (PSCONR)
23. Generator contactor relay (GENCONR)
24. Heat contactor 1 relay evaporator 1
(HTCONR1)
25. Compressor contactor relay (CCONR)
26. Glow plug relay (GPR)
27. Starter solenoid relay (SSR)
28. Main fuse (F5)
29. Phase reversal module
62-11039 2--6
2.3 CONDENSING SECTION
The condensing section (Figure 2-2) consists of an engine--compressor drive package, condenser fan, condenser/radiator coil, refrigerant controls, piping, wiring, defrost air switch, and associated components.
The drive equipment includes the engine, generator, air cleaner, muffler, coolant overflow bottle, and drive belts.
Refrigeration components mounted in the condensing section include: the compressor, defrost air switch, suction modulation valve, filter drier, and receiver.
2.3.1 Condenser Coil
The condenser coil is of the tube in fin type and acts as a heat exchanger in which the compressed refrigerant gas is condensed into a liquid and lowered in temperature. Air movement over the condenser is provided by a two electric motor driven fans mounted in the condensing section.
2.3.2 Engine
The engine (Refer to Section 2.9) gives excellent fuel economy and has easy starting characteristics. It is equipped with spin-on lube oil and fuel oil filters for easier filter changes.
Engine Transducers and Sensors: a. Engine RPM Sensor (ENRPM)
Provides micro with engine rpm information to be displayed and recorded in the data recorder. It is located on the front of the engine near the generator.
b. Engine Oil Pressure Switch (ENOPS)
This normally open switch allows the engine to operate when oil pressure is above 15 ¦ 3 PSIG (1.02 ¦ 0.2
Bars). The switch will close and automatically stop the engine when pressure drops below 12.3 ¦ 3 PSIG (0.84
Bar). There is a 15 second delay after the engine starts to allow the oil pressure to build up before the microprocessor looks at the input from this switch. The switch is located on the front of the engine below the fuel solenoid.
c. Engine Oil Level Switch (ENOLS) (Optional)
ENOLS sets off Alarm when oil level is low. Located on the oil pan next to the oil fill.
d. Engine Coolant Temperature Sensor (ENCT)
Provides micro with engine coolant temperature information to be displayed and recorded in the data recorder . The sensor is located on the starter side of the engine near the #4 Injector.
e. Engine Coolant Level Sensor (ENCLS)
(Optional)
Sets off Alarm when coolant level is low. Located in the coolant bottle.
9
2.3.3 Compressor
The compressor assembly includes the refrigerant compressor, suction and discharge service valves, high pressure switch, compressor discharge thermistor and the suction and discharge pressure transducers. The compressor draws refrigerant gas from the evaporator and delivers it to the condenser at an increased temperature and pressure. The pressure is such that refrigerant heat can be absorbed by the surrounding air at ambient temperatures.
Compressor Unloaders
The refrigeration compressor used is a 41cfm model
06D, equipped with unloaders as standard equipment.
Unloaders are used as a compressor capacity control to unload the compressor during periods of reduced loads.
This provides closer temperature control, reduces potential for top freezing and reduces power required to operate the compressor; thus reducing fuel consumption.
a. Major Working Parts
1. Solenoid and valve system
2. Spring loaded piston type bypass control valve
3. Spring loaded discharge check valve
2--7 62-11039
1
2 3
4
5
6
7
11
10
8
9
14
15
12
13
1. Solenoid Valve
2. Valve Stem
3. Gas Bypass Port
4. Spring Guide
5. Spring
6. Piston
7. Piston Bypass Valve
8. Bleed Orifice
9. Strainer
10. Suction Manifold
11. Cylinder Discharge Valve
12. Valve Plate
13. Cylinder Suction Valve
14. Discharge Piston Check Valve Assembly
15. Discharge Manifold
Figure 2-5. Compressor Cylinder Head Unloaded b. Unloaded Operation
Pressure from the discharge manifold (Figure 2-5, item
15) passes through the strainer (9) and bleed orifice (8) to the back of the piston bypass valve (7). Unless bled away, this pressure would tend to close the piston (6) against the piston spring (5) pressure.
With the solenoid valve (1) energized the solenoid valve stem (2) will open the gas bypass port (3).
Refrigerant pressure will be bled to the suction manifold
(10) through the opened gas bypass port . A reduction in pressure on the piston bypass valve will take place because the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice (8).
When the pressure behind the piston has been reduced sufficiently, the valve spring will force the piston bypass valve back, opening the gas bypass from the discharge manifold to the suction manifold.
Discharge pressure in the discharge manifold will close the discharge piston check valve assembly (14) isolating the compressor discharge manifold from the individual cylinder bank manifold.
The unloaded cylinder bank will continue to operate fully
unloaded until the solenoid valve control device is
de-energized and the gas bypass port is closed.
62-11039 2--8
9
4
5
6
7
11
2
3
1
10
9
8
14
15
12
13
1. Solenoid Valve
2. Valve Stem
3. Gas Bypass Port
4. Spring Guide
5. Spring
6. Piston
7. Piston Bypass Valve
8. Bleed Orifice
9. Strainer
10. Suction Manifold
11. Cylinder Discharge Valve
12. Valve Plate
13. Cylinder Suction Valve
14. Discharge Piston Check Valve Assembly
15. Discharge Manifold
Figure 2-6. Compressor Cylinder Head Loaded c. Loaded Operation
Discharge pressure bleeds from the discharge manifold
(Figure 2-6, item 15) through the strainer (9) and (8) bleed orifice to the solenoid valve stem (2) chamber and the back of the piston bypass valve (7).
With the solenoid valve (1) de-energized the solenoid valve stem will close the gas bypass port (3).
Refrigerant pressure will overcome the bypass valve spring (5) tension and force the piston (6) forward
closing the gas bypass from the discharge manifold to the suction manifold (10).
Cylinder discharge pressure will force open the discharge piston check valve assembly (14).
Refrigerant gas will pass into the compressor discharge manifold.
The loaded cylinder bank will continue to operate fully loaded until the solenoid valve control device is energized and the gas bypass port is opened. Refer to
Section 4.4.7 for more information on Loaded
Operation.
2.3.4 Filter Drier
The drier is a cylinder shell containing a drying agent and screen. It is installed in the liquid line and functions to keep the system clean and remove moisture from the refrigerant.
2.3.5 Receiver
Liquid refrigerant from the condenser drains into the receiver. The receiver serves as a liquid reservoir when there are surges due to load changes in the system; as a storage space when pumping down the system and as a liquid seal against the entrance of refrigerant gas into the liquid line.
The receiver is provided with two bull’s--eye sight glasses, for the observation of liquid level, and a pressure relief valve.
2--9 62-11039
2.3.6 Transducers and Sensors a. Compressor Suction Pressure Transducer
(CSP)
Provides micro with suction pressure information to be displayed, recorded in the data recorder and used to control the refrigeration system. It cannot be calibrated.
It is located near the oil pump on the compressor.
b. Compressor Discharge Pressure Transducer (CDP)
Provides micro with discharge pressure information to be displayed, recorded in the data recorder and used to control the refrigeration system. It can be calibrated. It is located on the center cylinder head of the compressor.
c. Compressor Discharge Temperature Sensor
Transducer (CDT)
Provides micro with discharge temperature information to be displayed, recorded in the data recorder and used to control the refrigeration system. It is located on the center cylinder head of the compressor.
d. Compressor Suction Modulation Valve (CSMV)
The CSMV opens and closes as required for capacity control of the refrigeration system cooling cycle. It is located in the suction line at the exit of the evaporator pod.
e. Compressor Suction Temperature Sensor (CST)
Provides micro with suction temperature information to be displayed, recorded in the data recorder and used to control the refrigeration system. It is located on the suction line near the filter drier.
f. Ambient Air Temperature Sensor (AAT)
AAT is a temperature control probe which provides micro with ambient air temperature information to be displayed, recorded in the data recorder and used to control the refrigeration system. It is located behind the condenser grille.
2.4 COMPARTMENT 1 EVAPORATOR SECTION
The main evaporator fits into a rectangular opening in the upper portion of the trailer or rail car front wall. When installed, the evaporator section is located inside this refrigerated compartment, and the condensing section is outside.
The main evaporator assembly consists of an evaporator coil, evaporator fan motors, electronic expansion valve, evaporator coil heaters, heat exchanger, defrost termination sensor and supply and return air sensors (See Figure 2-3) and high temperature safeties.
Heating is accomplished by electric evaporator coil heaters.
Automatic evaporator coil defrosting is initiated by either sensing the air pressure drop across the coil with a differential air switch or with the defrost timer in the microprocessor.
2.4.1 Electronic Expansion Valve (EVXV)
The electronic expansion valve is an electronic device which controls the flow of liquid to the evaporator according to changes in superheat to the refrigerant leaving the evaporator. The expansion valve maintains a relatively constant degree of superheat in the gas leaving the evaporator regardless of suction pressure. The valve has a dual function -- automatic expansion control and prevention of liquid return to the compressor.
2.4.2 Heat Exchanger
The heat exchanger is of the tube in tube type connected in the main suction line and liquid line. Within the heat exchanger, the cold suction gas is used to cool the warm liquid refrigerant. This results in greater system capacity and efficiency.
2.4.3 Evaporator Coil
The unit evaporator is a tube in fin type. The operation of the compressor maintains a reduced pressure within the coil. At this reduced pressure, the liquid refrigerant evaporates at a temperature sufficiently low enough to absorb heat from the air.
2.4.4 Transducers and Sensors a. Evaporator Outlet Pressure Transducer (EVOP)
Provides micro with evaporator outlet suction pressure information to be displayed, recorded in the data recorder and used to control the refrigeration system. It cannot be calibrated. It is located in the evaporator section near the electronic expansion valve in the suction line.
b. Evaporator High Temperature Switch (EVHTS)
EVHTS is a safety switch which turns off the electric heaters if the temperature in the evaporator compartment reaches 130°F (54.4°). It is located on the roadside evaporator support bracket above the coil.
c. Evaporator Outlet Temperature Sensor (EVOT)
Provides micro with evaporator outlet suction temperature information to be displayed, recorded in the data recorder and used to control the refrigeration system. It is located on the suction line near the electronic expansion valve and is wrapped with insulating tape.
d. Defrost Termination Temperature Sensor (1DTT)
1DTT is located on the center tube sheet of the evaporator section. It senses the temperature of the evaporator and allows defrost initiation once the temperature falls below 40°F (4.4°C)
e. Return Air Temperature Sensor (1RAT)
1RAT is a temperature control probe which provides micro with return air temperature information to be displayed, recorded in the data recorder and used to control the refrigeration system. It is located on roadside of the return air grille.
62-11039 2--10
f. Supply Air Temperature Sensor (1SAT)
1SAT is a temperature control probe which provides micro with supply air temperature information to be displayed, recorded in the data recorder and used to control the refrigeration system. It is located on the supply air grille.
2.5 REMOTE EVAPORATOR(S)
The compartments of the MultiTemp system are equipped with separate evaporators.
For MultiTemp remote compartment applications single and dual air discharge evaporators are available. The evaporators are different in size, capacity and number of fans, but all work on the same principle and use the same three-phase 45Hz to 60Hz fan assembly.
The remote evaporator(s) consist of evaporator coil(s), evaporator fan motor(s), thermostatic expansion valve(s), defrost termination sensor(s), 12V liquid line solenoid(s), 12V water drain heater(s), evaporator coil heaters, return air and optional supply air sensor(s) and high temperature safeties.
The bottom section of the evaporator allows easy access to both the electrical and refrigeration hardware.
2.6 SYSTEM OPERATING CONTROLS AND
COMPONENTS
The temperature controller is a Carrier Transicold
Advance Microprocessor controller (Refer to Section
2.6.3 and 3). Once the controller is set at the desired temperature, the unit will operate automatically to maintain the desired temperature within very close limits.
The microprocessor controller consists of two modules
-- the control module and display and keypad module.
The control box includes manual switches, microprocessor, fuses, and associated wiring.
Standard equipment includes an auto start--stop feature. This feature provides automatic cycling of the diesel engine, which in turn offers an energy efficient alternative to continuous operation of the engine with control of temperature by alternate cooling and heating of the supply air (evaporator outlet air).
9
2.6.1 Multiple Languages
Messages in the MessageCenter can be displayed in
English, French or Spanish.
Press and hold = key for 6 seconds to view or change the current language selection. See Section 3.17 for more information on functional parameters.
2.6.2 Special Features
The following special features are incorporated into the
Carrier Transicold Advance Microprocessor:
A MessageCenter which clearly displays all information in dot matrix form.
Unit Operation & Alarms are displayed in English (not in codes)
Large LCD Display
Unit Data and Functional Parameters
Programmable Maintenance Hour Meters
PM Hour Meters are resettable from the Keypad
Bright LED Alarm Light
Bright LED Mode Lights
Fully Automated Pretrip
Automated Micro Self--test
Data Recorder
Data Recorder date & time can be set from the Keypad
Auto Start--Stop
Trip Start to record date/time of trip in Data Recorder memory
PC card functionality for Downloading data, upgrade programming, and Configuration set up
FETs (Field Effect Transistors) for switching components on & off, and checking circuit current
Automatic or Manual Engine Starting
Functional Parameter locks
Alarms are stored in microprocessor memory for future reference
New Menu system to simplify keyboard and enhance functionality
2--11 62-11039
2.6.3 Microprocessor Component Description
And Location
The microprocessor controller consists of two modules
-- the control module (See Figure 2-7) and display and keypad module (See Figure 2-8). The control module is housed in the control box on the lower roadside (right) corner of the unit. This control module consists of a logic board and an input/output board. The control module contains externally accessible relays and fuses. The display and keypad module is located for driver access at the lower roadside corner of the unit.
The processor board in the control module includes the microprocessor, program memory and necessary input/output circuitry to interface with the unit. The microprocessor is totally self contained and does not contain any serviceable components.
The display board is mounted in the keypad and display module. The board includes the LCD display, keypad and keypad interface.
The keypad & display module provides the user with a panel to view and control the functions of the refrigeration unit. The module consists of a switch, keypad, MessageCenter, and Main Display. Setpoints and other system information are selected using the keypad.
Figure 2-8 shows the display & keypad module.
CAUTION
Under no circumstances should anyone attempt to repair the Logic or Display Boards. Should a problem develop with either of these components, contact your nearest Carrier Transicold dealer for replacement.
a. Control Module
Figure 2-7 shows the Control Module. The Control
Module has 3 relays and 4 fuses that are user accessible.
The PC card slot is also shown in Figure 2-7. This card slot is used with all Carrier Transicold PC Cards. The controller automatically detects the presence and type of PC Card inserted and responds accordingly. The different types of PC Cards are:
S
Download Card for copying unit data from Data
Recorder.
S
Options PC Card for installing optional software programs
S
Configuration PC Card for setting the Microprocessor
Functions, Configurations and Data Recorder configurations.
S
Program PC Card for upgrading the microprocessor software.
There are three LEDs associated with the function of the
PC card slot. These are:
• A green Micro Status LED which will blink steadily once per second indicating that the microprocessor is operating and will blink every 0.5 seconds if there is no software or if it is loading software.
• A green (PC) Card Status LED which comes on when there is a PC card inserted in the slot. This LED will:
1. Blink every 0.5 seconds when data is being transferred to or from the PC Card, and Will be on steady when the operation is complete and the PC Card may be removed.
2. During Download, the light will blink once per second and will blink every 1.5 seconds when the Download is complete.
•
A red (PC) Card Fault LED blinks if there is a problem transferring data from the PC card that has been plugged into the PC card slot. The red LED will continue to blink until the PC card is removed. The LED will also blink if there is an error reading the card. Check the
MessageCenter for description of error.
62-11039 2--12
PC CARD FAULT LED
(RED)
1MP (WHITE)
TEMP & PRESSURE
INPUTS
PC
CARD SLOT
2MP (BLACK)
STEPPER MOTORS,
(EVXV, CSMV)
PC CARD STATUS
LED (GREEN)
MICRO STATUS LED
(GREEN)
3MP (GREY)
FET OUT-
PUTS
QC5 (NOT
USED)
LED29
F4
(7.5A)
NOT
USED
9
RUN RELAY (K2)
QC4 (+12V OUTPUT
TO RR)
SPEED RELAY (K1)
QC3 (+12V OUTPUT
TO SR)
LED28
LED27
F3 (7.5A)
F2 (10A)
RELAY POWER
QC8 (12+ VDC
FET LEDs
See Table 2-4
DC CURRENT
SENSOR
LED30 (GPR)
LED31 (SSR)
6MP (DISPLAY/KEYPAD
CIRCUIT)
5MP
4MP
QC9
QC2 (MICRO GROUND)
QC1 (SYSTEM POWER
12+VDC FROM BATTERY)
F1 (7.5A)
Figure 2-7. Control Module
2--13 62-11039
FET
FET1
FET2
FET3
FET10
FET18
FET19
FET20
FET21
FET22
FET23
FET
FET7
FET8
FET14
FET15
FET16
FET17
Table 2-4. FIELD EFFECT TRANSISTORS (Transistors not listed are spares)
STANDARD
DESIGNATION
Condenser fan motor
Compressor contactor
Generator contactor
Heat contactor 1
Buzzer
Standby contactor
Evaporator motor
Heat contactor 2
Rear unloader
Front unloader
LIGHT BAR OPTIONS
DESIGNATION
Start--Stop/Continuous
Heat Light
Fault Light
Out--Of--Range Light
Defrost Light
Cool Light
62-11039 2--14
DOOR CLOSED
9
1
3
2
4
5
6
12
11
7
8
9
10
1. Compartments ON/OFF switches
2. Mode lights
3. Main Display
4. MessageCenter
5. Up and Down arrow keys
6. Enter key
7. Manual defrost key
8. Alarm list key
9. Start/Stop--Continuous key
10. Select key
11. Start/Run--Stop switch (RS)
12. Standby/Engine switch
Figure 2-8. Display And Keypad
2--15 62-11039
Display
The Main Display has 9 characters (7 seven--segment characters and 2 nine--segment characters), 2 decimal points, 2 commas, and a degree symbol. The display is used to provide the user setpoint and refrigerated compartment temperatures, either in degrees
Centigrade or Fahrenheit. The comma symbols are used as the decimal indicators in Europe. When Metric
Units is selected in the Functional Parameters, the two comma icons are used instead of decimal points. When
English Units is selected in the Functional Parameters, decimal points are used.
Temperature display is right justified, with unused digits blank. A negative sign will be displayed for all setpoint and box temperatures below zero. A positive sign will be displayed for all setpoint and box temperatures above
0°F (--17°C). 0° will not have a sign in front of it.
Indicator LEDs
The display has six LEDs across the top to indicate operation status. These indicators are:
Cool Indicator (Green) -- Turned on when the unit is in
Cool Mode.
Heat Indicator (Amber) -- Turned on when the unit is in
Heat Mode.
Defrost Indicator (Amber) -- Turned on when the unit is in
Defrost Mode.
Start--Stop Indicator (Green) -- Turned on when the
Start--Stop Mode has been selected.
Continuous Indicator (Green) -- Turned on when the
Continuous Mode has been selected.
Alarm Indicator (Red) -- Off or Flashes at a rate of 0.5
seconds.
NOTE
When the unit is in Null mode (fan only), the mode indicators (cool, heat and defrost) are all off.
NOTE
There is an opening between the Alarm and
Start--Stop LEDs that is not used at this time.
MessageCenter
The MessageCenter is used to show messages. Details of the messages are described in Section 6.1
MessageCenter.
NOTE
Messages can be displayed in multiple languages. See Section 3.17 for Functional Parameter settings.
Switch Descriptions a. ENGINE/STANDBY Switch (SS)
This switch is used to select mode of operation, either engine drive or standby electric motor drive. When this switch is placed in standby position, the electric motor will not start until the oil pressure safety switch (ENOPS) opens.
b. START/RUN--OFF Switch (RS)
When placed in the RUN position, this switch provides power to the microprocessor.
The microprocessor performs a self-test (all segments of display are illuminated). Then setpoint and
Box Temperature are displayed.
To stop the unit or remove power from the microprocessor, move the RS to the
OFF position.
c. REMOTE COMPARTMENT SWITCHES
On/Off toggle switches located above the display.
Placing a switch in the “ON” (I) position starts remote evaporator in that compartmen t.
62-11039 2--16
Key Descriptions
UP ARROW and DOWN ARROW Keys
These keys allow you to change the setpoints or other displayed data of the system.
They also allow you to scroll through the Unit Data List, Function
Parameters List, Alarm List, etc.
EQUAL Key (ENTER)
The EQUAL key is used for many things including entering a setpoint, changing a
Functional Parameter, clearing alarms, and locking the data menu.
MANUAL DEFROST Key
MANUAL
DEFROST
The MANUAL DEFROST key is used to initiate a defrost cycle when the proper conditions are met.
ALARM LIST Key
ALARM LIST
The ALARM LIST key allows you to view the alarms stored in the microprocessor. The alarm list is displayed in the
MessageCenter.
Pressing the ALARM
LIST key once displays the active alarm list.
Each successive press cycles through the list to the end. To view the inactive alarm list,
Refer to Section 3.14.
START--STOP/
CONTINUOUS
START--STOP/CONTINUOUS Key
This key allows you to change from
Start--Stop operation to Continuous Run operation. In Start--Stop operation, when the controller is in Off--Cycle mode, the unit will not be running. During Off--Cycle mode, the microprocessor monitors box temperature, battery voltage and engine coolant temperature and will restart the unit when needed.
9
SELECT
SELECT Key
Press the SELECT key to scroll through the menu selections. One of the five standard and 1 optional menu selections will appear in the MessageCenter when the SELECT key is pressed. These are: TO VIEW
HOURMETERS, TO START PRETRIP, TO
VIEW DATA, TO VIEW SETTINGS, TO
MARK TRIP START or TO VIEW PRINT
MENU, or one optional selection --TO VIEW
INTELLISET. Repeated pressing of the
SELECT key will sequence the menu through these selections. The menu wraps around. Press the SELECT key until the desired menu selection appears in the
MessageCenter.
The five standard selections are:
•TO VIEW HOURMETERS-- Displays the hours for individual hour meters. Refer to
Section 3.16.
• TO VIEW PRETRIP -- Used to initiate a pretrip. Refer to Section 3.5.
• TO VIEW DATA -- Displays Unit Data.
Refer to Section 3.15.
• TO VIEW SETTINGS -- Displays unit
Functional Parameter settings. Refer to
Section 3.17.
•
TO MARK TRIP START -- This menu selection is only used with the Data
Recorder. It is used to record a Trip Start event which is logged in the Data Recorder.
This records the time and date of the beginning of the trip. Data can then be downloaded and reviewed by trip, making data review much easier. Refer to Section
3.12.
• TO VIEW PRINT MENU -- Enables the user to use hand--held Strip Print printer kit
P/N 12--00543--10.
The optional selection is:
• TO VIEW INTELLISET -- Refer to Section
3.21.1.
2--17 62-11039
2.7 ELECTRONIC MODULES
2.7.1 Overload Ground Fault Module (OGF) 2.8
OPTIONS
2.8.1 Light Bar
The Light Bar is an external set of indicator lights which can be seen in the mirror from the cab of the tractor.
They are controlled by the microprocessor. The green
LED indicates “STATUS OK”. The amber LED indicates
“CHECK UNIT”. Amber follows the microprocessor fault light and alarms can be read on the micro display.
Figure 2-9. OGF Module
The OGF is located in the control box on the relay panel assembly. The module has two electrical safety features in diesel and standby modes:
1. Overload protection function -- Overload break current = 40A
2. Ground leakage current protection -- ground leakage break current -- 150mA
For each case, A100 “OVERLOAD GROUND FAULT” is activated and the unit shuts down.
In case of ground leakage detection, the red LED on the
OGF module will be on continuously.
2.7.2 Phase Reversal Module (PRM)
Figure 2-10. PRM Phase Reversal Module
The PRM phase reversal module is located in the control box on the standby panel assembly.
In standby mode, the phase reversal module checks the electrical phase and reverses if necessary.
2.8.2 Door Switch(es)
A two compartment unit has provisions to connect a
Door Switch (DS) directly to the microprocessor. (This provision is not available for three compartment units.)
The microprocessor will recognize switches with contacts that are either open when the door is open, or that are closed when the door is open. Additionally, the
Configuration List gives you the ability to determine whether the switch will: enable the alarm only, enable the alarm and also shut the unit down, enable the alarm and put the unit into low speed while the door is open, or to have no alarm and only record door openings & closings in the data recorder.
If the Door Switch is configured to shut the unit down when the door is open, the unit will shut down for a minimum of 3 minutes. Additionally, there is an Override
Door Switch in the functional parameters (Refer to
Functional Parameter List, Section 3.17.) When this parameter is set to YES, the Door Switch Alarm will come on when the door is open. However, the unit will not shut down. This feature is included in the event of a door switch failure.
For both two and three compartment units a separate provision is available. Individual door switches for each compartment can be wired directly into the remote compartment ON/OFF switch. This will allow the door switch to shut down a compartment when the door is opened. The Data Recorder will record this in the same manner as if the compartment ON/OFF switch was used to turn the compartment off.
62-11039 2--18
2.8.3 Out of Range Alarm
The Out Of Range Alarm is intended to notify the driver when the box temperature is moving away from Set
Point. The Out Of Range Alarm may be configured as an
Alarm Only, or as an Alarm and Unit Shutdown. (Refer to Section 5.2 Configuration Mode)
Generally, before the Out of Range Alarm can be triggered, the box temperature must have first been In
Range. In Range is defined as the temperature(s) of one or all of the compartments having been within
± 2.7°F (1.5°C) of setpoint in the Perishable Range, or within + 2.7°F (1.5°C) of setpoint in the Frozen Range.
If the Out--Of_Range configuration (Refer to Section
5.2.1) is YES for shutdown, only the compartment that is out of range will shut down IF that compartment has a setpoint in the frozen range or has a setpoint in the perishable range and the actual compartment temperature is out of range is above setpoint.
If the Out--Of--Range configuration is YES for shutdown
(Refer to Section 5.2.1), all compartments will shut down if the compartment that is out of range has a setpoint in the perishable range and the actual temperature in that compartment is out of range below setpoint.
If the unit shuts down due to a shutdown alarm, the Out
Of Range Alarm will come on after the timer expires (30 or 45 minutes), and when the box temperature goes out of range, regardless if the box temperature was ever within setpoint range or not.
Out of Range is determined by the Functional
Parameter setting. Selections of 4°F (2°C), 5.5°F (3°C),
7°F (4°C), and OFF are available. The OFF setting disables the Out of Range Alarm. All other settings allow the user to determine how far away from setpoint the box temperature may move before turning on the
Alarm. Once the box temperature has moved away from set point by the selected amount, the Out of Range timer begins. If the alarm is configured for Alarm Only, after 30 minutes the alarm will be activated. If the alarm is configured for Alarm & Shutdown, after 45 minutes the alarm will be activated and the unit will shutdown.
In Sleep Mode, Pretrip, Diagnostic Test Mode,
Component Test Mode, or if the unit has a Door Switch, and the door has been opened, the Out of Range Alarm is not in use. After exiting any of these modes, or closing the trailer or rail car door, the box temperature must again come In Range of the set point before the Out of
Range Alarm can be activated.
In Defrost and in Start/Stop Off Cycle, the 30 or 45 minute timer does not count. Once the unit leaves these modes, and goes into a temperature control mode
(heat, cool, or null), the timer will be reset for the full time, allowing the unit either 30 or 45 minutes to bring the box temperature into range before activating the Out of Range Alarm.
Individual settings are available in functional parameters for compartments 1, 2 and 3. (See
Table 3-2).
9
2.8.4 Remote Control Panel
User-friendly indicator and operator control panels clearly show individual compartment temperatures with easy-to-read displays.
These compact panels can be mounted to suit the individual operator’s preferences -- on the front bulkhead, or in the refrigerated compartment (including in the wall itself). See Section 3.21.2 for more information on the remote control panels.
2--19 62-11039
2.9 ENGINE DATA
Table 2-5. Engine Data
Engine Model
Displacement
No. Cylinders
Rated Horsepower
Weight
Coolant Capacity
Thermostat
Oil Capacity with Filter
Injection Setting
Fuel
Firing Order
Glow Plug Amperage
Valve Clearance (Cold)
(Intake and Exhaust)
Compression
V2203--DI--E2B--CTD--5S1
134 in
3 (
2.197 liters)
4
35 hp (26.1KW) @1850 rpm
NOTE: See Table 2-1 for actual engine RPM settings
417.8 lbs (189.5 kg)
2 gallons (7.6 liters) (50/50 mix -- never to exceed 60/40)
Starts to open 177 to 182°F (81 to 83°C )
Fully open 203°F (95°C)
15 quarts (14 liters)
1st stage:
2702 to 2915 PSIG (183.8 to 198.3 Bars)
2nd stage:
3271 to 3555 PSIG (222.6 to 241.9 Bars )
Winter: Diesel No. 1 Summer: Diesel No. 2
1--3--4--2
6 -- 9 amps per plug at 12 VDC
0.0071 to 0.0087 inch (0.18 to 0.22 mm)
Engine compression must be above 400 PSIG (27.2 Bars) (each cylinder)
a. Lubrication System
Oil Pressure
40 to 60 PSIG (2.7 To 4.1 Bars)
(Engine in high speed)
Oil Pressure Safety Switch Setting Closes
15 ( ¦ 3) PSIG [1.02(¦.2) Bars]
Lube Oil Viscosity:
Outdoor Temperature
Centigrade Fahrenheit
Below 32_ 0°
0_ to 25_
Over +25_
32_ to 77_
Over 77_
SAE
10W or 15W40
20W or 15W40
30W or 15W40
The only approved synthetic lube oil is Mobil
Delvac 1. The normal oil change intervals should be reduced if the equipment is operated under extreme conditions such as in dirty environments.
NOTE
Refer to Section 8.1 for more detailed information on service intervals.
2.10 ENGINE AIR SYSTEM
Extended Service Interval (ESI) packages are standard. The ESI package reduces the frequency of scheduled service intervals. The two tables below reflect the differences between standard and ESI packages.
Oil Change Intervals -- Standard Service Interval
API
Class CI or higher
MOBIL
DELVAC 1
2000 Hours or 1 yr 4000 Hours or 1 yr
Oil Change Intervals -- Extended Service Interval
API
Class CG or higher
3000 Hours or 2 yr
MOBIL
DELVAC 1
4000 Hours or 2 yr
The air cleaner prolongs the life and performance of the engine by preventing dirt and grit from getting into the engine and causing excessive wear on all operating parts.
It is the responsibility of the operator to give the air cleaner equipment regular and constant attention in accordance with the instructions. (Refer to section 8.6.6)
Clean air is supplied to the engine through the air cleaner. The air is necessary for complete combustion and scavenging of the exhaust gases. As the engine piston goes through the intake stroke, the piston draws clean fresh air down into the cylinder for the compression and power strokes. As the engine goes through its exhaust stroke, the upward movement of the piston forces the hot exhaust gases out of the cylinders through the exhaust valves and the exhaust manifold. If the air filter is allowed to become dirty, the operation of the engine would be impaired.
62-11039 2--20
2.11 COMPRESSOR DATA
Table 2-6. Compressor Data
Compressor Model
No. Cylinders
No. Unloaders
Weight
Oil Charge
Approved OIl
06D
6
2
260 lbs (118 kg)
7.6 pints (3.6 L)
Mobil Arctic EAL 68
9
2.12 REFRIGERATION SYSTEM DATA a. Defrost Air Switch (DAS)
Initiates Defrost:
1.40 ¦ .07 inch WG (35 ¦ 1.8 mm)
b. Defrost Timer (micro controlled)
1.5h, 3h, 6h, or 12 hours
c. Evaporator High Temperature Safety (EVHTS)
Opens on a temperature rise at:
130
°¦
1
°
F (55
°¦
0.5
°
C)
Closes on a temperature fall at:
100
°¦
1
°
F (37.8
° ¦
0.5
°
C)
d. Relief Valve Setting
Opens on a pressure rise at:
537  44 psig (
3
7  3 Bar)
e. High Pressure Switch (HP1)
Opens on a pressure rise at:
465
¦
10 psig (34
¦
0.7 bar)
Closes on a pressure fall at:
350
¦
10 psig (24
¦
0.7 bar)
f. Engine Oil Pressure Switch (ENOPS)
Closes on a pressure rise at :
15 psig (1 bar)
Opens on a pressure fall at:
12 psig (0.82 bar)
g. Unit Dry Weight: 2062 LBS. (937KG)
Change 09/11 2--21 62-11039
2.13 ELECTRICAL DATA
Compressor Motor
Condenser Fan Motor
HTCON2 and heater dual discharge evaps
HTCON1 and heater single discharge evaps
Main Evaporator Fan
Motor
Remote Evaporator Fan
Motor
Generator
Battery Charger
OGF Relay
Battery
Standby Power
Requirements
ELECTRICAL DATA
Full Load Amps (FLA)
Rating: 17.5 amps @460 VAC
System current limit -- high speed: 26 amps
System current limit -- low speed: 22 amps
Locked Rotor
Full Load Amps (FLA)
Horsepower
RPM
Voltage and frequency
Locked rotor amps: 77 at 460V
1.5 amps @ 65 Hz
0.83hp (610 watts) @ 65 Hz
3832 rpm @ 65 Hz
310 to 660 VAC; 45 to 65 Hz
Bearing lubrication
Rotation
Resistance
Number of heaters
Factory lubricated, additional grease not required
Clockwise when viewed from shaft end
20 to 21 ohms
3 (1 assembly)
Rating per rod 0.81 hp (600 watts) 335 VAC/60Hz ±5% each
Resistance (cold) per rod 187 ohms ±5
Type Sheath
Current (Low Speed)
Current (High Speed)
Number of heaters
4 Amps
5.1 Amps
6 (2 assemblies)
Rating per rod 1.56 hp (1150 watts) 335 VAC/60Hz ±5% each
Resistance (cold) per rod 97.6 ohms ±5
Type Sheath
Current (Low Speed) 2.5 Amps
Current (High Speed)
Full Load Amps (FLA)
Horsepower
Rotations Per Minute
Voltage and Frequency
Bearing Lubrication
Rotation
Resistance
Full Load Amps (FLA)
3.5 Amps
1.1 amps
0.66 hp (485 watts) @ 65hz
1850 rpm @ 65 hz
310 to 660 VAC 45 to 65 Hz
Factory lubricated, additional grease not required
Clockwise or Counter-Clockwise
34.2 to 41.8 ohms
1 amp
Frequency at High Speed 60 hz
Frequency at Low Speed 45 hz
Resistance
Output
Output amps
Output voltage
Input voltage
0.738 to 0.778 ohms
22 KVA @ 0.82 p.f @ 1950 rpm
20A
14.8 VDC @ 77°F (25°C)
340 to 590 VAC
Frequency
Trips
Voltage
Voltage
Current
43 Hz to 68 Hz
40 Amps
13.7 volts @ 80°F (27°C)
460/3/60
30A
62-11039 2--22
9
2.14 COMPONENT RESISTANCE & CURRENT DRAW
Table 2-7. Component Resistance & Current Draw
Component Ohms Amps
Unloader
Speed solenoid (SCS)
12VDC Relay
10--00328--00
10.6 ± 0.3 Ohms
1.5 to 2.5 Ohms
72 Ohms ±10%
1.0 to 2.0 Amps
3.0 -- 8.0 Amps
0.14 -- 0.18 Amps
12VDC Relay
10--00385--00 (RCR,
PSCONR, GENCONR,
HTCONR1, CCONR)
80 Ohms ±15% 0.12 -- 0.17 Amps
0.11 -- 0.14 Amps 12VDC Relay
10--00328--02
Fuel Solenoid
97 Ohms ±10%
Red--Black Wires 11.1 to 13.4 Ohms
White--Black wires: Can not be accurately measured with Coil
Commander in circuit.
0.25 -- 2.0 Amps
30.0 to 40.0 Amps
Indicator lights 4.8 ± 0.2 Ohms
Unit non-running amps (See Note 2 in Section 7.2)
Glow Plug Amps Each Plug
Glow Plug Total Circuit
Starter Motor Less than 1 ohm but more than 0
NA
6--9 Amps
6 - 9 Amps
25 -- 35 Amps
270 -- 380 amps
2.15 SAFETY DEVICES
System components are protected from damage caused by unsafe operating conditions by automatic shut--down of the unit when such conditions occur. This is accomplished by the safety devices listed in
Table 2-8.
Table 2-8. Electrical Safety Devices
Unsafe Conditions
Excessive current draw by microprocessor Fuse (F1)
Safety Device
Excessive current draw by speed relay
Excessive current draw by run relay
Excessive current draw by battery output
Excessive current draw by control circuit
Excessive current draw by battery charger input
Fuse (F2)
Fuse (F3)
Fuse (F5)
Fuse (F6)
Fuse (F7/8)
Fuse (F9) Excessive current draw by generator/power supply contactors
Excessive current draw Compartment 1 heaters
Excessive current draw remote evaporator high voltage
Fuse (F10/F11/12)
Fuse (F13/14/15)
Excessive current draw condensate htr.
evap 2/3
Excessive temperature in evaporator
Fuse (F16/17)
High temperature thermostat
(EVHTS)
Excessive condenser fan motor winding temperature
Excessive compressor motor winding temperature
Excessive evaporator motor winding temperature
Internal protector
Internal protector
Internal protector
Device Setting
Opens at 7.5 amps
Opens at 10 amps
Opens at 7.5 amps
Opens at 80 amps
Opens at 15 amps
Opens at 2A*
Opens at 10 amps
Opens at 12 amps
Opens at 12 amps -- 2 Comp.
Opens at 15 amps -- 3 Comp.
Opens at 5 amps
Opens at 130
Closes at 100
Auto reset
Auto reset
Auto reset
_
F (54.4
_
C)
_
F (37.8
_
C)
*4A Fuse is used when there is a second battery charger
2--23 62-11039
2.16 REFRIGERANT CIRCUIT DURING COOLING (See Figure 2-11 thru Figure 2-14)
When cooling, the unit operates as a vapor compression refrigeration system. The main components of the system are: the (1) reciprocating compressor, (2) air-cooled condenser, (3) electronic expansion valve, and (4) direct expansion evaporator.
pressure of the liquid and meters the flow of liquid refrigerant to the evaporator to obtain maximum use of the evaporator heat transfer surface.
The compressor raises the pressure and the temperature of the refrigerant and forces it into the condenser tubes. The condenser fan circulates surrounding air over the outside of the condenser tubes.
The tubes have fins designed to improve the transfer of heat from the refrigerant gas to the air. This removal of heat causes the refrigerant to liquify. Liquid refrigerant leaves the condenser and flows to the receiver.
The refrigerant pressure drop caused by the expansion valve is accompanied by a drop in temperature so the low pressure, low temperature fluid that flows into the evaporator tubes is colder than the air that is circulated over the evaporator tubes by the evaporator fan. The evaporator tubes have aluminum fins to increase heat transfer; therefore heat is removed from the air circulated over the evaporator. This cold air is circulated throughout the box to maintain the cargo at the desired temperature.
The receiver stores the additional charge necessary for low ambient operation. The receiver is equipped with a relief valve (See Section 2.12)
The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize.
The refrigerant leaves the receiver and flows through the manual shut off valve (King valve) to the subcooler.
The subcooler occupies a portion of the main condensing coil surface and gives off further heat to the passing air.
The refrigerant then flows through a filter-drier where an absorbent keeps the refrigerant clean and dry.
The refrigerant flows to the “Liquid/suction” heat exchanger.
Here the liquid is further reduced in temperature by giving off some of its heat to the suction gas.
The liquid then flows to an externally equalized electronic expansion valve (EVXV) which reduces the
This low temperature, low pressure vapor passes through the evaporator outlet temperature and pressure sensors (EVOT and EVOP) which aid in calculation of superheat. The vapor then passes through the “suction line/liquid line” heat exchanger where it absorbs more heat from the high pressure/high temperature liquid and then returns to the compressor through the compressor suction modulation valve (CSMV). The CSMV controls the compressor suction pressure thereby matching the compressor capacity to the load.
The remote evaporators are equipped with liquid solenoid valves which open or close depending on the thermostat, and are also equipped with externally equalized thermostatic expansion valves (TXV).
2.17 REFRIGERANT CIRCUIT -- HEATING AND DEFROSTING (See Figure 2-12 thru Figure 2-15)
Compressor is turned off for all heating and defrost cycles. Heating is always accomplished using electric resistance heaters. Defrost may be accomplished using either electric heaters or return air. See Section 4.4.10
for more information on heating and defrost.
62-11039 2--24
EXTERNAL
EQUALIZER
TXV
BULB
EXTERNAL
EQUALIZER
TXV
BULB
9
LSV3
TXV
REMOTE
EVAPORATOR
LSV2
TXV
REMOTE
EVAPORATOR
EVOT
EVOP
CSMV
DISCHARGE
SERVICE
VALVE
CDP
CSP
EVXV
HOST EVAPORATOR
RELIEF VALVE
RECEIVER
MANUAL
SHUT--OFF
VALVE
HP1
CDT
HEAT EXCHANGER
LIQUID LINE
CST
COMPRESSOR
SUCTION
SERVICE
VALVE
FILTER
DRIER
SUBCOOLER
CONDENSER
DISCHARGE
LIQUID
HOT GAS LINE
SUCTION LINE
Figure 2-11. Refrigerant Circuit All Compartments Cooling
2--25 62-11039
EXTERNAL
EQUALIZER
TXV
BULB
EXTERNAL
EQUALIZER
TXV
BULB
LSV3
TXV
REMOTE
EVAPORATOR
LSV2
TXV
REMOTE
EVAPORATOR
EVOT
EVOP
EVXV
HOST EVAPORATOR
RELIEF VALVE
RECEIVER
MANUAL
SHUT--OFF
VALVE
CSMV
DISCHARGE
SERVICE
VALVE
CDP
CSP
HP1
CDT
HEAT EXCHANGER
LIQUID LINE
CST
COMPRESSOR
SUCTION
SERVICE
VALVE
FILTER
DRIER
SUBCOOLER
CONDENSER
DISCHARGE
LIQUID
HOT GAS LINE
SUCTION LINE
Figure 2-12. Refrigerant Circuit -- Compartment One Cooling, Compartments 2 & 3 Heating
62-11039 2--26
EXTERNAL
EQUALIZER
TXV
BULB
EXTERNAL
EQUALIZER
TXV
BULB
9
LSV3
TXV
REMOTE
EVAPORATOR
LSV2
TXV
REMOTE
EVAPORATOR
EVOT
EVOP
CSMV
CDP
DISCHARGE
SERVICE
VALVE
CSP
HP1
CDT
HEAT EXCHANGER
LIQUID LINE
CST
COMPRESSOR
SUCTION
SERVICE
VALVE
EVXV
HOST EVAPORATOR
RELIEF VALVE
RECEIVER
MANUAL
SHUT--OFF
VALVE
FILTER
DRIER
SUBCOOLER
CONDENSER
DISCHARGE
LIQUID
HOT GAS LINE
SUCTION LINE
Figure 2-13. Refrigerant Circuit -- Compartments One And Two Cooling, Compartment 3 Heating
2--27 62-11039
EXTERNAL
EQUALIZER
TXV
BULB
EXTERNAL
EQUALIZER
TXV
BULB
LSV3
TXV
REMOTE
EVAPORATOR
LSV2
TXV
REMOTE
EVAPORATOR
EVOT
EVOP
CSMV
CDP
DISCHARGE
SERVICE
VALVE
CSP
HP1
CDT
HEAT EXCHANGER
LIQUID LINE
CST
COMPRESSOR
SUCTION
SERVICE
VALVE
EVXV
HOST EVAPORATOR
RELIEF VALVE
RECEIVER
MANUAL
SHUT--OFF
VALVE
FILTER
DRIER
SUBCOOLER
CONDENSER
DISCHARGE
LIQUID
HOT GAS LINE
SUCTION LINE
Figure 2-14. Refrigerant Circuit -- Compartments One And Three Cooling, Compartment 2 Heating
62-11039 2--28
EXTERNAL
EQUALIZER
TXV
BULB
EXTERNAL
EQUALIZER
TXV
BULB
9
LSV3
TXV
REMOTE
EVAPORATOR
LSV2
TXV
REMOTE
EVAPORATOR
EVOT
EVOP
CSMV
CDP
DISCHARGE
SERVICE
VALVE
CSD
HP1
CDT
HEAT EXCHANGER
LIQUID LINE
CST
COMPRESSOR
SUCTION
SERVICE
VALVE
EVXV
HOST EVAPORATOR
RELIEF VALVE
RECEIVER
MANUAL
SHUT--OFF
VALVE
FILTER
DRIER
SUBCOOLER
CONDENSER
Figure 2-15. Refrigerant Circuit -- All Compartments Heating
2--29 62-11039
SECTION 3
OPERATION
3.1 RS “ON” AND ALL COMPARTMENT SWITCHES “OFF”
1. When all compartment switches are in “OFF”
(0) position and RS is in “START/RUN” position.
MAIN DISPLAY will display
“OFF”
MODE LIGHTS
COMPARTMENT SWITCHES
0 1 0 1 0 1
COMPARTMENT 3 COMPARTMENT 2 COMPARTMENT 1
2. The START/RUN - OFF switch is in
START/RUN position.
off
STANDBY
ENGINE
DOOR
The microprocessor will power up and go through self test. It will then show “OFF” in the main display and
“UNIT OFF” in The MessageCenter.
MessageCenter will display “UNIT
OFF”
3--1 62-11039
3.2 STARTING UNIT -- ENGINE/ROAD OPERATION
WARNING
Under no circumstances should ether or any other starting aids be used to start engine.
COMPARTMENT NUMBER FOR DATA
BEING DISPLAYED
COMPARTMENT SWITCHES
0 1 0 1 0 1
COMPARTMENT 3 COMPARTMENT 2 COMPARTMENT 1
1. Place the desired compartment switch(es) in ON (1) position.
2. Place the ENGINE/STANDBY switch in ENGINE position.
-20
+36 F 1
STANDBY
ENGINE
62-11039
3. Place the START/RUN - OFF switch in START/RUN position.
4. Engine will then start automatically.
3--2
3.3 STARTING UNIT -- ELECTRIC STANDBY OPERATION
WARNING
When performing service and/or maintenance procedures, make certain the unit is disconnected from the power source and that the RS is in OFF position so that it is impossible for the unit to start up automatically during the maintenance operation.
WARNING
Make sure the power plug is clean and dry before connecting to any electrical outlet/receptacle.
Do not connect to any electrical outlet without checking that it meets the 460/3/60 and 30 Amp electrical requirements of the unit.
1. Put all compartment switches in OFF (0) position and place RS in OFF position AND turn off the external power circuit breaker.
COMPARTMENT SWITCHES
2. Connect standby cable to unit and then turn the external power circuit breaker on.
3. Place the ENGINE/STANDBY switch in STANDBY position
0 1
COMPARTMENT 3
0 1
COMPARTMENT 2
4. Place the desired compartment switch(es) to on (1)
0 1
COMPARTMENT 1
-20
+36 F 1
STANDBY
ENGINE
5. Place the START/RUN - OFF switch in START/RUN position.
6. The unit will then start automatically.
3--3 62-11039
NOTE
The unit is equipped with automatic phase reversal which insures that the electric motors will run in the correct direction.
For safe, reliable operation in electric standby mode, it is important to consider the following guidelines:
•
NEVER connect the unit to a high voltage power source with the RS in the START/RUN position.
• The power supply cable and circuit breaker must comply with local electrical code and unit specifications.
See 2.13.
• The power supply cable must be equipped with a ground connection.
•
Repairs or maintenance to the supply voltage circuit should only be performed by licensed/authorized personnel.
62-11039 3--4
3.4
U
NIT
S
TARTUP --
E
NGINE/
R
OAD AND
E
LECTRIC
S
TANDBY
8888888888888
STANDBY
ENGINE
SELF TEST
When first powered up:
•
The microprocessor controller will run a self test.
• All of the mode lights will light
•
All of the segments on the display will turn on
• All of the Liquid Crystal diodes (LCDs) in the MessageCenter will turn on to verify their operation
•
The display will then show the setpoint temperature and the compartment temperature. The next character indicates the temperature units as “F”
Fahrenheit or “C” Centigrade and the last character indicates the compartment number for the information being displayed.
• The MessageCenter will display the default message, unless there is an alarm(s) stored in the controller. If there is an alarm(s) stored in the controller,
“INACTIVE ALARMS IN MEMORY” will be displayed on the MessageCenter and the Alarm LED will flash for 5 seconds, then turn off.
“CHECK AT NEXT SERVICE INTERVAL” will then be displayed if there are any active non-shutdown alarms present. Engine hours (Refer to Section 5.5) and the Active IntelliSet (Refer to Section 3.21.1) will also be shown when configured.
• The MessageCenter will show “STATUS OK” as the microprocessor begins to position the EVXV and the CSMV to unit starting positions.
• In engine operation, after the valves open the glow plugs will energize (as required), the buzzer will sound, and the diesel engine will start.
•
For standby, after the valves open the buzzer will sound then the fans and compressor will start.
NOTE
Manual Start will automatically put the unit in
Continuous Run mode.
Placing the unit in
Start--Stop will automatically put it back into
Auto Start operation.
Manual Start Mode will automatically be cancelled when the Start/Run--Off switch is toggled to Off and then back to Start/Run.
3--5 62-11039
3.5 PRETRIP
1. Place RS in “START/RUN” position.
ALARM HEAT COOL DEFROST
PPPP
SETPOINT
TEST #1
BOX TEMPERATURE
START-STOP CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
2. Press the SELECT key until the MessageCenter displays “PRESS THE = KEY TO START PRETRIP”
4. Verify that during TEST#1 the complete display is turned on, that the buzzer comes on and that all lights on the Light Bar come on.
5. The remainder of Pretrip will take 7 to 15 minutes, and will run itself automatically.
The PRETRIP mode is for checking unit operation and evaluating operation of all modes. It will indicate a failure when one is detected.
TIP
All compartments will be tested whether compartment switches are in ON or OFF position.
A Pretrip can be started with any box temperature.
The MessageCenter displays the current test and the % complete of the test. When the Pretrip tests are complete the MessageCenter will display one of three different messages:
S
“PRETRIP PASS” or
S
“PRETRIP FAIL IN TEST X” or
S
“PRETRIP FAILED & COMPLETE” and alarm light is
ON
Press the ALARM LIST key to review the alarms triggered by the Pretrip tests.
62-11039 3--6
TIP
The Pretrip test “PASS” results message will stay displayed until a key is pressed, or until the
RS switch is in the Off position.
The Pretrip test “FAIL” results message will stay displayed until the alarms are cleared
Once Pretrip is started, the control panel keys are disabled until Pretrip is completed.
If “CAN NOT START PRETRIP” is displayed in the MessageCenter, check to see if the unit is in
PC Mode (Refer to Section 5.1) or defrost mode, or check the alarm list (Section 7) for active shutdown alarms.
TIP
PRETRIP (Continued)
NOTE
Pretrip will run until completed, unless an alarm occurs that causes Pretrip to be aborted. Only alarms that will result in other erroneous alarms or will affect future
Pretrip tests will allow Pretrip to be aborted.
TIP
Pretrip may be stopped by the user by either turning the unit off then back on again, or by pressing and holding the = Key for 5 seconds.
“PRETRIP STOPPED BY USER” will appear in the MessageCenter.
Once Pretrip is started: If the unit is running, the microprocessor will shut the unit down by de-energizing the fuel solenoid.
If the unit is not running Pretrip will begin.
NOTE
Before beginning Test 1, PreTrip looks at the status of alarms and if certain alarms are active
(for example: Low Fuel Warning, Check Engine
Oil Level, Check Coolant Level, Check Coolant
Temperature, PreTrip will show “FAILED”, indicating that the unit is not ready to be sent out for a load, but that the alarm list should be checked and all present alarm situations corrected.
TIP
It is always a good idea to clear all alarms from both Alarm Lists before starting Pretrip. The technician will then know that any alarms present following Pretrip occurred during Pretrip, and are not old alarms that had not been cleared.
NOTE
The operator MUST be present and validate this test by watching the microprocessor display during Test 1 -- Display Test. The microprocessor will turn on all segments of the LCD and
LED display.
Test 1 -- Display And Sound Test
The microprocessor activates the LCD/LED display, and all lights on the Light Bar. This test will last 5 seconds. All segments of the display, all LEDs on the microprocessor, all lights of the Light Bar, and the buzzer will be on during this test. This is the only portion of the Pretrip check that requires the operator to determine PASS or FAIL. A defective display and sound test is indicated if: any LCD/LED segments are not visible, any LEDs or lights do not come on, or the buzzer does not sound. Anything that fails during this test should be repaired at the conclusion of the Pretrip cycle.
Pretrip will continue regardless of the outcome of this test. A faulty display, light bar or buzzer will not affect the operation of the unit, but will affect what is displayed during unit operation.
Test 2 -- Amperage Check of 12VDC Electrical Components
Check the amperage (current) draw of the following components:
• Battery DC Current
(All Components Turned Off)
• UL1 Front Unloader
•
UL2 Rear Unloader
• Speed Solenoid
• Glow Plugs
•
Fuel Solenoid
• CDCON
•
CCON
• GENCON
• HTCON1
•
HTCON2
• 2HTCON1
•
2HTCON2
• 3HTCON1*
• 3HTCON2*
•
EVCON
• 2EVCON
•
3EVCON*
• 2LSV
• 3LSV*
NOTE
*Will run test if 3 compartment model is selected.
Each component individually will be individually checked for proper current draw. An alarm will be displayed for any component testing outside the current range (amps).
Test 3 -- Refrigeration System Equalization Check
With the engine and the unit off, the CSMV will open to
50% and the EVXV will open to 100% so that the pressure in the refrigeration system can equalize. If the pressure does not equalize to within 80 psig (5.4 Bar)
ALARM P171 -- Check Evap & Disc Press-- will be activated.
3--7 62-11039
PRETRIP (Continued)
Test 4 -- Temperature Sensor Check
Check the condition of all of the system temperature sensors.
Test 4 will last approximately 5 seconds. If a problem is detected with any of the sensors, the corresponding alarm will be displayed.
NOTE
Tests 5, 6 an 7 are only performed when unit is in Engine/Road mode. For Electric Standby mode, pretrip will skip to Step 8.
Test 5 -- Engine Low Speed
The engine starts up in Low Speed with condenser fans on. The microprocessor verifies that engine rpm are in low speed range. If the engine is not operating within the low speed range, the “CHECK LOW SPEED RPM” alarm will be displayed.
Test 6 -- Engine High Speed
The engine switches to High Speed and energizes
HTCON1 and HTCON2. The microprocessor verifies that engine rpm are in high speed range. If the engine is not operating within the high speed range, the “CHECK
HIGH SPEED RPM” alarm will be displayed.
Test 7 -- Engine Low Speed 2
The engine switches back to Low Speed and heaters turn off. The microprocessor verifies that engine rpm are in low speed range. If the engine is not operating within the low speed range, the “CHECK LOW SPEED RPM” alarm will be displayed.
Test 8 -- Electric Heater Amperage Check (All
Compartments)
Will energize each heater individually and check for proper current draw. An alarm will be displayed for any heater testing outside the current range (amps).
Test 9 -- Evaporator Fan Motors Amperage Check
(All Compartments)
Will energize each evaporator motor contactor individually and check for proper current draw. An alarm will be displayed for any fan motors testing outside the current range (amps).
Test 10 -- Condenser Fan Motors Amperage Check
Will energize condenser motor contactor and check for proper current draw. An alarm will be displayed if fan motor tests outside the current range (amps).
Test 11 -- Check Compressor Suction Modulation
Valve (CSMV)
This test ensures that the CSMV is opening and closing properly. If suction pressure doesn’t change as expected with CSMV closed then “CHECK SUCTION
MOD VALVE” alarm will be displayed. This test may take several minutes.
Test 12 -- Electronic Expansion Valve (EVXV)
This test checks the operation of the EVXV. If valve doesn’t test properly “CHECK EVAP SUPERHEAT” alarm will be displayed.
Test 13 -- Unloaders
This test checks the operation of the unloaders. If suction and discharge pressures do not change when
UL1 and UL2 are energized and de--energized, the
“CHECK UL1” or “CHECK UL2” alarm will be displayed.
Test 14 -- LSV2 and LSV3
This test will individually check 2LSV and 3LSV for proper opening and closing. The “C2 CHECK LSV
VALVE” or “C3 CHECK LSV VALVE” alarm will be displayed.
Test 15 -- Check For Other Alarms
Checks the current alarm list for other active alarms.
Pretrip Termination
When the Pretrip cycle is completed, the unit will return to normal temperature control operation.
“PRETRIP PASS” will be shown in the display until the operator presses any key. In the event that the Pretrip test triggered an alarm(s), the display will show either
“PRETRIP FAIL & COMPLETE” (if the entire Pretrip cycle was completed), or “PRETRIP FAIL IN TEST XX”,
(if the Pretrip cycle was aborted by an alarm before it was completed).
62-11039 3--8
3.6 CHANGING SETPOINT
1. Wait for desired compartment to be displayed.
HEAT
-20
COOL DEFROST ALARM
+36 F
SETPOINT BOX TEMPERATURE
SETPOINT CHANGED
START-STOP
2
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
2. With the setpoint of the desired compartment displayed, press the UP ARROW or DOWN ARROW key to change the setpoint to the desired value. The MessageCenter will show “↑↓ TO
SCROLL, THEN = TO SAVE”.
3. Press the = key to save the new setpoint.
Setpoints of --22°F to +89.6°F (--30°C to +32°C) may be entered via the keypad for each compartment. The controller always retains the last entered setpoint in memory for each compartment.
Depending on
Microprocessor set--up, the setpoint may be changed up or down in either 0.1° (one--tenth of a degree) or 1°
(one full degree) increments by pressing and releasing either the UP ARROW or DOWN ARROW key.
NOTE
Setpoint for a compartment cannot be changed unless the switch for that compartment is “ON”.
The microprocessor Configurations allow a
Minimum and Maximum Setpoint to be entered, so that only setpoints within that range may be selected.
“MAX SETPOINT HAS BEEN
REACHED” or “MIN SETPOINT HAS BEEN
REACHED” WILL APPEAR in the Message-
Center when either of these conditions are met.
3--9
You can not change the setpoint when viewing the
Alarm List, Data List or Functional Parameters, or when unit is in Pretrip or is in Sleep Mode. Setpoint may be changed any other time the RS is in the START/RUN position, or with the unit in PC Mode.
Pressing the = key will cause the new displayed setpoint value to become active and “SETPOINT CHANGED” is displayed. If the new value is not entered, after 5 seconds of no keypad activity, the entire display and
Light Bar will flash for 15 seconds with “SETPOINT NOT
CHANGED” displayed and then revert back to the last entered setpoint for that compartment. All other keys are active at this time and if pressed while the display is flashing, will stop the flashing, and perform the requested function.
TIP
You may press and hold the UP ARROW or
DOWN ARROW key to quickly change the setpoint. The longer the key is held, the faster the setting will change.
62-11039
3.7 START--STOP OPERATION -- ENGINE/ROAD AND ELECTRIC STANDBY
HEAT
-20
COOL DEFROST ALARM
+36 F
SETPOINT BOX TEMPERATURE
START/STOP MODE SELECTED
START-STOP
2
CONTINUOUS
START--STOP
LIGHT
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the START--STOP/CONTINUOUS key until the START--STOP Light on the controller illuminates.
2. Verify that “START/STOP MODE SELECTED” is displayed on the MessageCenter and that the START-STOP light is illuminated. The unit is now in Start-Stop operation.
Automatic Start--Stop is provided to permit starting/stopping/restarting of the unit as required. This feature allows full automatic control of the engine or compressor starting and stopping by monitoring box temperature, battery charging amps and engine coolant temperature (Engine/Road only). The main function of automatic cycling is to turn off the refrigeration system near setpoint to provide a energy efficient temperature control system and to initiate a restart sequence when certain conditions are met. The Start--Stop/Continuous key is pressed to select between Continuous Run and
Start--Stop operating modes. Refer to Section 4.2 for more detailed information on Start--Stop Mode.
For compartment 1 only Start-Stop operation may be tied to the setpoint ranges for frozen and perishable loads. The START-STOP/CONTINUOUS key is locked out if “START-STOP LOCKED” appears in the
MessageCenter when the key is pressed and the unit is in Start--Stop Mode or “CONTINUOUS LOCKED” appears in the MessageCenter when the key is pressed and the unit is in Continuous Run Mode. Refer to the configuration table Section 5.2.
If the engine fails to start after three start attempts, the
“FAILED TO START--AUTO MODE” alarm will be activated. While running, if the unit shuts down on a safety, or fails to run for the minimum run time, three consecutive times, the
“FAILED TO RUN MINIMUM TIME” Alarm will be activated. The shutdown counter is cleared when the unit has run for 15 minutes, or when the engine cycles off normally.
NOTE
In electric standby mode, the unit will stop for a minimum of 5 minutes instead of 15 minutes.
62-11039 3--10
3.8 CONTINUOUS RUN OPERATION
HEAT COOL DEFROST START-STOP
-20
ALARM
+36 F
SETPOINT BOX TEMPERATURE
CONTINUOUS RUN MODE SELECTED
2
CONTINUOUS
CONTINUOUS
RUN LIGHT
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the START-STOP/CONTINUOUS key until the CONTINUOUS RUN
Light on the controller illuminates.
2. Verify that “CONTINUOUS RUN MODE SELECTED” is displayed on the MessageCenter and that the
CONTINUOUS RUN light is illuminated. The unit is now in Continuous Run operation.
In the Continuous Run Mode, the unit will not shut down except for safeties or if the engine stalls. Refer to
Section 4.3 for more detailed information on Continuous
Run Operation.
Start-Stop and Continuous operation may be tied to the setpoint ranges for compartment 1 only for frozen and perishable loads. The START-STOP/CONTINUOUS key is locked out if “START-STOP LOCKED” appears in the MessageCenter when the key is pressed and the unit is in Start-Stop Mode or “CONTINUOUS LOCKED” appears in the MessageCenter when the key is pressed and the unit is in Continuous Run Mode. Refer to the configuration table Section 5.2.
If the unit fails to start after three start attempts, the
“FAILED TO START--AUTO MODE” alarm will be activated. While running, if the unit shuts down on a safety device three consecutive times, without running a minimum of 15 minutes between shutdowns, the
“FAILED TO RUN MINIMUM TIME” Alarm will be activated. The shutdown counter is cleared when the unit has run for 15 minutes.
NOTE
In electric standby mode, any compartment with setpoint equal to or less than 10°F (--12°C) will cycle off at setpoint. If all compartments are less than or equal to 10°F (--12°C) the unit will shut down at setpoint.
3--11 62-11039
3.9 SLEEP MODE ON
HEAT COOL DEFROST ALARM START-STOP CONTINUOUS
SETPOINT
SLEEP MODE SETTINGS
BOX TEMPERATURE
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the SELECT key until the MessageCenter displays
“PRESS ↑↓ TO VIEW SETTINGS”.
2. By pressing the UP or DOWN ARROW key, you will move through the
Function List until “SLEEP MODE SETTINGS” appears in the
MessageCenter.
3. Press the = key. “↑ ↓ TO SCROLL, THEN = TO SAVE” will show in the
MessageCenter.
4. Press the = key to select Sleep Mode Settings.
5. “SLEEP MODE: YES OR NO” will show in the MessageCenter. Press either the UP or
DOWN ARROW key to change the Sleep Mode to “YES”.
62-11039 3--12
3.10 SLEEP MODE OFF
HEAT COOL DEFROST ALARM START-STOP CONTINUOUS
SETPOINT BOX TEMPERATURE
SLEEP MODE WARNING: NO TEMP CONTROL
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the SELECT key until the MessageCenter displays
“PRESS ↑↓ TO VIEW SETTINGS”.
2. By pressing the UP or DOWN ARROW key, you will move through the
Function List until “SLEEP MODE SETTINGS” appears in the
MessageCenter.
3. Press the = key. “↑ ↓ TO SCROLL, THEN = TO SAVE” will show in the
MessageCenter.
4. Press the = key to select Sleep Mode Settings.
5. “SLEEP MODE: YES OR NO” will show in the MessageCenter. Press either UP or
DOWN ARROW key to change the Sleep Mode to “NO”.
OR
1. To take the unit out of Sleep Mode, place the START/RUN - OFF switch to OFF position, then back to Start/Run.
3--13 62-11039
SLEEP MODE ON (Continued)
No further menu selections are available when NO is selected from the
“SLEEP MODE: YES OF NO” menu. The following sub menus are available when YES is selected:
1. “WAKE UP TIME” a. When “WAKE UP TIME” is set to NO the unit will remain in Sleep Mode until it is taken out manually per Section 3.10
b. When “WAKE UP TIME” is set to YES the
“SET WAKEUP TIME” menu will become available.
Pressing the “=” key will allow the user to select the time the unit is to automatically wake up. The wake up time must be at least 1 hour and no more than 8 days from the time the clock is set. The following information can be entered:
S
Month
S
Day
S
Year
S
Hour
S
Minute
NOTE
The clock is a 24 hour clock. Hours 1 thru 12 are
AM and hours 13 thru 24 are PM.
2.’RUN PRETRIP TEST AT WAKE” a. When “PRETRIP TEST AT WAKE” is set to NO the unit will wake up at the designated time and control to setpoint.
b. When ”PRETRIP TEST AT WAKE” is set to YES.
the unit will wake up at the designated time, automatically run Pretrip and then control to setpoint.
“PRETRIP PASS/FAIL” will remain in the Message-
Center until it is manually cleared.
If Sleep Mode is selected, when the unit is not running
(Start-Stop Off Cycle), any remaining Minimum Off
Time will be ignored, and the engine will start. It will run for 4 minutes (minimum), until the Engine Coolant
Temperature is above 122°F (50°C), and the battery is fully charged (O.K. appears in the Data List voltage line, and charging amps are less than amps set in the
Configuration List). While the unit is running in Sleep
Mode, “SLEEP WARNING: NO TEMP CONTROL” will flash in the MessageCenter, and the Main Display
(setpoint and box temperature) will be turned off. This is because box temperature does not have to be at setpoint to allow the unit to cycle off (go to sleep).
If the unit is already running when Sleep Mode is selected, it will continue to run until the conditions described above are met, then shut off (go to sleep).
There is NO TEMPERATURE CONTROL in Sleep
Mode and it should never be used for hauling perishable or frozen products.
While the unit is cycled off in Sleep Mode,
“SLEEP MODE, OFF/ON TO WAKE” will be displayed in the MessageCenter. The display backlight will turn off after 5 minutes. Sleep Mode may be exited by either turning the Start / Run -- OFF switch to the OFF position, then back to the ON position, or by accessing the
Functional Parameter list, and selecting
“SLEEP MODE: OFF”.
While in Sleep Mode, Unit Data and Alarm Lists may be viewed, and Functional Parameters may be viewed and changed as necessary. However,
Start--Stop /Continuous Run selections, and setpoint can not be changed. Manual Defrost and Pretrip can be initiated.
The unit will restart when engine coolant temperature drops below 34°F (1°C) or if the battery voltage drops below the battery restart value selected in the configurations (See 5.2.1)
Sleep Mode is used generally in cold ambients when the trailer may be parked or not used and the unit is OFF for an extended period of time (1 day to several weeks) with no product inside the refrigerated compartment. Many times units are very difficult to start due to a discharged battery, thickened engine oil, etc. after that time in cold ambients.
In Sleep Mode in Engine/Road Operation the unit will
“Wake Up” periodically and run to keep the battery charged and the engine warm.
In Sleep Mode in Electric Standby Operation the compressor will be off and the the battery charger will keep the battery charged.
NOTE (FOR ENGINE OPERATION ONLY)
In the event that the Engine Coolant Temperature sensor fails, Sleep Mode will operate as follows:
In ambients above +32°F (0°C), the unit will run as above, and will monitor battery voltage and charging amps only (according to the configuration setting).
In ambients below +32°F (0°C), the unit will run for 20 minutes minimum run time, then restart every 60 minutes (maximum off time). Battery voltage and amperage will be monitored normally.
NOTE
Units equipped with IntelliSet option can select sleep mode by choosing IntelliSleep. (See Section 3.21.1).
62-11039 3--14
3.11 MANUAL DEFROST
DEFROST LIGHT
ALARM HEAT
-20
COOL DEFROST
d
F
SETPOINT BOX TEMPERATURE
DEFROST CYCLE STARTED
START-STOP
2
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the MANUAL DEFROST key. The DEFROST light will come on and the MessageCenter will display “DEFROST CYCLE STARTED” for
5 seconds, or flash “CANNOT START DEFROST CYCLE” for 5 seconds.
3.11.1 Manual Defrost
The defrost mode can not be manually initiated if:
• “CANNOT START DEFROST CYCLE” is displayed when the manual defrost key is pressed thus indicating that none of the Defrost Termination Temperature Sensors (1DTT, 2DTT or 3DTT) is below 40°F
(4°C).
• The engine has not run 15 seconds after starting.
• The unit is in PC Mode.
• The unit is in Pretrip.
• There is an active shutdown Alarm.
TIP
The Manual Defrost Key can be used at any time to start a Defrost Cycle as long as one of the DTTs is below 40°F (4.4°C).
NOTE
All compartments will go into defrost at the same time.
NOTE
Refer to Section 4.4.10 for more detailed information on Defrost.
3--15 62-11039
3.12 TRIP START
HEAT COOL DEFROST
-20
ALARM
+36 F
SETPOINT BOX TEMPERATURE
TRIP START ENTERED
START-STOP
2
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. To mark the start of a trip in the data recorder, press the SELECT key until
The MessageCenter displays “PRESS = TO MARK TRIP START”.
2. Press the = key.
3. If trip start is acknowledged by the data recorder, “TRIP START ENTERED” will be displayed for 5 seconds and then the display will revert back to the normal display. Otherwise CANNOT ENTER TRIP START will flash and then the display will revert back to the normal display.
Trip Start places a time stamp in the data recorder memory to allow easy review of the data from the last trip, and to allow downloading data from a specific trip. A trip begins at a Trip Start, and ends at the next Trip Start.
Trip Start tells the data recorder that the present date and time is the beginning of a new trip.
62-11039 3--16
3.13 VIEW ACTIVE ALARMS
ALARM LIGHT
HEAT COOL DEFROST
-20
ALARM
+36 F
SETPOINT BOX TEMPERATURE
NO ACTIVE ALARMS
START-STOP
2
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the ALARM LIST key. If there are no active alarms, the display will say “NO ACTIVE ALARMS” for 5 seconds.
2. If there are active alarms, the display will be ‘A’ and the alarm number and message. The last Alarm that occurred will be the first Alarm displayed and so on.
3. Press the ALARM LIST or UP ARROW key to scroll through the list of alarms.
4. When you reach the end of the alarm list, “LIST END, = TO CLEAR ALARMS” is displayed for 5 seconds.
5. To clear the alarm list, press the = key while “LIST END, = TO CLEAR ALARMS” is being displayed. “ACTIVE ALARMS LIST CLEAR” is displayed. This will move all Alarms to the
Inactive Alarm list.
Alarms that occur are stored in the Alarm List in the controller.
Stored alarms may be viewed in the
MessageCenter.
For a complete list of alarms, their meanings, and troubleshooting refer to Section 7.
3--17
TIP
Another way to clear active alarms is to turn the controller OFF and then back ON using the
START/RUN -- OFF switch (RS).
TIP
“CHECK MICROPROCESSOR” means there is a wiring problem between the microprocessor and the display module.
62-11039
3.14 VIEW INACTIVE ALARMS
HEAT
-20
COOL DEFROST ALARM
+36 F
SETPOINT BOX TEMPERATURE
NO INACTIVE ALARMS
START-STOP
2
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press and hold both the ALARM LIST key and the UP ARROW key for 6 seconds. If there are no inactive alarms, the display will say
“NO INACTIVE ALARMS” for 5 seconds.
2. If there are inactive alarms, the display will be ‘I’ and the alarm number and message.
3. Press the ALARM LIST or UP or DOWN key to scroll through the list of alarms.
4. When you reach the end of the alarm list, “LIST END, = TO CLEAR ALARMS” is displayed for 5 seconds.
5. To clear the active and inactive alarm list, press the = key while
“LIST END, = TO CLEAR ALARMS” is being displayed. “ALL ALARMS CLEAR” is displayed.
The microprocessor can hold up to 16 alarms within the
Active and Inactive Alarm Lists combined. The list can be read via the MessageCenter or using the
ReeferManager PC Program. There are 2 sections in the Alarm List, an Active Alarm Section and Inactive
Alarm Section. Alarms in these sections are in the order in which the alarms activate and deactivate, respectively. On startup, all alarms are marked as inactive in the entire list. If an inactive alarm becomes active, the alarm is moved from the Inactive Alarm List
(section) to the Active Alarm List (section).
As additional alarms occur, they will be placed first in the
Active Alarm List. An alarm can not be active and inactive at the same time. Each alarm can only be present in either the Active or Inactive Alarm List at any given time. As conditions changed, alarms may be moved from the Active Alarm List to the Inactive alarm list and back.
Alarms are also recorded in the Data Recorder. They are recorded at the time they occur (become active), and the time they become inactive.
62-11039 3--18
For a complete list of Alarms and troubleshooting information Refer to Section 7.
TIP
When alarms are cleared from the Inactive
Alarm List, both active and inactive alarm lists are cleared.
If there is a safety shutdown, UNIT SHUTDOWN -- SEE
ALARM LIST will be shown. See Section 7 for complete list of Alarms and their descriptions.
3.15 UNIT DATA
HEAT COOL DEFROST
-20
ALARM
+36 F
SETPOINT BOX TEMPERATURE
PRESS ↑ ↓ TO VIEW DATA
START-STOP
2
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the SELECT key until the MessageCenter displays “PRESS ↑↓ TO VIEW DATA”.
2. By pressing the UP ARROW key, you will move through the Data
List beginning at the top and moving toward the bottom, or by pressing the DOWN ARROW key, you will move through the
Data List beginning at the bottom, and moving toward the top.
3. Data items will remain in the MessageCenter for 10 seconds. After that, the default message will be displayed.
4. To lock a Data List item in the MessageCenter, press the = key. The Data item will flash continuously to indicate it is locked. Press any key to stop flashing and unlock the item.
4. Pressing UP or DOWN key will unlock that item and move to the next data item. Pressing the = key will unlock the item.
3--19 62-11039
Table 3-1. UNIT DATA
* Also appear in Configurations
+ May or may not be displayed depending on functional parameter settings
DATA DEFINITION
SUCTION PRESSURE Compressor suction pressure
DISCHARGE PRESSURE Compressor discharge pressure
EVAPORATOR PRESSURE Suction pressure in the evaporator section
ENGINE COOLANT TEMP Engine coolant temperature
RETURN AIR TEMP
C2 RETURN AIR TEMP
Compartment 1 return (air entering evaporator) air temperature
Compartment 2 return (air entering evaporator) air temperature
C3 RETURN AIR TEMP
SUPPLY AIR TEMP
Compartment 3 return (air entering evaporator) air temperature
Compartment 1 supply (air leaving evaporator) air temperature
C2 SUPPLY AIR TEMP
DELTA--T
AMBIENT AIR TEMP
Compartment 2 supply (air leaving evaporator) air temperature
Return air temperature minus Supply air temperature in compartment 1 only
Ambient (air entering condenser) air temperature
DEFROST TERM TEMP 1 Compartment 1 defrost termination temperature
C2 DEFROST TERM TEMP Compartment 2 defrost termination temperature
C3 DEFROST TERM TEMP Compartment 3 defrost termination temperature
SUCTION LINE TEMP
EVAP OUTLET TEMP
Suction line temperature at the compressor
Suction line temperature at the evaporator outlet
DISCHARGE TEMP
BATTERY
CURRENT DRAW
ENGINE RPM
Compressor discharge temperature
Battery voltage
Battery charging or discharging amps.
Engine revolutions per minute
UNIT AC CURRENT #1
UNIT AC CURRENT #2
High voltage current draw on circuit #1.
High voltage current draw on circuit #2.
FUEL LEVEL
SUCTION MOD VALVE
EXPANSION VALVE
START MODE
% of fuel in tank. (This is only shown when 0% -- 100% sensor is configured ON.)
% open of CSMV
% open of EVXV
AUTO if the engine will start automatically
MANUAL if the engine must be started manually
Applies only if unit has these installed options.
INSTALLED OPTIONS
INTELLISET INSTALLED
SOFTWARE REVISION Revision of the software that is operating the microprocessor
DISPLAY SOFTWARE REV Revision of the software that is operating the display
CONTROL SERIAL #
*
TRAILER ID #
*
UNIT SERIAL #
Serial Number of the microprocessor
ID (as entered by the user)
Unit serial number
62-11039 3--20
Table 3-1. UNIT DATA
* Also appear in Configurations
+ May or may not be displayed depending on functional parameter settings
*
UNIT MODEL # Unit model number (selected through configurations)
Number of engine hours until the next programmed engine maintenance.
*
+
*
+
+
*
+
*
+
+ HOURS TO UNIT MAINT
Number of engine hours until the next programmed electric standby motor maintenance.
Number of switch--on hours until the next programmed general unit maintenance.
Number of hours until the next programmed maintenance.
+ TIME LEFT TO PM (1--5)
*
PRODUCTSHIELD SETUP: Indicates that unit has IntelliSet installed and displays ProductShield settings.
PRODUCTSHIELD
ECONO:
Indicates if ProductShield Econo is OFF OR Go To Start/Stop OR Go
To Continuous Run
*
+
*
ECONO MIN TEMP Minimum ambient temperature of range for activation of ProductShield
Econo (Will only be displayed if Econo is NOT OFF)
ECONO MAX TEMP Maximum ambient temperature of range for activation of ProductShield
Econo (Will only be displayed if Econo is NOT OFF)
ECONO DELTA--T Delta--T value for activation of ProductShield Econo (Will only be displayed if Econo is NOT OFF)
PRODUCTSHIELD HIGH
AIR:
Indicates if Product Shield High Air is ON or OFF
HIGH AIR MIN TEMP Minimum ambient temperature of range for activation of Product Shield
High Air (Will only be displayed if High Air is ON)
HIGH AIR MAX TEMP Maximum ambient temperature of range for activation of Product Shield
High Air (Will only be displayed if High Air is ON)
HIGH AIR DELTA--T Delta--T value for activation of Product Shield High Air (Will only be displayed if High Air is ON)
PRODUCTSHIELD:
WINTER -- xx°
RANGE 1 LOCK
Indicates the ambient temperature that is controlling ProductShield
Winter (Will only be displayed if WINTER is NOT OFF)
OFF -- Temperature Range 1 Lock is turned off.
Compartment 1 Only CONTINUOUS -- When the setpoint is set between Range 1 Minimum &
Maximum Temperatures, the unit is set to operate only in Continuous
Run.
START--STOP -- When the setpoint is set between Range 1 Minimum &
Maximum Temperatures, the unit is set to operate only in Start--Stop.
RANGE 1 MINIMUM TEMP This is the lower limit for Range 1.
RANGE 1 MAXIMUM TEMP This is the upper limit for Range 1.
RANGE 2 LOCK
Compartment 1 Only
RANGE 2 MIN. TEMP
OFF -- Temperature Range 2 Lock is turned off.
CONTINUOUS -- When the setpoint is set between Range 2 Minimum &
Maximum Temperatures, the unit is set to operate only in Continuous
Run.
START--STOP -- When the setpoint is set between Range 2 Minimum &
Maximum Temperatures, the unit is set to operate only in Start--Stop.
This is the lower limit for Range 2.
RANGE 2 MAX. TEMP This is the upper limit for Range 2.
3--21 62-11039
Table 3-1. UNIT DATA
* Also appear in Configurations
*
+
+ May or may not be displayed depending on functional parameter settings
REMOTE SENSOR (1--3) This is the temperature at remote Temperature Sensor 1, 2, and 3.
(These sensors are optional, and may not be applicable to your unit. Up to 3 remote sensors may be listed.)
*
DATALOGGER This is the current Date and Time that the Data Recorder is using. This may be different than your actual time, depending on the Time Zone and
Daylight Savings Time selections made by the owner of the unit.
62-11039 3--22
3.16 VIEW HOURMETERS
HEAT
-20
COOL DEFROST ALARM
+36 F
SETPOINT BOX TEMPERATURE
TOTAL ENGINE HOURS: 0 HRS
START-STOP
2
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the SELECT key until the
MessageCenter displays
“PRESS ↑↓ TO VIEW HOURMETERS”.
2. Press the UP or DOWN ARROW key to move through the Hourmeter List.
3. Displayed hourmeters will depend on unit configurations (See Section 5.2.1). Typical displayed meters are: “TOTAL ENGINE HOURS”,
“STANDBY RUN HOURS” and “TOTAL SWITCH ON HOURS”.
4. Pressing the = key will access all other meters and display
“OTHER METERS AND COUNTERS”.
5. Selected Hourmeter will remain in the
MessageCenter for 10 seconds, then the default message (STATUS OK) or other customer specified message) will appear.
6. To lock an hourmeter in the MessageCenter, press the = key.
The Data item will flash continuously to indicate it is locked.
7
. Pressing any key on the keypad will unlock the item. Pressing the
UP or DOWN ARROW key will move to the next hourmeter.
Hourmeters available when “OTHER METERS AND
COUNTERS” is chosen are:
S
Meters listed in Step 3 above.
S
Switch On Standby Hours
S
Engine Protect Hours
S
Switch On Protect Hours
S
Switch On Sleep Hours
S
Engine Sleep Hours
S
High Speed Hours
S
Start cycles
3--23 62-11039
3.17 FUNCTIONAL CHANGE (PARAMETERS)
HEAT COOL DEFROST
-20
ALARM
+36 F
SETPOINT BOX TEMPERATURE
PRESS ↑ ↓ TO VIEW SETTINGS
START-STOP
2
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the SELECT key until the MessageCenter displays
“PRESS ↑↓ TO VIEW SETTINGS”.
2. By pressing the UP ARROW key, you will move through the
Function List beginning at the top or by pressing the DOWN
ARROW key, you will move through the Function List beginning at the bottom.
3. To change one of the Functions, bring the Function you wish to change into the MessageCenter, and press the = key. “↑ ↓ TO SCROLL, THEN = TO SAVE” will show in the MessageCenter.
Pressing either UP or DOWN ARROW key will begin to change the
Function setting. The MessageCenter will flash, indicating that a change has been made that has not been entered into memory.
4. Continue pressing UP or DOWN ARROW key until the desired value is showing, then press the = key. The MessageCenter will stop flashing. The new value is now in memory.
If the = key is not pressed within 10 seconds, the MessageCenter will change to
“FUNCTION NOT CHANGED”. This will appear for 5 seconds, then return to the last
Functional Parameter shown. If no further keys are pressed, the default message will be displayed another 10 seconds.
NOTE
Any Function that is shown with a padlock symbol cannot be changed from the keypad.
62-11039 3--24
Table 3-2. Functional Parameters
FUNCTIONAL
PARAMETER
SILENT MODE
NO
YES
SELECTIONS
DEFROST
INTERVAL TIMER
SET FOR
1.5HRS
3HRS
6HRS
12HRS
DESCRIPTION
NO -- Normal engine speed operation.
YES -- Low engine speed operation.
The defrost timer will automatically put the unit into the defrost cycle at the interval selected if any one compartment DTT is below 40°F
(4.4°C).
Shorter times are generally used for warm, humid products like produce.
Longer times can be used for dry and frozen products.
Time and Temperature values that control the Automatic Start--Stop operation are set in this section.
When “TOGETHER” is selected in
Configurations, only Perishable Settings are used.
SET S/S PARAMETERS
(These may be displayed individually (8 parameters) as PERISH and FROZEN, or combined (4 parameters) with no designation.)
S
(PERISH /
FROZEN)
MIN RUN
TIME:
4MINS
TO
60MINS
S
(PERISH /
FROZEN)
MIN OFF
TIME:
(in 1 minute increments)
10MINS
TO
90MINS
20MINS
S
(PERISH /
FROZEN)
OVERRIDE
TEMP:
(in 1 minute increments)
3.6
TO
18
°
F (2
°
C)
°
F (10
°
C)
11
°
F (6
°
C)
(in 0.5°F or C increments)
S
(PERISH /
FROZEN)
MAX OFF
TIME:
OFF
10MINS
TO
255MINS
(in 1 minute increments)
This determines the minimum length of time the unit will run every time the unit starts in Auto Start--Stop Modes.
This determines the minimum length of time the unit will remain off whenever the unit cycles off in Auto Start--Stop Modes.
This selects the override temperature for the Auto Start--Stop Off
Cycle. During the Minimum Off Time, should the refrigerated compartment temperature drift this far above or below setpoint in the Perishable Range, or above setpoint in the Frozen Range, the unit will override the Minimum Off Time, and restart.
OFF -- There is no maximum off time.
When a minute value is selected, this is the longest amount of time the unit will remain off during a (Perishable or Frozen or both) Auto Start---
Stop Off Cycle. When this time expires, the unit will restart and run for the Minimum Run Time, regardless of any temperature change inside the refrigerated compartment.
3--25 62-11039
FUNCTIONAL
PARAMETER
FROZEN SHUT-
DOWN OFFSET
TEMP CONTROL:
Compartment 1
Only
PERISH
SENSITIVE
PRODUCT
SELECTIONS
0
°
TO
F (0
3.6
° ments)
°
C)
F (2 ° C)
(in 0.5°F or C incre-
RETURN AIR
SUPPLY AIR
OFF
ON
DESCRIPTION
This only applies to Frozen Setpoints in Start--Stop operation.
This offset is the number of degrees below setpoint that the unit will run before cycling off. This will allow for a lower average refrigerated compartment temperature when considering temperature rises during off cycles.
Compartment 1 evaporator has both a Return Air Sensor and a Supply
Air Sensor. This selection determines which sensor temperature will be used for setpoint selections above 10°F (--12.2°C) to determine when setpoint is reached.
Return Air is generally selected for most products. Products that are sensitive to small temperature changes may use the Supply Air setting.
Supply Air limits the temperature of the air leaving the evaporator to the setpoint setting.
Used to determine the supply air temperature limit in cool mode when return air control is selected.
OFF -- 32°F (0°C) or colder depending on the pre set limit.
ON -- setpoint minus the selected limit value [0 to 21.6°F (0 to 12°C)]
The display will show temperatures & pressures in either English (°F &
PSIG) or Metric (°C & Bar)
NO -- Normal temperature control operation
YES -- Fuel saving operation
Maintenance Hour Meters that are enabled will appear in this list.
DISPLAY IN
ECO MODE
ENGLISH UNITS
METRIC UNITS
NO
YES
* RESET PM HOURMETERS
RESET PM
HOURMETERS
NO METERS TO
RESET
OR
Expired Hourmeters
S
ELECTRIC
STANDBY
S
SWITCH ON
S
PM 1 Thru 5
OUT OF RANGE
ALARM:
(For compartment 1)
C2 OUT OF
RANGE ALARM:
C3 OUT OF
RANGE ALARM:
RESET
RESET
RESET
English Metric
OFF
4°F
5°F
7°F
OFF
2°C
3°C
4°C
When the Hour Meter has timed out, and preventative maintenance has been performed, selecting RESET and pressing the = key will de--activate the alarm, and reset the Hour Meter for the next service interval.
Once the unit is at setpoint, then drifted away for more than 30 minutes, an Out--Of--Range Alarm will come on. (Or, if configured for Out
Of Range Shutdown, after 45 minutes the unit will shut down.) This setting determines how far away from setpoint the temperature must move before the timer is started. 4°F (2°C) may be used for very critical temperature products, 7°F (4°C) may be used for less critical products. The alarm may be turned off by selecting the OFF setting.
62-11039 3--26
FUNCTIONAL
PARAMETER
SLEEP MODE
SETTINGS
The following sub menus determine whether sleep mode is to be used and what the settings will be.
S
SLEEP MODE
The following two sub menu selections will be available if YES is selected.
NO
YES
SELECTIONS
DESCRIPTION
NO -- is the normal operating selection and no further selections will be available.
YES-- selects Sleep Mode. In this mode the unit will operate only as needed to keep the engine warm, and the battery charged. There is
NO TEMPERATURE CONTROL in Sleep Mode.
• MONTH
•DAY
•YEAR
•HOURS
•MINUTES
The following Sleep Mode parameters were added in Software Version 04.07.00
S
WAKE UP TIME
NO
YES
SET WAKE UP TIME
1--12
1--31
1998 -- 2037
0--23
0--59
NO -- the unit will remain in Sleep Mode until it is taken out manually.
This can be accomplished either through the Functional Parameter list or by turning the Run/Stop switch to STOP and then back to RUN.
YES-- the SET WAKE UP TIME sub menu will be available
This setting is used to set Sleep Mode wake up time. The clock is a 24 hour clock. Hours 1 thru 12 are AM and 13 thru 24 are PM. The wake up time must be at least 1 hour and no more than 8 days from the time the clock is set
Select the correct month of the year.
Select the correct day of the month.
Select the correct year.
Select the correct hour (0--11 is AM / 12--23 is PM)
Select the correct minute.
3--27 62-11039
FUNCTIONAL
PARAMETER
S
RUN PRETRIP
AT WAKE
NO
YES
SELECTIONS
DESCRIPTION
NO -- The unit will wake up at the designated time and control to setpoint.
YES -- The unit will wake up at the designated time, automatically run
Pretrip and then control to setpoint. The Pretrip Pass/Fail message will remain in the MessageCenter until the message is manually cleared.
* OVERRIDE
DOOR
SHUTDOWN
Two compartment only
* NO POWER --
SWITCH TO
DIESEL
NO
YES
NO
YES
NO -- allows the door switch to shut the unit down whenever the refrigerated compartment door is opened and the door switch is configured for shutdown.
YES -- allows you to override the refrigerated compartment door shutdown switch, and allow the unit to continue to run, even with the refrigerated compartment door open.
YES -- The unit will shutdown when electric standby power is lost.
NO -- The unit will change automatically to engine operation when standby power is lost.
LANGUAGE /
IDIOMAS:
LANGUE:
LINGUAGEM:
ENGLISH
ESPAÑOL
FRANÇAIS
PORTUGUÊS
ENGLISH-- All information displayed in the MessageCenter will be shown in English.
FRANÇAIS-- All information displayed in the MessageCenter will be shown in French.
ESPAÑOL-- All information displayed in the MessageCenter will be shown in Spanish.
PORTUGUÊS --
All information displayed in the MessageCenter will be shown in Portuguese.
NOTE: This parameter can be quickly accessed by pressing and holding the Select Key for 6 seconds.
Selections in BOLD are the default settings.
* This Functional Parameter may not appear in the list for your unit, depending on how the microprocessor has been configured.
62-11039 3--28
3.18 LANGUAGE SELECTION
HEAT COOL DEFROST
-20
SETPOINT
ESPAÑOL
ALARM
+36 F
BOX TEMPERATURE
START-STOP
2
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press and hold the SELECT key for 6 seconds until MessageCenter displays current language
(ENGLISH, ESPAÑOL, FRANÇAIS or
PORTUGUÊS
).
2. Press the UP or DOWN ARROW key until the MessageCenter indicates the desired language. Press the = key. The new language will now be active.
If the = key is not pressed within 10 seconds, the MessageCenter will change to “FUNCTION NOT CHANGED”. This will flash for 5 seconds, then return to the current language. If no further keys are pressed, the default display will return in another 10 seconds.
3--29 62-11039
3.19 STOPPING UNIT
WARNING
Always place RS in the OFF position and turn off the high voltage power supply before disconnecting the high voltage power plug from the unit.
off
STANDBY
ENGINE
The diesel engine will stop and the microprocessor controller will turn off.
The Microprocessor Main
Display, MessageCenter, and all indicator LEDs will also turn off.
NOTE
Due to internal processing within the microprocessor, turning the RS OFF then back to
START/RUN will result in a 4 to 50 second delay between the display going off and coming back on again.
1. To stop the unit, place the START/RUN -
OFF switch in the OFF position.
NOTE
The microprocessor will close the Electronic
Expansion Valve (EVXV) and the CSMV before turning off.
NOTE
If all compartments are off and the RS is still in the START/RUN position, the unit will stop but the microprocessor will stay energized.
62-11039 3--30
3.20 DATA RECORDING
The Advance Microprocessor contains a built--in Data
Recorder with 512K of memory. The Data Recorder reads the same input information as the microprocessor
(Functional Parameters, Configurations, and Unit Data) at all times. The Data Recorder records events as they occur, such as setpoint changes and Defrost Initiation and Termination, and also records all data values including temperature and pressure sensors in either averaged or snapshot format. The details are provided below.
3.20.1 Microprocessor Information
The microprocessor information that is available to be recorded is as follows:
Data Recorder Setup (Logging Intervals, Events and
Sensors)
Data Recorder Time Clock Date / Time
Setpoints (And all setpoint changes.)
ID Number
Unit Serial Number
Unit Model Number
Current System Mode
Functional Parameters
Controller Configurations
3.20.2 Data Recording
The Data Recorder data comes from four general categories of information:
1) Microprocessor Information as described in Section
3.20.1 above.
2) Sensor Data
This information is recorded at pre--determined intervals as a snapshot of the sensor at the time of the recording, or an averaged reading of the sensor readings since the last recording.
The user can determine which sensor(s) will be recorded, at what interval, and whether snapshot or averaged readings are preferred. (Snapshot readings of sensors are also taken at the time of a shutdown alarm.)
3) Event Occurrences
This information is any additional data that is recorded on a “when it occurs” basis. Events are recorded by the recorder as they occur. An Event is defined as something that happens (i.e. setpoint changed, Defrost
Cycle Started, or Main Power On, etc.). Hourmeters are recorded at midnight or the first time of day the switch is turned to the ON position.
4) User Area Data
The User or service technician is able to enter a
Comment into the Data Recorder using ReeferManager
Program.
3.20.3 Sensor & Event Data
Sensors
The following sensors may be recorded either with an averaged reading, or snapshot or may not be recorded at all.
Return Air Temperature
Supply Air Temperature
Ambient Air Temperature
1 Defrost Termination Temperature
Compressor Discharge Temperature
Engine Coolant Temperature
Compressor Discharge Pressure
Compressor Suction Pressure
Evaporator Outlet Pressure
Evaporator Outlet Temperature
Total AC #1 and #2
Battery Voltage
Battery DC Current
Engine RPM
C2 Return Air Temp
C2 Supply Air Temp
C3 Return Air Temp
2 Defrost Termination Temperature
Fuel Level Sensor
Compressor Suction Temperature
Events (Selectable)
User may determine whether the following events are recorded. All other events such as ON/OFF, Defrost start will be recorded.
Pretrip Start
Pretrip End
Trailer ID
Unit S/N
Unit Mode
Control Mode
Optional Sensors & Events
In addition to the above Sensors and Events, the Data
Recorder also has the capabilities to record the following:
Remote Temperature Sensor 1
Remote Temperature Sensor 2 (Two compartment units only)
Door Switch (Two compartment units only)
Fuel Tank % Level
3--31 62-11039
DATA RECORDING (CONTINUED)
Time Intervals
The following intervals are available for sensor recording:
2 Minutes
5 Minutes
10 Minutes
15 Minutes
30 Minutes
1 Hour
2 Hours
4 Hours
3.20.4 Data Downloading
The data within the Data Recorder can be downloaded by either the ReeferManager Program, using a PC and a
Download Cable connected to the Download Port
(Refer to Section 5.1) or with a Download PC Card
(Refer to Section 5.3).
3.20.5 Data Recorder Power--Up
The Data Recorder records data the entire time the
Start/Run--Off switch is in the Run position.
A configuration exists which allows the user to select either an additional 8 hours of sensor data to be recorded after the Start/Run--Off Switch (RS) is placed in the OFF position, or to stop recording at the same time the (RS) is turned to the Off position.
62-11039 3--32
3.21 OPTIONS
3.21.1 IntelliSet
HEAT COOL DEFROST
+34
SETPOINT
APPLES
ALARM
+34 F
BOX TEMPERATURE
START-STOP
2
CONTINUOUS
ACTIVE
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
DURING START UP
Observe the MessageCenter during the Power--Up process. If the unit is equipped with IntelliSet, the name of the active or modified IntelliSet will be displayed for approximately 10 seconds before the engine starts.
DURING OPERATION
Press the SELECT key to view current IntelliSet. You will be prompted to press either the “=” key or the UP or DOWN ARROW Key to scroll through list of
IntelliSets. The current IntelliSet will have either the word ACTIVE or
MODIFIED after it. MODIFIED indicates that one or more of the IntelliSet settings (other than setpoint) have been changed. To change MODIFIED to
ACTIVE, press = key while the IntelliSet is shown in the MessageCenter.
The Advance Microprocessor offers over 48 parameters that may be set depending on the product being carried. IntelliSet allows the owner to pre--program specific product settings into the microprocessor and give the settings a name. The operator may then call up these settings by simply selecting the IntelliSet name.
For example: Apples may require continuous operation at 35°F (1.7°C) with a defrost every 3 hours while a load of cheese may require the same operation with setpoints ranging from 35°F to 42°F (1.7°C to 5.6°C) and a load of ice cream requires Start--Stop operation at
--22°F (--30°C) with defrost at 12 hour intervals. The settings required for each product may be entered into the microprocessor and then locked so they cannot be changed. In the case of the cheese, the range of setpoints may be locked, leaving the operator the ability to change the setpoint within the locked range.
When a load of apples is going to be picked up, the operator simply selects “APPLES” from the IntelliSet
3--33 menu; for cheese, “CHEESE” is selected ; for ice cream,
“ICE CREAM” is selected. With each selection, the microprocessor automatically re--programs the settings to provide the best temperature control, fuel economy, and performance for that particular product.
NOTE
IntelliSet #31 is pre--programmed as
“IntelliSleep” which allows Sleep Mode (See
Section 3.9) to be entered by simply changing to that IntelliSet.
NOTE
The above settings are examples of possible settings. Except for IntelliSleep, IntelliSets are not factory set. They are developed by individual customers.
62-11039
a. Changing IntelliSets -- With “=” Key Enabled
HEAT COOL DEFROST
+36
SETPOINT
APPLES
ALARM
+36 F
BOX TEMPERATURE
START-STOP
1
CONTINUOUS
ACTIVE
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. PRESS the = Key to display current IntelliSet. (Enable IntelliSet at = Key must be configured ON. See Section 5.2.1.)
2. Pressing the UP or DOWN ARROW key, to move through the IntelliSet List.
The current IntelliSet will have either ACTIVE or MODIFIED to the right of the name.
3. To use a different IntelliSet, bring the IntelliSet you wish to use into the
MessageCenter and press the = Key.
NOTE: If pressing the = key does not bring up this message, press the
SELECT key until the message appears.
62-11039 3--34
b. Changing IntelliSets -- Without “=” Key Enabled
HEAT ALARM COOL DEFROST
+36
+36 F
SETPOINT BOX TEMPERATURE
PRESS ↑ ↓ TO VIEW INTELLISETS
START-STOP
1
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the SELECT key until MessageCenter displays PRESS ↑↓ TO VIEW INTELLISETS.
2. By pressing the UP ARROW key, you will move through the IntelliSet List beginning at the top or by pressing the DOWN ARROW key, you will move through the IntelliSet List beginning at the bottom. The current IntelliSet will have either
ACTIVE or MODIFIED to the right of the name.
3. After selecting the new IntelliSet press the = key.
3--35 62-11039
3.21.2Remote Control Panel
10
9
8
1
2
3
4
THREE COMPARTMENT PANEL SHOWN.
THERE IS ALSO A TWO COMPARTMENT
PANEL AVAILABLE
The remote control panel can be used to :
Turn on/off the unit
Check compartment 1, 2 or 3 temperature(s)
Check and change setpoint(s)
Initiate manual defrost
Check mode of operation for each compartment
NOTE
The unit can be shut down using either the remote panel or the main START/RUN--OFF switch. The RS must be in the “START/RUN” position in order for the remote panel to operate.
5
6
7
1 Compartment On/Off Key
2 Control Panel Power On LED
3 System On/Off Key
4 Manual Defrost Key
5 Control Panel Lock LED
6 Setpoint Display
7 Up And Down Arrow Keys
8 Cool Mode LED
9 Heat Mode LED
10Temperature Display in °F or °C
62-11039 3--36
a.Remote Control Panel Display
TEMP.
DISPLAY
SETPOINT
DISPLAY
WAITING FOR COMMUNICATION WITH MICROPROCESSOR
COMPARTMENT TEMPERATURE DISPLAY
SETPOINT TEMPERATURE DISPLAY
COMPARTMENT MODE STATUS (HEAT, COOL OR NULL)
COMPARTMENT WAS TURNED OFF VIA REMOTE CONTROL
COMPARTMENT IN DEFROST MODE
P1
COMPARTMENT TEMPERATURE SENSOR MALFUNCTION
PRESET SETPOINT
NOTE: TEMPERATURE IS DISPLAYED IN °F OR °C DEPEND-
ING ON CONFIGURATION OF MICROPROCESSOR b.Starting Unit with Remote Control Panel
1. Put RS in “START/RUN” position.
3. Press The On/Off Key To Energize
Selected Compartment.
2. Press The System On/Off Key.
Power Light Will Go On.
3--37 62-11039
c.Changing Setpoint with Remote Control Panel
1. Press the UP or DOWN ARROW key to increase or decrease setpoint.
This is the same operation for each compartment.
d.Lock/Unlocking the Remote Control Panel
CARRIER
LOGO
LOCK INDICATOR LIGHT
LOCKING THE PANEL:
Press and release the Carrier Logo
The lock indicator light will come on.
UNLOCKING THE PANEL:
Press the Carrier Logo for 10 seconds
The lock indicator light will go off.
62-11039 3--38
e.Pre--setting Setpoints with Remote Control Panel
1. Place RS in the “START/RUN” position and required compartment switches on the unit to the
“ON” (1) position.
3. Press compartment 1 UP AR-
ROW for 10 seconds. P1 will be displayed in all compartments.
4. Set lowest setpoint required.
5. Press Carrier logo and P2 will be displayed. Set next highest temperature required.
2. Press Carrier logo and the lock light will be displayed.
6. Follow same procedure for the next three temperatures.
7. Pressing the second compartment
UP or DOWN ARROW key for 10 seconds will allow P1 to be displayed and the lowest setpoint for compartment 2 to be set. Continue with steps
5 and 6.
8. Repeat step 7 for compartment 3.
Pre--setting Setpoints
The control panel allows the user to pre--set 5 different temperatures for each compartment.
f.Removing Pre--set Setpoints With Remote Control Panel
NOTE
Once pre--set setpoints have been chosen, only those 5 designated setpoints can be used.
1. Place RS in the “START/RUN” position and required compartment switches on the unit to the
“ON” (1) position.
3. Press compartment 1 UP AR-
ROW for 10 seconds. P1 will be displayed in all compartments.
4. Set temperature to lowest pre--set setpoint and OFF will be displayed
2. Press Carrier logo and the lock light will be displayed.
Pre--setting Setpoints
The control panel allows the user to pre--set 5 different temperatures for each compartment.
3--39
NOTE
Once pre--set setpoints have been chosen, only those 5 designated setpoints can be used.
62-11039
SECTION 4
TEMPERATURE CONTROL
4.1 SYSTEM START--UP
This section describes the unit operation in relation to temperature control in both diesel and electric standby operation.
Upon initial start up, when the starting conditions are met, CSMV and EVXV open to equalize the compressor discharge and suction pressures so that there is less than 70 psig (4.8 Bar) difference between them before the compressor starts.
Once the system is equalized, the CSMV and EVXV will both close (0% open).
LSV2 & LSV3 will be de--energized (closed)
UL1 & UL2 will be energized (unloaded)
If the unit is in an off cycle and operating in Electric
Standby, the buzzer will come on for 5 seconds prior to the compressor starting. This does not occur if the unit is operating in diesel engine mode, and the engine is already running.
The Speed Solenoid will be de--energized (low speed).
If the engine is not running, it will start now. If the engine is already running, then it doesn’t have to start again.
The condenser fans turn on.
The compressor starts.
If any compartment is calling for heat, there will be a 10 second delay after the compressor starts and the heater contactors energize.
The evaporator fan motors will start 10 seconds after the compressor has started if the suction pressure is lower than 100 psig (6.8 Bar), or after a maximum of 20 seconds after the compressor starts. Compartment 1 fans will come on first, then Compartment 2, then
Compartment 3, with a 5 second delay between each compartment.
The compressor will only turn on when the engine is operating in low speed. When the compressor starts, the engine will always continue to operate in low speed for a minimum of 2 minutes before high speed is allowed.
Whenever the compressor comes on, it will run for a minimum of 3 minutes. If all compartment temperatures are satisfied before the 3 minutes are up, the frozen compartment will continue to operate in cool. If all compartments have a perishable setpoint, then the lowest numbered compartment will continue to operate in cool mode, and the heaters will also come on at the same time if necessary to maintain the proper compartment temperature.
REPEAT “A”
+ 10 Seconds
GLOW
15 Seconds
STOP
REPEAT “A”
+ 5 Seconds
GLOW
15 Seconds
STOP
MAXIMUM
10 Seconds
Checked at
2 Seconds
CRANK
VARIABLE
0 to 55 SECONDS
GLOW
GLOW
THIRD
ATTEMPT
SECOND
ATTEMPT
FIRST
ATTEMPT “A”
HOMING CSMV
Figure 4--1. Auto Start Sequence
4--1 62-11039
4.1.1 Variable Glow Time
The glow time for the first start attempt will vary in duration based on engine coolant temperature and how the microprocessor is configured: TV/Short or
DI/Long as follows:
Table 4-1. Glow Time
Engine Coolant Temp
Glow Time in
Seconds
SHORT LONG
Less than 32_F (0_C)
33_F to 50_F (1_C to
10_C)
15
10
55
40
51_F to 77_F (11_C to
25_C)
Greater than 78_F
(26_C)
5
0
25
10
The second start attempt has 5 seconds of glow time added to the time shown in the table. The third start attempt will have 10 seconds added. If the coolant temperature sensor is defective the microprocessor assumes a temperature of less than 32_F (0_C) for the glow timing.
4.1.2 Engine Running
The engine is considered to be running when:
1.Engine RPM are greater than 1000, and
2. For ambient temperatures at or above
32°F (0°C), oil pressure is ok. For ambient temperature below than 2 amps.
32°F (0°C), oil pressure is ok and DC current is more
4.2 START--STOP OPERATION
Start--Stop is provided to permit starting/stopping/restarting of the engine–driven compressor as required. This feature allows full automatic control of the engine starting and stopping by monitoring box temperature, battery charging amps and engine coolant temperature. The main function of automatic engine cycling is to turn off the refrigeration system near setpoint to provide a fuel efficient temperature control system and to initiate a restart sequence after certain conditions are met. The
Start--Stop/Continuous key is pressed to select between Continuous Run and Start--Stop operating modes.
NOTE
The microprocessor may be locked so that the unit will always operate in Start--Stop whenever the setpoint is within a specific range. Refer to
Range Lock (Section 4.5) and ProductShield
(Section 4.6) for additional information.
4.2.1
Whenever the unit starts in Start--Stop Mode, it will continue to run until all four of the following criteria have been satisfied:
1) It has run for the pre--determined Minimum
Run Time. The Minimum Run Time is selected in the microprocessor Functional Parameter List. (Refer to
Section 3.17). The purpose of this is to force the unit to run long enough to completely circulate the air inside the compartment, and to ensure that the product temperature is at setpoint. This may be set for any value between 4 minutes and 60 minutes in 1 minute intervals.
The engine must run for the Minimum Run Time before cycling off. The factory setting is 4 minutes.
After the Minimum Run Time expires, the unit may be shut down when the compartment temperature is within
±0.5_F (±0.3_C) of setpoint for setpoints in the
Perishable range or is less than +0.5_F (+0.3_C) above setpoint for setpoints in the Frozen range.
NOTE
All enabled compartments must be within the specified range of setpoint in order for unit to go to an off cycle.
2) The engine coolant temperature is above
122°F (50°C). If the unit can not cycle off, it will operate as if in Continuous Run mode. The engine coolant temperature will override the minimum off time and out-of-range condition to force engine restarting when the engine coolant temperature drops below 34_F
(1_C).
3) The battery is fully charged. Provisions are made to sense when the battery charge is correct. A good battery is defined as having 13.4 VDC at 75_F
(23.9°C), and the charging rate is below that selected in the Configuration List. This condition is used to allow cycle off of the engine.
Voltage
10 VDC or Less
12.2 to
13.4 VDC
Table 4-2 Battery Voltages
Description
Unit will shut down except during cranking.
If the unit has cycled off in Start--Stop mode and battery voltage drops below voltage selected in the configurations
(See Section 5.2.1) , the unit is automatically started to charge battery.
Unit will operate until the battery voltage is high enough to allow unit to cycle off, provided that all other conditions required for an off cycle are met. When battery voltage is above minimum limits, “O.K.” will appear in the
MessageCenter right after the voltage in the Unit Data list.
17 VDC or more
Unit will shut down.
4) The box temperature is at setpoint.
62-11039 4--2
4.2.2
A restart will be initiated when one of the following conditions occurs:
1) Engine coolant temperature drops below
34_F (1_C). However, if the coolant sensor alarm is active, the unit will restart if the ambient air temperature drops to 32°F (0°C) after the unit has been in the OFF cycle for
60 minutes.
2) Battery voltage falls below voltage selected
in the configuration list. (See Section 5.2.1)
3) Box Temperature has exceeded Off Time
Override Temperature
During the Minimum Off Time, the microprocessor continually monitors the Box Temperature. If the temperature should go beyond the Off Time Override
Temperature (above or below setpoint in the perishable range or above setpoint in the frozen range), the unit will restart, regardless of how much Off Time remains.
The Off Time Override Temperature is selected in the microprocessor Functional Parameter List. (Refer to
Section 3.17) This can be set for 3.6_F to 18_F (2_C to
10_C) in 0.5° increments.
After the Minimum Off Time (if the unit is still in the off cycle), the unit will restart when the box temperature goes beyond ±3.6_F (±2.0_C) of setpoint for the Perishable range or above +3.6_F (+2.0_C) of setpoint for the Frozen range.
4) The Minimum Off Time Has Expired
The Minimum Off Time allows the unit to remain off for extended periods of time, maximizing fuel economy.
The Minimum Off Time is selected in the microprocessor Functional Parameter List. (Refer to
Section 3.17). Settings may be for 10 minutes to 90 minutes in 1 minute intervals. The factory setting is 20 minutes.
After the Minimum Off Time (if the unit is still in the off cycle), the unit will restart when the box temperature goes beyond ±3.6_F (±2.0_C) of setpoint for the Perishable range or above +3.6_F (+2.0_C) of setpoint for the Frozen range.
5) The Maximum Off Time has expired.
In some ambient conditions, there are times when the unit may be off for very long periods of time. To ensure that the entire load stays within safe temperature ranges, the Maximum Off Time may be used to force the unit to restart. Maximum Off Time is selected in the microprocessor Functional Parameter List. This may be set for OFF, or 10 minutes to 255 minutes in 1 minute intervals. When the Maximum Off Time expires, the unit will restart, regardless of any change in box temperature.
NOTE
The unit may remain in low speed for 10 minutes (Factory Setting) after engine start-up when in Start--Stop Mode. High speed delay can be set from Off to 255 minutes in 1 minute increments. (Refer to Functional Parameters,
Section 3.17).
4--3
TIP
While the unit is running, the status of the unit battery and engine coolant temperature can be readily checked by reading the Battery Voltage in the Data List. If “O.K.” appears after the voltage reading, bothbattery voltsand enginecoolant temperature are sufficient to allow the unit to cycle off. If “O.K.” does not appear, then one or both of these conditions have not been met, and the unit is not ready to cycle off.
4.2.3 Start--Stop Indicator
To indicate that the unit is in the “Start--Stop” mode, the
Start--Stop LED indicator and Engine Auto Start lights on the light bar will be illuminated.
4.2.4 Failed To Start -- Auto Mode
If the unit fails to start after three start attempts, the
Alarm A31 --FAILED TO START--AUTO MODE will appear in the MessageCenter, and the Alarm LED on the Keypad and the Fault light on the light bar will flash on and off once a second.
4.2.5 Start--Stop Parameters
The selectable Start--Stop parameters in the Functional
Parameter list can be applied to Start--Stop operation so that:
• The same settings apply to any setpoint, or
• The settings can be specified to be different, depending on whether the setpoint is above +10.4°F
(--12°C) (in the perishable range), or +10.4°F
(--12°C) or below (in the frozen range.)
The decision as to whether the same settings will be used together for all setpoints or if they will be separated between Perishable and Frozen is made in the
Configuration List. (Refer to Section 5.2.)
If TOGETHER is selected in the Configuration List, then the following Functional Parameter values will be available for use:
• MINIMUM RUN TIME
• MINIMUM OFF TIME
• OVERRIDE TEMP
• MAXIMUM OFF TIME
• FROZEN SHUTDOWN OFFSET
If SEPARATE is selected in the Configuration List, then the following Functional Parameter values will be available for use:
• PERISHABLE MINIMUM RUN TIME
• PERISHABLE MINIMUM OFF TIME
• PERISHABLE OVERRIDE TEMP
• PERISHABLE MAXIMUM OFF TIME
• FROZEN MINIMUM RUN TIME
• FROZEN MINIMUM OFF TIME
• FROZEN OVERRIDE TEMP
• FROZEN MAXIMUM OFF TIME
• FROZEN SHUTDOWN OFFSET
62-11039
In the event that different values for both Perishable and Frozen Start--Stop times are selected in the Functional Parameter list, then the
Configuration is changed from Separate to Together. The values from the Perishable times will be the ones that will be used.
4.2.6 Charging Amps
NOTE
A Configuration for Start--Stop Shutoff exists which allows the microprocessor to monitor battery charging amperage in addition to battery voltage. The battery charging rate (as seen in the Data List) must be below the selected amp setting to allow the unit to cycle off.
The Configuration may be set from 1.0 to 10.0 Amps in
0.5 amp increments. A weak or defective battery may show a suitable voltage charge while the alternator is putting a high charging rate into it, then not be sufficiently charged to restart the engine at the end of a
Start-Stop Off Cycle.
The factory setting for this configuration is 6.5 amps.
This is a general setting that may need to be adjusted for the operating environment of the unit. Units operated in colder ambient temperatures may want to decrease this setting to force a higher charge in the battery prior to
Start-Stop Off Cycle. Units operated in warmer ambient temperatures may use a higher setting.
As a battery ages, it is normal for it to require longer re-charging periods. If the running time is gradually increasing in Start-Stop operation due to the battery requiring a longer charging period, this run time may be shortened by raising the amp setting. (This may be seen by reviewing downloaded data and looking at the amp reading during prolonged engine Start-Stop On
Cycles.)
4.2.7 Restart Voltage
A configuration for Start--Stop Restart on Battery
Voltage allows the microprocessor to restart the unit when the voltage selection has been reached.
The Configuration may be set from 11.5 to 12.8 Amps in
0.1V increments. The factory setting for this configuration is 12.2VA.
A lower voltage selection may result in a longer off cycle
(based on battery voltage) and possibly overall shorter battery life. A higher voltage selection may result in a shorter off cycle (based on battery voltage) and possibly overall longer battery life.
4.3 CONTINUOUS RUN OPERATION
In the Continuous Run mode, the engine will not shut down except for safeties or if the engine stalls. Continuous
Run operation is normally used for fresh produce and other sensitive product loads. The Start-Stop/Continuous key is pressed to switch between Continuous Run and
Start-Stop operating modes.
62-11039 4--4
NOTE
The microprocessor may be locked so that the unit will always operate in Start--Stop or in Continuous Run whenever the setpoint is within a specific range. Refer to Section 4.5 -- Range
Lock for additional information.
NOTE
The unit will remain in low speed until water temperature reads 79°F (26°C) in Continuous
Run Mode. High Speed Delay can be changed from OFF to 255 minutes. Refer to Functional
Parameters in Section 3.17.
4.4 TEMPERATURE CONTROL
4.4.1 COOL MODE
When Compartment 1 is calling for cool (box temperature is above setpoint), the EVXV will open to the appropriate position and allow refrigerant to flow into
Compartment 1 evaporator.
When either the second or third compartment(s) are calling for cool, the LSV for that compartment(s) will be energized to allow refrigerant to flow into the evaporator for that compartment.
For compartments with setpoints in the perishable range [greater than 10° F (--12.2°C)]
When compartment 1 temperature reaches 1.5_ F
(0.8°C) above setpoint, the EVXV will close to 0%.
When the second or third compartment temperature reaches 1.5_ F (0.8°C) above setpoint, the LSV for that compartment will de--energize. Should all compartment temperatures reach setpoint and stop cooling, the compressor will turn off.
If the temperature within a compartment that has cycled off should rise to 3.5_ F (1.9°C) above setpoint, the compartment will begin to cool again.
For compartments with setpoints in the frozen range
[less than 10_ F (--12.2°C)] operating in Continuous
Run:
When temperature in compartment 1 reaches 3.5_ F
(1.9°C) below setpoint, the EVXV will close to 0%.
When the second or third compartment temperature reaches 3.5_ F (1.9°C) below setpoint, the LSV for that compartment will de--energize. Should all compartment temperatures reach setpoint and stop cooling, the compressor will turn off.
If the temperature within a compartment that has cycled off should rise to setpoint that compartment will begin to cool again.
For compartments with setpoints in the frozen range
[less than 10° F(--12.2°C)] operating in Start/Stop:
When temperature in compartment 1 reaches setpoint, the EVXV will close to 0%. When the second or third compartment temperature reaches setpoint, the LSV for that compartment will de--energize. Should all compartment temperatures reach setpoint and stop cooling, the compressor and engine will turn off.
If the temperature within a compartment that has cycled off should rise to 1_ F (0.6°C) above setpoint, the compartment will begin to cool again.
4.4.2 PULSE COOL MODE
When Frozen Compartment Priority Cooling (see section 4.4.3 below) is not used Pulse Cool Mode is available to provide additional cooling capacity for compartment(s) with frozen setpoints [+10.4°F (--12°C) or lower]. Pulse Cool Mode begins when the box temperatures in all compartment(s) with perishable setpoints [higher than +10.4°F (--12°C)] are no higher than +2.3°F (1.3°C) above setpoint, and are still calling for Cool.
When all compartment(s) with perishable setpoints have a box temperature of+2.3_F (1.3_C) below setpoint or less, and that compartment is still calling for
Cool, and there is another compartment which has a setpoint in the frozen range and is calling for Cool the perishable compartment(s) will go into Pulse Cool Mode to drop the cooling capacity in that compartment(s).
During Pulse Cool Mode, the refrigerant control device in the perishable compartment -- EVXV (Compartment
1) or the LSV (Compartments 2 and 3) -- will be open for
4 seconds, then close for 26 seconds. This 30 second cycle will repeat itself as long as the perishable compartment temperature remains less than 2.7_F
(1.5°C) above setpoint, and is still calling for Cool.
Should the return air temperature in the perishable compartment(s) rise more than 2.7_F (1.5_C) above setpoint, that/those compartment(s) will go into Cool
Mode. Should the return air temperature in the perishable compartment(s) fall to 1.5_ F (0.8_C) above setpoint, that/those compartment(s) will shut off.
4.4.3 PRIORITY MODES
Frozen Compartment Priority has 3 available settings:
OFF, NORMAL, and HI CAPACITY.
When either Normal or Hi Capacity is selected, the following settings are also available:
S
Frozen Priority Time (may be set from 5 – 60 minutes) – Factory setting is 5 minutes
S
Non--Priority Time (may be set from 5 – 60 minutes)
– Factory setting is 5 minutes
S
Perishable Override Temp (may be set from 3.6°F to
27°F (2°C to 15°C)) or OFF. – Factory setting is OFF
When OFF is selected, the unit will operate normally, providing Cooling and Heating to each compartment as required, without regard to any compartment priority over another.
a. Frozen Compartment Priority
Frozen Compartment Priority will operate when:
S
The Frozen Comp Priority configuration is set to either Normal or Hi Capacity; AND
S
One or more of the currently enabled compartments has a setpoint in the frozen range [10.4°F (--12°C) or less]; AND
S
The box temperature of the compartment with the frozen setpoint is less than 32°F (0°C); AND
S
The compartment with the frozen setpoint is calling for Cool; AND
S
One or more of the currently enabled compartments has a setpoint in the perishable range [higher than
10.4°F (--12°C)]; AND
S
The compartment(s) with the perishable setpoint is calling for Cool.
Hi Capacity
When the conditions described above are met, the unit will automatically switch to Frozen Compartment
Priority Hi Capacity Cool Mode and remain in this mode for the length of time selected (Frozen Priority Time).
During Frozen Compartment Priority Hi Capacity Cool
Mode, the refrigerant flow and the evaporator fans to the compartments with perishable setpoints will stop, and the evaporator fans in those compartments will also stop.
When the Frozen Priority Time runs out, the unit mode will change to Frozen Compartment Priority
Non--Priority Cool Mode. In Non--Priority Cool Mode, the fans for the perishable compartments will operate.
Compartment(s) with frozen setpoints will cool continually. Compartment(s) with perishable setpoints will operate by opening and closing the EVXV
(Compartment 1 only) or the LSV (remote compartments) to limit the refrigerant flow to those compartments. The EVXV or LSV will be open for 8 seconds, then close for 12 seconds. This cycle will repeat itself every 20 seconds for the duration of the time set for (Non--Priority Time), or until the compartment no longer is calling for cool.
In Frozen Compartment Priority Non--Priority Cool
Mode, the evaporator fans will operate continually in the
Perishable compartments.
When Perishable Override Temp is set to OFF, then the unit will remain in Frozen Compartment Priority Hi
Capacity Cool Mode for the Priority Cool Time.
When Perishable Override Temp is set to a temperature value, the unit will always operate in Frozen
Compartment Priority Hi Capacity Cool Mode for a minimum of 5 minutes. Once the box temperature in the perishable compartment moves away from setpoint by the selected number of degrees, Frozen Compartment
Priority Hi Capacity Cool Mode will end, and the unit will operate in Frozen Compartment Priority Non--Priority
Mode for the time selected before returning to Frozen
Compartment Priority Hi Capacity Cool Mode again.
4--5 62-11039
Normal
When the conditions described above are met, the unit will automatically switch to Frozen Compartment
Priority Normal Cool Mode and remain in this mode for the length of time selected for Frozen Priority Time. In
Frozen Compartment Priority Normal Cool Mode, compartment(s) with frozen setpoints will cool continually. Compartment(s) with perishable setpoints will operate by opening and closing the EVXV
(Compartment 1 only) or the LSV (remote compartments) to limit the refrigerant flow to those compartments. The EVXV or LSV will be open for 8 seconds, and then close for 12 seconds. This cycle will repeat itself every 20 seconds for the duration of the
Frozen Priority Time or until the compartment no longer is calling for cool.
Perishable Override Temp is not available when Normal is selected.
After the unit has operated in Frozen Compartment
Priority Normal Cool Mode for the Frozen Priority Time selected, the unit will change to Frozen Compartment
Priority Normal Non--Priority Mode. In this mode, all compartments will operate in Cool or Heat as needed.
The unit will continue to operate in this manner until the
Non--Priority Timer expires, and then the unit will return to Frozen Compartment Priority Normal Cool Mode.
4.4.4 SUPPLY AIR LIMIT CONTROL
Supply Air Limit Control is available for setpoints above
+32_F (0_C) only. In a 2 Compartment system, Supply
Air Temperature Control is always available for
Compartment 1 and is optional for Compartment 2.
When a Supply Air Temperature Sensor is installed for
Compartment 2, it must be configured ON in the configuration list.
For 3 Compartment units, Supply Air Temperature
Control is only available in Compartment 1. Supply Air
Temperature Control is selectable for both Continuous
Run and Start/Stop Operation. Two configurations allow the user to determine what the Supply Air Temperature limit(s) will be. Configuration “Supply Air Limit S/S” is the limit for the Supply Air Temperature when the unit is operating in Start/Stop. The default value is –10.8_F
(6_C), meaning that the Supply Air Temperature is allowed to go 10.8_F (6_C) below setpoint during temperature pulldown. Configuration “Supply Air Limit
Cont” is the limit for the Supply Air Temperature when the unit is operating in Continuous Run. The default value is –9_F (5_C), meaning that the Supply Air
Temperature is allowed to go 9_F (5_C) below setpoint during temperature pulldown.
For any compartment that has a perishable [32_F (0_C) or greater] setpoint and is calling for Cool, and the
Supply Air Temperature is less than the value selected in the configuration list for Supply Air Limit, the LSV
(Compartment 2) or the EVXV (Compartment 1) will shut off for that compartment until the Supply Air
Temperature increases 1.8_F (1_C) above the Supply
Air Limit.
62-11039 4--6
4.4.5 HEAT MODE
For both 2 and 3 Compartment units, only HTCON1 will be used for heating in Compartment 1. Compartment(s)
2 and 3 will use both HTCON1 and HTCON2 heaters, depending on how far below setpoint the box temperature is. Heat Mode is only allowed when the compartment setpoint is in the perishable range. Heat
Mode is not used for any compartment with a setpoint in the frozen range.
Contactor
1/2/3HTCON1
2/3HTCON2
1HTCON2
Turn On
Return Air Temp is more than 0.5_F
(0.8°C) below setpoint.
Return Air Temp is more than 1.8_F
(1.0°C) below setpoint.
OFF
Turn Off
Return Air Temp is less than 0.3_F
(0.2°C) below setpoint.
Return Air Temp is less than 1.5_F
(0.8°C) below setpoint.
OFF
When the compartment temperature falls more than
0.5_ F (0.8°C) below setpoint, (1/2/3)HTCON1 will energize for that compartment to bring the temperature up. The heat mode will turn off when the compartment temperature is 0.3_ F (0.2°C) below setpoint.
4.4.6 NULL MODE
In Null Mode, the compartment is not in Cool Mode OR
Heat Mode. If the set point is in the Frozen Range, the evaporator fan motors will stop. If the set point is in the perishable range, the fan motors will stop. If the
When only Compartment 1 is being used, and all other compartments are Off, 1HTCON2 will also operate if
Compartment 1 is calling for Heat.
Perishable Fan Mode Configuration is set for OFF, the evaporator fans will continue to run in Null Mode. If the
Perishable Fan Mode Configuration is set for ON, the evaporator fans will cycle off in Null Mode.
4.4.7 UNLOADERS
Compressor unloaders are only used when one or more compartment(s) are calling for cool. The unloaders energize (unload) and de--energize (load) depending on the compartment that is furthest away from setpoint.
When the unit is set for Start/Stop operation, and any compartment has a frozen setpoint, the compressor will
Mode
COOL
(Perishable)
Start/Stop or
Continuous
Run
COOL
(Frozen)
Start/Stop
LOAD (de--energize) UL1 and UL2 -- 6 Cylinder
Return Air Temp is more than
2.7°F (1.5°C) above setpoint
Return Air Temp is more than
1.8°F (1.0°C) above setpoint operate with both unloaders de--energized (fully loaded
/ 6--cylinder operation) while the compartment is calling for cool.
Unloader operation is shown in the following table for other cool modes:
LOAD (de--energize) UL1
UNLOAD (energize) UL2
-- 4 Cyl
Return Air Temp is between
2.3°F (1.3°C) and 1.5°F
(0.8°C) above setpoint.
UNLOAD (energize) UL1 and
UL2 -- 2 Cylinder
Return Air Temp is less than
0.9°F (0.5°C) above setpoint.
Return Air Temp reaches or falls below setpoint.
N/A
4--7 62-11039
4.4.8 SPEED CONTROL
The engine will operate the compressor at two different speeds (low and high). Speed Control will use the
Mode
COOL
(Perishable)
COOL
(Frozen)
HEAT
(Perishable)
HEAT
(Frozen)
NULL differences of Controlling Temperature and setpoint as follows:
HIGH SPEED (SCS ENERGIZED)
Return Air Temp is more than 2.7°F (1.5°C) above setpoint
LOW SPEED (SCS DE--ENERGIZED)
Return Air Temp is less than 2.3°F (1.3°C) above setpoint.
Return Air Temp is more than 3.6°F (2.0°C) above setpoint
Return Air Temp is more than 2.7°F (1.5°C) above setpoint
Return Air Temp is less than 1.8_F (1.0_C) below setpoint
Return Air Temp is less than 2.3°F (1.3°C)
Low Speed Only above setpoint.
Low Speed Only
NOTE
The compartment furthest away from setpoint is used to determine speed. This compartment will fluctuate depending on other control conditions.
4.4.9 DEFAULT MODE
When both the RAT and SAT alarms are on for
Compartment 1, or the RAT alarm is on for either
Compartment 2 or 3, the temperature control for that compartment will go to default mode.
For compartments where the setpoint is in the perishable range [+10.5_F (--12.1_C) or higher] or higher), the LSV, heaters and fan motors will be turned off for that compartment.
For compartments where the setpoint is in the frozen range [+10.4_F (--12_C) or lower] or lower, the compartment will operate in cool, and will only require low speed. If the unit is operating on engine/road, the compressor will fully unload (2--cylinder operation). If the unit is operating on electric standby, the compressor will be fully loaded (6--cylinder operation). (The engine may still operate in high speed if another compartment is calling for high speed.)
4.4.10DEFROST OPERATION
Defrost is an independent cycle overriding cooling and heating functions in order to de-ice the evaporators as required. When the unit is in defrost, the DEFROST LED will be on, the MessageCenter will display DEFROST
CYCLE STARTED for 5 seconds. The center of the Main
Display will show “dF”. The CSMV will close in the defrost cycle.
1) Defrost Modes
There are two different Defrost Modes available:
S
Return Air Defrost Mode does not use electric heaters, but uses the heat from the product to melt any ice. Return Air Defrost is ONLY available when the unit is being operated with Compartment 1 only, AND when the RAT is 35.6_F (2_C) or higher, AND the SAT is 39.2_F (4_C) or higher. Defrost will be accomplished by turning off the compressor and the refrigeration system, and allowing the evaporator fans to operate. Blowing compartment air over the evaporator coil will melt the ice and prevent heat from entering the compartment from the heaters.
S
Normal (Electric) defrost mode can be started when the DTT in any compartment is below 40_F (4.4_C).
When Defrost is called for, all active compartments will stop normal cooling (or heating) and defrost at the same time. Compartments where the DTT is above
40_F (4.4_C) will turn off and remain off until all other compartments have completed defrost.
NOTE
NOTE: For both 2 and 3 compartment units:
During defrost, if the RAT for any enabled compartment goes above 95_F (35_C), or if the
SAT in Compartment 1 is above 113_F (45_C), all of the electric heaters will de--energized, and wait until the RAT temperature drops below
89.6_F (32_C), or the SAT temperature drops below 107.6_F (42_C). This is an overheat protection feature.
TIP
Ice is not the only thing that will cause the air differential to increase across the evaporator coil.
Shrink wrap, paper, plastic bags, and other such items when caught in the return air stream and pulled up against the evaporator coil or the return air grille can also cause the DAS contacts to close.
NOTE
The unit will operate in high speed in the defrost mode.
a. For 2 compartment units, when both evaporators require defrost, HTCON1 and HTCON2 will be energized for Compartment 1, and 2HTCON1 and
2HTCON2 will be energized for Compartment 2. When the DTT for any compartment reaches 55_F (12.8_C), that compartment will stop defrost by de--energizing
HTCON1 & 2 for that compartment, and waiting for the remaining compartment to complete defrost.
b. For 3 compartment units, 1/2/3HTCON1 heaters may be used at the same time, but only 2 of the
HTCON2 heaters may be used. (There are a total of 6
HTCONs in a 3--compartment unit – HTCON1 and
HTCON2 for each compartment. A maximum of 5
62-11039 4--8
HTCONs may be energized at the same time.) All dual discharge style remote evaporators must have both
HTCON1 and HTCON2 on at the same time for defrost.
c. For 3 compartment units where both
Compartment 2 and Compartment 3 evaporators are dual air discharge style (Systems 6 & 16), and both are calling for defrost, HTCON2 will not be on in
Compartment 1 until one of the other evaporators terminates defrost. In this case,
2 HTCON1 and 2HTCON2 will be on in Compartment 2, and 3HTCON1 and 3HTCON2 will be on for
Compartment 3, and only HTCON1 will be on for
Compartment 1. When either of the remote evaporators terminate defrost and the HTCON1 & HTCON2 for that compartment turn off, and Compartment 1 is still in defrost, then HTCON2 will turn on for Compartment 1.
d. For 3 compartment units where only one of the evaporators used in Compartment 2 or Compartment 3 is a dual air discharge style, an d the other is a single air discharge style (Systems 5, 14, & 15) the evaporator with the dual air discharge (if it is calling for defrost) will have both of its HTCON1 and HTCON2 on. If only one other evaporator is calling for defrost, both HTCON1 and HTCON2 will be on in that compartment. If both other evaporators are calling for defrost, HTCON2 priority will be determined by RAT temperature for each compartment. The compartment with the coldest RAT temperature of the two will have HTCON2 energized, while the other uses only HTCON1.
When any compartment using both HTCON1 and HTCON2 ends defrost, if any compartment is still in defrost, and is using only HTCON1, then HTCON2 for that compartment will be energized.
e. For 3 Compartment units where both
Compartment 2 and Compartment 3 have single air discharge evaporators, and all 3 evaporators are calling for defrost, the compartments with the coldest RAT temperatures will use both HTCON1 and HTCON2, while the warmest compartment will use only HTCON1 until one of the other compartments terminates defrost.
2) Defrost Initiation And Start
Defrost can be initiated manually, by keypad, or automatically, by the microprocessor. Microprocessor initiation is based on expiration of the defrost timer or by measurement of coil condition.
In compartment 1, the microprocessor determines the condition of the coil by measuring the air pressure differential across the coil then closing the defrost air switch contacts when the pressure differential is great enough to indicate a restriction caused by ice build up. In compartments 1, 2 and 3, the microprocessor determines the condition of the coil by comparing the
DTT temperature to the RAT temperature (temperature difference across the coil). Defrost will be initiated in these compartments when the DTT is more than 18°F
(10°C) colder than the RAT for 15 continuous minutes.
This method of defrost initiation will only be used for 3 consecutive defrosts. After three consecutive defrost initiations by this method the counter will be reset to allow this defrost initiation again after a defrost cycle is initiated by another method (timer, air switch or manual).
Before defrost can be initiated, the DTT in at least one compartment must be below 40°F (4.4°C). Additionally, defrost will be performed only in those compartments where the DTT is 40°F (4.4°C) or below. During Defrost, the Defrost LED will be on, and dF will be displayed in place of the box temperature.
During Defrost, the Defrost LED will be on, and dF will be displayed in place of the box temperature.
NOTE
If the DTT Sensor Alarm is active, defrost initiation for that compartment will be based on the
RAT temperature for that compartment. If the
RAT temperature is 45°F (7.2°C) or lower, defrost will be allowed in that compartment. If the
DTT and RAT alarms are both active for the same compartment, and that compartment has an SAT, then the SAT temperature will be used.
If the SAT temperature is 45°F (7.2°C) or lower, defrost will be allowed in that compartment. If both DTT and RAT alarms are active in the same compartment, and there is no SAT, defrost will only be allowed if the set point is in the frozen range.
Any time there is a DTT alarm -- if other criteria allow that compartment to go into defrost -- that compartment will defrost for 10 minutes, then end the defrost cycle for that compartment.
When defrost is called for in any compartment, all compartments will go through defrost. Cooling is not allowed when any compartment is in defrost.
Compartments that do not require defrost (DTT above
40_F (4.4_C), or compartments that have already completed a defrost cycle will continue with their respective evaporator fans off, heaters off, and
LSV (s) off in compartments 2 & 3 or EVXV is closed (0% open) in compartment 1, and wait for any remaining compartments to complete defrost.
When the electric heaters are used for defrost, the engine will operate in high speed during the defrost cycle. When electric heaters are not used for defrost, the engine will operate in low speed.
3) Defrost Termination
When the DTT for an evaporator rises to 55_F (12.8_C), the heaters for that compartment will turn off, the evaporator fan motors will remain off, and the LSV will remain off until all other evaporators have also terminated Defrost.
If there is a DTT sensor alarm present, that compartment evaporator will end defrost after 10 minutes.
When Compartment 1 is operating in Return Air Defrost, it will operate in defrost for a minimum of 5 minutes, a maximum of 10 minutes, or until the SAT is equal to or higher than the RAT.
During Defrost Termination, all the heaters will de--energize, and the engine will go to low speed. dF will continue to be displayed in the place of Box
Temperature, and the Cool LED will come on when the compressor starts. Any compartments that call for Heat will have the heaters come on 10 seconds after the compressor starts.
4--9 62-11039
Each compartment that is calling for cool will have the
EVXV (Compartment 1) or LSV (Compartment(s) 2 and/or 3) open, and the evaporator coils will begin to cool down. The evaporator fans will not come on right away, so that warm air is not blown into the compartment, but will wait for the evaporator to cool down, up to a maximum of 8 minutes. Once all the evaporator fans have started, the DF will no longer be displayed, and Box Temperature will again be shown in the main display.
NOTE
Defrost Mode uses a Defrost Duration Timer that allows for a maximum of 45 minutes in defrost. If any compartments have not automatically terminated defrost during 45 minutes, the micro will end the defrost cycle, and show the alarm
“DEFROST NOT COMPLETE”. When this occurs, the Defrost Interval Timer is set for 1.5
hours, at which time the unit will go into defrost again.
4.5
Temperature Range Lock 1 & 2
NOTE
Temperature range locks are only permitted for
Compartment 1.
The unit can be locked into Start--Stop or Continuous
Run operation for various setpoints. Two ranges are available for setpoint range lock selection. Each Range can be independently set to lock it’s setpoint temperatures into either Start--Stop or Continuous Run.
Each Range has it’s own selectable minimum and maximum temperatures, which define the span of the range. If some setpoint temperatures are contained in both ranges due to range overlap, Range 1 will always have priority over Range 2.
For example (Refer to following figure), if Continuous
Run operation is ALWAYS required whenever the setpoint is between +28°F and +55°F (--2.2°C and
--12.8°C), Range 1 will be set for Continuous Run, with a
Minimum Temperature of +28°F (--2.2°C) and a
Maximum Temperature of +55°F (--12.8°C). Should
Continuous Run operation ALWAYS also be required with setpoints between --22°F (--30°C) and 0°F
(--17.8°C), then Range 2 will be set for Continuous Run, with a Minimum Temperature of --22°F (--30°C) and a
Maximum Temperature of 0°F (--17.8°C). Any setpoint outside of Range 1 or 2 will allow changes between
Start--Stop and Continuous Run.
62-11039 4--10
Range Lock 1 & 2
Range 2 is set for
0° to --22°F
(--17.8° to --30°C)
Range 1 is set for
+28° to +55°F
(--2.2° to +12.8°C)
°C
--30
Range 2
--23.3
--17.8
--12.2
--6.7
°F
--22 --10
0
10 20
Range 1
--1.1
4.4
10.0
15.6
30 40 50 60
21.1
26.7
70
80
In the same example as above, Range 1 or Range 2 can be changed to lock the unit operation into Start--Stop.
The primary time that it is important to determine which range is to be Range 1 and which is to be Range 2 is when the ranges overlap each other.
In example 2 (Refer to Figure below), the ranges will be set to lock all setpoints into Start--Stop, except for a small range between 0° and 5.6°C (+32° and +42°F) where the unit will always operate in Continuous Run.
Range 1 Minimum Temperature will be set for 0°C
(+32°F), and Maximum Temperature of 5.6°C (+42°F).
Range 2 will be set for a Minimum Temperature of --30°C
(--22°F) and a Maximum Temperature of 32°C
(+89.6°F).
Range 1 always has priority when Range 1 & 2 overlap
Range 2 is set for --22° to
89.6°F
(--30° to 32°C)
Set for Start--Stop
Range 1 is set for 32° to 42°F
(0° to 5.6°C)
Set for Continuous
°C
--30
°F
--22
--23.3
--17.8
--12.2
--6.7
--1.1
--10
0
10 20 30
4.4
10.0
15.6
40 50 60
21.1
26.7
70
80
4--11 62-11039
4.6 ProductShield
t
ProductShield is a group of configuration settings within the microprocessor that work together with the IntelliSet option to allow improved operating efficiency while providing customized product protection for up to 30 different commodities.
4.6.1 Modes
There are 4 modes to ProductShield:
a. ProductShield: Econo: Go To Start/Stop
ProductShield Econo allows the unit to have the ability to automatically switch from Start/Stop operation to
Continuous run or vice versa. This allows maximum product protection while providing for fuel savings depending on ambient conditions.
When the unit is set for Continuous Run, ProductShield
Econo: Go To Start/Stop allows the unit to change to
Start/Stop when the unit has run in Continuous Run for a minimum of 15 minutes and the ambient temperature falls within a pre--programmed temperature range.
(See Section d. below). The operator can also optionally pre--program a maximum temperature differential
(delta--t) between the return air and supply air sensors as an additional criteria for switching to Start/Stop if the
Econo Delta--T configuration is not OFF. The unit must bring the delta--t below this setting before going to
Start/Stop if this option is chosen. If unit is set for
Continuous Run and ProductShield Econo is configured for GO TO CONTINUOUS, the unit will remain in
Continuous Run.
Once the micro detects that the above criteria have been met, the unit will switch from Continuous Run to auto Start/Stop for a minimum of 30 minutes or until the unit cycles off. After 30 minutes the unit will return to
Continuous Run once the ambient temperature falls
outside the pre--programmed temperature range by
±3.6° F (±2° C).
If the unit shuts down in Auto Start/Stop, it will remain shut down according to the pre--programmed start/stop parameters. When the unit restarts it will return to
Continuous Run operation for a minimum of 15 minutes.
The original activation conditions must again be met in order for the unit to return to auto Start/Stop.
b. ProductShield: Econo: Go To Continuous Run
When the unit is set for Start/Stop, ProductShield
Econo: Go To Continuous Run allows the unit to run at
Continuous Run for periods providing ProductShield
Econo configuration is set to GO TO CONTINUOUS
(See Section 5.2.1), the unit has run in Start/Stop for a minimum of 15 minutes or the Minimum Run Time minus
60 seconds (See Table 3-2) and the ambient temperature falls
outside
a pre--programmed temperature range. If unit is set for Start/Stop and
ProductShield Econo is configured for GO TO
START/STOP, the unit will remain in Start/Stop.
Once the micro detects that the above criteria have been met, the unit will switch from Start/Stop to
Continuous Run for a minimum of 30 minutes. After 30 minutes the unit will return to Continuous Run once the ambient temperature falls within the pre--programmed temperature range by ±3.6° F (±2° C). Delta--t logic is not used when unit is configured for GO TO
CONTINUOUS.
c. ProductShield: High Air
High air mode allows the unit to provide increased airflow with a reduced delta--t under the pre--programmed criteria. This can maximize product protection under difficult conditions while allowing the unit to operate more efficiently during less demanding conditions.
When the refrigeration unit is set for normal airflow,
ProductShield High Air allows the unit to run at high air operation for periods providing the ambient temperature falls within a pre--programmed temperature range. The operator can also optionally pre--program a maximum temperature differential (delta--t) between the return air and supply air sensors as an additional criteria for switching to high air if the Econo Delta--T configuration is not OFF. The unit must bring the delta--t above this setting before going to high air if this option is chosen.
Once the micro detects that the pre--programmed criteria have been met, the unit will switch from normal operation to High Air. The unit will continue to operate in
High Air for a minimum of 30 minutes. After 30 minutes the unit will return to normal operation once the ambient temperature falls outside the pre--programmed temperature range by ±3.6° F ( ±2° C).
If the unit shuts down in Auto Start/Stop during high speed, it will not be in ProductShield High Air when it restarts and will return to normal operation for a minimum of 15 minutes. The original activation conditions must then be met in order for the unit to return to high air.
62-11039 4--12
d. ProductShield: Winter
When the unit is set for Start/Stop operation,
ProductShield Winter allows it to switch to continuous run when the ambient temperature falls below a pre--programmed temperature. This will protect the unit from the complication of fuel gelling.
Once the micro detects that the ambient temperature has dropped below the pre--programmed temperature, the unit will switch from auto Start/Stop to Continuous
Run. The unit will continue to operate in Continuous Run for a minimum of 30 minutes. After 30 minutes, the unit will return to auto Start/Stop once the ambient temperature has risen more than 3.6° F (2° C) above the pre--programmed ProductShield Winter temperature.
All of the ProductShield settings are in the Data List
(Refer to Section 3.15). The Data List will reflect the
ProductShield settings for the IntelliSet commodity that is currently active.
NOTE
ProductShield does not operate within Sleep
Mode.
4.6.2 Temperature Ranges
Each ProductShield setting allows the user to select a ambient temperature range in which to operate.
The Minimum and Maximum range values can be set to
OFF, or any value from --19°F to +119°F (--28.3°C to
+48.3°C ).
The examples below all use the same settings and illustrate the differences in unit operation for the various
ProductShield selections.
a. ProductShield: Econo: Go To Start/Stop
Examples
The following examples apply in situations where all other Start/Stop conditions have been met.
If the Minimum is set to 30°F (--1.1°C) and the Maximum is set to 42°F (5.6°C) and the ambient air temperature falls between these temperatures, the unit operation can change to Econo Start/Stop.
If the Minimum is set to OFF and the Maximum is set to
35°F (1.7°C) and the ambient air temperature falls
below 35°F (1.7°C), the unit operation can change to
Econo Start/Stop.
If the Minimum is set to 70°F (21.1°) and the Maximum is set to OFF and the ambient air temperature is above
70°F (1.7°C), the unit operation can change to Econo
Start/Stop.
b. ProductShield: Econo: Go To Continuous Run
Examples
If the Minimum is set to 30°F (--1.1°C) and the Maximum is set to 42°F (5.6°C) and the ambient air temperature falls outside these temperatures, the unit operation will change to Econo Continuous Run.
If the Minimum is set to OFF and the Maximum is set to
35°F (1.7°C) and the ambient air temperature falls
above 35°F (1.7°C), the unit operation will change to
Econo Continuous Run.
If the Minimum is set to 70°F (21.1°) and the Maximum is set to OFF and the ambient air temperature is below
70°F (1.7°C), the unit operation will change to Econo
Continuous Run.
c. ProductShield: High Air Examples
If the Minimum is set to 15°F (--9.4°C) and the Maximum is set to 85°F (29.4°C) and the ambient air temperature falls outside these temperatures, the unit operation will change to Econo High Air.
If the Minimum is set to OFF and the Maximum is set to
35°F (1.7°C) and the ambient air temperature falls
above 35°F (1.7°C), the unit operation will change to
Econo High Air.
If the Minimum is set to 70°F (21.1°) and the Maximum is set to OFF and the ambient air temperature is below
70°F (1.7°C), the unit operation will change to Econo
High Air.
4--13 62-11039
+1.8_F (+1.0_C )
Setpoint
RISING BOX
TEMPERATURE
+3.6_F ( +2.0_C )
High Speed
6 Cylinder Cool
Low Speed
6 Cylinder Cool
Low
Speed
4 Cylinder Cool
+1.8_F (+1.0_C )
Setpoint
Low Speed
4 Cylinder Cool
62-11039
Compressor Off
-3.6_F (-2.0_C )
FALLING BOX
TEMPERATURE
Figure 4--2. Continuous Run Frozen Temperature Control
RISING BOX
TEMPERATURE
+3.6_F ( +2.0_C ) *
High Speed
6 Cylinder Cool
+1.8_F (+1.0_C )
Setpoint
Low Speed
6 Cylinder Cool
+0.9_F (+0.5_C )*
Setpoint
Compressor Off
Start/Stop Off
Cycle
* During the minimum off time, the unit will restart at the override temperature selected in the functional parameter list
FALLING BOX
TEMPERATURE
Figure 4--3. Start/Stop Frozen Temperature Control
4--14
RISING BOX
TEMPERATURE
+2.3_F (+1.3_C )
+1.4_F (+0.8_C )
Setpoint
-0.5_F (-0.3_C )
-1.8_F (-1.0_C)
-2.7_F (-1.5_C )
High Speed
6 Cylinder Cool
Low Speed
4 Cylinder Cool
Null (Compressor Off)
Null (Compressor Off)
Low Speed
HTCON1 On
Low Speed HTCON1
(& 2*) On
High Speed HTCON1
(& 2*) On
+2.7_F (+1.5_C )
1.8_F (1.0_C )
Setpoint
-0.4_F (-0.2_C)
-1.5_F (-0.8_C )
-1.8_F (-1.0_C )
-3.2_F (-1.8_C )
FALLING BOX
TEMPERATURE
* HTCON2 in dual discharge evaporators only
* During the mimimum off time, the unit will restart at the override temperature selected in the functional parameter list
Figure 4--4. Continuous Run Perishable Temperature Control
RISING BOX
TEMPERATURE
+2.3_F (+1.3_C )
High Speed
6 Cylinder Cool
Low Speed
6 Cylinder Cool
Low Speed
4 Cylinder Cool
+3.6_F ( +2.0_C )
+2.7_F (+1.5_C )
1.8_F (1.0_C )
+1.4_F (+0.8_C )
Setpoint
-0.5_F (-0.3_C )
Null (Compressor Off)
Start/Stop Off Cycle
Start/Stop Off Cycle
Low Speed
HTCON1 On
Setpoint
-0.4_F (-0.2_C)
-1.8_F (-1.0_C)
-2.7_F (-1.5_C )
-3.6_F (-2.0_C )
-1.5_F (-0.8_C )
-1.8_F (-1.0_C )
Low Speed HTCON1
(& 2*) On
-3.2_F (-1.8_C )
UltraFresh 3
Low Speed
2 Cylinder Null
FALLING BOX
TEMPERATURE
High Speed HTCON1
(& 2*) On
* HTCON2 in dual discharge evaporators only
Figure 4--5. Start/Stop Perishable Temperature Control
4--15 62-11039
4.7 OUTPUT OVERRIDES
4.7.1 Speed Control Solenoid (SCS) Overrides
NOTE
When any enabled compartment is calling for
High Speed, the engine will operate in High
Speed, without regard to other compartments.
In order for the engine to operate in Low Speed, all compartments must be calling for Low
Speed.
With the complex control systems in use with the
Advance Microprocessor, there are many different reasons the engine may be operating in either High
Speed or in Low Speed besides the number of degrees the box temperature is away from setpoint . This section lists the different factors that determine the speed of the engine, in the order of their priority.
Speed Control Solenoid Overrides in priority order:
1. DEFAULT MODE
Refer to Section 4.4.9
2. HIGH SPEED TO LOW SPEED DELAY
When the unit is operating in High Speed, and the controller calls for Low Speed,k the engine will remain in
High Speed until the high voltage current draw is less than 22 Amps, or for 40 seconds if the amperage is already higher than 22 Amps. It will then to go Low
Speed.
3. SILENT MODE
When the Silent Mode is set for ON in the Functional
Parameter List, the unit will operate in low speed only
4. LOW SPEED ENGINE COOLANT WARM--UP
If engine Coolant Temperature Sensor Alarm is not active the engine will run in low speed until the coolant is above 79_F (26°C).
5. DEFROST -- Refer to Defrost Control (Section
4.4.10)
6. DOOR/REMOTE SWITCH CONFIGURED FOR
LOW SPEED
The unit will be forced into low speed if the door/remote switch is open (active) and is configured for low speed.
7. AUTO START/STOP ECONO MODE
When the unit restarts from an Off Cycle in
Start/Stop due to any reason except for box temperature away from setpoint, the engine will run in low speed for the same time as the Minimum Off Time
(unless all conditions are met for another Off Cycle, and the engine shuts off in less time). If ProductShield
Econo: Go To Continuous becomes active during this time, the engine will go to normal speed operation until the next On Cycle. (See Section 4.6 for more information on ProductShield)
8. HIGH SPEED DELAY
• The compressor must operate for 2 minutes before the engine will go to high speed.
• When the unit is operating in low speed, and the control calls for high speed, the engine will continue to operate in low speed for the length of time selected in the Configuration List (0 to 10 minutes). This includes engine start--up, defrost termination, and normal temperature control.
9. START--STOP WITH A FROZEN SETPOINT
In Start/Stop Mode, when any compartment setpoint is in the frozen range, and the minimum run time has expired, and the box temperature is not at setpoint, the engine will be forced to high speed.
10. FROZEN SETPOINT
If any compartment setpoint is in the frozen range, and the box temperature in that compartment is below setpoint, that compartment will call for low speed.
11. LOW SUCTION PRESSURE
If the suction pressure falls to 4 inHg (0.14 Bar) for more than 20 seconds, and both UL1 and UL2 are energized, the unit will be forced into low speed for a minimum of 5 minutes, then remain in low speed until the suction pressure is greater than 4 inHg (0.14 Bar).
12. START--STOP WITH A PERISHABLE SETPOINT
When only Compartment 1 is enabled, and the setpoint in Compartment 1 is in the perishable range, and the unit is operating in Start/Stop and all conditions for an OFF Cycle are met except for setpoint, the engine will operate in High Speed to pull down to setpoint and cycle off quicker.
NOTE
Generally, the unit will go into an Off cycle from
High Speed when this condition occurs. However, if one of the required conditions for shut down is no longer met during this time, (for example, the battery voltage drops below the configured value, or the charging amps increase above the configured value, or the engine coolant temperature drops below 122°F (50°C), the engine may return to Low Speed operation until the shut down condition is satisfied, then shut down from Low Speed.
13. HIGH SPEED PULLDOWN
When only Compartment 1 is enabled, and the setpoint for Compartment 1 is in the perishable range, and the unit is operating in Continuous Run, and the
High Speed Pulldown configuration is set for YES, the engine will operate in High Speed until the box temperature is within 0.4°F (0.2°C) of setpoint.
14. PRODUCT SHIELD HIGH AIR
•
When ProductShield High Air is configured on, the engine will operate in High Speed whenever the ambient air temperature is outside the Minimum / Maximum temperature range selected in the configuration list, and if the Delta--T parameter is not set for OFF in the configuration list, the Delta--T of the unit must be greater than the selected value. (See Section 4.6 for more information on ProductShield.
62-11039 4--16
4.7.2 Unloader Control Overrides
With the complex control systems in use with the
Advance Microprocessor, there are many different reasons -- other than the number of degrees the box temperature is away from setpoint -- that the compressor unloaders may be operating loaded or unloaded This section lists the different factors that determine the operation (loading and unloading) of the unloaders.
Unloaders operate in priority order for cool mode ONLY:
The overrides will be allowed in default mode if the override does not use the return or supply temperature.
There is always a minimum delay of 20 seconds between LOADING and UNLOADING cylinders under all operating conditions except when the engine is starting.
When the Compressor is Off the Unloaders are always de--energized.
1. LOW GENERATOR AMP DRAW
When alarm A128 “LOW AC AMPS” is active, the compressor will only operate on 2 or 4 cylinders.
2. HIGH GENERATOR AMP DRAW
When the compressor is operating and either one or both of the unloaders is energized (unloaded), they will not be allowed to de--energize whenever the compressor discharge pressure is above 415 psig (28.2
Bar) OR when the compressor Amp draw is more than
25 Amps when operating in diesel engine mode or more than 21 Amps when in standby.
3. FAN MOTOR DELAY
When ever any fan motor has been energized, there will be a 3 second delay before either unloader is allowed to de--energize.
4. 2--MINUTE DELAY
If the compressor is on and an unloader is energized due to a refrigeration system pressure (override overrides # 4, 7, 8, or 9), the unloader remains energized for 2 minutes.
5. COMPRESSOR STARTUP
•
UL1 remains energized (unloaded) for a minimum of 10 seconds when the ambient is above 100°F
(37.8°C) or 5 seconds when the ambient is at or below
100°F (37.8°C) after Compressor Motor Contactor is energized.
•
UL2 remains energized (unloaded) for a minimum of 60 seconds when the ambient is above 100°F
(37.8°C) or 30 seconds when the ambient is at or below
100°F (37.8°C) (ambient is greater than 37.8°C) after
Compressor Motor Contactor is energized
4--17 62-11039
6. HIGH EVAPORATOR PRESSURE
UL2 will always be energized (unloaded) when the suction pressure reaches the value shown in the chart below, according to the current ambient temperature. For example, at an ambient temperature of 100°F, UL2 will be energized when the suction pressure rises to approximately 75 psig (5 Bar).
100
80
60
40
20
0
90 100 110 120
Ambient Temperature
130 140
7. HIGH DISCHARGE PRESSURE
•
When the compressor discharge pressure reaches
435 psig (30 Bar) for more than 1 minute, UL2 will energize (unload). UL2 will remain energized until the compressor discharge pressure drops below 415 psig.
•
If both UL1 and UL2 are energized (unloaded), and the discharge pressure drops below 415 psig (28.2 Bar),
UL1 will be de--energized (loaded).
8. LOW SUCTION PRESSURE
•
If suction pressure falls below 4” Hg (vacuum) for more than 20 seconds, energize (unload) UL2.
•
Once the suction pressure rises above 5 psig, de--energize (load) UL2 (after the 2--Minute Delay mentioned above.) OR…
•
After 20 seconds: if suction pressure is still less than
4” Hg, energize (unload) UL1.
•
If both UL2 and UL1 are energized (unloaded) AND
20 seconds has elapsed since energizing (unloading)
UL1 AND the suction pressure rises above 5 psig, de--energize (load) UL1.
Figure 4--6.Evaporator Pressure Chart
9. HIGH CDT
If the compressor is operating with both UL1 and
UL2 energized (unloaded), and the CDT rises to 285°F
(140°C), UL1 will be de--energized (loaded), and will remain de--energized until the CDT drops below 265°F
(130°C) for at least 2 minutes.
10.DEFAULT MODE
Refer to Section 4.4.9
11.START--STOP WITH A FROZEN SETPOINT
In Start/Stop Mode, when any compartment setpoint is in the frozen range, and the minimum run time has expired, and the box temperature is not at setpoint, both UL1 and UL2 will be de--energized and the compressor will operate on 6--cylinders.
12.HIGH SPEED PULLDOWN
When only Compartment 1 is enabled, and the setpoint for Compartment 1 is in the perishable range, and the unit is operating in Continuous Run, and the
High Speed Pulldown configuration is set for YES, then the compressor will operate with both unloaders de--energized (6--cylinder operation) until the box temperature is within +/-- 0.4°F (0.2C) of setpoint.
62-11039 4--18
4.7.3 Suction Pressure Operation
At ambient temperatures of 90_F (32.2_C) or below
When the system is operating in high speed and the suction pressure is greater than 63 PSIG (4.29 Bars), both unloaders are unloaded. As the suction pressure drops below 63 PSIG (4.29 Bars), the UL2 unloader is loaded. If the suction pressure drops below 32 PSIG
(2.18 Bars), the UL1 unloader is loaded.
When the system is operating in low speed and the suction pressure is greater than 65 PSIG (4.42 Bars), both unloaders are unloaded. As the suction pressure drops below 64 PSIG (4.35 Bars), the UL2 unloader is loaded. If the suction pressure drops below 35 PSIG
(2.38 Bars), the UL1 unloader is loaded.
At ambient temperatures of 90_F (32.2_C) or higher
At ambient temperatures of 90_F (32.2_C) or higher the unloading suction pressure settings relative to ambient temperatures follow a descending straight line. (Refer to following chart)
SUCTION
PRESSURE
(Bars/PSIG)
4.76/
70
4.42/
65
4.08/
60
3.74/
55
3.40/
50
3.06/ 45
HIGH
SPEED
(UL2)
LOW SPEED (UL2)
UL1 = FRONT UNLOADER
UL2 = REAR UNLOADER
ABOVE THE LINE = UNLOADED
BELOW THE LINE = LOADED
2.72/ 40
2.38/ 35
LOW SPEED (UL1)
2.04/
30
1.70/ 25
HIGH
SPEED
(UL1)
1.36/
20
1.02/
15
26.7
32.2 37.8
43.3
48.9
54.4 °C
80 90 100 110 120 130
°F
AMBIENT TEMPERATURE
Figure 4--7.Refrigeration System Suction Pressures Unloading (Heat and Defrost Only)
4--19 62-11039
SECTION 5
TECHNICIAN INTERFACE
5.1 PC MODE/DOWNLOAD PORT
PC Mode allows the user to access and download data using a computer when the unit is not running and without starting the 8 hour data recorder timer.
Connecting a download cable to the Download Port, with the RS in the OFF position, allows the Advance
Microprocessor to power up, and communicate with the computer.
All functions available from the Keypad may be viewed or changed using the Reefer Manager Program, and a
Personal Computer (PC) connected to the Download
Port. Using the PC will provide additional programming and configuring capabilities that will not be available through the Keypad.
The Data Recorder may also be configured and downloaded through the Download Port using the Data
Manager Program.
5--1 62-11039
Some of the things that you may want to use PC Mode for are:
• Changing any of the functional parameters for the next load
• Reading Engine hour meters
• Reading Maintenance hour meters
• Resetting Maintenance hour meters
•
Viewing the Active and Inactive alarm lists.
•
Entering a Trip Start
• Keeping the microprocessor powered up after turning the RS to the OFF position.
• Demonstrating the operation of the microprocessor.
D
C
E
B
A
Insulated
Jumper
Download Port
Jumper P/N 22-50180-00
WHITE WIRE
To better utilize PC Mode, a PC Mode Jumper
22-50180-01 is available. This looks very similar to the
Configuration Jumper (Refer to Section 5.2), but has a
GREEN WIRE on it. With the unit off, locate the download port. Remove the protective plug to gain access to the wire terminals. Plug in Jumper or connect an insulated jumper wire to terminals C and E.
If the RS is put into the Start/Run position, the microprocessor will go to normal operation. If the unit is shut down with the PC Cable or jumper still in place, the engine will shut down, and the microprocessor will remain powered up.
WARNING
Do not place the Start/Run--OFF Switch
(RS) in the Start/Run position or the unit will start.
5.2
MICROPROCESSOR CONFIGURATION AND
TECHNICIAN TEST MODES
(REMOVE JUMPER MODE)
1. Turn the Start/Run-Off switch to the Off position.
2. With the unit off, locate the download port. Remove the protective plug to gain access to the wire terminals. Plug in Jumper P/N 22-50180-00 or connect an
insulated jumper wire between plug terminals A and
B.
WARNING
Do Not Allow Jumper Wire To Touch Any
Ground.
3. Turn the Start/Run-Off switch to the Start/Run position. The ALARM LED will come on, the setpoint will appear, but the Box Temperature will not, and
“REMOVE JUMPER” will appear in the
MessageCenter for 10 seconds. Remove the jumper at this time. ↑ ↓ TO SCROLL, THEN = TO SELECT” will appear in the MessageCenter for 10 seconds, or until either the UP or DOWN ARROW keys are pressed.
4. Press the UP ARROW Key to scroll through the Main
Menu beginning at the top.
Press the DOWN ARROW Key to scroll through the
Main Menu beginning at the bottom.
5. Select the Mode you wish to access, and press the = key. See the following pages for information on these test modes:
S
Configuration Mode
S
Component Test Mode
S
Service Mode
62-11039 5--2
5.2.1 Configuration Mode
NOTE
To enter Configuration Mode Refer to Section
5.2.
a. “↑ ↓ TO SCROLL, THEN = TO SELECT” will appear in the MessageCenter.
b. Press the UP ARROW Key to scroll through the Configuration list beginning at the top.
Press the DOWN ARROW Key to scroll through the
Configuration list beginning at the bottom.
c. To read through the Configuration list, continue to press either the UP or DOWN ARROW keys. The list is circular meaning that once the end is reached, it is repeated from the beginning.
CONFIGURATION
UNIT MODEL NUMBER #
Pick one of these two models from the Vector model family
SELECTIONS
NDP33GN6HBV2
NDP33GN6HBV3 d. To change one of the Configurations, bring the Configuration to change into the MessageCenter, and press “=”. ↑ ↓ TO SCROLL, THEN = TO SAVE” will show in the MessageCenter for 10 seconds Then the selected Configuration will flash, showing the current value. Press the UP or DOWN ARROW Key to scroll through the list of available selections for this Configuration.
e. Once a new value is showing in the MessageCenter, press the = Key to save the selection. The
MessageCenter will stop flashing. The new value is now in memory.
f. Press the UP ARROW Key to continue to scroll through the Configuration list.
DESCRIPTION
The correct model number must be selected for proper operation and control. This is also part of the Unit Data where user can read the information.
Configuration mode is the only way user can write information.
COMPARTMENT
CONFIGURATION
(NDP33GN6HBV2)
COMPARTMENT
CONFIGURATION
(NDP33GN6HBV3)
2
1 thru 4
6
5 thru 16
Select correct system from Table 2-2
UNIT SERIAL NUMBER #
TRAILER ID #
SET NEW HOURS
GLOW TIME
OUT OF RANGE SHUTDOWN:
(Refer to Section 2.8.3)
PARAMETERS LOCKOUT:
RPM ALARM SHUTDOWN:
LOW PRESSURE SHUTDOWN:
LP SHUTDOWN DELAY:
SHORT
LONG
YES / NO
YES / NO
YES / NO
YES / NO
255 SECS
(0 -- 255 seconds)
The unit S/N may be entered. This may be up to
10 characters long. Numbers, Letters, and a space are available by scrolling through the available list.
The ID # may be entered. This may be up to 10 characters long. Numbers, Letters, and a space are available by scrolling through the available list.
Hours from existing micro can be installed into replacement micro.
Indicates to the controller how long to energize the glow plugs
LONG = Longer glow times are used
SHORT= Shorter glow times are used.
NOTE: Refer to Section 4.1.1 for glow time table.
YES = When the box temperature has been out--of--range for 45 minutes, the alarm light will come on, and the unit will shut down.
NO = When the box temperature has been out--of--range for 30 minutes, the alarm light will come on and the unit will continue to run.
YES = All Functional Parameters in the function list are locked in place.
NO = All Functional Parameters in the function list can be changed using the keypad, unless individually locked out by Reefer Manager.
YES = When alarm 39 is active the alarm light will be on and the engine will shut off.
NO = When alarm 39 is active the alarm light will be on and the engine will continue to run.
YES = When alarm 18 is active the alarm light will be on and the unit will shut off.
NO = When alarm 18 is active the alarm light will be on and the unit continue to run.
After the Low Pressure signal is received, how long shall the unit continue to run before it is shut down.
5--3 62-11039
CONFIGURATION
HIGH SUCT PRESS SHUTDOWN
REFRIGERATION SYS
SHUTDOWN
COMPRESSOR ALARM
SHUTDOWN
(Special option card required)
SELECTIONS
YES / NO
YES / NO
YES / NO
DESCRIPTION
YES = When alarm 27 is active the alarm light will be on and the unit will shut off.
NO = When alarm 27 is active the alarm light will be on and the unit will continue to run.
YES = When alarm 28 is active the alarm light will be on and the unit will shut off.
NO = When alarm 28 is active the alarm light will be on and the unit will continue to run.
YES = The unit will shutdown and not restart when alarms 13, 17, 18 or 56 occur 3 times within 2 hours.
NO = Normal shutdown rules for above alarms.
SUCTION PRESSURE
CURRENT FOR S/S SHUTOFF
VOLTAGE FOR S/S RESTART
ALTERNATOR CHECK
SHUTDOWN:
ENGINE OIL LEVEL SWITCH
ENGINE OIL LEVEL SHUTDOWN
LOW COOLANT LEVEL
ENGINE OIL PRESS SHUTDOWN
HIGH ENGINE TEMP SHUTDOWN
FUEL TANK
30 PSIG (2.0 BAR)
0 -- 50 psig (0 to
3.4 Bar)
[in 1 psig (0.1 Bar) increments]
7.0A
1A TO 10A
(in 0.5A increments)
12.2V
11.5 TO 12.8V
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
NO DEVICE
SWITCH
INSTALLED
0 TO 100% SEN-
SOR
Pressure to maintain if discharge pressure transducer is opened or shorted.
This is the maximum charging amps permitted for start--stop off cycle.
The engine will restart from a Start/Stop Off cycle or a Sleep Mode Off cycle when the battery drops to this value.
YES = When alarm 51 is active the alarm light will be on and the unit will shut off.
NO = When alarm 51 is active the alarm light will be on and the unit will continue to run.
YES = An Engine Oil Level Switch is installed.
NO = An Engine Oil Level Switch is not installed.
YES = The low engine oil level alarm will shutdown the unit.
NO = The low engine oil level alarm will not shutdown the unit.
YES = A Coolant Level Sensor is installed.
NO = A Coolant Level Sensor is not installed..
YES = When the A11 -- “LOW ENGINE OIL PRES-
SURE“ alarm has been activated three times in the last two hours of engine operation the A21 --
“TECHNICIAN RESET REQUIRED“ alarm will be activated.
NO = A21 will not be activated.
YES = When the A12 -- “HIGH COOLANT TEM-
PERATURE” alarm has been activated three times in the last two hours of engine operation the A21 --
TECHNICIAN RESET REQUIRED alarm will be activated.
NO = A21 will not be activated.
NO DEVICE = There is no Low Fuel Level Sensor installed in the fuel tank.
SWITCH INSTALLED = A Low Fuel Level Switch is installed in the fuel tank.
0 to 100% SENSOR = A Low Fuel Level Sensor is installed in the fuel tank. The fuel level may be read in the unit data list.
62-11039 5--4 Change 09/11
CONFIGURATION
FUEL TANK SIZE
SELECTIONS
OFF
30 GALLONS
50 GALLONS
75 GALLONS
100 GALLONS
120 GALLONS
DESCRIPTION
OFF = No Low Fuel Level Switch or 0 to 100%
Sensor is installed in the tank; OR
A Low Fuel Level Switch or a 0 to 100% Sensor is installed in the tank, but the unit will not shutdown due to a Low Fuel Level Alarm.
DIESEL MAX GEN AMPS:xx.xA
STANDBY MAX GEN AMPS:xx.xA
STARTUP GEN MAX AMPS:xx.xA
DIESEL OFFSET MAX AMPS:xx.xA
STANDBY STARTUP DELAY
26A
10 TO 35 in 0.5A increments
22A
10 TO 35 in 0.5A increments
17A
10 TO 35 in 0.5A increments
4A
0 TO 10 in 0.5A increments
OFF
5
10
15
20 SECONDS
NO / YES
DISPLAY TOTAL ENGINE HR
DISPLAY STANDBY RUN HR
NO / YES
30 -- 120 GALLONS = When a Low Fuel Level
Switch is installed, and the LOW FUEL
LEVEL WARNING (alarm 1) is on, the unit will shutdown (alarm 19) after a time delay
(Refer to chart below)
30 gal 30 min
50 gal 60 min
75 gal 90 min
100 gal 120 min
120 gal 150 min
OR
If a 0 to 100% Sensor is installed, the low fuel level
WARNING (alarm 1) will come on when the level reaches 15% or less, and the unit will shutdown
(alarm 19) when the level reaches 10%.
Use factory default settings only.
DO NOT OPERATE UNIT WITH DIFFERENT SET-
TINGS.
Use factory default settings only.
DO NOT OPERATE UNIT WITH DIFFERENT SET-
TINGS.
Use factory default settings only.
DO NOT OPERATE UNIT WITH DIFFERENT SET-
TINGS.
Use factory default settings only.
DO NOT OPERATE UNIT WITH DIFFERENT SET-
TINGS.
Used in starting the system in standby from power up. This helps to prevent multiple units on the same power drop from restarting at the same time.
YES = This hourmeter will be displayed during the startup messaging sequence and will be in hourmeter menu.
NO = This hourmeter will not be displayed during the startup messaging sequence and will be shown with the “other meters and counters”.
YES = This hourmeter will be displayed during the startup messaging sequence and will be in hourmeter menu.
NO = This hourmeter will not be displayed during the startup messaging sequence and will be shown with the “other meters and counters”.
5--5 62-11039
PM (1--5)
CONFIGURATION
DISPLAY TOTAL SWITCH ON HR
DIESEL RESET VALUE
(Refer to Section 2.9 for oil change intervals)
STANDBY RESET VALUE
SWITCH ON RESET VALUE
SELECTIONS
NO / YES
0
50 TO 30,000 HRS in 50 hr increments
0
50 TO 30,000 HRS in 50 hr increments
0
50 TO 30,000 HRS in 50 hr increments
OFF
ENGINE HOURS
SWITCH ON
HOURS
DESCRIPTION
YES = This hourmeter will be displayed during the startup messaging sequence and will be in hourmeter menu.
NO = This hourmeter will not be displayed during the startup messaging sequence and will be shown with the “other meters and counters”.
0 = The Engine Maintenance Hour Meter is turned off.
50 – 30,000 hrs = The value selected here will be the number of hours between engine service intervals.
0 = The Standby Run Time Maintenance Hour Meter is turned off.
50 – 30,000 hrs = The value selected here will be the number of hours between standby run time service intervals.
0 = The Switch--On Maintenance Hour Meter is turned off.
50 – 30,000 hrs = The value selected here will be the number of hours between Switch--On service intervals.
OFF = The PM 1--5 Maintenance Hour Meter(s) is turned off.
ENGINE HOURS = PM Meter will count engine hours until the next service interval.
SWITCH ON HOURS = PM Meter will count Switch
On Hours until the next service interval.
STANDBY HOURS
START CYCLES
HIGH SPEED
HOURS
STANDBY HOURS = PM Meter will count Run
Time Hours until the next service interval.
START CYCLES = PM Meter will count how many times the engine has started until the next service interval.
HIGH SPEED HOURS = PM Meter will count how many hours the unit operated in high speed until the next service interval.
62-11039 5--6
CONFIGURATION
PM (1--5) RESET INTERVAL
PRODUCTSHIELD SETUP
Note: ProductShield is only available when IntelliSet is installed.
•PRODUCTSHIELD ECONO
• ECONO MIN. TEMP
SELECTIONS
NOT DISPLAYED
ENGINE HOURS
OFF or
50 TO 30,000 HRS in 50 hr increments
SWITCH ON
HOURS
OFF or
50 TO 30,000 HRS in 50 hr increments
DESCRIPTION
0 = PM (1--5) is not being used.
ENGINE HOURS = PM (1--5) is connected to the engine hour meter. The reset interval will be (50 –
30,000 hrs).
SWITCH ON HOURS = PM (1--5) is connected to the switch on hour meter. The reset interval will be
(50 – 30,000 hrs).
STANDBY HOURS
OFF or
50 TO 30,000 HRS in 50 hr increments
START CYCLES
1,000 TO 90,000
CYCLES
OFF or in 1,000 cycle increments
HIGH SPEED
HOURS
OFF or
50 TO 30,000 HRS in 50 hr increments
STANDBY HOURS = PM (1--5) is connected to the
Standby Run Time hour meter. The reset interval will be (50 – 30,000 hrs).
START CYCLES = PM (1--5) is connected to the clutch cycle meter. This meter counts every time the engine starter engages. The reset interval will be (1,000 to 90,000 cycles)
HIGH SPEED HOURS = PM (1--5) is connected to the high engine speed hour meter, which counts only high speed engine hours. The reset interval will be (50 – 30,000 hrs).
OFF
GO TO S/S
GO TO CONT
This message will only appear if ProductShield is installed. The information set in the following configurations can be read in the Unit Data List.
OFF = ProductShield Econo is OFF
GO TO START/STOP = Allows unit to be set for and operate in Continuous Run until ambient temperature falls within a user--defined range when unit will go to Start/Stop. This allows fuel savings while offering Continuous Run operation protection when ambient is outside range. Unit will return to
Continuous Run when ambient goes beyond range.
GO TO CONTINUOUS = Allows unit to be set for and operate in Start/Stop until ambient temperature falls outside a user--defined range when unit will go to Continuous Run. This provides continuous air flow and good product protection for extreme ambient temperatures. Unit will return to Start/Stop when ambient comes back inside range.
The minimum range allowed for this selection is
10°F (5.5°C).This means that the MIN temperature will never be closer to the MAX temperature than
10°
--19°F to +119°F
(--28.3°C to
+48.3°C ) in 0.5°F or °C increments
Default: 119°F
(48.3°C )
OFF
Select the lower limit of the ambient range desired for this parameter. See Section 4.6 for more information on Econo Min. Temp.
5--7 62-11039
CONFIGURATION
• ECONO MAX. TEMP
• ECONO DELTA--T
•PRODUCTSHIELD HIGH AIR
•HIGH AIR MIN. TEMP
•HIGH AIR MAX. TEMP
•HIGH AIR DELTA--T
PRODUCTSHIELD WINTER
RANGE (1--2) LOCK
COMPARTMENT 1 ONLY
SELECTIONS
--19°F to +119°F
(--28.3°C to
+48.3°C ) in 0.5°F or °C increments
Default: 119°F
(48.3°C )
OFF
OFF
+3.6°F to +27.0°F
(+2°C to 15°C) in 0.5° C or °F increments
OFF
ON
DESCRIPTION
Select the upper limit of the ambient range desired for this parameter. See Section 4.6 for more information on Econo Max. Temp.
Select the desired Delta--T value for activation of
ProductShield Econo: Go To S/S
This parameter is not available for Econo: Go To
Continuous Run
OFF = The unit will operate normally in high and low speeds.
ON = The unit will operate in high speed when the ambient air temperature falls OUTSIDE the minimum / maximum temperature range (selected settings for HIGH AIR MIN TEMP, HIGH AIR MAX
TEMP, AND HIGH AIR DELTA--T -- see below)
--19°F to +119°F
(--28.3°C to
+48.3°C ) in 0.5°F or °C increments
Default: 119°F
(48.3°C )
OFF
--19°F to +119°F
(--28.3°C to
+48.3°C ) in 0.5°F or °C increments
Default: 119°F
(48.3°C )
OFF
OFF
+3.6° F to +27.0°F
(+2°C to 15°C) in 0.5° C or °F increments
OFF
--20°F to +32.0°F
(--28.9°C to 0°C) in 0.5° C or °F increments
OFF
START--STOP
CONTINUOUS
Select the lower limit of the ambient range desired for this parameter. See Section 4.6 for more information on High Air Min. Temp.
Select the upper limit of the ambient range desired for this parameter. See Section 4.6 for more information on Econo Max. Temp.
Select the desired Delta--T value for activation of
ProductShield High Air
Select the desired ambient temperature for activation of installed ProductShield Winter. When ambient temperature falls below this selected value, the unit will run in Continuous Run only. See Section
4.6 for more information on ProductShield Winter.
OFF = If both Range 1 & Range 2 Locks are off,
Start--Stop or Continuous Run may be selected.
If either Range 1 or Range 2 is not OFF, the unit will operate in the selected mode whenever the setpoint is within that range.
START--STOP = The unit will always operate in
Start--Stop whenever the setpoint is between the minimum & maximum temperatures for that range
(see below).
CONTINUOUS = The unit will always operate in
Continuous Run whenever the setpoint is between the minimum & maximum temperatures for that range (see below).
62-11039 5--8
CONFIGURATION
RANGE (1--2) MINIMUM TEMP
RANGE (1--2) MAXIMUM TEMP
MIN SETPOINT
C2 MIN SETPOINT
C3 MIN SETPOINT
MAX SETPOINT
C2 MAX SETPOINT
C3 MAX SETPOINT
NO POWER
S/S PARAMETERS
REMOTE TEMP SENSOR 1
(Optional)
REMOTE TEMP SENSOR 2
(Optional and Available for 2
Compartment Units Only)
DOOR SWITCH:
(Optional)
NOT AVAILABLE FOR 3
COMPARTMENT UNITS
SELECTIONS
--22°F TO +89.6°F
(--30°C to +32°C) in 0.1°F or °C increments
--22°F TO +89.6°F
(--30°C to +32°C) in 0.1°F or °C increments
--22°F TO +89.6°F
(--30°C to +30°C) in 0.1°F or C increments
--22°F TO +89.6°F
(--30°C to +32°C) in 0.1°F or °C increments
NOT INSTALLED /
INSTALLED &
SHUTDOWN
SWITCH TO EN-
GINE
TOGETHER
SEPARATE
ON / OFF
SWITCH NOT
INSTALLED
DOOR OPEN
SWITCH OPEN
DOOR OPEN
SWITCH CLOSED
DESCRIPTION
Select the lowest temperature desired for either
Range 1 and/or Range 2.
Select the highest temperature desired for either
Range 1 and/or Range 2.
Select the lowest temperature that will ever be used as setpoint. Setpoint can not be set lower than this value.
Select the highest temperature that will ever be used as setpoint. Setpoint can not be set higher than this value.
NOT INSTALLED -- Standby operation is not installed
INSTALLED & SHUTDOWN -- Standby is installed.
If standby power is lost unit will shut down
SWITCH TO ENGINE -- Standby is installed. If standby power is lost diesel engine will start.
TOGETHER = When the Minimum Run Time, Minimum Off Time, Maximum Off Time, and Override
Temperatures are set in the Functional Parameter
List, the same values will be used for both Frozen and Perishable setpoints.
SEPARATE = When the Minimum Run Time, Minimum Off Time, Maximum Off Time, and Override
Temperatures are set in the Functional Parameter
List, different values may be entered for Perishable and Frozen setpoints.
ON=A remote sensor has been added to the unit, and connected into the wire harness at Remote
Temp Sensor (1--2) plug. This enables Remote
Temp Sensor ( 1--2) to be read through the Data
List.
OFF=There is no Remote Sensor (1--2) in this unit.
SWITCH NOT INSTALLED = There is no door switch in this box.
DOOR OPEN SWITCH OPEN = A Door Switch has been installed on one of the box doors. The switch contacts will be OPEN whenever the door is OPEN.
DOOR OPEN SWITCH CLOSED = A Door Switch has been installed on one of the box doors. The switch contacts will be CLOSED whenever the door is OPEN.
5--9 62-11039
CONFIGURATION
DOOR SWITCH UNIT SHUT-
DOWN:
(Optional)
NOT AVAILABLE FOR 3
COMPARTMENT UNITS
SET TIME
• MONTH
•DAY
•YEAR
•HOURS
•MINUTES
PERISHABLE FAN MODE
FROZEN PRIORITY COOLING
Refer to Section 4.4.3
This configuration is for units with software version prior to 04.07.00
SELECTIONS
ALARM ONLY
UNIT SHUTDOWN
LOW ENGINE
SPEED
DATA RECORDER
ONLY
DESCRIPTION
ALARM ONLY = When Door Switch indicates that the door is open, a warning alarm will be displayed in the MessageCenter.
UNIT SHUTDOWN = When Door Switch indicates that the door is open, a warning alarm will be displayed in the MessageCenter, and the unit will shutdown.
LOW ENGINE SPEED = When Door Switch indicates that the door is open, the engine will be forced to low speed.
DATA RECORDER ONLY = The data recorder will record every time the door is opened or closed.
There will be no alarms or messages displayed in the MessageCenter.
1--12
1--31
1998 -- 2037
0--23
0--59
ON / OFF
ON / OFF
The following will allow the Real Time Clock in the
Data Recorder to be set. The time set here can be read in the unit data list.
Select the correct month of the year.
Select the correct day of the month.
Select the correct year.
Select the correct hour (0--11 is AM / 12--23 is PM)
Select the correct minute.
If perishable setpoint is in a specified range and this mode is enabled, the fan will be set off.
ON = Coolant capacity priority will be to the compartments with setpoints in the frozen range.
OFF = Normal unit operation.
FRZN COMP PRIORITY
Refer to Section 4.4.3
This configuration is for for units with software version beginning with
04.07.00
•FROZEN PRIORITY TIME
Older units will display
FROZEN PRIORITY TIMER
•NON--PRIORITY TIME
Older units will display
PERISH PRIORITY TIMER
PERISHABLE OVERRIDE TEMP
Older units will display
PERISH PRIORITY TEMP
8 HR ADDITIONAL DATA:
OFF
NORMAL
HI CAPACITY
5 MIN
5--60 MINUTES IN
1 MINUTE INCRE-
MENTS
5 MIN
5--60 MINUTES IN
1 MINUTE INCRE-
MENTS
OFF
3.6°F to 27°F
(2°C to 15°C) (in
0.5° C or °F increments
YES / NO
NORMAL = Coolant capacity priority will be to the compartments with setpoints in the frozen range.
When NORMAL is chosen, FROZEN PRIORITY
TIME AND NON--PRIORITY TIME will be available.
OFF = Normal unit operation.
HI CAPACITY = Coolant capacity priority will be to the compartments with setpoints in the frozen range.
Defines the number of minutes spent in Frozen
Priority Cooling when enabled.
Defines the number of minutes spent in Perishable
Priority Cooling when Frozen Priority Cooling is enabled.
Allowable number of degrees from setpoint that box temperature can change before overriding frozen priority cooling mode and entering normal unit operation.
YES = When the RS is turned OFF, the data recorder will continue to record data for an additional
8 hours.
NO = When the RS is turned OFF, the data recorder will stop recording data.
62-11039 5--10
SATELLITE COMM
(Optional)
(NOT SUPPORTED IN VECTOR
MT)
CONFIGURATION
CONDENSER PRESS CONTROL
HIGH SPEED DELAY
UNIT OPERATION:
ENABLE INTELLISET AT = KEY
SUPPLY AIR LIMIT FOR S/S
SUPPLY AIR LIMIT FOR CONT
SAT2 (Optional and available for 2
Compartment Units)
SELECTIONS
YES/NO
DESCRIPTION
YES = Condenser fan will cycle on & off as discharge pressure rises or drops.
NO = Condenser fan will be on when the engine is running and in standby when the compressor is running.
1 MIN
0 TO 10 MINUTES
IN 0.5 MINUTE IN-
CREMENTS
Select the length of time unit remains in low speed before transitioning to high speed.
This feature is not supported for Vector MultiTemp models at this time.
STANDARD
RAIL
NO
YES
--21.6° to 0° F
(--12° to +0°C)
(in 0.5°F or °C increments)
DEFAULT: 10.8°F
(--6°C)
--21.6° to 0° F
(--12° to +0°C)
(in 0.5°F or °C increments)
DEFAULT: --9°F
(--5°C)
NOT INSTALLED
INSTALLED
STANDARD = The microprocessor is set to control trailer refrigeration operation.
RAIL = Not recommended for Vector MT
YES = Allows access to the Intelliset menu using the = key.
NO = Allows access to the Intelliset menu using the
SELECT key.
Coldest allowable supply air temperature for
Compartment 1 when unit is running in Start/Stop.
Coldest allowable supply air temperature for
Compartment 1 when unit is running in Continuous.
NOT INSTALLED-- Supply Air Temperature Sensor is not installed in Compartment 2 evaporator.
INSTALLED -- Supply Air Temperature Sensor is installed in Compartment 2 evaporator.
C2 SUPPLY AIR LIMIT FOR S/S
C2 SUPPLY AIR LIMIT FOR CONT
--21.6° to 0° F
(--12° to +0°C)
(in 0.5°F or °C increments)
DEFAULT: --5.4°F
(--3°C)
10.4°F TO +32°F
(--12° to +0°C)
(in 0.5°F or °C increments)
DEFAULT: 30.2°F
(--1°C)
ON / OFF
HIGH SPEED PULLDOWN
Coldest allowable supply air temperature for
Compartment 2 when unit is running in Start/Stop.
Coldest allowable supply air temperature for
Compartment 2 when unit is running in Continuous.
When active, this logic indicates if temperature limits regulating the exit of pulldown mode are modified or not.
ON = Allows for high speed cool pulldown when only one compartment is configured.
OFF = Normal unit operation.
5--11 62-11039
5.2.2 Component Test Mode
NOTE
To enter Component Test Mode Refer to Section 5.2.
WARNING
Voltage will be applied to high voltage components (i.e. the fan motor contactor) and those components will operate (i.e. the fan blades will turn) when those components are energized and the unit is in standby operation and using component test mode.
Component Test Mode allows the Technician to energize individual circuits for 5 minutes at a time. The engine is not allowed to start when the Micro is in
Component Test Mode.
From the Main Menu, select Component Test Mode, and press =. Use the UP or Down arrow keys to scroll through the list when
“↑ ↓ TO SCROLL, THEN = TO SELECT” appears in the
MessageCenter. Press = to select the component you wish to test. For example, if the Cool Light is selected, the Cool Light on the Light Bar will come on, and
“COOL LIGHT OFF IN 5 MINUTES” will appear in the
MessageCenter. The minutes will count down to 0 at which time the Cool Light circuit will be de-energized, and the MessageCenter will display the last component tested.
The test may be stopped at any time by turning the
Start/Run--Off Switch to the Off position, or by pressing and holding the = key for 6 seconds. Should you need more than 5 minutes, the timer may be reset to 5 minutes anytime during the test by pressing the = key.
The timer may only be reset once during each test. After the 5 minute timer expires, the MessageCenter will return to the Component Test Mode Menu, and display the last component tested.
To retest the same component and circuit again, press
=. To select another component to test, press the UP or
DOWN Arrow keys to select another component, and press = to select.
To go to Diagnostic Mode or
Configuration Mode, select Main Menu and press =.
The only keys that operate during Component Test
Mode are the Alarm and Select keys. The alarm list is available for you to look at any active or inactive alarms.
The Select key will only allow access to the Current
Draw item in the Data List.
When Component Test Mode is selected, the Main
Display will show OFF.
62-11039 5--12
The following components may be tested during the Component Test Mode:
Component / Menu List
Defrost Light
Auto Restart Light
Fault Light
Unloader 1 (front)
Unloader 2 (rear)
Speed Relay
Run Relay
Buzzer
Glow Plug Relay
Heater Contactor 1
Heater Contactor 2
C2 Heater Contactor 1
C2 Heater Contactor 2
C3 Heater Contactor 1
C3 Heater Contactor 2
Evaporator Motor Contactor 1
C2 Evap Contactor
C3 Evap Contactor
Power Supply Contactor
Compressor Motor Contactor 1
Condenser Motor Contactor 1
Generator Contactor
C2 LSV
C3 LSV
Main Menu (To access Component Test
Mode, or Configuration Mode)
MessageCenter
DEFROST LIGHT OFF IN X MINS
ARL LIGHT OFF IN X MINS
FAULT LIGHT OFF IN X MINS.
UL1 OFF IN X MINS
UL2 OFF IN X MINS
SR OFF IN X MINS
RR OFF IN X MINS
BUZZER OFF IN X MINS
GPR OFF IN X MINS
HEATER CONT 1 OFF IN 5 MINS
HEATER CONT 2 OFF IN 5 MINS
C2 HEATER CONT 1 OFF IN X MINS
C2 HEATER CONT 2 OFF IN X MINS
GPR OFF IN X MINS
C3 HEATER CONT 2 OFF IN X MINS
EVAPORATOR CONT 1 OFF IN 5 MIN
C2 EVAP CONTACTOR OFF IN X MIN
C3 EVAP CONTACTOR OFF IN X MIN
POWER SUPPLY CONT OFF IN X MIN
COMPRESSOR CONT OFF IN X MINS
CONDENSER CONT OFF IN X MINS
GENERATOR CONT OFF IN 5 MINS
C2 LSV OFF IN X MINS
C3 LSV OFF IN X MINS
FET
16
7
14
23
22
18
10
21
9
11
8
13
20
5
15
2
1
3
12
17
Board LED
14
15
17
4
5
27
7
9
25
12
22
8
24
16
28
11
30
6
10
19
20
23
5--13 62-11039
5.2.3 Service Mode
CAUTION
Service Mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating.
NOTE
Unit Start/Run--Off switch (RS) MUST be in
Start/Run position to keep unit in Service Mode.
If the switch is turned OFF, the unit exits Service Mode and closes CSMV to 0% open and de--energizes UL1.
a.
Press = key when SERVICE MODE appears in the
MessageCenter.
b.
ENTERING SERVICE MODE will appear in the
MessageCenter.
When entering Service Mode the microprocessor opens the CSMV to 100% open and energizes UL1.
c.
Once the CSMV is 100% open,
“RECOVER / LEAK CHK / EVAC MODE” is displayed in the MessageCenter.
d.
Refrigerant recovery, leak checking, or evacuation may be performed on the unit at this time. Refer to
Service Procedures in Section 8.11.2.
e.
To prevent refrigerant migration to the compressor during charging, if all pressure transducers (CSP and CDP) drop below –20 inHg (0.68 Bar), and then 3 of the 4 pressure transducers rise above 5
PSIG (0.34 Bar), the microprocessor will close the
CSMV to 0% open and de-energize UL1. When the valve is closed,
“CHARGE MODE – HOLD = TO EXIT” is displayed in the MessageCenter.
f.
If the unit shifts to Charge Mode and
“CHARGE MODE – HOLD = TO EXIT” is displayed in the MessageCenter, DO NOT perform refrigerant recovery, leak checking, or evacuation at this time. Exit Service Mode and then re-enter, making sure that
“RECOVER / LEAK CHK / EVAC MODE” is displayed in the MessageCenter before performing any of these services.
g.
To exit Service Mode at any time, press and hold the = key for 3 seconds. “EXITING SERVICE
MODE” will then appear in the MessageCenter.
When exiting Service Mode the microprocessor closes the CSMV to 0% open and de-energizes UL1.
62-11039 5--14
5.3 DOWNLOADING DATA WITH THE PC CARD
CAUTION
1. Place the Micro in PC Mode (Refer to Section 5.1), or place the RS switch in the Start/Run Position.
2. Insert a Download Card into the PC card slot on the front of the microprocessor. Be certain that the instruction label is facing the “Caution” label. Do not force card into slot.
3. The MessageCenter will show
“COPYING DATA--PLEASE WAIT”. While the data is being copied, the green PC CARD
STATUS LED will flash.
4. When the copy is complete,
“COPY COMPLETE, REMOVE CARD X” (“X” is the number of empty spaces remaining on the card) will show in the MessageCenter. The PC
Card Status LED will be solid. You may then remove the PC card. Do not remove the card
until prompted to do so.
5. When the card is removed, the MessageCenter will return to the default message.
6. If any other messages appear, refer to Section 6.1
MessageCenter for an explanation of the error message. If there is an error, the PC CARD FAULT
LED will be on until the card is removed.
7. Data must be uploaded off of the Download Card onto a computer drive before it can be viewed.
START-STOP
2
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
5--15 62-11039
5.4 INSTALLING NEW SOFTWARE
5.4.1 Using The Program PC Card
TIP
Whenever performing a major operation to a microprocessor, such as installing new operating software, it is always a good idea to start the unit and give it a quick check over prior to performing the operation.
NOTE
Once the unit shuts down to begin the software install process, the Compressor Suction Modulation Valve closing process begins. The software installation processes will not begin until the CSMV is completely closed, which will delay the actual process for about 45 seconds.
CAUTION
The display and MessageCenter may behave differently during the software loading process, depending on the version of software currently in the controller. DO NOT INTERRUPT THE SOFTWARE
INSTALLATION PROCESS ONCE IT HAS STARTED.
1. Place the Micro in PC Mode (Refer to Section
5.1), or place the RS switch in the Start/Run
Position.
CAUTION
2. Insert a Download Card into the PC card slot on the front of the microprocessor. Be certain that the instruction label on Download Card is facing the “Caution” label on the microprocessor. Do not force card into slot.
3. The MessageCenter will show one of 3 different messages:
Same SW: “= to Load,
Old SW: “= to Load,
New SW: “= to Load,
↑
To Cancel”
↑
To Cancel”
↑
To Cancel”
4. Choose New.
5. Press = to load the program. The MessageCenter will go blank. If the engine is running, it will shut down. After a few seconds, the display will power up, and the MessageCenter will show
INSTALLING PROGRAM SOFTWARE during the software install process. The Card Status
LED adjacent to the PC Card slot will blink together with the Micro Status LED during this installation process. Once the entire program has been loaded, the MessageCenter will show
INSTALL COMPLETE -- REMOVE CARD. At the same time, the Card Status LED will stop blinking and be on solid, indicating that the software install is complete.
6. When the card is removed, the Micro will power up as it was prior to inserting the card (PC
Mode or unit running). Allow the Micro to completely power up (Main Display and
MessageCenter displaying appropriate messages) once after installing the new software before turning the power off, or removing the PC Mode jumper.
DO NOT TURN THE RS
SWITCH OFF DURING THE INITIAL START FOLLOWING A SOFTWARE UPGRADE.
62-11039 5--16
5.4.2 Using MicroProgrammer
CAUTION
It is important that communications between the Micro and the computer are not disturbed during the software loading process. If using a laptop computer, turn all energy saving features off. Turn off any screen saver, or any hard drive time out settings.
New software can be installed using either the preferred previously described Program PC card method, or by using MicroProgrammer
3.14 and a computer. Existing Program PC cards may be upgraded to 04.03.00 by using the ReeferManager program.
Only MicroProgrammer version 3.14 is to be used to properly install new software. Earlier versions of MicroProgrammer should be discarded. MicroProgrammer ONLY RUNS ON
Windows 95/98. It will NOT RUN on
Windows 2000 or XP.
a. Connect the computer to the microprocessor using a
Download Cable. Once the cable is connected to the download port, the microprocessor will power up, and show “PC MODE”.
b. Start the program by double clicking on the
MicroProgrammer icon on your computer desktop.
c. Click on the Load File button. The Open box will appear on the screen.
d. Using the mouse, select the file you want to load (this will be a .bex file) by clicking once on it to highlight it.
e. Click the OK button. Watch the lower left message area of the program. Once the file is validated, the
Program Micro button will become active.
f. Turn the RS switch to the Start/Run position. Wait for the Main Display and MessageCenter to power up.
g. Click on the Program Micro button. The
MessageCenter will go blank. If the engine was running, it will shut down. Nothing will happen for the first
5--10 seconds, then the software will begin to load.
The Micro Status LED will start blinking at the rate of
.5 seconds on / .5 seconds off.
h. The % complete value on the computer screen will increment itself as the program is loaded. The % complete will stop several times during the loading process for up to 15 seconds. This is normal. DO NOT
STOP THE PROCESS. The time to load the program is dependent upon the speed of the computer. This will generally take from 4 to 6 minutes.
i. It is important that the program is not interrupted from the time the “Program Micro” button is clicked until the program is completely loaded. Once the % complete reaches 100%, the shutdown box will appear. Click the OK button.
j.The microprocessor will power up, and the unit will start. Allow the engine to start completely the first time after loading software. DO NOT TURN THE RS
SWITCH OFF DURING THE INITIAL START FOL-
LOWING A SOFTWARE UPGRADE.
5.4.3 Troubleshooting Software Loading
Problems
If after loading the software program, the microprocessor does not power up, or the engine does not start, use the following to isolate the problem.
a. Did the unit perform properly prior to loading the software? If not, the problem most likely is not a result of the software loading process.
b. Check the Micro Status LED near the PC Card slot on the microprocessor. It should be blinking continuously at the rate of 1 second on and 1 second off. This is the “normal” heartbeat rate of the microprocessor.
c. If the Micro Status LED is blinking at the rate of .5 seconds on and .5 seconds off, the microprocessor is still in Program Mode, and the software is not fully loaded into memory. Load the software again, being careful to follow each step completely in sequence.
d. If the Micro Status LED is not on at all, check voltage to QC1 & QC2. Also check for voltage from the RS at
5MPA1. If voltage and grounds check OK, the microprocessor may be dead and require replacement.
5--17 62-11039
5.5 SETTING PM (PREVENTATIVE MAINTENANCE) HOURMETERS
The programmable PM Hourmeters (PM1 – PM5) which can be configured to count any of the following
• Diesel Engine Hours
• Standby Electric Motor Hours
•
Switch On Hours
•
Start Cycles
•
High Speed Hours
The PM Hourmeters are activated and the reset interval is selected from the Configuration List. To turn on the
Engine PM Hourmeter, select the desired maintenance interval (in hours), and enter as the
“DIESEL RESET VALUE” in the Configuration List.
Selecting OFF will completely turn the Engine PM
Hourmeter off. The reset value selected here will be the value used when the PM Hourmeter is reset from the
Functional Parameter List.
To turn on the Switch On PM Hourmeter, select the desired maintenance interval (in hours), and enter as the “SWITCH ON RESET VALUE” in the Configuration
List. Selecting OFF will completely turn the Switch On
PM Hourmeter off.
To turn on any of the Programmable PM Hourmeters, they must first be programmed to count one of the available parameters from the list above. (For example,
PM 1 may be programmed to count start cycles.)
Selecting OFF will completely disable the PM
Hourmeter. Once a selection is made, then a reset interval may be selected. For hours, the PM Hourmeter may be set in 50 hour increments anywhere from 50 to
30,000 hours. For cycles, the PM Hourmeter may be set in 1,000 cycle increments anywhere from 1,000 to
90,000 cycles. Selecting OFF instead of an interval will also disable the PM Hourmeter.
Once the PM Hourmeters are activated from the
Configuration List, they can be turned OFF; once off the operation can be RESUMED; or it can be RESET for a new interval, all from the Functional Parameter List.
The PM Hourmeters may be reset using either a PC or the Keypad. RESET is only available when the accumulated hours are more than 95% of the reset value for that Hourmeter. (For example: the Engine PM
Hourmeter Reset Interval is 1000 hrs. Reset will be allowed anytime after 950 hours have expired.)
TIP
Factory default is OFF for all PM Hourmeters.
To change the PM Hourmeter to On and set the desired number of hours:
1. From the Configuration List, select the
PM Hourmeter.
2. Press = to enter.
3. Now select the desired new interval.
4. Press = to enter.
5. Turn the Start/Run Off switch off then back to Start/-
Run. Check the Data List. The correct number of hours should be showing as
“HOURS TO ENGINE MAINT”.
62-11039 5--18
5.6 ADVANCE MICROPROCESSOR REPLACE-
MENT & CONFIGURATION SETUP
When field diagnosis of a Carrier Transicold Trailer refrigeration unit determines that an Advance
Microprocessor is not performing properly and must be replaced, the following steps MUST be taken to ensure correct operation of the unit following the repair.
Prior to beginning work on the unit, be certain that the current configuration file has been downloaded for the customer, from the Carrier Transicold Information
Center, and written onto a Configuration PC Card, using the ReeferManager Program.
If the original microprocessor was equipped with the IntelliSet option, this file will need to be on a Config Card in order to install the IntelliSet parameters into the replacement microprocessor. A computer is needed to enter the engine and switch on hours into the new microprocessor.
5.6.1 Microprocessor Replacement
a. If possible, power the microprocessor up, either using a PC Mode Jumper, or by turning the RS to the
Run position. If the microprocessor will not power up, skip ahead to step 6.
b. Insert a Download PC Card into the PC Card slot and download all data from the data recorder. If a Download Card is not available, data may also be downloaded using a download cable and the ReeferManager PC Program.
c. Then, scroll through the Data List and make note of the following from the MessageCenter:
•
ID Number
• Unit Serial Number
• Unit Model Number
• Engine Hours
• Switch On Hours
• Date and Time d. Remove PC Jumper or turn RS to Off.
e. Remove negative battery cable from battery.
f. Remove Connectors 1MP, 2MP, & 3MP from the outside of the Control Box.
g. Open Keypad side door. Open control box door.
h. Remove Connectors 5MP & 6MP inside the Control
Box. Remove all wires from the Micro.
i. Locate wire to 80A fuse that runs through the Current
Sensor. Note the orientation of the wire through the
Current Sensor, to be certain that the wire is reinstalled through the new Current Sensor in the same direction. (Inserting the wire through the Current
Sensor in the opposite direction will result in erroneous current readings.) Remove wire from fuse holder and gently pull through the Current Sensor.
j. Remove the screws holding the sides of the Micro into the Control Box. Remove the single screw holding the top of the Micro in place.
k. Pull the Micro back, and twist out of the Control Box.
l. Install the new Micro by reversing steps a. thru k.
5--19 62-11039
5.6.2 Microprocessor Setup
NOTE
Before starting the unit, the microprocessor must be configured for the model unit it is installed in. Refer to Microprocessor Setup information below.
a. Ensure that the new microprocessor is in place, all wires connected and the negative battery cable is reconnected.
b. Place the RS in the Start/Run position. The controller will immediately go into the Configuration List so that the correct model number can be selected. Using the Up or Down Arrow Keys, scroll through the list until the correct Model Number appears (verify the
Model / Serial Plate on the unit). Press the = Key to enter the new model number.
c. Press the Up Arrow Key again, and the Unit Serial
Number field will appear. Press the = Key, then the
Up Arrow Key. You will see a blinking cursor in the field. Now, using the Up or Down Arrow Keys, scroll through the Number / Letter list, until the first letter of the serial number you recorded above appears.
Press the = Key to enter that letter, and advance the cursor to the next place. Repeat this process until the entire Unit Serial Number is entered (i.e.
HAY90512345).
d. Press the Up Arrow Key again, and the ID field will appear. Press the = Key, then the Up Arrow Key.
You will see a blinking cursor in the field. Using the
Up or Down Arrow Keys, scroll through the Number /
Letter list, until the first letter / number of the ID you recorded above appears. Press the = Key to enter that number / letter, and advance the cursor to the next place. Repeat this process until the entire ID number is entered. If the cursor is still blinking in a blank space after you are finished, slowly (wait 2--3 seconds between presses) press the = Key to leave blanks in the remaining spaces. When you reach the end, the message
“↑↓ TO SCROLL, THEN = TO SELECT” will appear
(i.e. XYZ5678).
e. Now, press the Down Arrow Key until SET TIME appears. Press the = Key then the Up Arrow Key to enter that menu.
CAUTION
Be certain that the clock you are using is accurate. Also, some customers are located in different time zones from the repair location. If you know the repair location time zone, enter that time. If you don’t, enter your current time.
f. When MONTH appears, press the = Key, then the
Up Arrow Key. The MessageCenter will begin to flash, indicating that it is ready to accept changes.
Use the Up or Down Arrow Keys to scroll through the number list until the correct number of the current month appears. Press the = Key to enter that number for the month.
g. Now, press the Up Arrow Key to go to Day.
h. Using the same key presses as in f. and g. above, continue to enter the correct numerical value for the
Day, Year, Hour and Minute.
i. When you are finished, the MessageCenter will show PRESS = TO SAVE TIME CHANGES.
NOTE
If you do not press the = Key, none of the time changes you just made will be saved.
NOTE
If a Config Card will be used to configure the microprocessor, skip ahead to CONFIGU-
RATION CARD, Section 5.6.7 If the Configurations and Functional Parameters will be set from the keypad, continue with following steps
5.6.3 and 5.6.4
5.6.3
Configurations Via Keypad
a. Refer to Section 5.2 for list of available microprocessor Configurations.
NOTE
Units equipped with IntelliSet MUST have the settings installed using ReeferManager.
IntelliSet settings CANNOT be installed by using either the Keypad, or by using a laptop computer.
b. Press the Up Arrow Key to go to the next Configuration. Compare the setting already in the micro with the setting required.
c. When a parameter needs to be changed, first press the = Key. This allows the parameter to be changed.
d. Press the Up or Down Arrow Keys to scroll through the selections for that parameter.
e. When the parameter you need is visible in the
MessageCenter, press the = Key.
f. Repeat steps b. thru e. until you have gone through the entire list.
g. To exit the Configuration Settings, place the RS in the Off position.
62-11039 5--20
5.6.4 Functional Parameters Via Keypad
a. Refer to Section 3.17 for list of available Microprocessor Functional Parameters.
b. Press the Select Key, until
PRESS ↑ ↓ TO VIEW SETTINGS appears in the
MessageCenter c. Pressing the Up Arrow Key will bring
↑ ↓ TO SCROLL, THEN = TO SELECT into the
MessageCenter.
d. Press the Up Arrow Key to go to the first Functional
Parameter. The MessageCenter will show
DEFROST TIMER SET FOR X HRS.
e. To keep this setting and go to the next setting, press the Up Arrow Key.
f. To change the parameter, press the = Key.
↑ ↓TO SCROLL, = TO SAVE will show in the
MessageCenter.
g. Press the Up Arrow Key and the parameter will be flashing on and off, indicating that changes are possible.
h. Press the Up Arrow Key to scroll through the available selections for the parameter. When the setting you desire appears, press the = Key to enter and save your selection.
i. Repeat steps e. thru h. and continue through the entire list of Functional Parameters.
j. Leave the microprocessor powered up as you continue with the next section.
5.6.5 DataRecorder Via
ReeferManager PC Program
NOTE
If the factory settings are used, you can skip this section and proceed to Hourmeter Setup.
a. Refer to Section 3.20 for list of DataRecorder Setups.
b. Power up the microprocessor. If it is not already powered up, refer to directions under Microprocessor Setup – Functional Parameters via Keypad, Section 5.6.4 above.
c. Connect your computer to the Download Port of the unit (use cable 22--001737) and start the
ReeferManager program. You will need ReeferManager version 03.00.00 or higher.
NOTE
ReeferManager 03.00.00 is REQUIRED in order to view, change and send new features to and from the microprocessor.
d. In ReeferManager, go to the Serial Operations Tab, and then click on Data Recorder/Microprocessor setup button.
e. Select the Sensors to be recorded and whether you wish averaged or snapshot recordings (averaged is recommended for all temperature sensors; snapshot is recommended for voltage, amperage, &
RPM).
f. When the setup is correct, press the Send button to send the new settings to the microprocessor.
g. Verify that the settings were sent, by waiting for the confirmation pop up message.
NOTE
If the data recorder date and time were not set earlier, they can be set from this screen by clicking on Tools>set date and time.
h. Leave the microprocessor powered up as you continue with the next section.
5.6.6 Engine And Switch--on Hour Meters Via ReeferManager PC Program
a. Start the ReeferManager program. Go to the Serial
Operations Tab.
b. Click on Microprocessor Setup button.
c. In the upper left menu bar, click on Tools>Set New
Micro Hours.
d. At this screen, enter the Engine and Switch On hours that were recorded in step b. of Section 5.6.1. Send the new readings to the microprocessor.
NOTE
The program will only allow hours to be changed until the Engine Hourmeters reach 25.
Once the Hourmeter shows 25 or more hours, no changes may be made to it. BE CERTAIN
THAT YOU HAVE ENTERED ALL HOUR AND
CYCLE METER NUMBERS BEFORE
PRESSING THE OK BUTTON.
e. Your computer may now be disconnected and turned off.
5--21 62-11039
5.6.7 Configuration/IntelliSet Card
a. Place the RS in the Off position to power down the microprocessor and to take it out of Configuration
Mode.
b. Power the microprocessor up by either turning the
RS to the Start/Run position (ok to place in Manual
Start Operation if desired), or by inserting a PC Mode jumper into the Download Port.
c. Insert your Configuration PC Card into the PC Card slot in the microprocessor and watch the
MessageCenter. When the MessageCenter shows
“CFG, = TO LOAD, ↑ TO CANCEL”, press the
= Key. It will take 10 – 15 seconds to load the Intelli-
Sets off the card. “LOADING INFO” will be displayed during this time. When finished, the MessageCenter will show “ALL INFO LOADED – REMOVE CARD”.
Remove the PC Config Card.
d. If the unit is not equipped with the IntelliSet Option, or there is only a single set of settings on the PC Card, the MessageCenter will show
“MICRO WILL RESET AND RESTART NOW”.
NOTE
Units with IntelliSet will not automatically reset and shutdown when the PC Card is removed, as do units without IntelliSet. Units with
IntelliSet will NOT indicate ANY change inoperating parameters UNTIL an IntelliSet is selected e. Press the = Key to display default IntelliSet. (Enable
IntelliSet at = Key must be configured ON.
See
Section 5.2.1.
) f. Default Intelliset will appear in the MessageCenter.
Press either the UP or Down Arrow keys to move through the IntelliSet List. Move to the desired IntelliSet and press the = Key. The desired IntelliSet is automatically active.
5.6.8 Microprocessor Final Checkout
a. Start the unit and allow it to run for a few minutes.
b. While the unit is running, scroll through the Data List of the microprocessor. Verify that all the data that was recorded in Step b. of Section 5.6.1 is now accurately displayed in the Data List. Also, verify that the correct date and time is being displayed.
c. Initiate a Pretrip test. Allow the unit to complete the
Pretrip and check for any alarms. Make any necessary repairs before returning the unit into service.
62-11039 5--22
SECTION 6
MessageCenter
6.1 MessageCenter MESSAGES
The following table lists all of the messages which do not appear in other lists in this manual and a description of their meaning. Refer to Section 7 for a list of Alarm messages. Refer to Section 3.15 for a list of Unit Data messages. Refer to Section 3.17 for a list of Functional Parameter messages. Refer to Section 5.2.1 for a list of Configuration messages.
Message
↑↓ TO SCROLL, THEN = TO LOCK
↑↓ TO SCROLL, THEN = TO SAVE
↑↓ TO SCROLL, THEN = TO SELECT
= TO INSTALL, INSTALLS LEFT XX
ACTIVE ALARM LIST CLEARED
MessageCenter MESSAGES
Description
This message is used when viewing Unit Data. Use the UP &
DOWN arrow keys to move through the Data list. Press the = key to lock a Data item in the MessageCenter
Press the UP or DOWN arrow keys to scroll through menu selections available in this mode. When you reach the desired selection, press the = key to store new value in microprocessor’s memory.
Press the UP or DOWN arrow keys to scroll through menu selections available in this mode. When you reach the desired selection, press the = key to select it.
An Options PC Card has been inserted into the PC Card slot.
Press = to install the option into the Micro. The number of installs remaining on the PC Card will be shown.
The list of active alarms in the Micro alarm has been erased. (This does not remove alarms from the data recorder.)
ALL ALARMS CLEARED
ALL INFO LOADED -- REMOVE CARD
CALIBRATION UNSUCCESSFUL
CANNOT ENTER TRIP START
CANNOT START DEFROST CYCLE
CANNOT START PRETRIP
CARD FULL, REMOVE CARD
CARD LOCKED -- REMOVE CARD
CARD REMOVED, DATA NOT COPIED
CARD REMOVED, REINSERT CARD
CFG: =TO LOAD,↑ TO CANCEL
CHANGE INTELLISET TO EXIT
CHARGE MODE--HOLD=TO EXIT
CHECK AT NEXT SERVICE INTERVAL
CHECK COOLANT LEVEL
CHECK ENGINE OIL LEVEL
The list of active and inactive alarms in the Micro alarm lists have been erased. (This does not remove alarms from the data recorder.)
All data has been loaded into the Micro from the PC Card. The card may be safely removed from the Micro.
Transducer calibration was unsuccessful.
Cannot enter trip start. A problem has been detected within the
Data Recorder.
Cannot start defrost cycle. Refer to Defrost Sections 3.11, 4.4.10, and 8.25.
Cannot start pretrip. Refer to Pre Trip Section 3.5.
The PC Downloader Card is full of downloaded files. There is no additional room to download the Micro. You may safely remove the
PC Card from the slot.
The lock switch on the PC Card is in the “Locked” position. To use the PC Card, move the switch to the “Unlocked” position.
The PC Card was removed before all data was copied onto the card.
The PC Card was removed from the card slot before the operation was completed. Reinsert the PC Card into the card slot to perform the operation.
A Configuration Card has been inserted into the PC Card slot.
Press = to load configurations or IntelliSets into microprocessor.
Sleep Mode and IntelliSleep Intelliset is active. Alternates with
IntelliSleep Mode at 5 second interval whether unit is running or not.
Ready to charge system with refrigerant.
The unit needs to be checked at next service interval.
There is currently an active non--shutdown alarm in the alarm list.
The engine coolant level is not full. (Requires optional sensor)
The oil level in the diesel engine is low. (Requires optional sensor)
6--1 62-11039
Message
CHECK FUEL LEVEL
CONFIG ERROR, REMOVE CARD
MessageCenter MESSAGES
Description
The level in the fuel tank is very close to empty. (Requires optional sensor)
There was an error configuring the Micro with the Configuration
PC Card. Remove the PC Card from the slot.
CONFIGS COMPLETE,= TO EXIT
CONFIGURATION MODE
CONFIGURATION NOT CHANGED
CONTINUOUS LOCKED
DATA RECORDER FAILURE
DEFROST CYCLE STARTED
DOOR OPEN
DOOR OPEN -- LOW SPEED
The user has reached the end of the Configurations List. Pressing the ↑ or ↓ arrow keys will start list over. Press = to exit Configuration List.
Press = to enter Configuration Mode.
New configuration selection was not Entered (saved).
The current setpoint is within a range that has been locked into the
Continuous Run mode. Start--Stop can not be selected.
CONTINUOUS RUN MODE SELECTED Continuous run mode is selected.
COPY COMPLETE, REMOVE CARD XX A DownLoad PC Card has been inserted into the PC Card slot, and all data from the Data Recorder has been copied onto the PC Card.
You may safely remove PC Card from the slot. XX=number of empty download slots remaining on the card.
COPY ERROR, REMOVE CARD XX
COPYING DATA--PLEASE WAIT
A DownLoad PC Card has been inserted into the PC Card slot, and an error occurred while the data was being copied onto the PC
Card. You may safely remove the PC Card from the slot.
XX=number of empty download slots remaining on the card.
A DownLoad PC Card has been inserted into the PC Card slot, and all data from the Data Recorder is being copied onto the PC Card.
DO NOT REMOVE THE CARD WHILE THIS MESSAGE IS BE-
ING DISPLAYED.
The controller has stopped recording unit data.
The unit has gone into defrost.
The trailer compartment door is open.
Shows that the door is open and that the unit is running in low speed.
The initial message for Service Mode.
ENTERING SERVICE MODE
ERROR: ENG HRS > SWITCH ON HRS
ERROR: HI SP HRS >TOTAL ENG HRS
ERROR: SBY HRS > SW ON SBY HRS
EVAC / CHARGE MODE
Incorrect hours have been entered.
EXITING SERVICE MODE
This message will be displayed when the unit is in Service Mode and the system is ready for recovery and leak testing.
Service Mode has been turned off and unit is returning to normal operation.
FUNCTION NOT CHANGED
HOUR METERS NOT CHANGED
INACTIVE ALARMS IN MEMORY
INSTALLED, REMOVE CARD XX
INSTALLING OPTION, PLEASE WAIT
INSTALL STOPPED, REINSERT CARD
The = key was not pressed in the allotted amount of time to select the new Functional Parameter setting. The new setting was not stored and the old setting will be used.
Indicates that no changes have been made to the hourmeters in either the configuration or functional parameter lists.
There are inactive alarms in the Micro alarm list which have not yet been cleared out.
An Option PC Card has been inserted into the PC Card slot, and the option has been installed in the Micro. The PC Card may safely be removed from the slot. XX indicates number of option installations remaining on card.
An Option PC Card has been inserted into the PC Card slot, and the option is being installed in the Micro. DO NOT REMOVE THE
CARD WHILE THIS MESSAGE IS BEING DISPLAYED.
An Option PC Card has been inserted into the PC Card slot, and the install process has been stopped by the PC Card not being fully inserted in the slot, or by being removed. Remove and reinsert PC
Card to continue.
62-11039 6--2
Message
INTELLI--SLEEP MODE
MessageCenter MESSAGES
Description
Sleep Mode and IntelliSleep Intelliset is active. Alternates with
CHANGE INTELLISET TO EXIT at 5 second interval whether unit is running or not
KEYPAD LOCKED--BATTERY TOO LOW If any keys are pressed while “UNIT BATTERY--xx V” message is being displayed this message will be displayed as a warning that no changes can be made and information can not be viewed until the battery voltage is brought back up above 10 volts for more than 10 seconds.
LOADING INFO A Configuration PC Card has been inserted into the PC Card slot, and information from the Config card is being loaded into the Micro.
DO NOT REMOVE THE CARD WHILE THIS MESSAGE IS BE-
ING DISPLAYED.
MAIN MENU Consists of Configuration Mode, Component Test and Service
Modes.
MAX SETPOINT HAS BEEN REACHED
MICRO WILL STOP IN XXX SECONDS
MIN SETPOINT HAS BEEN REACHED
NEW SW: = TO LOAD, TO ↑ CANCEL
NO ACTION TAKEN, REMOVE CARD
NO ACTIVE ALARMS
NO DATA ON CARD, REMOVE CARD
NO DATA TO COPY, REMOVE CARD
NO INACTIVE ALARMS
NO INSTALLS LEFT, REMOVE CARD
OLD INTELLISETS--USE REEFERMAN
OLD SW:CANNOT LOAD--REMOVE
CARD
OLD SW, = TO LOAD, ↑ TO CANCEL
PC MODE
PM DUE
PRESS ↑↓ TO VIEW DATA
PRESS ↑↓ TO VIEW SETTINGS
PRESS ↑↓ TO VIEW PRINT MENU
Maximum setpoint allowed by configuration settings has been reached.
The RS has been turned OFF and the system valves are closing.
The display will turn off when the count down reaches zero.
Minimum setpoint defined by functional parameters has been reached.
A Program PC Card has been inserted into the PC Card slot, and the program on the PC Card is a newer version than what is already loaded in the Micro. Press = to load the program.
A Program PC Card has been inserted into the PC Card slot, and no key presses have been made to install the program into the
Micro. The PC Card may be safely removed from the slot.
There are no active alarms in the Micro Alarm List.
A Program or Configuration PC Card has been inserted into the PC
Card slot, and no valid data is present on the PC Card. The PC
Card may safely be removed from the unit.
A Download PC Card has been inserted into the PC Card slot, and there is no valid data in the Data Recorder to copy onto the PC
Card. The PC Card may safely be removed from the unit.
There are no inactive alarms in the Alarm List
An Option PC Card has been inserted into the PC Card slot, and all install options have been used. The PC Card may safely be removed from the unit.
A Program PC Card has been inserted into the PC Card slot and the unit model type on the card is not within the same unit family as the controller model type
A Program PC Card has been inserted into the PC Card slot, and the program on the PC Card is a much older version that can not be loaded in the Micro.
A Program PC Card has been inserted into the PC Card slot, and the program on the PC Card is an older version than what is already loaded in the Micro. Press = to load the older program.
Start/Run--Off Switch is OFF, the PC Mode Jumper is connected and engine is not running in order to enter PC Mode. PC Mode allows the user to access and download data using a computer when the unit is not running and without starting the 8 hour data recorder timer. Refer to Section 5.1.
Preventative Maintenance is now due on the unit.
Press the up or down arrow key to scroll through the Data List.
Press the up or down arrow key to scroll through Functional Parameter Settings
Press the up or down arrow key to view the Strip Print setup menu.
6--3 62-11039
Message
PRESS = TO MARK TRIP START
PRESS = TO START PRETRIP
PRETRIP FAIL & COMPLETED
PRETRIP FAIL IN TEST XX
PRETRIP PASS
PRETRIP STOPPED BY USER
PRODUCTSHIELD: HIGH AIR ON
PRODUCTSHIELD: WINTER ON
PRODUCTSHIELD: ECONO ON
MessageCenter MESSAGES
Description
Press the = key to mark the start of the trip in the Data Recorder.
RECOVER / LEAK CHK / EVAC MODE
Press the = key to begin pretrip tests.
Some of the pretrip tests did not pass.
Some pretrip tests did not pass and the pretrip was not completed.
All of the pretrip tests were ok.
Pretrip has been stopped by user.
The unit is operating in ProductShield High Air which overrides normal unit operation. See Section 4.6
The unit is operating in ProductShield Winter which overrides normal unit operation. See Section 4.6
The unit is operating in ProductShield Econo which overrides normal unit operation. See Section 4.6
This message will be displayed when the unit is in Service Mode and the system is ready for recovery and leak testing.
REMOVE JUMPER
SAME SW, = TO LOAD, ↑ TO CANCEL
SERVICE MODE
SETPOINT CHANGED
SETPOINT NOT CHANGED
SETTING SMV: XXX %
The Configuration / Technician Test Mode has been entered. Remove the jumper wire before continuing.
A Program PC Card has been inserted into the PC Card slot, and the program on the PC Card is the same as the program currently in the Micro. Press = to reload the same program or ↑ to cancel and remove card.
Selection in Configuration and Test Modes which allows servicing of the refrigeration system.
The new setpoint has been entered (saved into Micro memory), the new setpoint will be used.
The new setpoint has NOT been entered (NOT saved into Micro memory), the old setpoint will be used.
The Start/Run--Off switch has been placed in the Start/Run position and at least one compartment is on and CSMV is opening.
SLEEP MODE, OFF / ON TO WAKE The unit is cycled off in Sleep Mode. Turn the Start/Run--Off
Switch OFF, then back ON to wake the Micro up.
SLEEP WARNING: NO TEMP CONTROL The unit is running in Sleep Mode.
SMV CLOSING: WAIT XXX SECONDS Power Up and CSMV is closing. XX is number of seconds remaining until valve is fully closed.
START STOP LOCKED The setpoint has been locked into the Start--Stop mode. Continuous Run can not be selected.
START/STOP MODE SELECTED
STATUS OK--COMPARTMENT X
TECHNICIAN RESET REQUIRED (A21)
TEST #1 to #15
TIME SELECTION NOT CHANGED
TRIP START ENTERED
UNIT BATTERY DEAD --xx V
UNIT OFF
UNIT SHUTDOWN -- SEE ALARM LIST
UNKNOWN CARD -- REMOVE CARD
WARNING: DIESEL RESTART ON
Start/Stop Mode has been selected.
Everything is working well where X is the compartment number.
AL11 (Low Engine Oil Pressure) or AL12 (High Coolant Temperature) has been activated three times in the last two hours and the unit has been locked out. The unit must be brought to a Carrier
Transicold Dealer for Service.
Pretrip is currently running this test and is x% complete
A time change was started but not in Configuration List.
The Trip start marker has been placed in the Data Recorder.
Unit battery has dropped below 7 volts for more than 10 seconds.
All compartment enable switches are Off
An active shutdown alarm has shut the unit down.
A defective PC Card has been inserted into the PC Card slot. The
Micro can not recognize any data on the card. The card may be safely removed from the Micro.
When electric power is not available while the unit is operating in
Electric Standby mode, the unit will switch to diesel operation.
62-11039 6--4 Change 09/11
Message
WARNING: NO TEMP CONTROL
MessageCenter MESSAGES
Description
The temperature sensor(s) have failed In a compartment with a frozen setpoint and the compartment is operating only in cool mode
OR one one of the active compartments has shut down on an alarm and is not operating. Check active alarm list.
WRONG UNIT TYPE, REMOVE CARD A config PC Card has been inserted into the PC Card slot. The unit model family type on the PC card is not in the same unit family type as the controller. The card may be safely removed from the
Micro.
6--5 62-11039
SECTION 7
ALARM TROUBLESHOOTING
7.1 INTRODUCTION TO ALARM TROUBLESHOOTING GUIDE
The Alarm Troubleshooting Guide should be used whenever an alarm occurs. Alarms will appear in the
Message Center and will begin with the alarm number.
Alarms are listed in the Troubleshooting Guide by alarm number.
When an alarm occurs, look through both Active and
Inactive alarm lists in the microprocessor. (See Note 1
Section 7.2 ) and make note of all alarms.
inactivate themselves automatically must be cleared manually. (See Note 1 Section 7.2 )
When you are finished making repairs, run the unit through a Pretrip cycle and verify that no further active alarms occur. Also, both alarm lists should be cleared so that there are no ‘old’ alarms in memory when the unit leaves your repair facility.
Before beginning to actually troubleshoot a unit, visually inspect the unit, in particular the area of the unit that is causing a problem. In many cases the cause of the problem will be obvious once a visual inspection is performed. For those cases where the cause of the problem is not obvious, this troubleshooting guide will be of assistance.
Usually you should begin troubleshooting with the first alarm that appears in the active alarm list. Other alarms in the list may have contributed to the occurrence of the first alarm. The first alarm that appears is the last alarm that was recorded.
If the message CHECK MICROPROCESSOR or
CHK WIRES FROM MICRO TO KEYPAD appears in the MessageCenter, there is a communication error between the keypad and the microprocessor. With no communication, there will not be an associated alarm.
Should this occur, check the wire connections behind the keypad assembly, at the keypad itself (remove the rear cover from it to check), and at connector 5 on the microprocessor. Check for microprocessor status led blinking at 1 second rate (1 second ON/1 second OFF).
When working on the refrigeration system, an accurately calibrated manifold test set should always be installed. It is not necessary to connect an additional high pressure gauge to the king valve. The
MessageCenter, under DATA, will display suction pressure, discharge pressure and evaporator pressure.
The check items in the troubleshooting guide are listed in order of their likeliness of occurrence and ease of testing. We recommend that you follow the order in which they are presented; however, there may be times when situations or experience directs you to use a different order. For example, if the trailer is loaded, you may want to perform all the condensing unit checks first, even though some evaporator section checks may be listed before them.
In high or low ambients it may be necessary to cool or warm the box temperature before performing specific tests providing that the compartment is not loaded with perishable product.
WARNING
As you go through the troubleshooting steps, you will find the cause of the problem. When you find and correct the problem, it is not necessary to continue through the remainder of the steps. Some active alarms will clear (inactivate) themselves automatically once the cause has been corrected. You then only need to go to the inactive list to clear all alarms before verifying the remainder of the unit operation. Alarms that do not
When performing service and/or maintenance procedures, make certain the unit is disconnected from the power source and that the RS is in OFF position so that it is impossible for the unit to start up automatically during the maintenance operation.
7--1
62-11039
7.2 NOTES
Note 1 Active alarms will always be in the Alarm List.
They will have an “A” in front of the alarm number. Active alarms may be inactivated by going to the end of the Active Alarm list.
“LIST END, = TO CLEAR ALARMS” will appear in the MessageCenter. Pressing = will clear or inactivate the alarms. This moves the alarm to the Inactive Alarm list, if the condition that caused the alarm has been corrected.
When Shutdown Alarms are cleared, the unit will attempt to restart (if the micro is set for auto-start).
When non-Shutdown Alarms are cleared, there will be no noticeable change in the unit’s operation.
The Inactive Alarm list is reached by first pressing and holding the Alarm List key, then the UP Key, and holding both of them for 3 seconds. Alarms in this list will begin with “I”
(Inactive) followed by the alarm number.
Clearing alarms from the Inactive Alarm list will also clear alarms from the Active Alarm
List. Go to the end of the Inactive Alarm List.
“LIST END, = TO CLEAR ALARMS” will show in the Message Center. Press = to clear all alarms from both lists.
Note 2 Many electrical circuits may be tested by leaving all compartment switches in the “O”
(OFF) position and turning the RS to the
START/RUN position.
At least one compartment must be in the “1” (ON) position. In this mode, RCR will be energized and the main display will show “OFF”.
Note 3 Many checks will be made with the microprocessor powered up, but with no outputs to the unit components. The unit may be put into PC Mode to do this. For additional information see PC Mode --
Section 5.1.
Note 4 Sensors may be tested at the component plug using an ohmmeter. If required, sensor circuits may be tested at the 1MP plug.
Remove plug from Microprocessor and, using an ohmmeter, test resistance of circuits. Be careful not to damage the connector pins. (See Section 8.29 for chart of resistances for different sensors.)
Note 5 The Defrost Air Switch, RPM Sensor, Engine
Oil Level Switch, Fuel Level Sensor, Door
Switch, or HP1 can be tested as components alone. If required, the circuits may be tested at the 2MP plug.
Remove plug from
Microprocessor and using the wiring diagram, check for voltage at the appropriate terminal.
Note 6 Some tests can only be conducted with the unit operating. The unit may be started automatically by placing the RS in the
Start/Run position and at least one compartment also in the “1” (ON) position.
62-11039
7--2
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
1
7.3 DRIVER/OPERATOR ALARMS
LOW FUEL LEVEL WARNING
Note: This is an optional alarm which will not occur unless a fuel level sensor is present and configured ON.
• TRIGGER ON: Fuel level is 15% or less for more than 30 seconds.
• UNIT CONTROL: Engine operation: Alarm only. Standby operation: Will not activate in standby.
• RESET CONDITION: Auto reset when the fuel level is above 17% for more than 30 seconds, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check For Low Fuel Level
Add fuel as needed to the fuel tank.
2.
a. Check fuel level in the fuel tank
Check Fuel Level Sensor
a. Inspect fuel level sensor& connector pins & terminals
No physical damage to switch.
No damaged or corroded pins in plug.
b. Check fuel level sensor operation Energize circuit. See Note 2.
c. Check for voltage at harness plug between pins for BLACK (SP24) negative and RED (SPK5) positive wires
Voltage should be approximately12VDC.
3.
4.
d. Check for voltage at harness plug between pins for BLACK (SP24) negative and WHITE (1MP26) e. Check continuity of the wire from the harness plug, pin C to the microprocessor plug 1MP26
Voltage should be greater than 0 VDC and less than
5 VDC, unless the probe is completely dry.
Place Start--Run/Off Switch in OFF position prior to checking for continuity. Must be less than 10 ohms.
Check Fuel Level Sensor Calibration
a. Check fuel level sensor calibration See Section (8.5.1) for sensor calibration procedure.
Check Circuits With Test (Substitute) Sensor
a. Substitute known good sensor and clear alarm. Start unit and run for
30 seconds.
b. Check to see if alarm re-occurs.
Alarm should not come on. (Install new sensor if necessary)
7--3
62-11039
Alarm
NO.
2
Steps ALARM / CAUSE
LOW ENGINE OIL LEVEL
CORRECTIVE ACTION
Note: This is an optional alarm which will not occur unless a fuel level sensor is present and configured ON.
•
TRIGGER–ON: Engine oil level is sensed approx. 4 or more qts. (4.54 or more liters) low for longer than 30 seconds.
• UNIT CONTROL: Engine Operation: Alarm only or (if configured for shutdown) engine and unit shutdown.
Standby operation: Alarm only.
• RESET CONDITION: Auto reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Engine Oil Level
a. Check engine oil dipstick Add engine oil as needed to fill.
2.
Check Engine Oil Level Switch
a. Inspect engine oil level switch & connector pins & terminals
No physical damage to switch.
No damaged or corroded pins in plug.
b. Check engine oil level switch operation
Contacts open when level is more than 7 qts low
Contacts closed when level is less than 4 qts low
3.
4.
Check Engine Oil Level Switch Harness
a. Inspect harness & control box connector pins & terminals (See wiring schematic) b. Check for shorted circuit in harness, and continuity through the harness
No physical damage to harness.
No damaged or corroded pins
Energize circuit (See Note 2). DO NOT START
UNIT.
Battery voltage reading (12--13 VDC) between wires in plug
Check Oil Level Switch
a. Drain oil level to approximately 2.8
to 3--4 quarts (3.8 liters) low.
Remove switch.
b. Visually and physically inspect upper and lower float stops.
Must be securely fastened to center rod.
62-11039
7--4
Alarm
NO.
3
Steps ALARM / CAUSE
LOW COOLANT LEVEL
CORRECTIVE ACTION
Note: This is an optional alarm which will not occur unless a fuel level sensor is present and configured ON.
• TRIGGER ON: Engine coolant level is 1 or more quarts (.95 or more liters) low for more than 30 seconds.
• UNIT CONTROL: Engine operation: Alarm only. Standby operation: Will not activate in standby.
• RESET CONDITION: Auto reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check For Low Coolant Level
a. Check engine coolant level in the coolant bottle b. Check coolant hoses for leaks or breaks
Add coolant as needed to the coolant reservoir and to the fill tube on the radiator
Repair all leaks and breaks as necessary
Add coolant as needed to the coolant reservoir and to the fill tube on the radiator
2.
3.
Check Engine Coolant Level Switch
a. Inspect engine coolant level switch
& connector pins & terminals
No physical damage to switch.
No damaged or corroded pins in plug.
b. Check harness wiring to plug.
c. Check engine coolant level switch operation
Verify wires are in correct plug orifice.
Energize circuit. See Note 2. DO NOT START UNIT.
d. Check for voltage at harness plug between pins A and B
Voltage should be 12 volts at harness plug between pins A and B.
e. Check continuity of the wire from the harness plug, pin C to the microprocessor plug 2MP15
Place Start--Run/Off Switch in OFF position prior to checking for continuity. Must be less than 10 ohms.
Check Circuits With Test (Substitute) Switch
a. Substitute known good sensor and clear alarm. Start unit and run for 30 seconds.
b. Check to see if alarm re-occurs.
Alarm should not come on. (Install new sensor)
7--5
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
11 LOW ENGINE OIL PRESSURE
7.4 SHUTDOWN ALARMS
• TRIGGER–ON: Engine oil pressure is below 12 PSIG (0.82 Bar) for longer than 5 seconds while the engine is running.
• UNIT CONTROL: Engine operation: Engine and unit shutdown and alarm. Standby operation: This alarm will not activate in standby operation.
• RESET CONDITION: Auto Reset or Alarm may be manually reset via Keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the active alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active active alarm occurs. Continue with the steps below as necessary.
1.
Check For Low Engine Oil Level Alarm
a. Check for alarm 2 Alarm conditions must be corrected and the alarm cleared to continue
2.
3.
Check Engine Oil Level
a.Check engine oil dipstick.
Check Engine Oil Pressure Switch
a. Inspect switch & connector pins & terminals
Add engine oil as needed to fill.
No physical damage to switch.
No damaged or corroded pins in plug.
b. Check engine oil switch operation. Contacts closed when oil pressure is above 15 PSIG
(1.02 Bars)
Contacts open when oil pressure is below 12 PSIG
(0.82 Bar)
4.
Check Engine Oil Switch Harness
a. Inspect harness & control box connector pins & terminals (See wiring schematic) b. Check for shorted circuit in harness, and continuity through the harness
No physical damage to harness.
No damaged or corroded pins
Energize circuit. See Note 2. Battery voltage reading
(12--13 VDC) between wires in plug
5.
Check Engine Oil Pressure
a. Connect mechanical oil gauge Oil pressure must be greater than 15 PSIG (1.02
Bars)
62-11039
7--6
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
12 HIGH COOLANT TEMPERATURE
• TRIGGER–ON: If system in engine mode: For ambient temperatures below 120°F (48.9°C) Engine coolant temperature is above 230°F (110°C), or Ambient temperatures above 120°F (48.9°C), engine coolant temp is over 241°F (116°C), or Engine coolant temperature is between 230°F and
241°F
(110°C and 116°C) for more than 5 minutes.
•
UNIT CONTROL: Engine operation: Engine and unit shutdown and alarm. Standby operation: This alarm will not activate in standby operation.
•
RESET CONDITION: Auto Reset after 15 minutes if the engine coolant temp falls below 212°F
(100°C), or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Coolant Level
a. Check coolant level in overflow bottle b. Check coolant level in radiator
Level must be in the Normal range.
Level must be at the top of the radiator fill tube.
Do not remove the cap from a hot radiator; if the cap must be removed, do so very slowly in order to release the pressure without spray.
2.
3.
4.
5.
6.
c. Inspect connecting tube between overflow bottle and radiator
Connections must be airtight. No leakage or holes in tube.
Check For Bad Eng Coolant Sensor Alarm
a. Check for Alarm 129 Alarm conditions must be corrected and the alarm cleared to continue
Check Freeze Point Of Coolant
a. Use Coolant Tester to check concentration of anti-freeze mixture.
Must be between 40% to 60% Ethylene Glycol to water mixture.
Check Airflow Through Radiator / Condenser Coil
a. Inspect condenser/ radiator fins Fins must be straight. 90% or more of the coil surface must be undamaged. No “dead” air spaces.
Condenser / Radiator coil must be clean.
b. Check condenser fan rotation / operation
Fans should operate correctly. Air should be directed in through the grill, and into the engine compartment.
Check Water Pump Belt
a. Check engine water pump belt.
Check Engine Cooling System
a. Compare actual engine temperature to the microprocessor reading b. Test operation of engine coolant thermostat c. Check water pump operation d. Check water pump bypass hose to thermostat housing for internal blockage
No Glazing, no cracking, no slipping
Temperature must be within ±20°F (±11.1°C).
Must operate correctly
No seepage at weep hole. Bearings tight and quiet.
Impeller firmly attached to shaft.
Must be clear and open
7--7
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
13 HIGH DISCHARGE PRESSURE (ALARM 75 WILL ACTIVATE)
• TRIGGER–ON: Compressor discharge pressure is over 465 PSIG (31.6 Bars)
• UNIT CONTROL: Engine operation: engine and unit shutdown and alarm. Standby operation: refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Auto Reset after 15 minutes if the compressor discharge pressure falls below
350 PSIG (23.8 Bars), or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check System Pressures
a. Install Manifold Test Set and check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Suction & Discharge Pressures must have the same reading on gauges & on micro display.
Pressures must be in the normal range for ambient & box temperature conditions.
NOTE: Microprocessor suction pressure reading has a maximum value of 100 psig (7.5 bar)
2.
3.
4.
5.
6.
7.
Check For Refrigerant Overcharge
a. Check refrigerant level in the receiver tank.
Level must be between upper & lower sight glasses with a box temperature of 35°F (1.0C) or lower
Check Airflow Through Condenser Coil
a. Inspect condenser / radiator fins Fins must be straight. 90% or more of the coil surface must be undamaged. No “dead” air spaces.
Condenser / Radiator coil must be clean.
b. Check airflow (with unit running).
Even airflow through the entire coil
No “dead” spots c. Check condenser rotation/operation fan Both fans should operate correctly. Air should be directed in through the grill, and into the engine compartment.
Check HP1 Switch
a. Inspect switch & connector pins & terminals
No physical damage to switch.
No damaged or corroded pins in plug.
b. Check switch operation
(Refer to Section 2.12 for pressure settings)
Contacts open when compressor discharge pressure is above cut-out point ± 10 PSIG (±0.68 Bar)
Contacts closed when compressor discharge pressure is below cut-in point ± 10 PSIG (±0.68 Bar)
Check HP1 Switch Harness
a. Inspect harness & control box connector pins & terminals (See wiring schematic) b. Check for shorted circuit in harness, and continuity through the harness
No physical damage to harness.
No damaged or corroded pins
Energize Circuit. (See Note 2). Battery voltage reading (12--13 VDC) between wire HP1A--SPKS and between HP1B to Ground.
Perform Pretrip Check
a. Run Pretrip & check for alarms
See Refrigeration Trouble Shooting Section 9
Any active alarms must be corrected and cleared before proceeding.
Discharge Pressure must be in normal range for the current ambient and box temperature conditions.
62-11039
7--8
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
14 ELECTRICAL CIRCUIT
• TRIGGER–ON: AC Current Sensor 1 is greater than 40A or AC Current Sensor 2 is greater than
40A for 3 seconds
• UNIT CONTROL: Engine operation: alarm will not activate. Standby operation: refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Auto reset after 15 minutes if the AC current sensor readings are less than
38 amps or alarm may be manually reset via keypad or by turning unit off then back on.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Generator Voltage (If Used When Alarm Occurred)
a. Check voltage at GENCON L1--L2,
L1--L3, L2--L3
Should be 440 to 580 VAC
2.
3.
Check Power Source Voltage (If Used When Alarm Occurred)
a. Check voltage at PSCON L1--L2,
L1--L3, L2--L3
Should be 440 to 580 VAC
Check Voltage Output From Contactors
a. Check voltage at GENCON T1--T2,
T1--T3, T2--T3
Should be 440 to 580 VAC
4.
5.
b. Check voltage at CCON with compressor operating.
T1--T2,
T1--T3, T2--T3
Should be 440 to 580 VAC
Verify AC Current Sensor Accuracy
a. Turn all compartment switches
OFF, and RS ON.
Unit AC Current #1 and #2 reading in Data List must be 0.0  1.0 amp.
Check High Voltage Components Amp Draw
a. Check condenser fan amp draw on all
3 legs.
b. Check evaporator fan motor amp draw for Compartment 1 on all 3 legs.
c. Check evaporator fan motor amp draw for Compartment 2 on all 3 legs.
d. Check evaporator fan motor amp draw for Compartment 3 on all 3 legs.
e. Check compressor amp draw on all
3 legs.
f. Check Compartment 1 Heater amp draw for HTCON1
See Section 2.13
g. Check Compartment 1 Heater amp draw for HTCON2 h. Check Compartment 1 Heater amp draw for 2HTCON1 i. Check Compartment 1 Heater amp draw for 2HTCON2 j. Check Compartment 1 Heater amp draw for 3HTCON1 k. Check Compartment 1 Heater amp draw for3HTCON2
7--9
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
15 BATTERY VOLTAGE TOO HIGH
• TRIGGER–ON: Voltage at the microprocessor is greater than 17 VDC.
• UNIT CONTROL: Engine operation: engine and unit shutdown and alarm. Standby operation: refrigeration system shutdown and alarm. PSCON de--energized.
• RESET CONDITION: Auto Reset after 15 minutes when the voltage at the microprocessor is between
11 and 14 VDC, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Battery Voltage
a. Test voltage at battery with unit off.
Must be between 12--16 VDC
Must be between 12--16 VDC
2.
b. Test voltage at battery with unit running.
Check Battery Charger Voltage
a. Test voltage at battery charger output terminal with unit off b. Test voltage at battery charger output terminal with unit running.
Must be between 12--16 VDC
Must be between 12--16 VDC
3.
Check Voltage At Microprocessor
a. Check voltage reading at microprocessor input (QC1+ to
QC2--) b. Check voltage reading on microprocessor display
Energize circuit. (See Note 2)
Must be between 12--16 VDC
Must be within 0.5 VDC of reading obtained in 3a
(above)
62-11039
7--10
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
16 BATTERY VOLTAGE TOO LOW
• TRIGGER–ON: Voltage at the microprocessor is less than 10 VDC (except when the engine starter is engaged)
• UNIT CONTROL: Unit Shutdown & Alarm. Alarm condition only if activated while starting unit.
• RESET CONDITION: Auto Reset after 15 minutes when the voltage at the microprocessor is between
11 -- 14 VDC, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check For Alarm 51
a. Check for Alternator Not Charging
Alarm
Alarm conditions must be corrected and the alarm cleared to continue
2.
Check Battery Voltage
a. Inspect battery cable ends and posts
Must be clean and tight b. Test voltage at battery with unit off. Must be above 11 VDC c. Test voltage at battery with unit running.
Must be above 11 VDC d. Test specific gravity of battery e. Perform load test on battery (Follow battery manufacturer’s procedure)
(Check for battery specifications)
(Check for battery specifications)
3.
Check Voltage At Microprocessor
a. Check voltage reading at microprocessor input (MPQC1+ to
MPQC2--).
b. Check voltage reading on microprocessor display
Energize circuit. (See Note 2)
Must be above 11 VDC
Must be within 0.5 VDC of reading obtained in 3a
(above)
7--11
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
17 HIGH COMP DISCHARGE TEMP
• TRIGGER–ON: Discharge sensor alarm not active AND:
Ambient temp below 120°F (48.9°C) and discharge temp was between 310°F -- 349°F
(154.4°C -- 176.7°C) for 3 minutes, or
Ambient temp above 120°F (48.9°C) and discharge temp was between 340°F -- 349°F
(171.1°C -- 176.7°C) for 3 minutes, or
Discharge temp ever reaches 350°F (176.7°C)
• UNIT CONTROL: Engine operation: engine and unit shutdown and alarm. Standby operation: refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Auto Reset after 15 minutes with Ambient temp below 120°F (48.9°C) the discharge temp falls below 300°F (148.8°C), or Auto Reset after 15 minutes with Ambient temp above 120°F (48.9°C) the discharge temp falls below 330°F (165.4°C), or alarm may be manually reset via Keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check For Bad Compressor Discharge Temperature Sensor
a. Check for Alarm 125 Alarm conditions must be corrected and the alarm cleared to continue
2.
3.
Check Refrigerant Charge
a. Check for undercharged system Level must be above lower sight glass
Check Airflow Through Condenser Coil
a. Inspect condenser / radiator fins Fins must be straight. 90% or more of the coil surface must be undamaged. No “dead” air spaces.
Condenser / Radiator coil must be clean.
4.
Check CSMV
a. Check compressor modulation valve suction See procedure “How To Check CSMV,” Section 8.24
5.
6.
7.
8.
9.
Check System Pressures
a. Install Manifold Test Set and check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Perform Pretrip Check
a. Run Pretrip & check for alarms
Suction & Discharge Pressures must have the same reading on gauges & on micro display.
NOTE: Microprocessor suction pressure reading has a maximum value of 100 psig (7.5 bar)
Any active alarms must be corrected and cleared before proceeding.
Check Compressor Reed Valves & Gaskets
a. Remove compressor heads & inspect condition of all reeds & gaskets
Must be in good condition.
Check Expansion Valve (EVXV)
a. Check superheat of valve Refer to Section 2.12 See 8.17
Check System For Non-Condensables
a. Check refrigeration system for non-condensable gas(es)
No non–condensable gas(es) may be present.
62-11039
7--12
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
18 LOW REFRIGERANT PRESSURE
• TRIGGER–ON (A):
Both UL1 and UL2 are energized AND unit is in engine mode AND in low speed AND compressor is running AND low suction pressure shutdown delay in configurations has elapsed since energizing
UL1 AND Suction Pressure is less than --10 in. Hg (0.3 Bar)
•
UNIT CONTROL: Engine operation: alarm only or (if configured for shutdown) engine and unit shutdown and alarm. Standby operation: alarm only or (if configured for shutdown) refrigeration system shutdown and alarm with PSCON still energized.
•
RESET CONDITION: If alarm only, auto reset when either UL1 or UL2 is de--energized. If unit and system shut down and alarm, auto reset after 15 minutes. Alarm may be manually reset via keypad or by turning the unit OFF, then ON again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Check Refrigerant Charge
a. Check for undercharged system
Check System Pressures
a. Install Manifold Test Set and check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Level must be above lower sight glass
Suction pressure must be above 3 PSIG (0.2 Bar)
Suction & Discharge Pressures must have the same reading on gauges & on micro display.
NOTE: Microprocessor suction pressure reading has a maximum value of 100 psig (7.5 bar)
3.
Manually Defrost Unit
a. Defrost unit and terminate automatically.
Typical defrost cycle time is 5--20 minutes
Suction pressure should rise gradually during cycle.
4.
5.
6.
Perform Pre--Trip Check
a. Run Pre--Trip & check for alarms Any active alarms must be corrected and cleared before proceeding.
Check Unloader Operation
a. Check front and rear unloaders
Check CSMV
a. Check compressor suction modulation valve
See Alarms 85 and 86
See procedure “How To Check CSMV” See Section
8.23
b. Check airflow (with unit running).
Even airflow through the entire coil
No “dead” spots
7.
8.
9.
a. Check evaporator section, return air bulkhead, air chute, cleanliness of evap. coil
Good Air Flow
Return air not restricted
Air chute in good condition
No damage to blower wheel
Evap. coil clean
Evap. fan rotation ok
Check Expansion Valve (EVXV)
Check Expansion Valve For Compartment 2
a. Check superheat of valve Refer to Section 8.19.2
10.
Check Expansion Valve For Compartment 3
a. Check superheat of valve Refer to Section 2.12
7--13
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
19 LOW FUEL SHUTDOWN
This is an optional alarm. This alarm will not occur unless a fuel level sensor is present and configured ON and a fuel tank size must be selected.
• TRIGGER ON: Fuel level is 10% or less for more than 1 minute AND the unit is operating on diesel
AND Alarm 126 is not active.
•
UNIT CONTROL: Engine operation: alarm only or (if configured for shutdown) engine and unit shutdown and alarm. Standby operation: this alarm will not activate in standby operation.
• RESET CONDITION: Auto reset when fuel level is above 12% for more than 1 minute, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Check For Low Fuel Level Warning Alarm
a. Check for alarm 1 Must be cleared.
Check For Low Fuel Level
a. Check fuel level in tank.
Add fuel as needed to the fuel tank.
20 MAXIMUM COMPRESSOR ALARMS
• TRIGGER ON: Option must be installed and alarm must be enabled by configuring the Compressor
Alarm Shutdown to YES. Alarms 13, 17, 18, 27, 28, 29 or 56 individually occur 3 times within the last 2 hours of engine running time.
• UNIT CONTROL: Engine operation: engine and unit shutdown and alarm. Standby operation: refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Reset from inactive alarm list only. Can not be reset by turning switch OFF and then ON again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Determine Which Alarm Caused This Alarm To Be Active.
a. Check active alarm list for
Alarm #’s 13, 17, 18, 27, 28, 29, or
56.
One or more of these alarms will be present.
All alarms condition must be fixed.
2.
b. Follow the steps for the alarm(s) found above, and correct the alarm condition.
Reset Alarm
a. Reset all alarms from the inactive alarm list.
All alarms must be cleared to start unit.
62-11039
7--14
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
21 TECHNICIAN RESET REQUIRED
• TRIGGER ON: The High Engine Temp Shutdown Configuration and/or Engine Oil Pressure
Shutdown Configuration is/are set to YES, and either Alarm 11 – Low Engine Oil Pressure, or
Alarm 12 – High Coolant Temperature has become active and shut the unit down three times within the past 2 hours
•
UNIT CONTROL: Unit shutdown and alarm
• RESET CONDITION: Reset from inactive alarm list only. Can not be reset by turning switch OFF and then ON again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Determine Which Alarm Caused This Alarm To Be Active.
a. Check active alarm list for
Alarm #’s 11 or 12.
One or more of these alarms will be present.
b. Follow the steps for the alarm(s) found above, and correct the alarm condition.
All alarms condition must be corrected.
Reset Alarm
Reset all alarms from the inactive alarm list.
All alarms must be cleared to start unit.
22 LOW SUCTION SUPERHEAT
• TRIGGER ON: Compressor suction superheat less than 9°F (5°C) for more than 2 minutes.
•
UNIT CONTROL: Engine operation: engine and unit shutdown and alarm. Standby operation: refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Auto reset after 15 minutes, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check System Pressures
a. Install Manifold Test Set and check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Suction & Discharge Pressures must have the same reading on gauges & on micro display.
NOTE: Microprocessor suction pressure reading has a maximum value of 100 psig (7.5 bar)
2.
Restricted Evaporator Airflow
a. Check for restricted evaporator airflow in compartments.
all enabled
Check for proper Evaporator Fan operation
Check data sheet for proper defrost air switch specs and air switch hoses
3.
4.
5.
Check for restricted bulkhead or air chute installation
Check For Any Ice On Compartment 2 Or 3 Suction Lines
a. Check fans for compartment.
Must be running and blow in the correct direction.
b. Run through defrost.
c. Recheck for ice on suction line.
Clean all ice off coil.
If suction line continues to show signs of ice, check expansion valve superheat.
Run Pre--Trip. See Alarm 18, Step 4
Check EVXV
a. Check for defective EVXV See Section 8.18
Change 09/11
7--15
62-11039
Alarm
NO.
Steps ALARM / CAUSE
23 A/C CURRENT OVER LIMIT
CORRECTIVE ACTION
• TRIGGER ON: The high voltage amp draw is over the limit shown in the table below for more than
10 seconds.
Condition
Diesel High Speed Cool
Diesel Low Speed or
Standby Cool
Diesel High Speed Heat
Diesel Low Speed or
Standby Heat
Diesel High Speed Heat
Defrost
Diesel Low Speed or
Standby Heat Defrost
Diesel High Speed Null or
Fan Defrost
Diesel Low Speed or
Standby Null or Fan Defrost
1 Compartment
Enabled
30A
30A
18A
14A
16A
12A
8A
6A
2 Compartments
Enabled
30A
30A
24A
20A
22A
18A
10A
8A
3 Compartments
Enabled
30A
30A
28A
24A
26A
22A
12A
9A
62-11039
7--16
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
23 A/C CURRENT OVER LIMIT (Continued)
• UNIT CONTROL: Engine operation: refrigeration system shutdown and alarm. Standby operation: refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Auto reset after 15 minutes or alarm may be manually reset via keypad or by turning the unit OFF, then back ON.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check For Electrical Failure In System
a. Check electrical motors Run pre--trip; Determine motor or refrigeration component failure per pre--trip Alarm. Ohm test component per Section 2.13
Listen for noise caused by failed bearing or motor obstruction b. Defective wiring Check for discolored wiring at contactors and loose connections
2.
3.
4.
c. Defective contactor Remove and replace suspected contactor
Check High Voltage Components Amp Draw
a. Check condenser fan amp draw on all
3 legs.
b. Check evaporator fan motor amp draw for Compartment 1 on all 3 legs.
c. Check evaporator fan motor amp draw for Compartment 2 on all 3 legs.
d. Check evaporator fan motor amp draw for Compartment 3 on all 3 legs.
e. Check compressor amp draw on all
3 legs.
See Section 2.13
f. Check Compartment 1 Heater amp draw for HTCON1 g. Check Compartment 1 Heater amp draw for HTCON2 h. Check Compartment 1 Heater amp draw for 2HTCON1 i. Check Compartment 1 Heater amp draw for 2HTCON2 j. Check Compartment 1 Heater amp draw for 3HTCON1 k. Check Compartment 1 Heater amp draw for3HTCON2
Check Generator Voltage (If Used When Alarm Occurred)
a. Check voltage at GENCON
L1--L2, L1--L3, L2--L3
Should be 440 to 580 VAC
Check Power Source Voltage (If Used When Alarm Occurred)
a. Check voltage at PSCON L1--L2,
L1--L3, L2--L3
Should be 440 to 580 VAC
7--17
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
23 A/C CURRENT OVER LIMIT (Continued)
5.
Check Voltage Output From Contactors
Should be 440 to 580 VAC a. Check voltage at GENCON
T1--T2, T1--T3, T2--T3 b. Check voltage at CCON with compressor operating. T1--T2,
T1--T3, T2--T3
Should be 440 to 580 VAC
6.
Verify AC Current Sensor Accuracy
a. Turn all compartment switches
OFF, and RS ON.
Unit AC Current #1 and #2 reading in Data List must be 0.0  1.0 amp.
7.
8.
Defective OGF
a. Opens prematurely
Defective Current Sensor
a. Reads too high
Remove and replace
Remove and replace
62-11039
7--18
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
27 HIGH SUCTION PRESSURE
• TRIGGER ON: The refrigeration system is running and the suction pressure has been greater than
98 PSIG (6.7 Bars) for more than 10 minutes
•
UNIT CONTROL: Engine operation: alarm only or (if configured for shutdown) engine and unit shutdown and alarm. Standby operation: alarm only or (if configured for shutdown) refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Auto reset when suction pressure is less than 75 PSIG (5.1 Bars) for 5 minutes and configured for Alarm Only, or Auto Reset after 15 minutes if configured as a Shutdown
Alarm or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check System Pressures
a. Install Manifold Test Set and check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Suction pressure must be above 3 PSIG (0.2 Bar)
Suction & Discharge Pressures must have the same reading on gauges & on micro display.
NOTE: Microprocessor suction pressure reading has a maximum value of 100 psig (7.5 bar)
2.
Check For Refrigerant Overcharge
a. Check refrigerant level in the receiver tank.
Level must be between upper & lower sight glasses with a box temperature of 35°F (1.0C) or lower
3.
Perform Pre--trip Check
a. Run pre--trip & check for alarms Any active alarms must be corrected and cleared before proceeding.
4.
Check EVXV
a. Check wiring and connections to
EVXV.
No physical damage to harness. No damage or corroded pins. Connector tight on valve.
See Section 8.18
5.
b. Check EVXV Superheat.
Check Compressor.
a. Perform Pump--Down Test.
See Section 8.11.1
Must pump down to 5 PSI and hold for minimum of 1 minute.
Must be able to pump up to 400 PSI.
b. Cover condenser and build--up discharge pressure.
c. Disassemble and inspect compressor valve plates, reeds, pistons, etc.
Must be intact, clean, and in good working order.
7--19
62-11039
Alarm
NO.
Steps ALARM / CAUSE
28 CHECK REFRIGERATION SYSTEM
CORRECTIVE ACTION
• TRIGGER ON: The refrigeration system is running and the discharge pressure is less than 5 PSIG
(0.34 Bar) higher than suction pressure for more than 10 minutes
• UNIT CONTROL: Engine operation: alarm only or (if configured for shutdown) engine and unit shutdown and alarm. Standby operation: alarm only or (if configured for shutdown) refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Auto reset when discharge pressure is more than 20 PSIG (1.36 Bars) above the suction pressure when in alarm only, or auto reset after 15 minutes when shutdown is configured or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Verify Compressor Is Running.
a. Check compressor Amp draw --
CCON T1--T2, T1--T3, T2--T3.
2.
Check System Pressures
a. Install Manifold Test Set and check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Suction pressure must be above 3 PSIG (0.2 Bar)
Suction & Discharge Pressures must have the same reading on gauges & on micro display.
NOTE: Microprocessor suction pressure reading has a maximum value of 100 psig (7.5 bar)
3.
Perform Pre--trip Check
a. Run pre--trip & check for alarms Any active alarms must be corrected and cleared before proceeding.
4.
Check Compressor.
a. Perform Pump--Down Test.
See Section 8.11.1
Must pump down to 5 PSI and hold for minimum of 1 minute.
Must be able to pump up to 400 PSI.
b. Cover condenser and build--up discharge pressure.
c. Disassemble and inspect compressor valve plates, reeds, pistons, etc.
Must be intact, clean, and in good working order.
62-11039
7--20
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
7.5 START UP/ENGINE ALARMS
30 FAILED TO RUN MINIMUM TIME
• TRIGGER–ON: Engine has shut down on an alarm 3 times without having run for at least 15 minutes between each shutdown (not including Door or Remote Switch shut downs) AND unit is in automatic start mode.
•
UNIT CONTROL: Engine operation: engine and unit shutdown and alarm. Standby operation: refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1
Check For Alarms
a. Check for shut down alarms Alarm conditions must be corrected and the alarm(s) cleared to continue.
7--21
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
31 FAILED TO START -- AUTO MODE
• TRIGGER–ON: In engine mode, engine has tried to start 3 times unsuccessfully in the auto start mode.
• UNIT CONTROL: Engine operation:engine and unit shutdown and alarm. Standby operation: this alarm will not activate in standby operation.
• RESET CONDITION: Change unit to standby operation or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
2.
Check Fuel Level In Tank
a. Check fuel gauge on tank.
Check For Alarms
a. Check for the following alarms:
71 Check for Bad F2 or F3 Fuse alarm
40 Check Glow Plugs alarm
35 Check Starter Circuit alarm
Fill tank as needed.
Alarm conditions must be corrected and the alarm cleared to continue
3.
Check Fuel Solenoid
a.Check run relay.
b. Check Run Relay LED c. Check voltage to fuel solenoid d. Inspect solenoid & connector pins & terminals
Unit in component test mode -- run relay ON.
Must be ON.
12 VDC between FSC--C (ground) & FSH--A (hold) with engine starter energized
12 VDC between FSC--C (ground) & FSP--B (pick)
No damage to solenoid
No damaged or corroded pins
No physical damage to harness.
No damaged or corroded pins
4.
e. Inspect harness & control box connector pins & terminals (See wiring schematic) f. Check resistance of solenoid g. Check operation of solenoid
Check Fuel System
a. Check fuel system prime b. Check fuel flow c. Check voltage to glow plugs
Refer to Section 2.14
Plunger must move in when energized
No air in fuel system
Unrestricted fuel flow through system
Glow Plug switch ON, Manual Start Mode
More than 11 VDC
5.
Check Engine Air–intake System
a. Check air filter indicator b. Inspect air intake system
Flag must not be visible.
Hoses & tubes in good condition.
No kinks or restrictions
6.
Check For Correct Engine Oil
a. Check for correct oil viscosity
(weight) for conditions
Refer to Section 2.9
Must be correct for ambient conditions
7.
8.
9.
Check Engine Exhaust System
a. Inspect the exhaust system
Check Engine
a. Check engine compression
Check RPM Sensor
a. Check sensor
Must be clear and un--obstructed
Refer to Section 2.9
See Section 8.6.3
62-11039
7--22
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
34 ENGINE FAILED TO STOP
• TRIGGER–ON: In engine mode, engine is turning more than 500 RPM for 20 seconds after unit shut down or cycled off or Oil Pressure Switch is closed longer than 20 seconds after unit shut down or cycle off.
•
UNIT CONTROL: Engine operation: alarm only. Standby operation: this alarm will not activate in standby operation.
• RESET CONDITION: Alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check For Engine Running
2.
a. Verify that engine is still running.
Engine should not be running.
Check For Rpm Sensor
a. Check actual engine RPM using hand held tachometer.
Refer to Section 8.6
Adjust engine linkage setting as needed.
3.
b. Compare actual RPM with those shown on display.
Both readings within +/-- 50 RPM.
Check For Bad Engine RPM Sensor Alarm
a. Check for Alarm 130 Alarm conditions must be corrected and the alarm cleared to continue
4.
5.
6.
Check Engine Oil Pressure Switch
a. Inspect switch & connector pins & terminals
No physical damage to switch.
No damaged or corroded pins in plug.
b. Check engine oil switch operation. Contacts closed when oil pressure is above 15 PSIG
(1.02 Bars)
Contacts open when oil pressure is below 12 PSIG
(0.82 Bar)
Check Engine Oil Switch Harness
a. Inspect harness & control box connector pins & terminals (See wiring schematic) b. Check for shorted circuit in harness, and continuity through the harness
No physical damage to harness.
No damaged or corroded pins
Energize circuit. (See Note 2)
Battery voltage reading (12--13 VDC) between wires in plug
Check Fuel Solenoid & Circuit
a. Check Run Relay LED b. Check voltage at harness to fuel solenoid c. Check voltage at harness to fuel solenoid d. Check fuel solenoid stopper
LED 28 must be OFF.
Must be 0 VDC
Must be 0 VDC
Must be free to move
7--23
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
35 CHECK STARTER CIRCUIT
• TRIGGER–ON: Engine speed fails to reach 50 RPM during 2 start attempts.
• UNIT CONTROL: Engine operation:engine and unit shutdown and alarm. Standby operation: this alarm will not activate in standby operation.
• RESET CONDITION: Change unit to standby operation or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Starter Relay Circuit
a. Check operation of starter solenoid relay
Energize Circuit. (See Note 2)
Relay contacts closed when SSR85 is grounded.
b. Check relay socket and terminals No signs of discoloration from overheating
No corrosion
2.
c. Check voltage to starter solenoid relay d. Inspect wiring to starter solenoid and starter motor
Negative lead on 85, Positive lead on 86 = 12 VDC
Negative lead on Gnd, Positive lead on 87 & 30 = 12
VDC
No physical damage to wiring or battery cable end.
No damaged or corroded terminals.
e. Check voltage to starter solenoid Must be above 11.5 VDC f. Check voltage to starter motor Must be above 10 VDC while cranking
Check Starter
a. Inspect starter and wiring No damage or corrosion
Wiring and battery cable must be clean and tight
3.
4.
b. Check resistance of starter motor See Section 2.14
c. Check amperage draw of starter See Section 2.14
Check Battery Voltage
a. Inspect battery cable ends and posts
Must be clean and tight
No corrosion b. Test voltage at battery with unit off Must be above 11 VDC c. Test specific gravity of battery Check d. Perform load test on battery (Follow battery manufacturer’s procedure)
Check For Correct Engine Oil
Check a. Check for correct oil viscosity
(weight) for conditions
Refer to Section 2.9
Must be correct for ambient conditions
62-11039
7--24
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
36 CHECK COOLANT TEMPERATURE
• TRIGGER–ON: Coolant temperature is below 32°F (0°C) after the engine has been running for 5 minutes
• UNIT CONTROL: Engine operation: alarm only. Standby operation: this alarm will not activate in standby operation.
• RESET CONDITION: Auto reset when coolant temperature >36°F (2.2°C) or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Coolant Temperature
a. Check temperature of coolant or upper radiator hose
Must be above 32°F (0°C)
2.
Check Engine Coolant Sensor
a. Check resistance of engine coolant sensor (See Note 4) b. Check harness and control box connector pins and terminals (See wiring diagram)
See Section 2.14
No physical damage to harness
No damaged or corroded pins
7--25
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
37 CHECK LOW SPEED RPM
• TRIGGER–ON: Controller is set for low engine speed operation, and engine RPM are: less than 1300 or greater than 1550 for more than 60 seconds
•
UNIT CONTROL: Engine operation: alarm only. Standby operation: this alarm will not activate in standby operation.
• RESET CONDITION: Auto Reset if controller is set for low speed operation and RPM falls back between 1320 and 1530 RPM for 60 seconds. Change unit to standby operation, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Verify That Correct Model Number Is Selected
a. Compare model number from unit
I.D. label and model number in micro Data List.
Check Speed Solenoid & Linkage
The model numbers must be the same.
3.
a. Check speed solenoid plunger Must move in and out freely b. Check engine speed arm & linkage Must move freely
Check Engine RPM
a. Check actual engine RPM using hand held tachometer
Refer to Section 2.9
Adjust engine linkage setting as needed.
4.
5.
6.
b. Compare actual RPM with those shown on display.
Force Low Speed Operation
a.Change setpoint to within  0.5°
( 0.3°C) of box temperature.
Both readings within ± 50 RPM
Unit will run in low speed. RPM must be within range shown above for each specific model. Adjust speed linkage as needed.
LED 27 must be OFF b. Check operation of Speed Relay
LED c. Check voltage to speed solenoid Must be 0 VDC
Check Engine Air–intake System
a. Check air filter indicator b. Inspect air intake system
Flag must not be visible.
Hoses & tubes in good condition.
No kinks or restrictions
Check Engine Exhaust System
a. Inspect the exhaust system Must be clear and unobstructed
62-11039
7--26
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
38 CHECK HIGH SPEED RPM
• TRIGGER–ON: Controller is set for low engine speed operation, and engine RPM are: Less than 1670, or greater than 1900 for more than 60 seconds
• UNIT CONTROL: Engine operation: alarm only. Standby operation: this alarm will not activate in standby operation.
• RESET CONDITION: Auto Reset if controller is set for high speed operation and RPM is between 1670 and
1930 for 60 seconds or change unit to standby operation or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Verify That Correct Model Number Is Selected
a. Compare model number from unit
I.D. label and model number in
Micro Data List.
The model numbers must be the same.
2.
3.
Check Speed Solenoid Linkage
a. Check speed solenoid plunger a. Change setpoint if necessary to more than 10°F (5.6°C) away from setpoint.
Must move in and out freely b. Check engine speed arm & linkage Must move freely
Force High Speed Operation (See Note 6)
Controller will call for High Speed operation.
4.
5.
b. Check operation of Speed Relay LED 27 must be ON c. Check voltage to speed solenoid Must be 12--14 VDC
Check Speed Circuit
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins or terminals b. Check resistance of speed solenoid Refer to Section 2.14
c. Check amp draw of speed solenoid Refer to Section 2.14
Check Engine RPM
a. Check actual engine RPM using hand held tachometer
Refer to Section 2.9
Adjust engine linkage setting as needed.
6.
b. Compare actual RPM with those shown on display
Check Engine Air–intake System
a. Check air filter indicator b. Inspect air intake system
Both readings within ± 50 RPM
Flag must not be visible.
Hoses & tubes in good condition.
No kinks or restrictions
7.
Check Engine Exhaust System
a. Inspect the exhaust system Must be clear and unobstructed
7--27
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
39 CHECK ENGINE RPM
• TRIGGER–ON: In engine mode and Alarm 130 is not active and engine rpm is less than 1250 or greater than 2000 for 5 minutes or engine rpm drops to less than 1200 for 2 seconds after the engine rpm has been greater than 1250.
•
UNIT CONTROL: Engine operation: alarm only or (if configured for shutdown) engine and unit shutdown and alarm. Standby operation: this alarm will not activate in standby operation.
• RESET CONDITION: Auto Reset if engine rpm is greater than 1250 and less than 2000 for 5 minutes or after 15 minutes if the engine has been shutdown or change unit to standby operation or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check For Engine Stalled Alarm
a. Check for Alarm 41 When both alarms are present, unit may have been run out of fuel.
2.
3.
Check Speed Solenoid & Linkage
a. Check speed solenoid plunger a. Check for Alarm 1. Check fuel tank level.
Must move in and out freely b. Check engine speed arm & linkage Must move freely
Check Fuel System
Fill tank as needed b. Check fuel flow Unrestricted fuel flow through system
Fuel not gelled
No air in fuel system
4.
c. Check fuel system prime
Check Engine Air–intake System
a. Check air filter indicator b. Check air filter c. Inspect air intake system
Flag must not be visible.
Must be clean.
Hoses and tubes in good condition.
No kinks or restrictions.
5.
Check Low Speed Engine RPM
a. Check actual engine RPM using hand held tachometer
Refer to Section 2.9
Adjust engine linkage setting as needed.
Both readings within ± 50 RPM
6.
b. Compare actual RPM with those shown on display
Check High Speed Engine RPM
a. Check actual engine RPM using hand held tachometer b. Compare actual RPM with those shown on display
Refer to Section 2.9
Adjust engine linkage setting as needed.
Both readings within ± 50 RPM
62-11039
7--28
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
40 CHECK GLOW PLUGS
• TRIGGER–ON: During engine startup glow plug amperage is less than 30 Amps, or greater than
43 Amps after 13 seconds of glow time (NOTE: In auto start, this can only occur when the Engine
Coolant Temperature is below 32°F (0°C) and the glow time is configured SHORT.)
•
UNIT CONTROL: Engine operation: alarm only. Standby operation: this alarm will not activate in standby operation.
• RESET CONDITION: Auto Reset if glow plug amperage is between 30 to 43 amps for at least
13 seconds during the glow cycle or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Glow Plug Circuit
a. Inspect glow plug relay & socket No signs of discoloration from overheating
No corrosion b. Check operation of Glow Plug
Relay
Energize circuit. (See Note 2). Put GPR on GPR85.
LED 30 must be ON
2.
3.
c. Check Non–Running Amps View Current Draw in Data List
Refer to Section 2.14.
Energize GPR using component test mode.
d. Check Glow Plug circuit amperage Current Draw = Non–Running Amps + Glow Plug
Amps e. Check voltage to glow plugs
Check Glow Plug Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Must be 11 VDC or higher
No physical damage to harness.
No damaged or corroded pins
Check Glow Plugs
a. Check amp draw of each glow plug Refer to Section 2.14
7--29
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
41 ENGINE STALLED
• TRIGGER–ON: In engine mode, the engine is running, RPM sensor is good, and engine speed is less than 10 RPM; or
The engine is running, RPM sensor alarm is ON, and the Oil Pressure switch contacts are open.
•
UNIT CONTROL: Unit shutdown in electric. Alarm only in standby.
• RESET CONDITION: Auto Reset after 15 minutes, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
2.
Was Engine Shut Off Manually?
a. Check for external cause
Check For RPM Sensor Alarm
a. Check for Alarm 130
Correct problem.
When both Alarm 41 and (usually) Alarm 130 are present, there is insufficient fuel to run engine.
3.
Check Engine Oil Pressure Switch
a. Inspect switch, connector pins, and terminals.
No physical damage to switch.
No damaged or corroded pins in plug.
4.
5.
6.
b. Check engine oil switch operation. Contacts closed when oil pressure is above 15 PSIG
(1.02 Bars).
Contacts open when oil pressure is below 12 PSIG
(0.82 Bars).
Check For Bad F2 or F3 Fuse Alarm
a. Check for Alarm 71 Alarm conditions must be corrected and the alarm cleared to continue.
Check Fuel System
a. Check for Alarm 1 b. Check fuel gauge and fuel tank level.
Fill tank as needed
Fill tank as needed c. Check fuel flow Unrestricted fuel flow through system
Fuel not gelled
No air in fuel system
Check valve must hold fuel and not leak back d. Check fuel system prime e. Check fuel system check valve from filter to injection pump.
Check Fuel Solenoid
a. Check run relay.
b. Check Run Relay LED c. Check voltage to fuel solenoid d. Inspect solenoid, connector pins, and terminals.
e. Inspect harness, connector pins, and terminals. (See wiring schematic).
control f. Check resistance of solenoid g. Check operation of solenoid box
Unit in Component Test mode -- Run Relay ON.
Must be ON
12 VDC between FSC--C (ground) and FSH--A (hold) with engine starter energized.
12 VDC between FSC--C (ground) and FSP--B (pick)
No damage to solenoid.
No damaged or corroded pins.
No physical damage to harness.
No damaged or corroded pins.
Refer to Section 2.14.
Plunger must move in when energized.
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7--30
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
41 ENGINE STALLED (Continued)
•
TRIGGER–ON: In engine mode, the engine is running, RPM sensor is good, and engine speed is less than 10 RPM; or
The engine is running, RPM sensor alarm is ON, and the Oil Pressure switch contacts are open.
• UNIT CONTROL: Unit shutdown in electric. Alarm only in standby.
• RESET CONDITION: Auto Reset after 15 minutes, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
7.
8.
Check Engine RPM
a. Check actual engine RPM using hand held tachometer.
b. Compare actual RPM with those shown on display.
Check Engine Air–intake System
a. Check air filter indicator b. Inspect air intake system
Adjust engine linkage setting as needed.
Both readings within  50 RPM.
Flag must not be visible.
Hoses & tubes in good condition.
No kinks or restrictions
9.
Check Engine Exhaust System
a. Inspect the exhaust system
10.
Check Engine
a. Check Injection pump timing b. Check engine valve adjustment c. Check engine compression
11.
Check Refrigeration System
a. Check discharge & suction pressures
Must be clear and unobstructed
Timing must be correct
Rocker arm clearance must be correct
Compression must be above 400 PSIG (27.2 Bar)
Must be within normal operating range for conditions
12.
Check Electrical System For Overload
a. Generator or motor electrical overload (short to ground, phase to phase short)
Ohm the electrical components and circuits to ground.
Repair and replace damaged parts as necessary
7--31
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
7.6 WARNING / STATUS ALARMS
51 ALTERNATOR NOT CHARGING
• TRIGGER–ON: Unit is running on either engine or standby and the current flow is more than
--1.0 amps (discharge) between the battery charger and the battery for 3 continuous minutes.
• UNIT CONTROL: Engine operation: alarm only or (if configured for shutdown)engine and unit shutdown and alarm. Standby operation: alarm only.
• RESET CONDITION: Auto Reset (if not shut down) when alternator is charging if not shutdown or change unit to standby operation or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Microprocessor Current Sensor
a. Check micro current value Power up micro in PC Mode. (See Note 3.) Must be
--2.0 to 1.5A with no load.
2.
3.
Check Wire Direction Through Current Sensor
a. Visually inspect wire at current sensor.
Must go through current sensor in the direction of the arrow on the sensor toward F--5 (80A) fuse.
Check Battery Charger Wiring
a. Check output & ground wire (unit
OFF)
Negative lead on Ground terminal
Positive lead on Output terminal = same as battery voltage.
b. Check battery charger input c. Inspect harness & control box connector pins & terminals (See wiring schematic)
Must be between 350 VAC and 575 VAC
Must be between the two red Wires
No physical damage to harness.
No damaged or corroded pins
4.
5.
d. Check output wire (unit running) Must have 13 or more VDC (when tested against -battery post) e. Check ground wire (unit running) Must have 13 or move VDC (when tested against + battery post)
Check For Add–on Equipment Drawing Too Much Current
a. Check amperage of added–on components & accessories
All add–on components & accessories must draw less than 20 Amps
Perform Pre--trip Check
a. Run pre--trip & check for alarms Any active alarms must be corrected and cleared before proceeding.
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7--32
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
53 BOX TEMP OUT--OF--RANGE
•
TRIGGER–ON:
Alarm Only:
Condition One: If the unit is not running in Sleep Mode and Compartment One box temperature has been in range [within ±2.7°F (±1.5°C) for perishable setpoints or +2.7°F (±1.5°C) for frozen setpoints] at least once since the unit was started and is now further away from setpoint than the limit set in the functional parameters for the Out--of--Range Value [ 4°, 5°, or 7°F (2°, 3°, or 4°C)] for 30 continuous minutes OR
Condition Two: If SAT is configured ON and Compartment One is running in cool and the DeltaT
(SAT minus RAT) is not greater than --1°F (0.56°C) for 30 continuous minutes or if Compartment
One is running in heat and the SAT2 is not greater than the RAT2 for 30 continuous minutes. OR
Condition Three: If a shutdown alarm occurs and the RAT2 temperature is further away from setpoint than the limit set in the functional parameters for the Out--of--Range value [
4°, 5°, or 7°F (2°, 3°, or 4°C)]
Shut Down & Alarm:
for more than 30 continuous minutes regardless if Compartment One box temperature has been in--range.
Condition One: When configured for shutdown the unit will shut down when the conditions for
Alarm Only Condition One are met for 45 continuous minutes.
Condition Two: When configured for shutdown the unit will shut down when the conditions for
Alarm Only Condition Two are met for 30 continuous minutes.
• UNIT CONTROL: Engine and standby operation: If the micro is configured for shutdown and the setpoint for Compartment 2 is in the perishable range -- engine and unit shutdown and alarm. If the micro is configured for shutdown and the setpoint for Compartment 2 is in the frozen range, only
Compartment 2 will shut off. Otherwise, alarm only.
• RESET CONDITION: Auto Reset or Alarm may be manually reset via Keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Compartment Doors
a. Inspect all trailer compartment doors
Must be closed, no air leakage
2.
3.
4.
5.
6.
7.
Defrost Evaporator
a. Initiate Manual Defrost Cycle Must terminate automatically.
Check For Low Refrigerant Pressure Alarm
a. Check for alarm 18 Alarm conditions must be corrected and the alarm cleared to continue
Check Refrigerant Level
a. Visually check refrigerant level in receiver tank.
Must be at correct level.
Check Evaporator Airflow Alarm
a. Check for alarm 56
Perform Pre--trip Check
a. Run pre--trip & check for alarms
Must be corrected and cleared to continue
Any active alarms must be corrected and cleared before proceeding.
Check System Pressures
a. Install Manifold Test Set and check system pressures.
Suction & Discharge Pressures must be in the normal range. Suction & Discharge Pressures must have the same reading on gauges & on micro display.
7--33
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
53 TEMP OUT--OF--RANGE (Continued)
NOTE: For Condition One, the temperature criteria for this alarm is reset, and the box temperature must again go In--Range before this alarm can be triggered if any of the following occur:
•pre--trip is started
•Setpoint is changed
•A door switch or remote switch is installed and configured as a door switch
NOTE: The15, 30, or 45 minute timer is reset and starts again whenever:
S
The unit cycles off and restarts in Start--Stop
S
The unit goes into and comes out of Defrost
NOTE: This alarm does not go into the Inactive alarm List when it becomes inactive or is cleared.
NOTE: This alarm will not be used in Sleep Mode
54 DEFROST NOT COMPLETE
•
TRIGGER–ON: Defrost cycle did not complete within 45 minutes
• UNIT CONTROL: Engine and standby operation: alarm only. While this alarm is active, the Defrost
Timer will be set to initiate a defrost cycle 90 minutes (1.5 hours) of unit running time after the alarm comes on.
• RESET CONDITION: Auto Reset when defrost cycle is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Perform Pre--trip Check
a. Run pre--trip & check for alarms Any active alarms must be corrected and cleared before proceeding.
2.
3.
Check For Defective Defrost Sensor Location/ Correct Installation
a. Has sensor fallen from location Must be corrected to continue
Check Evaporator Fan Contactor
a. Check that contactor is in operation in defrost
Must disengage fan during defrost
62-11039
7--34
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
55 CHECK DEFROST AIR SWITCH
• TRIGGER–ON: The defrost air switch has called for a defrost cycle within 8 minutes of a defrost termination for 2 consecutive defrost cycles. (The air switch contact must be closed continuously for
15 seconds before the defrost cycle is started.)
•
UNIT CONTROL: Engine and standby operation: alarm only. While this alarm is active, the defrost air switch will NOT be used to initiate a defrost cycle; however the Defrost Timer will initiate a defrost cycle 90 minutes after the alarm comes on, and the manual defrost switch will remain operative.
•
RESET CONDITION: Auto Reset when defrost cycle terminates correctly, and the air switch does not call for a defrost cycle within the 8 minutes following defrost termination, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Defrost Air Switch
a. Inspect switch & connector pins & terminals
No damaged or corroded pins b. Check switch setting and resistance of switch contacts
Refer to Section 2.12
Contacts closed with pressure applied to high side
Contacts open with no pressure applied
2.
Check Switch Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Note 5
No physical damage to harness.
No damaged or corroded pins
3.
Check Air Switch Hoses
a. Inspect air hoses to switch No kinks or other obstructions
No holes
Connected to correct nipple
4.
Check Condition Of Evaporator
a. Visually inspect following defrost.
evaporator Coil must be clean and cleared of ice or any other material.
5.
6.
7.
8.
Perform Pre--Trip
a. Run Pre--Trip and check for alarms. Any active alarms must be corrected and cleared before proceeding.
Check Evaporator Pressure Drop
a. Check pressure reading with
Magnehelic Gauge
Refer to Section 2.12
Check Evaporator Contactor
a. Check Evap Fan operation in defrost
Must disengage fan.
Check Condition Of Trailer Compartment & Load
a. Check condition of trailer compartment doors & seals
Doors must be closed, and door seals must seal and prevent outside air from leaking in.
b. Check condition of product. If it is warm and moist, frequent defrost cycles can be expected.
7--35
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
59 DATALOGGER NOT RECORDING
• TRIGGER–ON: No data is being recorded by the data recorder.
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Alarm may be manually reset via keypad.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Clear Alarm
a. Clear Active Alarm(s) b. Check for Active Alarm reoccurrence
Alarms Clear
If Inactive, download all data & retain.
If Active, go to next step
2.
Microprocessor Defective
a. Download previous data using
Download PC Card, or
DataManager Program.
Data retrieval OK b. Replace microprocessor & set
Configurations, Functional
Parameters, Enter hours from removed microprocessor, set
Maintenance Hour Meters, and
Data Recorder Setup.
New microprocessor in place
NOTE: Specific configurations or IntelliSet settings may be found on the TransCentral Website (Authorized
Carrier Transicold Dealers only.)
62-11039
7--36
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
60 DATALOGGER TIME WRONG
• TRIGGER–ON: The real time clock in the Data Recorder does not contain a valid date.
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset when the Data Recorder Real Time Clock is reset, or alarm may be manually reset by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Real Time Clock
2.
a. Check Real Time Clock in the Data
List, or using DataManager or
Service Manager.
Reset Microprocessor
a. Turn main switch off for 30 seconds, then turn on.
b. Check for valid Real Time Clock reading in Data List
Must show correct date and time. Change as needed (Configuration List).
Microprocessor powers up OK
Valid date and time in memory.
Alarm is cleared automatically c. Real Time Clock can not be changed.
Replace microprocessor
3.
Microprocessor Defective
a. Download previous data using
Download PC Card, or
DataManager Program.
b. Replace microprocessor & set
Configurations, Functional
Parameters, Enter hours from removed microprocessor, set
Maintenance Hour Meters, and
Data Recorder Setup.
Data retrieval OK
New microprocessor in place
7--37
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
62 C2 BOX TEMP OUT--OF--RANGE
• TRIGGER–ON:
Alarm Only:
Condition One: If the unit is not running in Sleep Mode and Compartment Two box temperature has been in range [within ±2.7°F (±1.5°C) for perishable setpoints or +2.7°F (±1.5°C) for frozen setpoints] at least once since the unit was started and is now further away from setpoint than the limit set in the functional parameters for the Out--of--Range Value [ 4°, 5°, or 7°F (2°, 3°, or 4°C)] for 30 continuous minutes OR
Condition Two: If SAT is configured ON and Compartment 2 is running in cool and the DeltaT
(SAT minus RAT) is not greater than +1°F (0.56°C) for 30 continuous minutes or if Compartment 2 is running in heat and the SAT2 is not greater than the RAT2 for 30 continuous minutes. OR
Condition Three: If a shutdown alarm occurs and the RAT2 temperature is further away from setpoint than the limit set in the functional parameters for the Out--of--Range value [
4°, 5°, or 7°F (2°, 3°, or 4°C)]
Shut Down & Alarm:
for more than 30 continuous minutes regardless if Compartment 2 box temperature has been in--range.
Condition One: When configured for shutdown the unit will shut down when the conditions for
Alarm Only Condition One are met for 45 continuous minutes.
Condition Two: When configured for shutdown the unit will shut down when the conditions for
Alarm Only Condition Two are met for 30 continuous minutes.
• UNIT CONTROL: Engine and standby operation: If the micro is configured for shutdown and the setpoint for Compartment 2 is in the perishable range -- engine and unit shutdown and alarm. If the micro is configured for shutdown and the setpoint for Compartment 2 is in the frozen range, only
Compartment 2 will shut off. Otherwise, alarm only.
• RESET CONDITION: Auto Reset or Alarm may be manually reset via Keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Check Trailer Compartment Doors
a. Inspect all trailer compartment doors
Defrost Evaporator
Must be closed, no air leakage
3.
a. Initiate Manual Defrost Cycle Must terminate automatically.
Check For Low Refrigerant Pressure Alarm
a. Check for Alarm 18 Alarm conditions must be corrected and the alarm cleared to continue
4.
5.
Check Refrigerant Level
a. Visually check refrigerant level in receiver tank.
Check Evaporator Airflow Alarm
a. Check for Alarm 56
Must be at correct level.
Must be corrected and cleared to continue
62-11039
7--38
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
62 C2 BOX TEMP OUT--OF--RANGE (Continued)
6.
Perform Pre--trip Check
a. Run pre--trip & check for alarms Any active alarms must be corrected and cleared before proceeding.
7.
Check System Pressures
a. Install Manifold Test Set and check system pressures.
Suction & Discharge Pressures must be in the normal range. Suction & Discharge Pressures must have the same reading on gauges & on micro display.
NOTE: The temperature criteria for this alarm is reset, and the box temperature must again go In--Range before this alarm can be triggered if any of the following occur:
•pre--trip is started
•Setpoint is changed
•A door switch or remote switch is installed and configured as a door switch
7--39
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
63 C3 BOX TEMP OUT--OF--RANGE
• TRIGGER–ON:
Alarm Only:
Condition One: If the unit is not running in Sleep Mode and Compartment 3 box temperature has been in range [within ±2.7°F (±1.5°C) for perishable setpoints or +2.7°F (±1.5°C) for frozen setpoints] at least once since the unit was started and is now further away from setpoint than the limit set in the functional parameters for the Out--of--Range Value [ 4°, 5°, or 7°F (2°, 3°, or 4°C)] for 30 continuous minutes OR
Condition Two: If SAT is configured ON and Compartment 3 is running in cool and the DeltaT
(SAT minus RAT) is not greater than --1°F (0.56°C) for 30 continuous minutes or if Compartment 3 is running in heat and the SAT3 is not greater than the RAT3 for 30 continuous minutes. OR
Condition Three: If a shutdown alarm occurs and the RAT3 temperature is further away from setpoint than the limit set in the functional parameters for the Out--of--Range value [
4°, 5°, or 7° F (2°, 3°, or 4° C)]
Shut Down & Alarm:
for more than 30 continuous minutes regardless if Compartment 3 box temperature has been in--range.
Condition One: When configured for shutdown the unit will shut down when the conditions for
Alarm Only Condition One are met for 45 continuous minutes.
Condition Two: When configured for shutdown the unit will shut down when the conditions for
Alarm Only Condition Two are met for 30 continuous minutes.
• UNIT CONTROL: Engine and standby operation: If the micro is configured for shutdown and the setpoint for Compartment 3 is in the perishable range -- engine and unit shutdown and alarm. If the micro is configured for shutdown and the setpoint for Compartment 3 is in the frozen range, only
Compartment 3 will shut off. Otherwise, alarm only.
• RESET CONDITION: Auto Reset or Alarm may be manually reset via Keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Check Trailer Compartment Doors
a. Inspect all trailer compartment doors
Defrost Evaporator
Must be closed, no air leakage
3.
a. Initiate Manual Defrost Cycle Must terminate automatically.
Check For Low Refrigerant Pressure Alarm
a. Check for Alarm 18 Alarm conditions must be corrected and the alarm cleared to continue
4.
5.
Check Refrigerant Level
a. Visually check refrigerant level in receiver tank.
Check Evaporator Airflow Alarm
a. Check for Alarm 56
Must be at correct level.
Must be corrected and cleared to continue
62-11039
7--40
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
63 C3 BOX TEMP OUT--OF--RANGE (Continued)
6.
Perform Pre--trip Check
a. Run pre--trip & check for alarms Any active alarms must be corrected and cleared before proceeding.
7.
Check System Pressures
a. Install Manifold Test Set and check system pressures.
Suction & Discharge Pressures must be in the normal range. Suction & Discharge Pressures must have the same reading on gauges & on micro display.
NOTE: The temperature criteria for this alarm is reset, and the box temperature must again go In--Range before this alarm can be triggered if any of the following occur:
S pre--trip is started
S
Setpoint is changed
S
A door switch or remote switch is installed and configured as a door switch
7--41
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
7.7 ELECTRICAL ALARMS
71 BAD F2 OR F3 FUSE
• TRIGGER–ON: One or more of the following fuse circuits have been open for more than 2 seconds:
F2, F3
•
UNIT CONTROL: Engine operation: this alarm will not activate in engine operation. Standby operation: if the “No Power” configuration is set for “Installed and Shut Down” the refrigeration system will shut down with the alarm on and PSCON still energized.
•
RESET CONDITION: Alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Unit Operation
a. Did engine shut down?
Yes Check F3
No Check F2
2.
Check Fuses
a. Locate blown fuse(s) b. Verify fuse size c. Inspect fuse & fuse holder
Will have open circuit
Refer to Section 2.15
Must be correct rating for circuit (see wiring diagram)
Terminals tight; No signs of overheating, melting or discoloration
3.
Check Circuit
a. Check amperage draw on Speed
Relay circuit b. Check amperage draw on Run
Relay circuit
Refer to Section 2.14
Refer to Section 2.14
62-11039
7--42
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
73 NO POWER--CHECK POWER CORD
• TRIGGER–ON: In standby mode AND no AC power
• UNIT CONTROL: Engine operation: this alarm will not activate in engine operation. Standby operation: if the “No Power” configuration is set for “Installed and Shut Down” the refrigeration system will shut down with the alarm on and PSCON still energized.
• RESET CONDITION: Auto Reset when AC power is present AND configuration is set to shutdown or if the user changes the switch to standby operation or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Circuit Breaker On The Main Supply
2.
a. Check circuit breaker b. Check the voltage in the plug
Check Power Cord
a.Inspect connections in the socket and the plug
30A supply circuit breaker
460V/3/60Hz
Connections must be tight
3.
4.
b. Inspect the cable
Check For Power In The Control Box
Cable must not be frayed, cut or damaged a.Check for voltage at PSCON L1--L2,
L2--L3, L1--L3 b. Check for voltage at PSCON2
L1--L2, L2--L3, L1--L3
All three readings must be 460V 10%
All three readings must be 460V 10%
Check Connections
a. Check for bad connections in the control box
Connections and wire crimps must be tight
7--43
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
75 COMP MOTOR OVERLOAD
• TRIGGER–ON: Compressor Motor Overload (IPC) circuit is open.
• UNIT CONTROL: Engine operation: engine and unit shutdown and alarm. Standby operation: refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Auto Reset when motor overload input is within limits, or change to engine operation, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check For A--13 (Check Download)
a. A13 will always cause this alarm to activate
Review steps for A13 and correct if necessary.
2.
3.
Check For Power At MP1
a. If no power (0VDC) a. Inspect the three contacts behind the top cover b. Check tightness of the contactor wire connections
Test IP circuit from compressor motor to microprocessor b. If 12VDC
Check Compressor Motor Contactor
Continue troubleshooting
If the contactor buttons are blue due to chattering caused by a defective compressor internal protection device, replace the contactor.
Tighten with screwdriver and check for discoloration of wires.
4.
Check Motor Operation
a. Turn the unit ON in Engine or
Standby mode b. If current is high
Check voltage and current on each phase (must be less than 22 amps)
Run pre--trip to check if unloaders and current are excessive
62-11039
7--44
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
76 CONDENSER MOTOR OVERHEATED
• TRIGGER–ON: One or both of the condenser fan motor (IPCDM1 AND 2) in Compartment One circuit is open.
• UNIT CONTROL: Engine operation: engine and unit shutdown and alarm. Standby operation: refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Auto Reset when motor overload input is within limits, or change to engine operation, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Condenser Fan Motor Contactor
a. Inspect the three contacts behind the top cover
If the contactor buttons are blue due to chattering caused by a defective IP, replace the contactor.
2.
b. Check tightness of the contactor wire connections
Check Condenser Fan Motors
a. Disconnect power plug at motor
Tighten with screwdriver and check for discoloration of wires.
Test IP circuit for continuity using ohmmeter
If open, remove and replace motor
If closed, then an intermittent IP circuit is suspect.
Check phase to phase and phase to ground for short or open circuits See Section 2.13.
If motor tests good, check the DC IP circuit to microprocessor.
3.
Check Motor Operation
a. Turn the unit ON Check current on each phase (must be less than shown on Section 2.13).
Check voltage on each phase (must be at least
440VAC).
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
77 EVAP MOTOR OVERHEATED
• TRIGGER–ON: One or both of the evaporator fan motor (IPEVM1 AND 2) in Compartment One circuit is open.
• UNIT CONTROL: Engine and standby operation: compartment 1 evaporator will shut down. All other enabled compartments will continue to run.
• RESET CONDITION: Auto Reset when motor overload input is within limits, or change to engine operation, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Evaporator Fan Motor Contactor
a. Inspect the three contacts behind the top cover
If the contactor buttons are blue due to chattering caused by a defective IP, replace the contactor.
2.
3.
4.
b. Check tightness of the contactor wire connections
Check Evaporator Fan Motors
a. Disconnect power plug at motor
Tighten with screwdriver and check for discoloration of wires.
Test IP circuit for continuity using ohmmeter
If open, remove and replace motor
If closed, then an intermittent IP circuit is suspect.
Check phase to phase and phase to ground for short or open circuits See Section 2.13.
If motor tests good, check the DC IP circuit to microprocessor.
Check Motor Operation
a. Turn the unit ON Check current on each phase (must be less than shown on Section 2.13).
Check voltage on each phase (must be at least
440VAC)
Check Motor Operation
a. Turn the unit ON Check current on each phase (must be less than shown on Section 2.13).
Check voltage on each phase (must be at least
440VAC).
83 CHECK REMOTE DEFROST LIGHT
• TRIGGER–ON: Defrost light current (amp) draw is higher than 0.8 Amps.
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset when Defrost light current (amp) draw is normal, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Defrost Light
a. Inspect Defrost light & socket b. Check resistance of light bulb
No damaged or corroded pins
Refer to Section 2.14
2.
Check Defrost Light Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
84 CHECK REMOTE ALARM LIGHT
• TRIGGER–ON: Remote Alarm light current (amp) draw is higher than 0.8 Amps.
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset when Alarm light current (amp) draw is normal, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Alarm Light
a. Inspect Remote Alarm light & socket b. Check resistance of light bulb
No damaged or corroded pins
Refer to Section 2.14
2.
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
85 CHECK UL1 CIRCUIT
• TRIGGER–ON: Front Unloader Coil current (amp) draw is higher than 2.0 Amps.
• UNIT CONTROL: Engine and standby operation: alarm only.
•
RESET CONDITION: Auto Reset when the UL1 Coil current (amp) draw is normal, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check UL1 (Front) Unloader Coil
a. Inspect UL1 Unloader coil & terminals
No damage to coil
No damaged or corroded pins
2.
3.
b. Check resistance of coil c. Check amp draw of coil.
Check UL1
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check UL1 Unloader Coil Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14
Refer to Section 2.14. Use ammeter.
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
7--47
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
86 CHECK UL2 CIRCUIT
• TRIGGER–ON: Rear Unloader Coil current (amp) draw is higher than 2.0 Amps.
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset when the UL2 Coil current (amp) draw is normal, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check UL2 (Rear) Unloader Coil
a. Inspect UL2 Unloader coil & terminals
No damage to coil
No damaged or corroded pins
2.
3.
b. Check resistance of coil c. Check amp draw of coil.
Check UL2 Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check UL2 Coil Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14
Refer to Section 2.14. Use ammeter.
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
89 CHECK REMOTE AUTO LIGHT
• TRIGGER–ON: Remote Auto light current (amp) draw is higher than 0.8 Amps.
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset when Auto light current (amp) draw is normal, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Auto Light
a. Inspect Auto light & socket b. Check resistance of light bulb
No damaged or corroded pins
Refer to Section 2.14
2.
Check Auto Light Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
91 CHECK HTCON1 RELAY COIL
• TRIGGER–ON: Heater Contactor 1 Relay (HTCON1R) coil current is more 5 Amps
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check HTCON1R
a. Inspect heater contactor relay coil and terminals
No damage to coil
No damaged or corroded pins b. Check contactor coil resistance Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
3.
c. Check amp draw of coil.
Check HTCON1R Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check HTCON1R Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
92 CHECK HTCON2 RELAY COIL
•
TRIGGER–ON: Heater contactor 2 Relay (HTCONR2) coil current is more than 5 Amps
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check HTCON2R
a. Inspect heater contactor coil and terminals b. Check contactor coil resistance
No damage to coil
No damaged or corroded pins
Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
3.
c. Check amp draw of coil.
Check HTCON2R Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check HTCON2R Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
7--49
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
93 CHECK START UP BUZZER
• TRIGGER–ON: The Buzzer circuit is shorted. (The Buzzer output from the micro is negative, so the itself, or to a circuit will not be shorted to ground, but is shorted either within the Buzzer positive wire.
•
UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset when Buzzer amp draw is normal, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Check Buzzer
a. Inspect Buzzer & wire connections No damage to buzzer
No damaged or corroded pins b. Check resistance of buzzer
Check Buzzer Wiring
Refer to Section 2.14
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
3.
Check Buzzer Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Refer to Section 2.14 for normal current values.
View current draw in Data List.
94 CHECK COMP CONTACTOR 1
•
TRIGGER–ON: Compressor motor contactor relay (CCONR) coil current is excessive.
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check CCONR
a. Inspect compressor contactor relay coil and terminals
No damage to coil
No damaged or corroded pins b. Check contactor coil resistance Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
c. Check amp draw of coil.
Check CCONR Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
3.
Check CCONR Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Refer to Section 2.14 for normal current values.
View current draw in Data List.
62-11039
7--50
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
95 CHECK CDCON RELAY COIL
• TRIGGER–ON: Condenser fan motor contactor coil (CDCON) current is more than 5 Amps
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check CDCON
a. Inspect condenser fan contactor coil and terminals
No damage to coil
No damaged or corroded pins b. Check contactor coil resistance Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
3.
c. Check amp draw of coil.
Check CDCON Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check CDCON
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
96 CHECK GENCONR RELAY COIL
•
TRIGGER–ON: Generator contactor relay coil (GENCONR) current is more than 5 Amps
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check GENCONR
a. Inspect generator contactor relay coil and terminals b. Check contactor coil resistance
No damage to coil
No damaged or corroded pins
Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
3.
c. Check amp draw of coil.
Check GENCONR Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check GENCONR Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
7--51
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
98 CHECK HIGH TEMP THERMOSTAT
• TRIGGER–ON: With RS in ON position and EVHTS circuit is open.
• UNIT CONTROL: Alarm AND no heat allowed for any compartment.
• RESET CONDITION: Auto Reset when temperature is okay for 15 minutes, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check High Temperature Thermostat
a. Inspect high temperature thermostat and connector
No damage to switch
No damage or corrosion in connector
2.
Check High Temperature Contact
a. Contact must be closed when temperature is normal
Unplug EVHTS and check for continuity
Check for power on SPK5.
Check for power at 4MP4
99 CHECK STANDBY CONTACTOR
•
TRIGGER–ON: Standby motor contactor relay (PSCONR) current is higher than normal. (See
Table 2-7).
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset when the PSCONR Coil current (amp) draw is normal, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check PSCONR
a. Inspect standby contactor relay coil and terminals
No damage to coil
No damaged or corroded pins b. Check contactor coil resistance Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
3.
c. Check amp draw of coil.
Check PSCONR Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check PSCONR Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
62-11039
7--52
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
100 OVERLOAD / GROUND FAULT
• TRIGGER–ON: The RS switch is ON and the overload and ground fault detector is reading more than 40 Amps on any A/C current leg OR there is A/C voltage leaking to ground of more than 150 mAmps.
•
UNIT CONTROL: Engine operation: engine and unit shutdown and alarm. Standby operation: refrigeration system shutdown and alarm with PSCON still energized.
• RESET CONDITION: Auto Reset in engine mode. Alarm may be manually reset via Keypad or, alarm may be reset by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check For Electrical Overload
a. Check amp draw from GENCON if running on engine or PSCON2 if running on standby.
Must be less than 40 Amps
2.
Check For High Voltage Short To Ground
a. Check for ohm reading from T1, T2 and T3 of ALL High voltage contactors to ground
Reading must be greater than 25.000 Ohms
3.
4.
Perform Pre--trip Check
a. Run pre--trip b. Further test circuit from Step a.
Note during which test Alarm 100 occurs
If necessary use a megohmmeter to test
Check Overload / Ground Fault Device
a. With the engine OFF and standby power disconnected, turn the RS switch one of the compartment switches ON
Must have 12 VDC at HC19 and 2MP26
7--53
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
101 C2 EVAP MOTOR OVERHEATED
• TRIGGER–ON: One or more of the two EVM Internal Motor Protectors (IP) is open.
• UNIT CONTROL: In engine and standby: Compartment 2 shutdown only
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Compartment 2 Evaporator Motor Contactor
a. Inspect the three contacts behind the top cover
If the contactor buttons are blue due to chattering caused by a defective IP, replace the contactor.
2.
3.
4.
b. Check tightness of the contactor wire connections
Tighten with screwdriver and check for discoloration of wires.
Check Motor Operation
a. Turn the unit ON
Perform Pre--trip Check
a. Run pre--trip & check for alarms
Check current on each phase (must be less than shown on Section 2.13).
Check voltage on each phase (must be at least
440VAC).
Check Compartment 2 Evaporator Motors
a. Disconnect power plug at motor Test IP circuit for continuity using ohmmeter
If open, remove and replace motor
If closed, then an intermittent IP circuit is suspect.
Check phase to phase and phase to ground for short or open circuits See Section 2.13.
If motor tests good, check the DC IP circuit to microprocessor.
Any active alarms must be corrected and cleared before proceeding.
62-11039
7--54
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
102 C3 EVAP MOTOR OVERHEATED
•
TRIGGER–ON: The Remote Fan (3rd compartment) input is outside limits AND not cranking the engine and RS is on.
• UNIT CONTROL: Engine and standby: Compartment 3 shutdown only
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Compartment 3 Evaporator Motor Contactor
a. Inspect the three contacts behind the top cover
If the contactor buttons are blue due to chattering caused by a defective IP, replace the contactor.
2.
3.
4.
b. Check tightness of the contactor wire connections
Tighten with screwdriver and check for discoloration of wires.
Check Motor Operation
a. Turn the unit ON
Perform Pre--trip Check
a. Run pre--trip & check for alarms
Check current on each phase (must be less than shown on Section 2.13).
Check voltage on each phase (must be at least
440VAC).
Check Compartment 3 Evaporator Motor
a. Disconnect power plug at motor Test IP circuit for continuity using ohmmeter
If open, remove and replace motor
If closed, then an intermittent IP circuit is suspect.
Check phase to phase and phase to ground for short or open circuits See Section 2.13.
If motor tests good, check the DC IP circuit to microprocessor.
Any active alarms must be corrected and cleared before proceeding.
7--55
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
103 CHECK 2HTCON1 RELAY COIL
• TRIGGER–ON: Heater contactor coil current is more than 5 Amps
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check 2HTCON1
a. Inspect heater contactor coil and terminals
No damage to coil
No damaged or corroded pins b. Check contactor coil resistance Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
3.
c. Check amp draw of coil.
Check 2HTCON1 Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check HTCON1 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
104 CHECK 2HTCON2 RELAY COIL
•
TRIGGER–ON: Heater contactor coil current is more than 5 Amps
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check 2HTCON2
a. Inspect heater contactor coil and terminals b. Check contactor coil resistance
No damage to coil
No damaged or corroded pins
Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
3.
c. Check amp draw of coil.
Check 2HTCON2 Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check 2HTCON2 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
62-11039
7--56
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
105 CHECK 3HTCON1 RELAY COIL
• TRIGGER–ON: Heater contactor coil current is more than 5 Amps
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check 3HTCON1
a. Inspect heater contactor coil and terminals
No damage to coil
No damaged or corroded pins b. Check contactor coil resistance Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
3.
c. Check amp draw of coil.
Check 3HTCON1 Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check 3HTCON1 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
106 CHECK 3HTCON2 RELAY COIL
•
TRIGGER–ON: Heater contactor coil current is excessive
• UNIT CONTROL: Alarm only
• RESET CONDITION: Auto reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check 3HTCON2
a. Inspect heater contactor coil and terminals b. Check contactor coil resistance
No damage to coil
No damaged or corroded pins
Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
3.
c. Check amp draw of coil.
Check 3HTCON2 Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check 3HTCON2 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
7--57
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
107 CHECK 2LSV CIRCUIT
• TRIGGER–ON: Compartment 2 Liquid Solenoid Valve (LSV2) current is more than 5 Amps
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check LSV2
a. Inspect component and wire connections
No damage to coil
No damaged or corroded pins b. Check coil resistance Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
3.
c. Check amp draw of coil.
Check LSV2 Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check LSV2 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
108 CHECK 3LSV CIRCUIT
•
TRIGGER–ON: Compartment 3 Liquid Solenoid Valve (LSV3) current is more than 5 Amps
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check LSV3
a. Inspect component and wire connections b. Check coil resistance
No damage to coil
No damaged or corroded pins
Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
2.
3.
Check LSV3 Current Draw
a. Use Component Test Mode (Refer to Section 5.2.5.2.2) to test actual current draw of the circuit.
Check LSV3 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Refer to Section 2.14 for normal current values.
View current draw in Data List.
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
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7--58
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
109 CHECK 1EVCON RELAY COIL
• TRIGGER–ON: Evaporator fan motor contactor (EVCON) current is more than 5 Amps
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check EVCON
a. Inspect evaporator fan contactor coil and terminals
No damage to coil
No damaged or corroded pins b. Check coil resistance Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
c. Check amp draw of coil.
Check EVCON Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
110 CHECK 2EVCON RELAY COIL
• TRIGGER–ON: Evaporator fan motor contactor (2EVCON) current is more than 5 Amps
•
UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check 2EVCON
a. Inspect compartment 2 evaporator fan contactor coil and terminals
No damage to coil
No damaged or corroded pins b. Check coil resistance Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
c. Check amp draw of coil.
Check 2EVCON Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
7--59
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
111 CHECK 3EVCON RELAY COIL
• TRIGGER–ON: Evaporator fan motor contactor (3EVCON) current is more than 5 Amps
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check 3EVCON
a. Inspect compartment 3 evaporator fan contactor coil and terminals
No damage to coil
No damaged or corroded pins b. Check coil resistance Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
Refer to Section 2.14. Use ammeter.
2.
c. Check amp draw of coil.
Check 3EVCON Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
62-11039
7--60
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
7.8 SENSOR ALARMS
121 CHECK AMBIENT AIR SENSOR
• TRIGGER–ON: Ambient Air Sensor is not within the range of --53°F to +158°F (--47°C to +70° C)
• UNIT CONTROL: A value of 122°F (50°C) will be used for any calculations.
• RESET CONDITION: Auto Reset when Ambient Air Sensor is in range or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Ambient Air Sensor
a. Inspect Ambient Air Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector
(Refer to Section 8.29 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
2.
b. Check Ambient Air Sensor resistance
(See Note 4)
Check Ambient Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals. (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
122 CHECK RETURN AIR SENSOR
• TRIGGER–ON: Return Air Sensor is not within the range of --53°F to +158°F (--47°C to +70° C)
• UNIT CONTROL:
If Alarm 123 -- Check Supply Air Sensor -- is not active: alarm only and switch to supply air control.
If Alarm 123 is active and functional parameter temperature control is set for return air and the setpoint for compartment One is in the perishable range: alarm and compartment 1 will shut down.
If Alarm 123 is active and setpoint is frozen: alarm and compartment one will operate in reduced capacity cool mode.
• RESET CONDITION: Auto Reset when Return Air Sensor is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Return Air Sensor
a. Inspect Return Air Sensor & connector b. Check Return Air Sensor resistance
(See Note 4)
No damage to sensor
No damage, moisture, or corrosion in connector
(Refer to Section 8.29 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
2.
Check Return Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
7--61
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
123 CHECK SUPPLY AIR SENSOR
• TRIGGER–ON: Supply Air Sensor is not within the range of --53°F to +158°F (--47°C to +70° C)
• UNIT CONTROL: Engine and standby:
If Alarm 122 is not active and functional parameter temperature control is set for supply air and the setpoint for compartment One is in the perishable range: alarm only and switch to return air control.
If Alarm 122 is active: set unit control for Alarm 122
• RESET CONDITION: Auto Reset when Supply Air Sensor is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Supply Air Sensor
a. Inspect Supply Air Sensor & connector b. Check resistance
Supply
(See Note 4)
Air Sensor
No damage to sensor
No damage, moisture, or corrosion in connector
(Refer to Section 8.29 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
2.
Check Supply Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
124 CHECK DEFROST TERM 1 SENSOR (COMPARTMENT #1)
• TRIGGER–ON: Defrost Term Sensor is not within the range of --53°F to +158°F (--47°C to +70° C)
• UNIT CONTROL: Engine and standby:
If Alarm 122 is not active: Alarm and RAT will be used for defrost initiation and a heat defrost will end after 10 minutes.
If Alarms 122 and 123 are also both active: alarm and defrost will not be allowed.
• RESET CONDITION: Auto Reset when DTT1 is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Defrost Termination Sensor 1
a. Inspect Defrost Termination
Temperature Sensor 1 & connector
No damage to sensor
No damage, moisture, or corrosion in connector b. Check Defrost Termination
Temperature Sensor 1 resistance
(See Note 4)
(Refer to Table 8-8 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
2.
Check Defrost Termination Sensor 1 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
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7--62
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
125 CHECK COMP DISCHARGE SENSOR (CDT)
• TRIGGER–ON: Compressor Disch Sensor is not within the range of –40°F to +392°F (--40°C to
+200°C)
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when Compressor Discharge Sensor is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Compressor Discharge Sensor
a. Inspect Compressor Discharge
Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector
2.
b. Check Compressor Discharge
Sensor resistance (See Note 4)
(Refer to Table 8-8 for complete resistance chart)
100,000 Ohms @ 77°F (25°C)
Check Compressor Discharge Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See
Wiring schematic)
No physical damage to harness.
No damaged or corroded pins
126 CHECK FUEL SENSOR CIRCUIT
• TRIGGER–ON: The fuel level reading (in the data list) is less than 2% for 30 seconds.
• UNIT CONTROL: Alarm Only
•
RESET CONDITION: Auto Reset when fuel level is sensed above 4% for 30 seconds or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Check For Low Fuel Level
a. Check fuel level in the fuel tank c. Check for voltage at harness plug between pins for BLACK (SPK6) and RED (SPK5) wires
Add fuel as needed to the fuel tank.
Check Fuel Level Sensor
a. Inspect fuel level sensor& connector pins & terminals
No physical damage to sensor.
No damaged or corroded pins in plug.
b. Check fuel level sensor operation Energize circuit (see Note 2), DO NOT START UNIT.
Voltage should be 12 volts at harness plug between pins for BLACK (SP24) and RED (SPK5) wires
3.
d. Check continuity of the wire from the harness plug, pin C to the microprocessor plug 1MP26
RS in OFF position prior to checking for continuity.
Must be less than 10 ohms.
Check Fuel Level Sensor Calibration
a. Check fuel level sensor calibration See Section (8.5.1) for sensor calibration procedure.
4.
Check Circuits With Test (Substitute) Sensor
a.Substitute known good sensor and clear alarm. Start unit and run for 30 seconds.
b.Check to see if alarm re-occurs.
Alarm should not come on. (Install new sensor)
NOTE: If new sensor is not available, the sensor may be configured OFF temporarily. See Section 5.2.1 --
Configurations.)
7--63
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
127 CHECK SUCTION TEMP SENSOR (CST)
• TRIGGER–ON: Suction temp. sensor is not within the range of--53°F to +158°F (--47_C to +70° C)
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Suction Temp Sensor
a. Inspect Suction Temp Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector
2.
b. Check Suction Temp Sensor resistance (See Note 4)
(Refer to Table 8-8 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
Check Suction Temp Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
128 LOW A/C AMPS
• TRIGGER–ON: If the compressor is on and AC Current Sensor 1 or 2 is less than 5 amps for 10 seconds OR If the difference between AC Current 1 and AC Current 2 is greater than 10 amps for
10 seconds
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Change unit to standby operation when AC Current Sensor 1 and 2 is greater than 7 amps for 5 minutes AND difference between AC Current 1 and AC Current 2 is less than 7 amps for
5 minutes OR alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Perform Pre--trip Check
a. Run pre--trip & check for alarms Any active alarms must be corrected and cleared before proceeding.
2.
Check Current Draw
a. Use a clamp around A/C ammeter to check amps at power wires
Must be 1.0 Amp of reading in Data List.
b. Check A/C amps with compressor running c. Compare A/C Amp readings between L1--L2--L3
Must be greater than 5 Amps.
Maximum allowable difference is 10 Amps.
62-11039
7--64
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
129 CHECK ENG COOLANT SENSOR
• TRIGGER–ON: Engine Coolant Sensor is not within the range of --58°F to +266°F
(--50°C to +130°C)
• UNIT CONTROL: Engine and standby operation: alarm only.
• RESET CONDITION: Auto Reset or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Engine Coolant Sensor
a. Inspect Engine Coolant Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector
2.
b. Check Engine Coolant Sensor resistance (See Note 4)
(Refer to Table 8-8 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
Check Engine Coolant Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
7--65
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
130 CHECK ENGINE RPM SENSOR
• TRIGGER–ON: Engine mode only. This alarm does not activate in standby.
In Auto Start, after the 2nd or 3rd start attempt the Engine Oil Pressure switch is closed (oil pressure good) and engine RPM are sensed at less than 1000 RPM;
NOTE: This alarm can only be triggered during the engine starting sequence and during the 20 seconds immediately following.
• UNIT CONTROL: Alarm Only and engine will be considered running.
• RESET CONDITION: Auto Reset in Auto Start when engine RPM are greater than 1,000 or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Alarm List
a. Check for Alarm 41 When both Alarm 41 and (usually) Alarm 130 are present, there is insufficient fuel to run engine.
2.
Check Engine RPM Sensor
a. Inspect Engine RPM Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector
Must be ± 20 RPM
Must be a steady reading.
3.
b. Compare actual engine RPM with those shown on the display using hand held tachometer.
Check Engine RPM Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic) b. Check RPM wiring
See Note 6
No physical damage to harness.
No damaged or corroded pins
Energize circuit (see Note 2). DO NOT START
UNIT.
c. Check voltage reading between plug terminals A & B.
With + lead on A and -- lead on C reading should be
5 VDC ±.2 volts. If it is not, check for grounded positive circuit at CSP and CDP transducers.
4.
Check Circuits With Test Sensor
a. Substitute known good sensor and check Data reading.
Must be within ± 20 RPM or reading on tachometer
62-11039
7--66
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
131 CHECK EVAP TEMP SENSOR
• TRIGGER–ON: Evap Temperature Sensor is not within the range of --53°F to +158°F (--47°C to
+70°C)
• UNIT CONTROL: Engine and standby: alarm only and superheat will be calculated using SAT
• RESET CONDITION: Auto Reset when Evap Temp Sensor is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Evap Temp Sensor
a. Inspect Evap Temp Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector b. Check Evap Temp Sensor resistance (See Note 4)
(Refer to Table 8-8 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
2.
Check Evap Temp Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
133 CHEEK REMOTE TEMP SENSOR 1 (2 Compartment Units Only)
• TRIGGER–ON: Remote Temperature Sensor 1 is not within the maximum range of --53°F to
+158°F (--47 °C to +70°C)
• UNIT CONTROL: Alarm only.
•
RESET CONDITION: Auto Reset when Remote Temperature Sensor 1 is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Remote Temp Sensor 1
a. Inspect Remote Temp Sensor 1 & connector
No damage to sensor
No damage, moisture, or corrosion in connector
2.
b. Check Remote Temp Sensor 1 resistance (See Note 4)
(Refer to Table 8-8 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
Check Remote Temp Sensor 1 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
7--67
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
134 CHEK REMOTE TEMP SENSOR 2 (2 Compartment Units Only)
• TRIGGER–ON: Remote Temperature Sensor 2 is not within the maximum range of --53°F to
+158_F (--47° C to +70°C)
• UNIT CONTROL: Alarm only.
• RESET CONDITION: Auto Reset when Remote Temperature Sensor 2 is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Remote Temp Sensor 2
a. Inspect Remote Temp Sensor 2 & connector
No damage to sensor
No damage, moisture, or corrosion in connector
2.
b. Check Remote Temp Sensor 2 resistance (See Note 4)
(Refer to Table 8-8 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
Check Remote Temp Sensor 2 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
136 C2 CHK SUPPLY AIR SENSOR (2 Compartment Units Only)
• TRIGGER–ON: Supply Air Temp Sensor 2 is not within the range of --53°F to +158°F (--47°C to
+70°C)
• UNIT CONTROL: Engine and standby operation: alarm only.
•
RESET CONDITION: Auto Reset when sensor is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Supply Air Temp Sensor 2
a. Inspect Remoter Temp Sensor & connector b. Check Remote Temp Sensor resistance (See Note 4)
No damage to sensor
No damage, moisture, or corrosion in connector
(Refer to Table 8-8 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
2.
Check Supply Air Temp 2 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
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7--68
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
137 C2 CHECK RETURN AIR SENSOR (2RAT)
• TRIGGER–ON: Return Air Sensor 2 is not within the range of --53°F to +158°F (--47°C to +70°C)
• UNIT CONTROL: Engine and standby: If setpoint is in the perishable range, compartment 2 will shut down. If setpoint is in the frozen range, compartment 2 will run in reduced capacity cool.
• RESET CONDITION: Auto Reset when sensor is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check 2RAT Sensor
a. Inspect Return Air Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector b. Check Return Air Sensor resistance
(See Note 4)
(Refer to Table 8-8 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
2.
Check 2RAT Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
138 C3 CHECK RETURN AIR SENSOR (3RAT)
• TRIGGER–ON: Return Air Sensor 3 is not within the range of --53°F to +158°F (--47°C to +70°C)
• UNIT CONTROL: Engine and standby: If setpoint is in the perishable range, compartment 3 will shut down. If setpoint is in the frozen range, compartment 3 will run in reduced capacity cool.
•
RESET CONDITION: Auto Reset when sensor is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check 3RAT Sensor
a. Inspect Return Air Sensor & connector b. Check Return Air Sensor resistance
(See Note 4)
No damage to sensor
No damage, moisture, or corrosion in connector
(Refer to Table 8-8 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
2.
Check 3RAT Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
7--69
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
139 C2 CHECK DEFROST SENSOR (COMPARTMENT 2)
• TRIGGER–ON: Defrost Temp Sensor for Comp 2 is not within the range of
--53°F to +158°F (--47°C to +70°C)
• UNIT CONTROL: Engine and standby:
If Alarm 137 is not active: alarm and 2RAT will be used for defrost initiation and defrost will terminate after 10 minutes. OR
If Alarm 137 is active and 2SAT is installed and Alarm 136 is not active: alarm and 2SAT will be used for defrost initiation and defrost will terminate after 10 minutes.
If Alarm 137 is active and there is no 2SAT OR if both Alarm 137 and 138 are active: alarm and defrost is not allowed for compartment 2.
•
RESET CONDITION: Auto Reset when sensor is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Compartment 2 Defrost Sensor
a. Inspect compartment 2 Defrost
Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector
2.
b. Check compartment 2 Defrost
Sensor resistance
(See Note 4)
(Refer to Table 8-8 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
Check Compartment 2 Defrost Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
140 C3 CHECK DEFROST SENSOR (COMPARTMENT 3)
• TRIGGER–ON: Defrost Temp Sensor for Comp 3 is not within the range of
--53°F to +158°F (--47°C to +70°C)
• UNIT CONTROL: Engine and standby:
If Alarm 138 is not active: alarm and 3RAT will be used for defrost initiation and defrost will terminate after 10 minutes.
If Alarm 138 is active : alarm and defrost is not allowed for compartment 3.
•
RESET CONDITION: Auto Reset when sensor is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Compartment 3 Defrost Sensor
a. Inspect compartment 3 Defrost
Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector
2.
b. Check compartment 3 Defrost
Sensor resistance
(See Note 4)
(Refer to Table 8-8 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
Check Compartment 3 Defrost Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
62-11039
7--70
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
7.9 pre--trip ALARMS
P141 PRE--TRIP STOPPED BY USER
• TRIGGER–ON: Pre--trip cycle was stopped by user before the pre--trip cycle ended automatically
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check For Any Pre--trip Alarms
a. Scroll the alarm list for any Active pre--trip alarms
Alarm conditions must be corrected and the alarm cleared to continue
2.
Rerun Pre--trip Check (If Desired)
a. Place into pre--trip mode b. Allow to terminate automatically
Unit running in pre--trip mode pre--trip cycle operates normally.
P144 CHECK UL1 CIRCUIT
• TRIGGER–ON: Normal Amps for the UL1 (Front) Unloader Circuit is 0.75 to 2.0 Amps. The circuit tests outside this range.
•
UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
2.
Check For Bad F4 And F6 Alarm
a. Check for Alarm 72
Check UL1
a. Check amp draw of coil.
Pull fuse and test. Replace if required.
Use Component Test Mode (Section 5.2.5.2.2) to test.
Refer to Section 2.14 for amp values.
View current draw in Data List.
3.
b. Check resistance of UL1 coil
Check UL1 And Circuit
a. Inspect UL1 and wiring
Refer to Section 2.14
No damage or corrosion
Connector fits together tightly, no moisture inside b. Check operation of UL1 FET (23) Energize circuit (see Note 2) LED must be ON
4.
c. Check voltage to front unloader
Check UL1 Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Must be 11 VDC or higher across the 2 wires
No physical damage to harness.
No damaged or corroded pins
7--71
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P145 CHECK SPEED SOL CIRCUIT
• TRIGGER–ON: Normal Amps for the Speed Solenoid Circuit is 3.0 to 9.0 Amps. The circuit tests outside this range.
•
UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “pre--trip FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check For Bad F2 Or F3 Fuse Alarm
a. Check for Alarm 71 Alarm conditions must be corrected and the alarm cleared to continue.
2.
3.
Check Speed Solenoid
a. Check amp draw of speed solenoid. Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
b. Check resistance of solenoid.
Refer to Section 2.14
Check Speed Solenoid & Circuit
a. Inspect speed solenoid and wiring No physical damage to harness.
No damaged or corroded pins
No damage to solenoid b. Start unit, put setpoint more than
10° away from box temperature and set for Continuous Run. See
Note 6
Controller will call for High Speed operation.
4.
c. Check operation of Speed Relay
LED
LED 27 must be ON d. Check voltage to speed solenoid Must be 11 VDC or higher across the 2 wires
Check Speed Solenoid Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
62-11039
7--72
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P146 C2 CHECK HEATER 1 CIRCUIT
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON TEST 2: Normal amps for the 2HTCON1 contactor coil are .05 to 2.0 D/C Amps (12
VDC). The circuit tests outside this range.
• TRIGGER–ON TEST 8: Normal amps for the 2HTCON1 heaters are 1.0 to 7.0 A/C Amps (460
VAC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Determine Which Test This Alarm Occurred In
a. Review active alarm list b. Clear active alarm list
Make a note of all alarms c. Restart and monitor pre--trip Stop pre--trip during Test #3 by holding = Key for 6 seconds d. Review active alarm list for Alarm
146
If alarm is present, follow steps 2 thru 4. If alarm is not present, follow steps 5 thru 10.
2.
Check 2HTCON1
a. Inspect heater contactor coil and wire connections
No damage to coil
No damaged or corroded pins
Refer to Section 2.14
12 VDC
CIR-
CUIT
3.
b. Check contactor coil resistance
Check 2HTCON1 Amp Draw
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
4.
Check 2HTCON1 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
7--73
62-11039
Alarm
NO.
460
VAC
CIR-
CUIT
Steps
8.
ALARM / CAUSE CORRECTIVE ACTION
P146 C2 CHECK HEATER 1 CIRCUIT (Continued)
5.
Check Evaporator High Temperature Switch (2EVHTS)
6.
a. Inspect for open 2EVHTS per wiring diagram
If open, replace switch as required
Check Amp Draw of 2HTCON1 Heater Circuit
a. Use a clamp on ammeter to check the current draw of all 3 legs.
Must be within range shown in Section 2.13 for all three legs.
7.
Check Heater Elements
a. Check heater elements No visual physical damage
No blockage due to debris
Remove and replace if required
Check Heater Element Plugs And Connections
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required
9.
b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Verify Accuracy of AC Current Sensor
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
10.
Check Heater Wiring
a. Use a clamp on ammeter to check the total current draw b. If no fault was found in previous tests
Compare to Unit Data
Remove and replace contactor
62-11039
7--74
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P147 C2 CHECK HEATER 2 CIRCUIT
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON TEST 2: Normal amps for the 2HTCON2 contactor coil are .05 to 5.0 D/C Amps (12
VDC). The circuit tests outside this range.
• TRIGGER–ON TEST 8: Normal amps for the 2HTCON2 heaters are 1.0 to 7.0 A/C Amps (460
VAC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “pre--trip FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Determine Which Test This Alarm Occurred In
a. Review active alarm list b. Clear active alarm list
Make a note of all alarms c. Restart and monitor pre--trip Stop pre--trip during Test #3 by holding = Key for 6 seconds d. Review active alarm list for Alarm
146
If alarm is present, follow steps 2 thru 4. If alarm is not present, follow steps 5 thru 10.
2.
Check 2HTCON2
a. Inspect heater contactor coil and wire connections b. Check contactor coil resistance
No damage to coil
No damaged or corroded pins
Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
12 VDC
CIR-
CUIT
3.
Check 2HTCON2 Amp Draw
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
4.
Check 2HTCON2 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
7--75
62-11039
Alarm
NO.
460
VAC
CIR-
CUIT
Steps
8.
ALARM / CAUSE CORRECTIVE ACTION
P147 C2 CHECK HEATER 2 CIRCUIT (Continued)
5.
Check Evaporator High Temperature Switch (2EVHTS)
6.
a. Inspect for open 2EVHTS per wiring diagram
If open, replace switch as required
Check Amp Draw of 2HTCON2 Heater Circuit
a. Use a clamp on ammeter to check the current draw of all 3 legs.
Must be within range shown in Section 2.13 for all three legs.
7.
Check Heater Elements
a. Check heater elements No visual physical damage
No blockage due to debris
Remove and replace if required
Check Heater Element Plugs And Connections
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required
9.
b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Verify Accuracy of AC Current Sensor
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
10.
Check Heater Wiring
a. Use a clamp on ammeter to check the total current draw b. If no fault was found in previous tests
Compare to Unit Data
Remove and replace contactor
62-11039
7--76
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P151 CHECK GLOW PLUG CIRCUIT
• TRIGGER–ON: Normal Amps for the Glow Plugs Circuit is 23 to 35 Amps after 15 seconds.
The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “pre--trip FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Glow Plug Circuit
a. Check voltage to glow plugs Must be 11 VDC or higher
If Power is present, remove buss bar from glow plugs and test individual glow plugs per Table 2-7 b. Check operation of Glow Plug
Relay c. Check Glow Plug circuit Amps in
Component Test Mode
If Power is not present, go to step b.
Use component test mode. Energize glow plug circuit. LED 30 must be ON. 12VDC to glow plugs
Refer to Section 2.14 for amp values. Use ammeter.
2.
d. Inspect glow plug relay & socket No signs of discoloration from overheating
No corrosion
Check Glow Plug Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
7--77
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P152 CHECK FUEL SOLENOID CIRCUIT
• TRIGGER–ON: Normal Amps for the Fuel Solenoid Hold Circuit is 0.4 to 3.5 Amps (including possible electric fuel pump). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check For Bad F2 Or F3 Fuse Alarm
a. Check for Alarm 71 Alarm conditions must be corrected and the alarm cleared to continue.
2.
Check Fuel Solenoid & Circuit
a. Inspect fuel solenoid and wiring b. Check operation of Run Relay c. Check voltage to fuel solenoid
No physical damage to harness.
No damaged or corroded pins
No damage to solenoid
Energize circuits. (See Note 2) LED 28 must be ON
RS in Start/Run, Manual Start Mode (See Note 2)
12 VDC between FSCC (ground) & FSHA (hold)
With Manual Crank Switch in crank position
12 VDC between FSCC (ground) & FSPB (pick)
3.
4.
Check Fuel Solenoid Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic) b. Check operation of solenoid
Check Fuel Solenoid
No physical damage to harness.
No damaged or corroded pins
Plunger must move in when energized a. Check resistance of fuel solenoid Refer to Section 2.14
b. Check amp draw of fuel solenoid.
Use Component Test Mode (Section 5.2.5.2.2) to test.
Refer to Section 2.14 for amp values.
View current draw in Data List.
c. Check operation of solenoid Plunger must move in when energized
62-11039
7--78
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P153 CHECK RETURN AIR SENSOR
• TRIGGER–ON: Return Air Sensor is not within the range of --53°F to +158°F (--47°C to +70°C)
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
2.
3.
Check Return Air Sensor
a. Inspect Return Air Sensor & connector b. Check Return Air Sensor resistance
(See Note 4)
No physical damage to harness.
No moisture, damaged or corroded pins
1MP Plug is connected tightly to microprocessor. No wires are pushed back through plug.
10,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
Check Return Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
Check Remote Sensor Connector (2 Compartment Unit Only)
a.Locate and inspect remote sensor connector
Cap is in place.
No physical damage.
No moisture or corrosion.
P154 CHECK SUPPLY AIR SENSOR
•
TRIGGER–ON: Supply Air Sensor is not within the maximum range of --53°F to +158°F (--47°C to
+70°C)
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Supply Air Sensor
a. Inspect Supply Air Sensor & connector
No physical damage to harness.
No moisture, damaged or corroded pins b. Check Supply Air Sensor resistance
(See Note 4)
10,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
2.
3.
Check Supply Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Check Supply Sensor Connector
a.Locate and inspect remote sensor connector
No physical damage to harness.
No damaged or corroded pins
Cap is in place.
No physical damage.
No moisture or corrosion.
7--79
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P155 CHECK COOLANT TEMP SENSOR
• TRIGGER–ON: Engine Coolant Temp Sensor is not within the maximum range of --58°F to +266°F
(--50°C to +130°C)
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Engine Coolant Sensor
a. Inspect Engine Coolant Sensor & connector
No damage to sensor
No moisture, damage or corrosion in connector
2.
b. Check Engine Coolant Sensor resistance (See Note 4)
10,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
Check Engine Coolant Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
P156 CHECK BATTERY VOLTS
• TRIGGER–ON: Battery voltage is less than 11 VDC or greater than 17 VDC
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “pre--trip FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
2.
Check for Battery Voltage Too High Alarm
a. Check for Alarm 15 Alarm conditions must be corrected and the alarm cleared to continue.
Test battery charger output
Test battery condition
Check wiring connections between battery and battery charger
Check for Battery Voltage Too Low Alarm
a. Check for Alarm 16 Alarm conditions must be corrected and the alarm cleared to continue.
Test battery charger output
Test battery condition
Check wiring connections between battery and battery charger
62-11039
7--80
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P157 CHECK BATTERY CURRENT
• TRIGGER–ON: With all circuits off current flow of more than 1.5 amps is detected in the electrical circuits.
pre--trip
NOTE: If this alarm occurs, pre--trip Test #2 will not be performed. You will need to run again.
•
UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Battery Current Draw.
Must show plus or minus 0.2 amps
2.
a. Observe current draw on microprocessor display. (See Note
3)
Check No Load Current Draw
a. Check current draw at 12 VDC current sensor at micro
Energize circuit (see Note 2) b. Check micro current reading with no load
Remove wire from inside current sensor and check current draw in Unit Data List. Must be less than 1.0
Amp
3.
Check Individual Circuits
a. Isolate individual circuits and test amp draw
Must be in range. (Refer to Section 2.14)
P158 CHECK AMBIENT AIR SENSOR
•
TRIGGER–ON: Ambient Air Sensor is not within the maximum range of --53°F to +158°F (--47°C to
+70°C)
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Ambient Air Sensor
a. Inspect Ambient Air Sensor & connector
No damage to sensor
No moisture, damage or corrosion in connector
2.
3.
b. Check resistance
Ambient
(See Note 4)
Air Sensor 10,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
Check Ambient Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
Check Ambient Air Sensor Connector
a.Locate and inspect remote sensor connector
Cap is in place.
No physical damage.
No moisture or corrosion.
7--81
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P159 CHECK DEFROST TERM 1 SENSOR (COMPARTMENT 1)
• TRIGGER–ON: Defrost Termination Temperature Sensor 1 is not within the maximum range of
--53°F to +158°F (--47 °C to +70°0 C)
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Defrost Termination Temperature Sensor 1
a. Inspect Defrost Termination
Temperature Sensor 1 & connector
No damage to sensor
No moisture, damage or corrosion in connector
2.
3.
b. Check Defrost Termination
Temperature Sensor 1 resistance
(See Note 4)
10,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
Check Defrost Termination Temperature Sensor 1 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
Check Defrost Termination Temperature Sensor 1 Connector
a.Locate and inspect remote sensor connector
Cap is in place.
No physical damage.
No moisture or corrosion.
P160 CHECK DISCHARGE TEMP SENSOR
•
TRIGGER–ON: Compressor Discharge Temp Sensor is not within the maximum range of
--40°F to +392°F (--40°C to +200°C )
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Compressor Discharge Temp Sensor
a. Inspect Compressor Discharge
Temp Sensor & connector
No damage to sensor
No damage or corrosion in connector
1MP Plug is connected tightly to microprocessor. No wires are pushed back through plug.
2.
b. Check Compressor Discharge
Temp Sensor resistance (See Note
4)
100,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
Check Compressor Discharge Temp Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
62-11039
7--82
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
161 CHECK SUCTION TEMP SENSOR (CST)
• TRIGGER–ON: Suction Temp Sensor (CST) is not within the maximum range of --53°F to +158°F
(--47°C to +70°C)
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset when suction temperature sensor is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Suction Temp Sensor
a. Inspect Suction Temp Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector
2.
3.
b. Check Suction Temp Sensor resistance (See Note 4)
(Refer to Section 8.29 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
Check Suction Temp Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
Check Suction Temp Sensor Connector
a.Locate and inspect remote sensor connector
Cap is in place.
No physical damage.
No moisture or corrosion.
7--83
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P163 C3 CHECK HEATER 1 CIRCUIT
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON TEST 2: Normal amps for the 3HTCON1 contactor coil are .05 to 2.0 D/C Amps (12
VDC). The circuit tests outside this range.
• TRIGGER–ON TEST 8: Normal amps for the 3HTCON1 heaters are 0.5 to 7.0 A/C Amps (460
VAC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Determine Which Test This Alarm Occurred In
a. Review active alarm list b. Clear active alarm list
Make a note of all alarms c. Restart and monitor pre--trip Stop pre--trip during Test #3 by holding = Key for 6 seconds d. Review active alarm list for Alarm
146
If alarm is present, follow steps 2 thru 4. If alarm is not present, follow steps 5 thru 10.
2.
Check 3HTCON1
a. Inspect heater contactor coil and wire connections b. Check contactor coil resistance
No damage to coil
No damaged or corroded pins
Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
12 VDC
CIR-
CUIT
3.
Check 3HTCON1 Amp Draw
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
4.
Check 3HTCON1 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
62-11039
7--84
Alarm
NO.
460
VAC
CIR-
CUIT
Steps
8.
ALARM / CAUSE CORRECTIVE ACTION
P163 C3 CHECK HEATER 1 CIRCUIT (Continued)
5.
Check Evaporator High Temperature Switch (2EVHTS)
6.
a. Inspect for open 2EVHTS per wiring diagram
If open, replace switch as required
Check Amp Draw of 3HTCON1 Heater Circuit
a. Use a clamp on ammeter to check the current draw of all 3 legs.
Must be within range shown in Section 2.13 for all three legs.
7.
Check Heater Elements
a. Check heater elements No visual physical damage
No blockage due to debris
Remove and replace if required
Check Heater Element Plugs And Connections
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required
9.
b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Verify Accuracy of AC Current Sensor
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
10.
Check Heater Wiring
a. Use a clamp on ammeter to check the total current draw b. If no fault was found in previous tests
Compare to Unit Data
Remove and replace contactor
7--85
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P164 CHECK UL2 CIRCUIT
• TRIGGER–ON: Normal Amps for the UL2 (Rear) Unloader Circuit is 0.75 to 2.0 Amps. The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: Pretrip will fail and display “PRETRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check For Bad F4 And F6 Alarm
Pull fuse and test. Replace if required.
2.
a. Check for Alarm 72
Check UL2
a. Check amp draw of coil.
Use Component Test Mode (Section 5.2.5.2.2) to test.
Refer to Section 2.14 for amp values.
View current draw in Data List.
3.
b. Check resistance of UL1 coil
Check UL2 And Circuit
a. Inspect UL1 and wiring
Refer to Section 2.14
No damage or corrosion
Connector fits together tightly, no moisture inside b. Check operation of UL1 FET (23) Energize circuit (see Note 2) LED must be ON
4.
c. Check voltage to front unloader
Check UL2 Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Must be 11 VDC or higher across the 2 wires
No physical damage to harness.
No damaged or corroded pins
62-11039
7--86
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P166 C2 CHK SUPPLY AIR SENSOR
• TRIGGER–ON: Supply Air Sensor is not within the range of --53°F to +158°F (--47°C to +70°C)
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
2.
3.
Check Supply Air Sensor
a. Inspect Return Air Sensor & connector b. Check Return Air Sensor resistance
(See Note 4)
No physical damage to harness.
No moisture, damaged or corroded pins
1MP Plug is connected tightly to microprocessor. No wires are pushed back through plug.
10,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
Check Supply Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
Check Remote Sensor Connector (2 Compartment Unit Only)
a.Locate and inspect remote sensor connector
Cap is in place.
No physical damage.
No moisture or corrosion.
7--87
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P167 C3 CHECK HEATER 2 CIRCUIT
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON TEST 2: Normal amps for the 3HTCON2 contactor coil are .05 to 5.0 D/C Amps (12
VDC). The circuit tests outside this range.
• TRIGGER–ON TEST 8: Normal amps for the 3HTCON2 heaters are 0.5 to 7.0 A/C Amps (460
VAC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Determine Which Test This Alarm Occurred In
a. Review active alarm list b. Clear active alarm list
Make a note of all alarms c. Restart and monitor pre--trip Stop pre--trip during Test #3 by holding = Key for 6 seconds d. Review active alarm list for Alarm
146
If alarm is present, follow steps 2 thru 4. If alarm is not present, follow steps 5 thru 10.
2.
Check 3HTCON2
a. Inspect heater contactor coil and wire connections b. Check contactor coil resistance
No damage to coil
No damaged or corroded pins
Cannot be opened (infinite ohms); Shorted (Zero
Ohms) or shorted to ground
12 VDC
CIR-
CUIT
3.
Check 3HTCON2 Amp Draw
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
4.
Check 3HTCON2 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
62-11039
7--88
Alarm
NO.
460
VAC
CIR-
CUIT
Steps
8.
ALARM / CAUSE CORRECTIVE ACTION
P167 C3 CHECK HEATER 2 CIRCUIT (Continued)
5.
Check Evaporator High Temperature Switch (2EVHTS)
6.
a. Inspect for open 2EVHTS per wiring diagram
If open, replace switch as required
Check Amp Draw of 3HTCON2 Heater Circuit
a. Use a clamp on ammeter to check the current draw of all 3 legs.
Must be within range shown in Section 2.13 for all three legs.
7.
Check Heater Elements
a. Check heater elements No visual physical damage
No blockage due to debris
Remove and replace if required
Check Heater Element Plugs And Connections
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required
9.
b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Verify Accuracy of AC Current Sensor
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
10.
Check Heater Wiring
a. Use a clamp on ammeter to check the total current draw b. If no fault was found in previous tests
Compare to Unit Data
Remove and replace contactor
7--89
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P168 C2 CHECK LSV VALVE
• TRIGGER–ON: In Test 2: Compartment 2 Liquid Solenoid Valve (LSV2) current is outside the range of 0.75A to 2.0A; OR
In Test 14: The suction pressure did not rise as expected when the LSV2 was energized (opened).
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset when LSV2 output is active, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Test 2 alarm:Check C2 LSV Coil
a. Inspect component & wire connections b. Check resistance of UL1 coil
No damage to coil
No damage, moisture, or corrosion in pins
Use component test mode to check circuit
Refer to Section 2.14
2.
3.
Test 2 alarm:Check C2 LSV Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Test 14 alarm: Check C2 LSV Valve
a. Manually check operation of C2
LSV valve for proper opening and closing.
No physical damage to harness.
No damaged or corroded pins
Refer to section 8.10.
C2 LSV must open and close correctly.
62-11039
7--90
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P171 CHECK EVAP & DISC PRESS
• TRIGGER–ON: During Test 3, prior to the engine starting, the SMV and the EVXV are both opened to allow the refrigerant system high and low side pressures to equalize. The compressor discharge pressure is less than 170 psig, and the evaporator pressure is more than 80 psig less than the discharge pressure. (This alarm will not become active when the discharge pressure is above 170 psig.)
•
UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset when LSV2 output is active, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check that King Valve is open
a. Verify that the King Valve is fully backseated.
King Valve must be backseated to proceed.
1.
Check SMV
a. Inspect component & wire connections b. Check
No damage to coil
No damage, moisture, or corrosion in pins
Connections all plugged in securely.
Refer to Section 2.14.
2.
a.Check CSMV operation using check out procedure (See Section 8.24.2)
Check EVXV
a. Inspect EVXV b. Inspect component and wire connections c.Check coil resistance
Must perform correctly.
Check to see if coil is seated on valve properly.
(See Section 8.18 for checking and servicing EVXV) d.Check coil resistance e. Check basic refrigeration system f. Check the EVXV electrical system a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
7--91
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P174 CHECK LOW SPEED RPM
• TRIGGER–ON: With speed relay turned off (speed solenoid de--energized), engine speed is NOT between 1350 and 1580 rpm. If rpm sensor alarm is active, this test will be skipped.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Verify That Correct Model Number Is Selected
a. Compare model number from unit
I.D. label and model number in micro Data List.
The model numbers must be the same.
2.
3.
Check Speed Solenoid & Linkage
a. Check speed solenoid plunger a.Change setpoint to within  0.5°
( 0.3°C) of box temperature.
b. Check operation of Speed Relay
LED
Must move in and out freely b. Check engine speed arm & linkage Must move freely
Force Low Speed Operation
Unit will run in low speed. RPM must be within range shown above for each specific model. Adjust speed linkage as needed.
LED 27 must be OFF
4.
5.
6.
c. Check voltage to speed solenoid Must be 0 VDC
Check Engine Air-intake System
a. Check air filter indicator b. Inspect air intake system
Flag must not be visible.
Hoses & tubes in good condition.
No kinks or restrictions
Check Engine Exhaust System
a. Inspect the exhaust system
Check Engine RPM
a. Check actual engine RPM using hand held tachometer b. Compare actual RPM with those shown on display.
Must be clear and unobstructed
Refer to Section 2.9
Adjust engine linkage setting as needed.
Both readings within ± 50 RPM
62-11039
7--92
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P175 CHECK HIGH SPEED RPM
• TRIGGER–ON: With Speed Relay turned on (speed solenoid energized), engine RPM are NOT between 1700 and 2075. If RPM sensor alarm is active, this test will be skipped
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Verify That Correct Model Number Is Selected
a. Compare model number from unit
I.D. label and model number in micro Data List.
The model numbers must be the same.
2.
3.
Check Speed Solenoid Linkage
a. Check speed solenoid plunger a. Change setpoint if necessary to more than 10°F (5.6°C) away from setpoint.
Must move in and out freely b. Check engine speed arm & linkage Must move freely
Force High Speed Operation (See Note 6)
Controller will call for High Speed operation.
4.
b. Check operation of Speed Relay LED 27 must be ON c. Check voltage to speed solenoid Must be 12--14 VDC
Check Engine Air-intake System
a. Check air filter indicator b. Inspect air intake system
Flag must not be visible.
Hoses & tubes in good condition.
No kinks or restrictions
5.
6.
Check Engine Exhaust System
a. Inspect the exhaust system
Check Engine RPM
a. Check actual engine RPM using hand held tachometer b. Compare actual RPM with those shown on display
Must be clear and unobstructed
Refer to Section 2.9
Adjust engine linkage setting as needed.
Both readings within ± 50 RPM
7--93
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P176 C3 CHECK LSV VALVE
• TRIGGER–ON: Compartment 3 Liquid Solenoid Valve (LSV3) current is outside the range of 0.75A
to 2.0A
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset when LSV2 output is active, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check LSV3
a. Inspect component & wire connections b. Check resistance of LSV3 coil
No damage to coil
No damage, moisture, or corrosion in pins
Use component test mode to check circuit
Refer to Section 2.14
2.
Check LSV3 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
P177 CHECK EVAP SUPERHEAT
• TRIGGER–ON: After microprocessor closes the EVXV, evaporator pressure fails to drop by 20 psig
(1.36 Bar) or fails to go below 0 psig
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Valve
a. Inspect EVXV b. Inspect component and wire connections
Check to see if coil is seated on valve properly.
(See Section 8.18 for checking and servicing EVXV) c.Check coil resistance d.Check coil resistance e. Check basic refrigeration system f. Check the EVXV electrical system
62-11039
7--94
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P178 CHECK UL1
• TRIGGER–ON: The pressure differential between suction and discharge pressures did not change as expected when the UL1 (Front/Rear) Unloader was de-energized/loaded (discharge pressure should rise and suction pressure should drop) or when it was energized/unloaded (discharge pressure should drop and suction pressure should rise.
•
UNIT CONTROL: Engine and standby operation: Pretrip will fail and display “PRETRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check wiring to DPT & SPT
a. Verify that correct wires are connected to each transducer
Plugs to transducers are the same. The correct wire plug must be connected to the proper transducer.
2.
3.
Check for Check UL1 Alarm
a. Check for alarm 85 or P144 Alarm conditions must be corrected and the alarm cleared to continue
Confirm Compressor Suction Pressure Transducer Is Working
a. Check CSP Attach manifold gauge set and compare CSP reading from microprocessor display.
Repair and Replace if required.
7--95
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P180 CHECK SUCTION MOD VALVE
• TRIGGER–ON: After microprocessor attempts to close CSMV, suction pressure fails to drop below
4in. Hg (--0.14 Bar)
• UNIT CONTROL: Engine and standby operation: Pretrip will fail and display “PRETRIP FAIL IN
TEST 11”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Software Revision Level
Revision level must be 04.06.00 or higher.
2.
a.Upgrade software.
Check Compressor Operation
a.Close suction service valve Check to see if compressor is capable of pulling a vacuum. During test, do not stay in a vacuum longer than 2 minutes. Vacuum should read --4.13--in. Hg
(–0.14 Bar)
3.
4.
If compressor will not pump down, repair or replace compressor.
Check Suction Modulating Valve
a.Check CSMV operation using check out procedure (See Section 8.24.2)
Must perform correctly.
Check Suction Modulating Valve (With Good Compressor)
a.Inspect CSMV Check to see if coil is operating per Section 8.24.1
b.Inspect
component and wire connections
No damage to coil
No damaged or corroded pins c.Check the CSMV electrical system Remove and replace piston and coil assembly if required
See Section 8.24.1
62-11039
7--96
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P184 C2 CHECK EVAP FAN MOTOR
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON TEST 2: Normal amps for the 2EVCON contactor coil are .05 to 2.0 D/C Amps (12
VDC). The circuit tests outside this range.
• TRIGGER–ON TEST 8: Normal amps for the Compartment 2 Evap Fan motors are 0.1 to 2.0 A/C
Amps (460 VAC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Determine Which Test This Alarm Occurred In
a. Review active alarm list b. Clear active alarm list
Make a note of all alarms c. Restart and monitor pre--trip Stop pre--trip during Test #3 by holding = Key for 6 seconds d. Review active alarm list for Alarm
146
If alarm is present, follow steps 2 thru 4. If alarm is not present, follow steps 5 thru 10.
2.
Check 2EVCON
a. Inspect heater contactor coil and wire connections
No damage to coil
No damaged or corroded pins
Refer to Section 2.14
12 VDC
CIR-
CUIT
3.
b. Check contactor coil resistance
Check 2EVCON Amp Draw
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
4.
Check 2EVCON Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
7--97
62-11039
Alarm
NO.
460
VAC
CIR-
CUIT
Steps
8.
ALARM / CAUSE CORRECTIVE ACTION
P184 C2 CHECK EVAP FAN MOTOR (Continued)
5.
Check Evaporator High Temperature Switch (2EVHTS)
6.
a. Inspect for open 2EVHTS per wiring diagram
If open, replace switch as required
Check Amp Draw of 2EVCON Heater Circuit
a. Use a clamp on ammeter to check the current draw of all 3 legs.
Must be within range shown in Section 2.13 for all three legs.
7.
Check Heater Elements
a. Check heater elements No visual physical damage
No blockage due to debris
Remove and replace if required
Check Heater Element Plugs And Connections
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required
9.
b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Verify Accuracy of AC Current Sensor
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
10.
Check Heater Wiring
a. Use a clamp on ammeter to check the total current draw b. If no fault was found in previous tests
Compare to Unit Data
Remove and replace contactor
62-11039
7--98
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P185 C3 CHECK EVAP FAN MOTOR
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON TEST 2: Normal amps for the 3EVCON contactor coil are .05 to 2.0 D/C Amps (12
VDC). The circuit tests outside this range.
• TRIGGER–ON TEST 8: Normal amps for the Compartment 3 Evap Fan motors are 0.1 to 2.0 A/C
Amps (460 VAC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Determine Which Test This Alarm Occurred In
a. Review active alarm list b. Clear active alarm list
Make a note of all alarms c. Restart and monitor pre--trip Stop pre--trip during Test #3 by holding = Key for 6 seconds d. Review active alarm list for Alarm
146
If alarm is present, follow steps 2 thru 4. If alarm is not present, follow steps 5 thru 10.
2.
Check 3EVCON
a. Inspect heater contactor coil and wire connections
No damage to coil
No damaged or corroded pins
Refer to Section 2.14
12 VDC
CIR-
CUIT
3.
b. Check contactor coil resistance
Check 3EVCON Amp Draw
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
4.
Check 3EVCON Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
7--99
62-11039
Alarm
NO.
460
VAC
CIR-
CUIT
Steps
8.
ALARM / CAUSE CORRECTIVE ACTION
P185 C3 CHECK EVAP FAN MOTOR (Continued)
5.
Check Evaporator High Temperature Switch (2EVHTS)
6.
a. Inspect for open 2EVHTS per wiring diagram
If open, replace switch as required
Check Amp Draw of 3EVCON Heater Circuit
a. Use a clamp on ammeter to check the current draw of all 3 legs.
Must be within range shown in Section 2.13 for all three legs.
7.
Check Heater Elements
a. Check heater elements No visual physical damage
No blockage due to debris
Remove and replace if required
Check Heater Element Plugs And Connections
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required
9.
b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Verify Accuracy of AC Current Sensor
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
10.
Check Heater Wiring
a. Use a clamp on ammeter to check the total current draw b. If no fault was found in previous tests
Compare to Unit Data
Remove and replace contactor
62-11039
7--100
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P186 CHECK EVAP OUTLET TEMP
• TRIGGER–ON: Evaporator Outlet Temperature Sensor is not within the maximum range of --53°F to +158°F (--47°C to +70°C)
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Return Air Sensor
a. Inspect Return Air Sensor & connector
No physical damage to harness.
No moisture, damaged or corroded pins
1MP Plug is connected tightly to microprocessor. No wires are pushed back through plug.
2.
3.
b. Check Return Air Sensor resistance
(See Note 4)
10,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
Check Return Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
Check Remote Sensor Connector (Two Compartment Units Only)
a.Locate and inspect remote sensor connector
Cap is in place.
No physical damage.
No moisture or corrosion.
7--101
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P187 CHECK HEATER 1 CIRCUIT
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON TEST 2: Normal amps for the HTCON1R relay coil are 0 to 1.0 D/C Amps (12
VDC). The circuit tests outside this range.
• TRIGGER–ON TEST 8: Normal amps for the HTCON1 heaters are 2.0 to 7.5 A/C Amps (460
VAC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Determine Which Test This Alarm Occurred In
a. Review active alarm list b. Clear active alarm list
Make a note of all alarms c. Restart and monitor pre--trip Stop pre--trip during Test #3 by holding = Key for 6 seconds d. Review active alarm list for Alarm
146
If alarm is present, follow steps 2 thru 4. If alarm is not present, follow steps 5 thru 10.
2.
Check HTCON1R
a. Inspect heater contactor coil and wire connections
No damage to coil
No damaged or corroded pins
Refer to Section 2.14
12 VDC
CIR-
CUIT
3.
b. Check contactor coil resistance
Check HTCON1R Amp Draw
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
4.
Check HTCON1R Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
62-11039
7--102
Alarm
NO.
460
VAC
CIR-
CUIT
Steps
8.
ALARM / CAUSE CORRECTIVE ACTION
P187 CHECK HEATER 1 CIRCUIT (Continued)
5.
Check Evaporator High Temperature Switch (2EVHTS)
6.
a. Inspect for open 2EVHTS per wiring diagram
If open, replace switch as required
Check Amp Draw of HTCON1R Heater Circuit a. Use a clamp on ammeter to check the current draw of all 3 legs.
Must be within range shown in Section 2.13 for all three legs.
7.
Check Heater Elements
a. Check heater elements No visual physical damage
No blockage due to debris
Remove and replace if required
Check Heater Element Plugs And Connections
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required
9.
b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Verify Accuracy of AC Current Sensor
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
10.
Check Heater Wiring
a. Use a clamp on ammeter to check the total current draw b. If no fault was found in previous tests
Compare to Unit Data
Remove and replace contactor
7--103
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P188 CHECK HEATER 2 CIRCUIT
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON TEST 2: Normal amps for the HTCON2 contactor coil are .05 to 2.0 D/C Amps (12
VDC). The circuit tests outside this range.
• TRIGGER–ON TEST 8: Normal amps for the HTCON2 heaters are 1.0 to 3.5 A/C Amps (460
VAC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Determine Which Test This Alarm Occurred In
a. Review active alarm list b. Clear active alarm list
Make a note of all alarms c. Restart and monitor pre--trip Stop pre--trip during Test #3 by holding = Key for 6 seconds d. Review active alarm list for Alarm
146
If alarm is present, follow steps 2 thru 4. If alarm is not present, follow steps 5 thru 10.
2.
Check HTCON2
a. Inspect heater contactor coil and wire connections
No damage to coil
No damaged or corroded pins
Refer to Section 2.14
12 VDC
CIR-
CUIT
3.
b. Check contactor coil resistance
Check HTCON2 Amp Draw
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
4.
Check HTCON2 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
62-11039
7--104
Alarm
NO.
460
VAC
CIR-
CUIT
Steps
8.
ALARM / CAUSE CORRECTIVE ACTION
P188 CHECK HEATER 2 CIRCUIT (Continued)
5.
Check Evaporator High Temperature Switch (2EVHTS)
6.
a. Inspect for open 2EVHTS per wiring diagram
If open, replace switch as required
Check Amp Draw of HTCON2 Heater Circuit
a. Use a clamp on ammeter to check the current draw of all 3 legs.
Must be within range shown in Section 2.13 for all three legs.
7.
Check Heater Elements
a. Check heater elements No visual physical damage
No blockage due to debris
Remove and replace if required
Check Heater Element Plugs And Connections
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required
9.
b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Verify Accuracy of AC Current Sensor
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
10.
Check Heater Wiring
a. Use a clamp on ammeter to check the total current draw b. If no fault was found in previous tests
Compare to Unit Data
Remove and replace contactor
7--105
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P189 CHECK EVAPORATOR FAN MOTOR
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON TEST 2: Normal amps for the 1EVCON contactor coil are .05 to 2.0 D/C Amps (12
VDC). The circuit tests outside this range.
• TRIGGER–ON TEST 8: Normal amps for the Compartment 1 Evaporator Fan motors are 0.7 to 3.5
A/C Amps (460 VAC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Determine Which Test This Alarm Occurred In
a. Review active alarm list b. Clear active alarm list
Make a note of all alarms c. Restart and monitor pre--trip Stop pre--trip during Test #3 by holding = Key for 6 seconds d. Review active alarm list for Alarm
146
If alarm is present, follow steps 2 thru 4. If alarm is not present, follow Steps 5 thru 10.
2.
Check 1EVCON
a. Inspect heater contactor coil and wire connections
No damage to coil
No damaged or corroded pins
Refer to Section 2.14
12 VDC
CIR-
CUIT
3.
b. Check contactor coil resistance
Check 1EVCON Amp Draw
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
4.
Check 1EVCON Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
62-11039
7--106
Alarm
NO.
460
VAC
CIR-
CUIT
Steps
8.
ALARM / CAUSE CORRECTIVE ACTION
P189 CHECK EVAPORATOR FAN MOTOR (Continued)
5.
Check Evaporator High Temperature Switch (2EVHTS)
6.
a. Inspect for open 2EVHTS per wiring diagram
If open, replace switch as required
Check Amp Draw of 1EVCON Heater Circuit
a. Use a clamp on ammeter to check the current draw of all 3 legs.
Must be within range shown in Section 2.13 for all three legs.
7.
Check Heater Elements
a. Check heater elements No visual physical damage
No blockage due to debris
Remove and replace if required
Check Heater Element Plugs And Connections
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required
9.
b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Verify Accuracy of AC Current Sensor
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
10.
Check Heater Wiring
a. Use a clamp on ammeter to check the total current draw b. If no fault was found in previous tests
Compare to Unit Data
Remove and replace contactor
7--107
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P190 CHECK CONDENSER FAN MOTOR
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON TEST 2: Normal amps for the CDCON contactor coil are .05 to 2.0 D/C Amps (12
VDC). The circuit tests outside this range.
• TRIGGER–ON TEST 8: Normal amps for the condenser fan motors are 0.8 to 3.5 A/C Amps (460
VAC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Evaporator High Temperature Switch (2EVHTS)
a. Inspect for open 2EVHTS per wiring diagram
If open, replace switch as required
2.
Check Amp Draw of CDCON Heater Circuit
a. Use a clamp on ammeter to check the current draw of all 3 legs.
Must be within range shown in Section 2.13 for all three legs.
3.
460
VAC
CIR-
CUIT
4.
5.
6.
Check Heater Elements
a. Check heater elements No visual physical damage
No blockage due to debris
Remove and replace if required
Check Heater Element Plugs And Connections
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Verify Accuracy of AC Current Sensor
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Check Heater Wiring
a. Use a clamp on ammeter to check the total current draw b. If no fault was found in previous tests
Compare to Unit Data
Remove and replace contactor
62-11039
7--108
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P191 CHECK UL2
• TRIGGER–ON: The pressure differential between suction and discharge pressures did not change as expected when the UL2 (Front/Rear) Unloader was de-energized/loaded (discharge pressure should rise and suction pressure should drop) or when it was energized/unloaded (discharge pressure should drop and suction pressure should rise.
•
UNIT CONTROL: Engine and standby operation: Pretrip will fail and display “PRETRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check wiring to DPT & SPT
a. Verify that correct wires are connected to each transducer
Plugs to transducers are the same. The correct wire plug must be connected to the proper transducer.
2.
3.
Check for Check UL2 Alarm
a. Check for alarm 86 or P164 Alarm conditions must be corrected and the alarm cleared to continue
Confirm Compressor Suction Pressure Transducer Is Working
a. Check CSP Attach manifold gauge set and compare CSP reading from microprocessor display.
Repair and Replace if required.
7--109
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P199 C2 CHECK RETURN AIR SENSOR
• TRIGGER–ON: Compartment 2 Return Air Sensor is not within the maximum range of --53°F to
+158°F (--47°C to +70°C)
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Return Air Sensor
a. Inspect Return Air Sensor & connector
No physical damage to harness.
No moisture, damaged or corroded pins
1MP Plug is connected tightly to microprocessor. No wires are pushed back through plug.
2.
b. Check Return Air Sensor resistance
(See Note 4)
Check Return Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
10,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
No physical damage to harness.
No damaged or corroded pins
62-11039
7--110
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P206 CHECK CONDENSER FAN CIRCUIT
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON TEST 2: Normal amps for the CDCON contactor are .05 to 2.0 D/C Amps (12
VDC). The circuit tests outside this range.
• TRIGGER–ON TEST 8: Normal amps for the Condenser Fan motors are 0.7 to 3.5 A/C Amps (460
VAC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
•
RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Determine Which Test This Alarm Occurred In
a. Review active alarm list b. Clear active alarm list
Make a note of all alarms c. Restart and monitor pre--trip Stop pre--trip during Test #3 by holding = Key for 6 seconds d. Review active alarm list for Alarm
146
If alarm is present, follow steps 2 thru 4. If alarm is not present, follow Steps 5 thru 10.
2.
Check CDCON
a. Inspect heater contactor coil and wire connections
No damage to coil
No damaged or corroded pins
Refer to Section 2.14
12 VDC
CIR-
CUIT
3.
b. Check contactor coil resistance
Check CDCON Amp Draw
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
4.
Check CDCON Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
7--111
62-11039
Alarm
NO.
460
VAC
CIR-
CUIT
Steps
8.
ALARM / CAUSE CORRECTIVE ACTION
P206 CHECK CONDENSER FAN CIRCUIT (Continued)
5.
Check Evaporator High Temperature Switch (2EVHTS)
6.
a. Inspect for open 2EVHTS per wiring diagram
If open, replace switch as required
Check Amp Draw of 1EVCON Heater Circuit
a. Use a clamp on ammeter to check the current draw of all 3 legs.
Must be within range shown in Section 2.13 for all three legs.
7.
Check Heater Elements
a. Check heater elements No visual physical damage
No blockage due to debris
Remove and replace if required
Check Heater Element Plugs And Connections
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required
9.
b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
Verify Accuracy of AC Current Sensor
a. Disconnect heater element plug Heater resistance per Section 2.13
Remove and replace heaters if required b. Inspect plugs, plug seal and connectors.
No corrosion, water damage or burning/discoloration
Remove and replace if required
10.
Check Heater Wiring
a. Use a clamp on ammeter to check the total current draw b. If no fault was found in previous tests
Compare to Unit Data
Remove and replace contactor
62-11039
7--112
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P207 CHK COMPRESSOR CONTACT CIRC
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON: Normal amps for the CCONR relay coil are .0 to 1.0 D/C Amps (12 VDC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
2.
Check CCONR
a. Inspect heater contactor coil and wire connections b. Check contactor coil resistance
Check CCONR Amp Draw
No damage to coil
No damaged or corroded pins
Refer to Section 2.14
12 VDC
CIR-
CUIT
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
3.
Check CCONR Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
7--113
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P208 CHK GENERATOR CONT CIRC
This device is checked twice in pre--trip -- once in Test 2 and again in Test 8.
•
TRIGGER–ON: Normal amps for the GENCONR relay coil are .0 to 1.0 D/C Amps (12 VDC). The circuit tests outside this range.
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
2.
Check GENCONR
a. Inspect heater contactor coil and wire connections b. Check contactor coil resistance
Check GENCONR Amp Draw
No damage to coil
No damaged or corroded pins
Refer to Section 2.14
12 VDC
CIR-
CUIT
a. Check 2HTCON1 amp draw Use Component Test Mode (Section 5.2) to test.
Refer to Section 2.14 for amp values. View current draw in Data List.
3.
Check GENCONR Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes 2 & 6
No physical damage to harness.
No damaged or corroded pins
62-11039
7--114
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P209 CHECK STANDBY CONT CIRCUIT
• TRIGGER–ON: Normal amps for the PSCONR relay coil and PSCON or PSCON2 contactor coils is 0.0 to 1.0 amps. The circuit(s) test outside this range. (During this test either PSCON or
PSCON2 will be tested depending on the phase reversal module.)
•
UNIT CONTROL: Engine and standby operation: Pretrip will fail and display “PRETRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
NOTE: IF PRE--TRIP IS DONE IN STANDBY MODE, THIS PRE--TRIP ALARM WILL GENERATE MANY
OTHER PRE--TRIP ALARMS. THEREFORE, IT SHOULD BE ADDRESSED FIRST
1.
Determine Which Component/Circuit Is At Fault
a.Test
PSCONR,
PSCON2
PSCON and Use Component Test Modes
Refer to Section 2.14 for Amp Values
2.
b. Check relay coil resistance
Check Faulty Component/Circuit From Test 1 Above
a. Check relay coil resistance Refer to Section 2.14
3.
4.
Check Component Circuit Wiring
a. Inspect component and wiring b. Check operation of component FET
(19)
No damage or corrosion
Connector fits together tightly, no moisture inside
Energize circuit (see Note 2) LED must be ON c. Check voltage to component
Check Component Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Must be 11 VDC or higher across the 2 wires
No physical damage to harness.
No damaged or corroded pins
7--115
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P210 C3 CHECK RETURN AIR SENSOR
• TRIGGER–ON: Compartment 3 Return Air Sensor is not within the maximum range of --53°F to
+158°F (--47°C to +70°C)
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Return Air Sensor
a. Inspect Return Air Sensor & connector
No physical damage to harness.
No moisture, damaged or corroded pins
1MP Plug is connected tightly to microprocessor. No wires are pushed back through plug.
2.
b. Check Return Air Sensor resistance
(See Note 4)
Check Return Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
10,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
No physical damage to harness.
No damaged or corroded pins
62-11039
7--116
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P211 CHECK DEFROST SENSOR (2DTT)
• TRIGGER–ON: Defrost Sensor for Compartment 2 is not within the range of --53°F to +158°F
(--47°C to +70°C)
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Compartment 2 Defrost Sensor
a. Inspect Return Air Sensor & connector
No physical damage to harness.
No moisture, damaged or corroded pins
1MP Plug is connected tightly to microprocessor. No wires are pushed back through plug.
2.
3.
b. Check Return Air Sensor resistance
(See Note 4)
10,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
Check Compartment 2 Defrost Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
Check Remote Sensor Connector (2 Compartment Units Only)
a.Locate and inspect remote sensor connector
Cap is in place.
No physical damage.
No moisture or corrosion.
P212 C3 CHECK DEFROST SENSOR (3DTT)
•
TRIGGER–ON: Defrost Sensor for Compartment 3 is not within the range of --53°F to +158°F
(--47°C to +70°C)
• UNIT CONTROL: Engine and standby operation: pre--trip will fail and display “PRE--TRIP FAIL AND
COMPLETED”.
• RESET CONDITION: Auto Reset if pre--trip mode is started again, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs.
Continue with the steps below as necessary.
1.
Check Compartment 3 Defrost Sensor
a. Inspect Return Air Sensor & connector
No physical damage to harness.
No moisture, damaged or corroded pins
1MP Plug is connected tightly to microprocessor. No wires are pushed back through plug.
2.
b. Check Return Air Sensor resistance
(See Note 4)
10,000 Ohms @ 77°F (25°C) [See manual for complete table of temperatures and resistance values.]
Check Compartment 3 Defrost Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No physical damage to harness.
No damaged or corroded pins
7--117
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
223 ENGINE MAINTENANCE DUE
7.10 MAINTENANCE ALARMS
• TRIGGER–ON: The Engine Maintenance Hour Meter time has expired.
• UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on.
• RESET CONDITION: Alarm may be manually reset via keypad.
1.
Check Unit Maintenance Records
a. Schedule unit into service facility for maintenance
Must be done soon!
2.
3.
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Follow instructions on proper maintenance form
Reset Engine Maintenance Hour Meter
a. Check that the Engine Maintenance
Hour Meter interval is set for your requirements.
Reset Interval in Configuration List as required.
b. Reset Engine Maintenance Hour
Meter for the next service interval
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in
Section 8.1.
224 STANDBY MAINTENANCE DUE
• TRIGGER–ON: The electric motor Hour Meter time has expired.
• UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on.
•
RESET CONDITION: Alarm may be manually reset via keypad.
1.
2.
3.
Check Unit Maintenance Records
a. Schedule unit into service facility for maintenance
Perform Maintenance
Must be done soon!
a. Perform appropriate engine & unit maintenance
Follow instructions on proper maintenance form
Reset General Maintenance Hour Meter
a. Check that the set for your requirements.
General
Maintenance Hour Meter interval is
Reset Interval in Configuration List as required.
b. Reset General Maintenance Hour
Meter for the next service interval
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in
Section 8.1.
62-11039
7--118
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
225 GENERAL MAINTENANCE DUE
• TRIGGER–ON: The General Maintenance Hour Meter time has expired.
• UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on.
• RESET CONDITION: Alarm may be manually reset via keypad.
1.
Check Unit Maintenance Records
a. Schedule unit into service facility for maintenance
Must be done soon!
2.
3.
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Follow instructions on proper maintenance form
Reset General Maintenance Hour Meter
a. Check that the set for your requirements.
General
Maintenance Hour Meter interval is
Reset Interval in Configuration List as required.
b. Reset General Maintenance Hour
Meter for the next service interval
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in
Section 8.1.
226 SERVICE SOON--PM #1 DUE
• TRIGGER–ON: The Maintenance Hour Meter #1 time has expired.
• UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on.
•
RESET CONDITION: Alarm may be manually reset via keypad.
1.
2.
3.
Check Unit Maintenance Records
a. Schedule unit into service facility for maintenance
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Reset Maintenance Hour Meter #1
a. Check that Maintenance Hour
Meter #1 interval is set for your requirements.
b. Reset Maintenance Hour Meter #1 for the next service interval
Must be done soon!
Follow instructions on proper maintenance form
Reset Interval in Configuration List as required.
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in
Section 8.1.
7--119
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
227 SERVICE SOON--PM #2 DUE
• TRIGGER–ON: The Maintenance Hour Meter #2 time has expired.
• UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on.
• RESET CONDITION: Alarm may be manually reset via keypad.
1.
Check Unit Maintenance Records
a. Schedule unit into service facility for maintenance
Must be done soon!
2.
3.
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Reset Maintenance Hour Meter #2
a. Check that Maintenance Hour
Meter #2 interval is set for your requirements.
b. Reset Maintenance Hour Meter #2 for the next service interval
Follow instructions on proper maintenance form
Reset Interval in Configuration List as required.
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in
Section 8.1.
228 SERVICE SOON--PM #3 DUE
• TRIGGER–ON: The Maintenance Hour Meter #3 time has expired.
• UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on.
•
RESET CONDITION: Alarm may be manually reset via keypad.
1.
2.
3.
Check Unit Maintenance Records
a. Schedule unit into service facility for maintenance
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Reset Maintenance Hour Meter #3
a. Check that Maintenance Hour
Meter #3 interval is set for your requirements.
b. Reset Maintenance Hour Meter #3 for the next service interval
Must be done soon!
Follow instructions on proper maintenance form
Reset Interval in Configuration List as required.
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in
Section 8.1.
62-11039
7--120
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
229 SERVICE SOON--PM #4 DUE
• TRIGGER–ON: The Maintenance Hour Meter #4 time has expired.
• Alarm Light will NOT be turned on.
• RESET CONDITION: Alarm may be manually reset via keypad.
1.
Check Unit Maintenance Records
a. Schedule unit into service facility for maintenance
Must be done soon!
2.
3.
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Reset Maintenance Hour Meter #4
a. Check that Maintenance Hour
Meter #4 interval is set for your requirements.
b. Reset Maintenance Hour Meter #4 for the next service interval
Follow instructions on proper maintenance form
Reset Interval in Configuration List as required.
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in
Section 8.1.
230 SERVICE SOON--PM #5 DUE
• TRIGGER–ON: The Maintenance Hour Meter #5 time has expired.
• UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on.
•
RESET CONDITION: Alarm may be manually reset via keypad.
1.
2.
3.
Check Unit Maintenance Records
a. Schedule unit into service facility for maintenance
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Reset Maintenance Hour Meter #5
a. Check that Maintenance Hour
Meter #5 interval is set for your requirements.
b. Reset Maintenance Hour Meter #5 for the next service interval
Must be done soon!
Follow instructions on proper maintenance form
Reset Interval in Configuration List as required.
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in
Section 8.1.
7--121
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
7.11 MICROPROCESSOR ALARMS
232 SETPOINT ERROR
• TRIGGER–ON: There is an error in the Setpoint that is stored in the microprocessor memory
• UNIT CONTROL: Unit Shutdown & Alarm
• RESET CONDITION: Auto Reset when a valid Setpoint is entered, or alarm may be manually reset by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Setpoint
a. Check Setpoint setting b. Enter new Setpoint
Must be between --30°C to +32°C (--22°F to +89.6°F)
2.
Reset Microprocessor
a. Turn the RS off for 30 seconds, then turn back on.
b. Valid Setpoint can not be entered.
The microprocessor powers up OK and the latest setpoint appears in the display.
Replace microprocessor
233 MODEL # ERROR
•
TRIGGER–ON: There is an error in the Model Number that is stored in the microprocessor memory
• UNIT CONTROL: Unit Shutdown & Alarm
• RESET CONDITION: Auto Reset only when a valid Model number is entered.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Model Number
a. Check Model Number in microprocessor
Must be a valid Model Number from Configuration
List.
b. Enter correct Model Number
From Configuration List, select correct Model
Number.
2.
Reset Microprocessor
a. Turn RS off for 30 seconds, then turn back on.
Microprocessor powers up OK b. Check for valid Model number in
Data List.
Valid number is present.
Alarm is cleared c. Valid model number can not be entered.
Replace microprocessor
62-11039
7--122
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
234 UNIT SERIAL # ERROR
• TRIGGER–ON: There is an error in the Unit Serial Number that is stored in the microprocessor memory
• UNIT CONTROL: Unit Shutdown & Alarm
• RESET CONDITION: Auto Reset only when a valid Model number is entered.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Unit Serial Number
a. Check Model Number in microprocessor
Must be a valid Model Number from Configuration
List.
b. Enter correct Model Number
From Configuration List, select correct Model
Number.
2.
Reset Microprocessor
a. Turn RS off for 30 seconds, then turn back on.
Microprocessor powers up OK b. Check for valid Model number in
Data List.
Valid number is present.
Alarm is cleared c. Valid model number can not be entered.
Replace microprocessor
235 CONTROL SERIAL # ERROR
• TRIGGER–ON: There is an error in the Microprocessor Serial Number that is stored in the microprocessor memory
•
UNIT CONTROL: Unit Shutdown & Alarm
• RESET CONDITION: Auto Reset only when a valid Model number is entered.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Check Microprocessor Serial Number
a. Check Model Number in microprocessor
Must be a valid Model Number from Configuration
List.
b. Enter correct Model Number
From Configuration List, select correct Model
Number.
Reset Microprocessor
a. Turn RS off for 30 seconds, then turn back on.
Microprocessor powers up OK b. Check for valid Model number in
Data List.
c. Valid model number can not be entered.
Valid number is present.
Alarm is cleared
Replace microprocessor
7--123
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
236 TRAILER ID # ERROR
• TRIGGER–ON: There is an error in the Trailer ID Number that is stored in the Microprocessor memory
• UNIT CONTROL: Unit Shutdown & Alarm.
• RESET CONDITION: Auto Reset when valid Functional Parameters are entered, or alarm may be manually reset by turning the unit off, then back on again
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Trailer ID Number
a. Check Functional Parameters All must be set for selectable values
2.
Reset Microprocessor
a. Turn RS off for 30 seconds, then turn back on.
Microprocessor powers up OK
Valid number is present.
Alarm is cleared b. Check for valid Functional
Parameters in Functional
Parameters List.
c. Valid Functional Parameter(s) can not be entered.
Replace microprocessor
237 FUNCTION PARAMETERS ERROR
• TRIGGER–ON: There is an error in one or more of the Functional Parameters that are stored in the microprocessor memory
•
UNIT CONTROL: Incorrect Functional Parameter(s) will be automatically set for default value.
• RESET CONDITION: Auto Reset when valid Functional Parameters are entered, or alarm may be manually reset by turning the unit off, then back on again
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Functional Parameters
All must be set for selectable values
2.
a. Check Functional Parameters
Reset Microprocessor
a. Turn RS off for 30 seconds, then turn back on.
Microprocessor powers up OK
Valid number is present.
Alarm is cleared b. Check for valid Functional
Parameters in Functional
Parameters List.
c. Valid Functional Parameter(s) can not be entered.
Replace microprocessor
62-11039
7--124
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
238 CONFIGURATIONS 1 ERROR
• TRIGGER–ON: There is an error in Configuration Group 1 that is stored in the microprocessor memory
• UNIT CONTROL: Incorrect Configuration(s) will be automatically set for default value.
• RESET CONDITION: Auto Reset when valid Configuration(s) are entered, or alarm may be manually reset by turning the unit off, then back on again
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Check Configurations
a. Check Configurations
Reset Microprocessor
a. Turn RS off for 30 seconds, then turn back on.
All must be set for selectable values
Microprocessor powers up OK b. Check for valid Configurations in
Data List.
c. Valid Configurations can not be entered.
Valid number is present.
Alarm is cleared
Replace microprocessor
239 CONFIGURATIONS 2 ERROR
•
TRIGGER–ON: There is an error in Configuration Group 2 that is stored in the microprocessor memory
• UNIT CONTROL: Incorrect Configuration(s) will be automatically set for default value.
• RESET CONDITION: Auto Reset when valid Configuration(s) are entered, or alarm may be manually reset by turning the unit off, then back on again
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Check Configurations
a. Check Configurations
Reset Microprocessor
a. Turn RS off for 30 seconds, then turn back on.
All must be set for selectable values
Microprocessor powers up OK b. Check for valid Configurations in
Data List.
c. Valid Configurations can not be entered.
Valid number is present.
Alarm is cleared
Replace microprocessor
7--125
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
240 HOUR METER ERROR
• TRIGGER–ON: there is an error in the number of hours in memory for one or more of the system
Hour Meters
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when the Discharge Pressure Sensor is calibrated successfully, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Check Hour Meters
a. Check Configurations
Reset microprocessor
a. Turn RS off for 30 seconds, then turn back on.
All must be set for selectable values
Microprocessor powers up OK b. Check for valid Configurations in
Data List.
c. Valid Configurations can not be entered.
Valid number is present.
Alarm is cleared
Replace microprocessor
241 ALARM STATUS ERROR
•
TRIGGER–ON: There is an error in an Alarm that is stored in the Microprocessor memory
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when valid Configuration(s) are entered, or alarm may be manually reset by turning the unit off, then back on again
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
2.
Check Alarms
a. Check Configurations
Reset microprocessor
a. Turn RS off for 30 seconds, then turn back on.
b. Check for valid Configurations in
Data List.
c. Valid Configurations can not be entered.
All must be set for selectable values
Microprocessor powers up OK
Valid number is present.
Alarm is cleared
Replace microprocessor
62-11039
7--126
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
242 DIS PRESS CALIBRATE ERROR
• TRIGGER–ON: There is an error in the Discharge Pressure Sensor Calibration value stored in memory
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when the Discharge Pressure Sensor is calibrated successfully, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Discharge Pressure Reading
a. Check
Reading
Discharge Pressure Must read valid data.
2.
Calibrate Discharge Pressure Sensor
a. Calibrate
Sensor.
Discharge Pressure Calibration successful.
Replace microprocessor b. Discharge Pressure Sensor can not be successfully calibrated.
243 SUCTION/EVAP CALIBRATE ERROR
• TRIGGER–ON: There is an error in the Suction / Evaporator Pressure Sensor Calibration value stored in the microprocessor memory
• UNIT CONTROL: Alarm only
•
RESET CONDITION: Auto Reset when the Suction / Evaporator Pressure Sensor is calibrated successfully, or alarm may be manually reset via keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Suction / Evaporator Pressure Reading
a. Check Suction
Pressure Reading
/ Evaporator Must read valid data.
2.
Calibrate Suction / Evaporator Pressure Sensor
a. Calibrate Suction / Evaporator
Pressure Sensor.
Calibration successful.
Replace microprocessor b. Suction / Evaporator Pressure
Sensor can not be successfully calibrated.
7--127
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
245 MICRO SW REV ERROR
• TRIGGER–ON: There is an error in the Microprocessor Revision Number that is stored in the
Microprocessor memory.
• UNIT CONTROL: Alarm only
• RESET CONDITION: Alarm may be manually reset via Keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Microprocessor Software Revision
a. Check Microprocessor Software
Revision
Will be a 6 digit number
2.
Reset microprocessor
a. Turn RS off for 30 seconds, then turn back on.
Microprocessor powers up OK b. Check for valid Configurations in
Data List.
Valid number is present.
Alarm is cleared c. Valid Configurations can not be entered.
Replace microprocessor
246 EEPROM WRITE FAILURE
• TRIGGER–ON: here is an error in the ability to write information to be stored in the memory.
•
UNIT CONTROL: Alarm only
•
RESET CONDITION: Alarm may be manually reset via Keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Microprocessor
a. Check Setpoint setting Must be between --22°F to +89.6°F (--30°C to +32°C) b.Enter new Setpoint
Must be between --22°F to +89.6°F (--30°C to +32°C)
2.
Reset Microprocessor
a. Turn main switch off for 30 seconds, then turn on.
Microprocessor powers up OK
Replace microprocessor b. Alarm 246 remains active.
62-11039
7--128
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
247 CONFIGURATIONS 3 ERROR
• TRIGGER–ON: There is an error in Configuration Group 3 that is stored in the microprocessor memory
• UNIT CONTROL: Incorrect Configuration(s) will be automatically set for default value.
• RESET CONDITION: Alarm may be manually reset via Keypad or by turning the unit off, then back on again.
NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check Configurations
a. Check Configurations All must be set for selectable values
2.
Reset microprocessor
a. Turn RS off for 30 seconds, then turn back on.
b. Check for valid Configurations in
Data List.
c. Valid Configurations can not be entered.
Microprocessor powers up OK
Valid number is present.
Alarm is cleared
Replace microprocessor
248 CONFIGURATION MODE / HP2 ERROR
• TRIGGER–ON: EEPROM configuration is out of range
•
UNIT CONTROL: Shutdown and alarm
• RESET CONDITION: Auto Reset only when valid info is available for the microprocessor are entered.
Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s).
(See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1.
Check microprocessor
a. Check Setpoint setting Must be between --22°F to +89.6°F (--30°C to +32°C) b. Enter new Setpoint c. Check Functional Parameters
Must be between --22°F to +89.6°F (--30°C to +32°C)
All settings must be valid.
2.
Reset microprocessor
a. Turn RS off for 30 seconds, then turn back on.
b. Alarm 248 remains active.
Microprocessor powers up OK
Replace microprocessor.
7--129
62-11039
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
249 MICROPROCESSOR ERROR
• TRIGGER–ON: Microprocessor Input Conversion Error
• UNIT CONTROL: Shutdown and alarm
• RESET CONDITION: Auto Reset when input conversions are valid, or Alarm may be manually reset by turning the unit off, then back on again.
Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s).
(See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.
1
Check Microprocessor
a. Check Temperature Sensor Data Must be valid reading for RAT, SAT, AAT, etc.
b. Check for any Active Sensor
Alarms
Must all be cleared.
2
3
Check Microprocessor & Unit Wiring
a. Check Wiring to Micro and at input devices to the micro.
Must not be miss wired to allow 12 VDC on any of the sensor input circuits.
Reset Microprocessor
a. Turn Start/Run--Off switch off for 30 seconds, then turn back on.
b. Alarm 249 remains active.
Microprocessor powers up OK
Replace microprocessor.
62-11039
7--130
WARNING
When performing service and/or maintenance procedures, make certain the unit is disconnected from the power source and that the RS is in OFF position so that it is impossible for the unit to start up automatically during the maintenance operation.
SECTION 8
SERVICE
8.1 MAINTENANCE SCHEDULE
For the most reliable operation and for maximum life, your unit requires regular maintenance. This includes oil and filter changes, fuel and air filter replacement, coolant replacement and pretrip inspections.
Maintenance should be performed according to the following schedule:
CAUTION
Unit uses R404A and POE oil. The use of inert gas brazing procedures is mandatory for all Carrier Transicold refrigeration units; otherwise compressor failure will occur.
For more information Refer to Technical
Procedure 98-50553-00 Inert Gas Brazing
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, U.S.A. EPA section 608.
Table 8-1. Maintenance Schedule
REFERENCE
SECTION
SYSTEM OPERATION a. Daily Maintenance
Pre-Trip Inspection -- before starting
Pre-Trip Inspection -- after starting
Check Engine Hours
b. Every Service Interval or Annually
Unit
Engine
1. Check unit mounting bolts
2. Check engine and compressor mounting bolts
3. Check door latches & hinges
4. Check gauges, switches and electrical connections
5. Check control box / relay box condition
1. Change lube oil and filter(refer to section e.of this table)
2. Check low oil pressure safety
3. Clean crankcase breather
4. Check engine speeds
3.5
3.5
Check
Check
Check
Check
Check
Check
8.6.4
Check
2.15
2.3
8--1 62-11039
SYSTEM OPERATION
REFERENCE
SECTION b. Every Service Interval or Annually (Continued)
Fuel System 1. Clean fuel pump strainer
2. Change fuel filter
3. Check fuel heater (if equipped)
Cooling
System
1. Check antifreeze using a refractometer (CTD P/N 07--00435--00)
2. Clean radiator/condenser fin surface
3. Check water pump
4. Check water temperature sensor
Exhaust
System
Air Intake
System
Starting
System
1. Check mounting hardware
2. Check muffler and exhaust pipes
1. Check and reset air filter indicator (if equipped)
2. Check air cleaner element
1. Check battery condition
2. Clean battery connections and cable ends
3. Check battery hold down clamps
4. Check starter operation
Charging
System
A.C.
Generator
Refrigeration
System
1. Check battery charger output voltage
2. Check battery charger amperage
1. Check voltage output
2. Check amperage output
3. Check condenser and evaporator fan amperages
4. Check compressor amperage
5. Check heater amperages
1. Check air switch and calibrate
2. Check & clean evaporator coil and defrost drain hoses
3. Check operating refrigerant pressure
4. Check calibration of suction pressure transducer
5. Perform Quick Check procedure
6. Perform Pre--Trip inspection
7. Check manual defrost operation
Remote
Evaporators
1. Check remote evaporator mounting bolts
2. Check & clean remote evaporator coil(s)
3. Check and clear all remote evaporator defrost drains
4. Check remote compartment switches and electrical connections
5. Check remote compartment manual defrost operation
6. Check remote evaporator fan amperage
7. Check remote evaporator heaters
8. At annual service interval see Technical Instruction 98--50264--00 for proper installation and wiring ground inspections.
c. Every 6000 Hour Maintenance (Normal Operating Conditions)
Cooling
System
1. Drain and flush cooling system (12,000 hours with Extended Life
Coolant) d. Every 10,000 Hour Maintenance
Perform complete annual Preventive Maintenance and the following:
Fuel System 1. Clean and adjust injector nozzles.
2.13
2.13
2.13
2.13
2.13
2.13
2.13
2.12
8.27
Check
8.22
8.2
8.2
Check
Check
8.27
Check
8.12
Check
2.13
8.7
8.4
8.4
------
8.6.2
8.6.2 and 8.28
Check
2.9
Check
Check
Check
8.6.6
Check/Replace
Check/Replace
Check
Check
Engine Service Guide
Engine Service Guide
62-11039 8--2
e. Oil Change Intervals
Oil Type
Petroleum
Synthetic*
Oil Change/ESI Filter Change
3000 hours/2 yrs
4000 hours /2 yrs
* Mobil Delvac1 is the only approved synthetic oil. Maximum oil drain interval is two (2) years.
These maintenance schedules are based on the use of approved oils and regular Pretrip inspections of the unit.
Failure to follow the recommended maintenance schedule may affect the life and reliability of the refrigeration unit.
8.2 PRETRIP INSPECTION
The following pretrip inspection should be performed before every trip and at regular maintenance intervals.
WARNING
Inspect battery cables for signs of wear, abrasion or damage at every pre trip inspection and replace if necessary. Also check battery cable routing to ensure that clamps are secure and that cables are not pinched or chafing against any components.
BEFORE STARTING ENGINE
Drain water from bottom of fuel tank
Drain water from water separator on fuel filter (if applicable)
Check radiator coolant level
Check condenser coil for cleanliness
Check radiator coil for cleanliness
Check air cleaner and hoses
Check engine oil level
Check condition of water pump belt
Check battery fluid level (if applicable)
Check battery cables and terminals
Check evaporator coil(s) for cleanliness
Check bulkhead and return air screen
Check all defrost water drains
Place in Continuous Run, and start unit.
IMMEDIATELY AFTER STARTING EN-
GINE
Check fuel lines and filters for leaks
Check oil lines and filters for leaks
Check coolant hoses for leaks
Check exhaust system for leaks
Check condenser fan for proper airflow.
Check evaporator fan for proper airflow.
Check for unusual noises
PRETRIP
Initiate Pre--Trip
List any Pre--trip Alarms
AFTER OPERATING UNIT FOR 15
MINUTES OR MORE
Check refrigerant level
Check compressor oil level
Check for proper temperature control
Check auto--start/stop operation
Initiate defrost and allow to terminate
Check engine speeds
OPERATE IN HIGH SPEED COOL
AND RECORD
(From Microprocessor Unit Data List)
SUCTION PRESSURE . . . . . . . . . . . . . .
DISCHARGE PRESSURE . . . . . . . . . . . .
ENGINE COOLANT TEMP . . . . . . . . . . .
C1 RETURN AIR TEMP . . . . . . . . . . . . . .
C2 RETURN AIR TEMP . . . . . . . . . . . . . .
C3 RETURN AIR TEMP . . . . . . . . . . . . . .
AMBIENT AIR TEMP . . . . . . . . . . . . . . . .
DEFROST TERM TEMP #1 . . . . . . . . . .
DEFROST TERM TEMP #2 . . . . . . . . . .
DEFROST TERM TEMP #3 . . . . . . . . . .
COMP DISCH TEMP . . . . . . . . . . . . . . . .
CSMV % . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXV % . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY VOLTAGE . . . . . . . . . . . . . . . .
DC CURRENT DRAW . . . . . . . . . . . . . . .
ENGINE RPM . . . . . . . . . . . . . . . . . . . . . .
SOFTWARE REVISION . . . . . . . . . . . . . .
CONTROL SERIAL # . . . . . . . . . . . . . . . .
UNIT MODEL # . . . . . . . . . . . . . . . . . . . . .
HOURS TO ENGINE MAINTENANCE .
HOURS TO UNIT MAINTENANCE . . . .
TIME LEFT TO PM1 . . . . . . . . . . . . . . . . .
TIME LEFT TO PM2 . . . . . . . . . . . . . . . . .
TIME LEFT TO PM3 . . . . . . . . . . . . . . . . .
TIME LEFT TO PM4 . . . . . . . . . . . . . . . . .
TIME LEFT TO PM5 . . . . . . . . . . . . . . . . .
DATALOGGER TIME & DATE . . . . . . . .
FINAL
Review Functional Parameters
Download recorder data (if required)
Enter Trip Start in Micro
Change 09/11 8--3 62-11039
8.3 PRIMING FUEL SYSTEM
8.3.1 Mechanical Fuel Pump
The mechanical fuel lift pump is mounted on the engine next to the injection pump. This pump has a manual plunger for priming the fuel system when the fuel tank has been run dry. (See Figure 8--1).
To prime the fuel system, use the following steps: a. Turn the bleed valve (Red) counter-clockwise until fully opened.
b. Turn the top of the manual fuel pump plunger counter-clockwise to unlock it. S--L--O--W--L--Y
(up/down once per second) pump the manual plunger until positive pressure (resistance) is felt.
This may take up to 200 strokes. This will indicate fuel flow.
c. Continue to pump S--L--O--W--L--Y (up/down once per second) approximately 100 more strokes to fill the filter and bleed the air out of the lines.
d. Start engine. It may be necessary to continue to pump until the engine starts.
e. Depress and turn the top of the manual plunger clockwise to lock in place. f.
When engine is running smoothly, turn bleed valve clockwise until fully closed.
Figure 8--1. Priming Fuel Pump
Red
Fuel Bleed
Valve
Manual
Fuel Pump
Plunger
62-11039 8--4
8.4 SERVICING FUEL PUMP
8.4.1 Mechanical Pump (See Figure 8--2)
Due to foreign particles in the fuel and wax as a result of using the wrong grade of fuel or untreated fuel in cold weather, the fuel filter may become plugged or restricted, and the engine will lose capacity. The filter must be cleaned on a regular schedule such as unit pre-trip or when the oil and fuel filters are changed
(Refer to Section 8.1).
2
4
1
3
1
8.4.2 Electrical Pump -- Optional (See Figure 8--3)
To Check or Replace Filter a. Remove 3 screws from cover (item 1, Figure 8--3).
b. Remove cover, gasket and filter.
c. Wash filter in cleaning solvent and blow out with air pressure. Clean cover.
WARNING
Carefully protect eyes from solvent.
d. To Install reverse above steps.
1 Cover
2 Gasket
3 Filter
3
2
1
1. Nut
2. Banjo
3. Filter
4. Copper Rings
Figure 8--2. Mechanical Fuel Pump
a. Turn nut counter-clockwise to loosen and remove
(item 1, Figure 8--2).
b. Remove banjo fitting (item 2) and let it hang loose, making sure to keep copper rings (item 4) for replacement.
c. Turn filter (item 3) counter-clockwise and remove.
Check and clean.
d. To install reverse steps 1 through 3.
Figure 8--3. Electric Fuel Pump (Optional)
8.5 FUEL LEVEL SENSOR
An optional fuel level sensor (p/n 12-00548-07) supplies an input signal to the microprocessor as to the % of fuel remaining in the fuel tank. The microprocessor then turns on the Check Fuel Level Alarm when the level reaches 15%, and (if configured to do so) turns the engine off when the level reaches 10%.
The 12-00548-07 sensor has the capability of sending the fuel level (from 0% to 100%) to the microprocessor.
The fuel tank level will be displayed in the Unit Data List.
This sensor may be calibrated if necessary.
8--5 62-11039
8.5.1 Calibrating The 0 To 100% Fuel Level Sensor
NOTE
Both the Empty and the Full level settings should be calibrated whenever a new sensor is installed into a fuel tank.
a. Verify that the wiring is correct. See Figure 8--4 for correct wiring.
b. To adjust the Empty setting, make certain that the fuel tank is empty, and that the sensor is dry. If the sensor has been in the fuel, let it hang to dry for 2 hours before attempting to calibrate.
c. With the sensor in the tank, dry, and the tank empty, turn both the Full and Empty Adjustments to the full
clockwise position.
d.Turn all Compartment switches OFF and place SROS in Start/Run position.
e. Press the Select Key to bring up the Unit Data List.
Scroll through the list until you reach
FUEL LEVEL :___%. Press the = key to lock the fuel level into the MessageCenter.
f. Slowly turn the Empty screw counter--clockwise until the display indicates 0%. DO NOT ADJUST ANY
FURTHER.
g. Fill the tank with fuel until full.
h. Slowly turn the Full adjusting screw counter--clockwise until the display indicates 100%. DO NOT AD-
JUST ANY FURTHER.
8.5.2 Testing The 0 To 100% Fuel Level Sensor
a. Verify that the wiring to sensor is correct.
b. Check voltage at the Fuel Level Sensor with the
SROS in the Start/Run position.
c. Voltage between Red Wire (positive) and Black Wire
(negative) should be 12.5 to 13.5 VDC. Do not disconnect the Red or Black wires from the switch.
d. Disconnect the White Wire (output) from the sensor.
Voltage between Black Wire (negative) and White
Wire (output) should be 0 VDC when the switch is dry and out of the fuel.
e. When the switch is immersed into fuel, the voltage reading between Black Wire (negative) and White
Wire (output) increase up to 5 VDC when fuel has reached the full mark.
GROUND
SUPPLY
VOLTAGE
OUTPUT
Figure 8--4. Fuel Level Sensor Wiring
62-11039 8--6
8.6 ENGINE SERVICE AND COMPONENTS
8.6.1 Engine RPM Setup
NOTE
1. The Engine Speeds can ONLY be checked if the Machine is in Defrost.
2. Check operation of speed solenoid before setting speed. If solenoid is sticking, clean and lubricate the solenoid in accordance with Technical Instruction 98--50234.
Control
a. Start the unit in Cool Mode.
NOTE
ALL Remote Compartments MUST be Shut Off and only Compartment 1 enabled.
b. Check DDT Temp in Data Menu (See Section 3.15),
DTT must be less than 39.9°F (4.4°C) c. Initiate Manual Defrost (See Section 3.11) d. Check total current on each phase at AC1 & AC2 output of generator e. Monitor current and adjust RPM on the engine to obtain 1850 RPM for a current range of 10 to 11.5A. If adjustment is required:
1) Loosen but do not remove the 4--speed solenoid mounting nuts.
2) Turn the jacking nut, allowing the solenoid to move along the slots until the desired high speed is reached. Tighten the solenoid mounting bolts and verify correct high and low speed RPM.
f. Force the machine into low speed
NOTE
NEVER disconnect the Speed Control Solenoid
(SCS)
Select Functional Change menu (See Section
3.17)
Select the Parameter “Silent Mode” -- “Yes” g. Check total current on each phase at AC1 & AC2 h. Monitor current & adjust RPM to obtain 1450 RPM for a current range of 8.5 to 8.9A. If adjustment is required hold the speed lever against the low speed stop and check the RPM. Adjust the low speed stop screw if necessary.
i. Check for proper unit operation by running Pretrip
(Refer to Section 3.5)
8.6.2 Cooling System
Air flows through the condenser/radiator. The condenser/radiator must be internally and externally clean for adequate cooling. The water pump V-belt must be adjusted periodically to provide maximum air flow.
(Refer to Section 8.6.9)
CAUTION
Use only ethylene glycol anti-freeze (with inhibitors) in system as glycol by itself will damage the cooling system. Always add pre-mixed 50/50 anti-freeze and water to radiator/engine. Never exceed more than a
60% concentration of anti-freeze. Use a low silicate anti-freeze meeting GM specifications GM 6038M for standard life coolant or use Texaco Havoline extended life coolant or any other extended life coolant which is
Dexcool approved and has 5/150 (5 years/150,000 miles) on the label.
Do the following to service the cooling system:
a. Remove all foreign material from the condenser/radiator coil. Compressed air or water may be used as a cleaning agent. It may be necessary to use warm water mixed with any good commercial dishwasher detergent. Rinse coil with fresh water if a detergent is used.
NOTE
Draining the coolant from the engine petcock will leave approximately 1 quart (.9 liters) of coolant in the block.
b. Drain coolant completely by removing lower radiator hose and radiator cap.
c. Install hose and fill system with clean, untreated water to which 3 -- 5% of an alkaline based radiator cleaner is added -- 6 oz. (151 grams) to 1 gallon (3.78
liters) of water.
d. Run engine 6 to 12 hours and drain system while warm. Rinse system three times after it has cooled down. Refill system with water.
e. Run engine to operating temperature. Drain system again and fill with 50/50 water/anti-freeze mixture.
(see Caution Note and Refer to Section 2.9)
NEVER POUR COLD WATER INTO A HOT EN-
GINE, however hot water can always be added to a cold engine.
Change 09/11 8--7 62-11039
8.6.3 Testing The RPM Sensor
a. Verify that the wiring to sensor is correct. See wiring schematic Section NO TAG.
b. Check voltage at the RPM Sensor connector with the
Run Relay energized (Unit running, Unit off, Manual
Start Mode selected, and test must be completed within 5 minutes -- before the Failed To Start Manual
Mode occurs, or Component Test Mode will energize the Run Relay for 5 minutes without starting the unit.) c. Voltage between ENRPMA--2MP31
ENRPMC--2MP7 should be 5.0 VDC.
and d. Check continuity between ENRPMB and 2MP18.
e. If the above tests check OK, read Warning below. If the RPM display is still not correct, replace the RPM sensor.
WARNING
The +5.0 VDC (terminal B) is common between the Compressor Discharge Pressure
Transducer, the Compressor Suction Pressure Transducer, and the RPM sensor. If this circuit is shorted to ground (due to one of the mentioned components being defective, or a worn wire) the MessageCenter will show
Suction Pressure: --14.7 PSIG (--1 Bar)
Discharge Pressure: PSIG/0 Bar
Engine RPM: 0.
8.6.4 Lube Oil Filters
After warming up the engine, stop engine, place shallow drain pan under filter and remove filter. Lightly oil gasket on new filter before installing. Tighten per the filter manufacturer’s directions.
CAUTION
When changing oil filters, the new filters should be primed (partially filled) with clean oil if possible. If the filters are not primed, the engine may operate for a period with no oil supplied to the bearings.
Replace filter(s) and add lube oil. (Refer to Section 2.9)
Warm up engine and check for leaks.
a. Lube Oil And Fuel Flow Diagrams
5
6
3
1
2
4
11
10
9 8
1. Fuel Tank
2. Fuel Supply Line
3. Electric Fuel Pump
(Optional)
4. Mechanical Lift Pump
5. Fuel Filter
6. Fuel Warmer (Opti
7. Fuel Bleed Valve
8. Injection Pump
9. Injector Nozzles
10. Fuel Leak-off Line
11. Fuel Return Line
Figure 8--5. Fuel System Diagram
1
5
2
4
3
7
1. Engine Block
2. Oil Pan
3. Full Flow Oil Filter
4. Engine Oil Connection
5. Oil Pressure Switch
Figure 8--6. Lube Oil Flow Diagram
62-11039 8--8
8.6.5 Servicing The Speed Control Solenoid And
Linkage
2
1
3
5
4
1. Solenoid
2. Bolt
3. Solenoid Bracket
4. Linkage (Speed)
5. Clip
Figure 8--7. Speed Control Solenoid
Solenoid Removal/Replacement (See Section 8.6.1
for RPM adjustment) a. Disconnect wiring to solenoid. Disconnect linkage arm (Item 4, Figure 8--7) from solenoid. Remove mounting hardware from solenoid and then remove solenoid.
b. Install replacement solenoid and mounting hardware.
Do not tighten at this time.
c. Attach linkage to solenoid and install the clip to the linkage rod.
8.6.6 Engine Air Cleaner
Inspection
The dry type air cleaner should be inspected regularly for leaks. A damaged air cleaner or hose can seriously affect the performance and life of the engine. The air cleaner is designed to effectively remove contaminants from the air stream entering the engine. An excessive accumulation of these contaminants in the air cleaner will impair its operation; therefore, a service schedule should be set up and followed. The following simple service steps are easily made while the engine is being serviced in the field: a. Check all connections for mechanical tightness. Be sure cleaner outlet pipe is not fractured.
b. In case of leakage and if adjustment does not correct the trouble, replace necessary parts or gaskets.
Swelled or distorted gaskets must always be replaced.
Air Cleaner Service Indicator
The air cleaner indicator is connected to the engine air intake manifold and its function is to indicate when the air cleaner requires replacing. When a plugged air cleaner decreases intake manifold pressure to 20” (500 mm) WG, the indicator moves to the red line. The air cleaner should be replaced and the indicator reset by pressing the reset button.
Service Procedure
1. Stop the engine, remove air cleaner. Install new air cleaner.
8.6.7 Engine Crankcase Breather
The engine uses a closed type breather with the breather line attached to the cylinder head cover. (See
Figure 8--8)
The breather assembly should be cleaned once a year or at every 3000 hours maintenance interval (whichever comes first).
1
2
3
4
1. Screw
2. Breather Cover
3. Breather Valve
4. Breather Tube
Figure 8--8. Engine Crankcase Breather
8--9 62-11039
8.6.8 Servicing Glow Plugs
The total circuit amp draw for the glow plug circuit is checked during a Pretrip cycle. When servicing, the glow plug is to be fitted carefully into the cylinder head to prevent damage to glow plug. Torque value for the glow plug is 14 to 18 ft-lb (1.9 to 2.5 Mkg).
Checking for a Defective Glow Plug
8.6.9 Water Pump V--Belt
The water pump v-belt is driven by a sheave on the engine crankshaft. Frayed, cracked or worn belts must a. The entire circuit may be tested using Component
Test Mode. (Refer to Section 5.2.2.) b. To test individual glow plugs, disconnect all glow plugsfromeachother, andplace anammeter (orclip-on ammeter) in series with each glow plug and energize the plugs. See Table 2-5 for glow plug amperage.
be replaced. This belt is a one time use only type and require no tension adjustment.
Water Pump Belt
62-11039
Figure 8--9. Water Pump V--Belt
8--10
8.7 EVAPORATOR HEATERS
8.7.1 Description
The evaporator coil heaters are energized through the power supply or the AC generator driven by the diesel engine. They are used to defrost or heat the evaporator coil.
8.7.2 Replacing Heaters
WARNING
When performing service and/or maintenance procedures, make certain the unit is disconnected from the power source and that the RS is in OFF position so that it is impossible for the unit to start up automatically during the maintenance operation.
a. Remove the access panel.
b. Determine which heater(s) need replacing by checking resistance on each heater as shown in section
2.13.
c. Remove hold-down clamp securing heaters to coil.
d. Lift the “U” portion of the heater (with the opposite end down and away from coil). Move heater left (or right) enough to clear the heater end support.
8.7.3 Compartment One Evaporator Blower and
Motor
The evaporator blowers circulate air throughout the compartment. The air is drawn through the evaporator coil where it is either heated or cooled and then discharged out the nozzles into the compartment.
(Refer to section 2.16.) The blower motor bearings are factory lubricated and do not require additional grease.
NOTE
The evaporator blower assemblies are different for each side and will rotate in opposite directions. There are two blower motor assemblies.
identification.
See Table 8-2 for correct
Table 8-2 Blower wheels identification
DESCRIPTION ROTATION FAN COLOR
Road Side Blower
Curb Side Blower
Counter
Clockwise
Clockwise
Black
Off White
Replacing Blower Assembly (See Figure 8--10)
a. From condenser topside of unit : open electrical junction box and disconnect wires for motor to be removed.
b. From condenser topside of unit : unscrew the 4 screws (item 1) and remove. Leave cover plate
(item 2) in place.
c. From inside of trailer, remove access grill, back panel and fan guard by removing screws.
d.Evaporator blower assembly (wheel and motor) is an integral part of the blower housing. Unscrew the 4 screws (item 7) and remove both parts (blower assembly and housing) from the pod.
e. Remove blower assembly from housing.
f. Remove spacer (item 5) from old motor and install on new motor.
g. Install new blower assembly into blower housing.
Install blower assembly and housing back into the pod.
h. From condenser topside of unit : use a screwdriver
(item 6) through cover plate and spacer to align spacer.
i. Install bolts (item 1). Start with 2 screws, remove screwdriver and finish assembly with the last 2 screws.
j. Check that fan does not touch ring of the blower housing.
k. Complete the assembly in reverse order of removal.
8--11 62-11039
1.
2.
8.8 BATTERY CHARGER
8.8.1 Description
The battery charger is powered by the generator and charges the 12 Vdc battery.
1. Screws
2. Cover plate
3. Blower housing
4. Evaporator fan
3.
5. Spacer
6. Screw driver
7. Screws
4.
5.
6.
7.
Figure 8--10 Evaporator fan bolts
8.7.4 Condenser Fan And Motor Assemblies
The condenser fans pull air through the condenser coil and discharges over the engine. To replace motor assembly: a. Open the front door b. Disconnect wiring. Loosen securing bolts.
c. Remove motor assembly and replace the motor.
d. Install the condenser fan assembly in reverse order of removal.
Figure 8--11. Battery Charger
8.8.2 Checking Battery Charger
NOTE
The battery must be in good condition before doing the following test.
a. Run the unit with the battery charger connected as usual.
NOTE
If there is no load connected at the Vdc output, the battery charger will not deliver voltage.
b. Put an ammeter on the +12 Vdc output of the battery charger. If current are between 3 and 21 Amps the battery charger is functioning correctly.
c. If Amps = 0 check the battery charger input AC voltage. It must be between 350 and 670 Volts.
d. If there is no AC voltage, stop the unit and, if required, disconnect the standby plug. Check the high voltage 3--way connector and the 12 Vdc 2--way connections.
e. If connections are good, replace battery charger.
62-11039 8--12
8.9 GENERATOR
8.9.1 Description
Driven by the diesel engine, the generator delivers AC power to the battery charger, and all the electric motors for the compressor, condenser fans and evaporator fans.
When the unit is in heating or defrost mode, the generator also delivers the AC power to the heater rods located on the evaporator coil.
8.9.2 Preventive Maintenance and
Operating Precautions
Costly repairs and down time can usually be prevented by operating electrical equipment under conditions which are compatible with those at which the equipment was designed. Follow the instructions outlined below to ensure maximum efficiency of the electrical equipment.
Cooling
Keep all cooling parts clean. DO NOT EXCEED
TEMPERATURE RISE OF 80_C (176_F) ABOVE A
40_C (104_F) AMBIENT. This ensures that the NEMA
Class “F” insulation will not be damaged. DO NOT
EXCEED RATED LOAD except as specified for the equipment. OPERATE GENERATOR AT RATED
SPEED. Failure to operate generators at rated load or speed will cause overheating and possible damage to windings due to over voltage or current.
Drying the Generator Windings
WARNING
Do not direct water or steam into the generator openings. Do not allow any soap and water solutions to enter the generator.
the generator up to full nameplate voltage. If this precaution is not taken, serious damage to the generator can result.
The windings may be dried by placing generator in drying oven or hot room or dry with warm air blower directed through windings.
WARNING
High voltage (dielectric) testing must not be performed to the machine without first observing NEMA rules. The insulation of this generator winding may be safely checked by using a megohm meter. A high reading indicates good insulation.
WARNING
Generators of this type should not be
“flashed”. Operation with external voltage source or momentary shorting of leads will damage the generator and may cause injury.
Generators that have been in transit, recently steam cleaned, or in storage for long periods may be subjected to extreme temperature and moisture changes. This can cause excessive condensation, and the generator windings should be thoroughly dried out before bringing
8--13 62-11039
8.9.3 Generator Removal
WARNING
Be aware of HIGH VOLTAGE supplied by the generator as the unit may start automatically. Before servicing the unit, make sure the START/RUN--OFF switch is in the OFF position. Also disconnect the negative battery cable.
MAGNETIC FIELD INSIDE!
NEVER dis--assemble the generator: HIGH
1. Disconnect the battery.
2. Remove the engine oil fill cap.
3. Remove muffler nuts.
Figure 8--12 Generator Removal
Figure 8--13 Generator Removal
8.
3.
2.
9.
7. Loosen the harness plate on the right side (4 bolts)
8. Remove the engine frame bolts (H1, H2, H3,
-- H2 shorter than H3)
9. Place the engine support tool (P/N
SKM 5670)
10. Unscrew the engine frame bolt
Figure 8--14 Generator Removal
8.
7.
5.
6.
4.
4. Disconnect ground wire.
5. Disconnect the 2 generator sensors (GENT)
(if existing)
6. Cut the 3 generator cables (near ground strap)
62-11039 8--14
11. Disconnect the RPM sensor.
12. Use tool (P/N : 07--60083--00) to lock the engine flywheel
Figure 8--15 Generator Removal
11.
12.
13.
CAUTION
The mica shim must be used during disassembly of the generator from the engine.
Never attempt to remove the rotor from the stator. Leave the shim in place until the generator is re installed on the engine.
16.
15.
20.
17.
13. Pull the harness on the top of generator out of the way.
14. Swing out the engine.
15. Remove the fan cover (4 bolts)
16. Remove the fan blade. (1 screw)
Figure 8--16 Generator Removal
19.
17. Remove 3 of the 6 flywheel bolts on generator.
18. Insert 3 guiding rods (P/N : SKM 5671)
19.Place the mica shim between the rotor and the stator prior to loosening any other bolts.
20. Remove the last 3 flywheel bolts.
Figure 8--17 Generator Removal
8--15 62-11039
23.
22.
21.
21.
21. Install the lifting tool (P/N :07--60085--00).
22. Remove the remaining stator bolts.
23. Remove the generator with a sling.
Figure 8--18 Generator Removal
8.9.4 Generator Assembly Procedure
7
8
9
6
2
4 5
3
1
10
9
11
12
15
14
13
1. Screw, Stator/ Cover
2. Washer, Stator/Cover
3. Fan Cover
4. Fan Mount Screw
5. Fan Mount Washer
6. Rotor
7. Stator
8. Spacer
9. Dowel Pin
10. Bell Housing
11. Flywheel Bolt
12. Fan
13. Generator Leads
14. Access Cover
15. Grommet
Figure 8--19 Generator Assy (P/N 54--00553--51)
62-11039 8--16
a. Install two dowel pins (CTD P/N 34--06210--00 -- not included in the kit) in the bell housing. Install the pins with the chamfer facing out into the two holes indicated in Figure 8--20.
DOWEL
8 O’CLOCK
11 O’CLOCK
0.5 in (12.7mm)
DOWEL
5 O’CLOCK
Figure 8--20 Bolt Hole Pattern For Bell Housing and Crankshaft
b. Remove the flywheel and inspect it for any debris or damage.
c. Install spacer (Item 8) onto the bell housing using the dowel pins.
NOTE
The spacer is in two pieces. Install them so the irregularly shaped piece covers the starter opening.
d. Locate two screw holes on the face of the crankshaft which are located approximately 0.5 in (12.7mm) apart. All other screw holes are approximately 0.75
in (19mm) apart (See Figure 8--20).
e. Assemble two guide rods into the two holes on the crankshaft located in the previous step. Assemble the third rod across from the first two rods. See
Figure 8--20.
f. Install the flywheel on the crankshaft using the guide rods to align properly. Make sure the flywheel mates with the crankshaft with no rocking or side to side movement.
g. Lift the generator using the lifting tool and hang it in front of the engine. Make sure the generator leads
(Item 13) exit the stator winding on the side away from the engine.
h. The mounting holes on the generator rotor (Item 6) have two holes offset to match the ones in the crankshaft and flywheel. Locate them and turn the engine to line up the guide rods in the crankshaft with the offset holes in the generator rotor.
NOTE
The generator rotor does not turn in the stator.
i. Slide the generator rotor over the guide rods and mate the stator with the spacer installed in step c.
Ensure the dowel pins in the bell housing are fully engaged in the stator.
8--17
NOTE
The generator should slide freely on the guide rods if the holes in the generator rotor are matched correctly with the crank shaft holes.
Otherwise it will bind up and the stator will not mate properly with the spacer.
j. Install three screws and three washers to the rotor and tighten.
NOTE
The screws will be torqued later.
k. Remove the guide rods and assemble and tighten the remaining three rotor screws and washers.
NOTE
The screws will be torqued later.
l. Install and tighten three stator screws and two washers with each screw in the following locations (See
Figure 8--20) :
One in five o’clock location
One in eight o’clock location
One in eleven o’clock location
NOTE
The remaining four stator mounting bolts will be installed and will all be torqued after the fan cover is installed.
m. Torque the rotor bolts to 90--110 foot--pounds (12.5
to 15.2 Mkg) using an alternating sequence.
NOTE
Mark each rotor screw after it is torqued to ensure that all the screws are torqued.
n. Remove the mica shim that is between the stator and the rotor.
o. Install the fan onto the rotor using two washers and one screw).
NOTE
The fan must be installed with blades away from the engine.
p. Torque the fan screws to 10--12 foot--pounds (1.4 to
1.7 Mkg.
q. Remove the connectors from the thermistors using a pin extraction tool. (Packerd Tool No. 12014012) r. Feed all the wires through the inside of the fan cover side opening.
s. Install the fan cover (Item 3) onto the generator stator and install the remaining mounting screws and washers.
NOTE
Make sure the insulation on lead wires is not damaged during assembling of the fan cover.
Each mounting screw must be assembled with two washers.
62-11039
t. Torque the stator mounting screws to 33--37 foot pounds (4.6 to 5.1 Mkg).
NOTE
Mark each stator screw after it is torqued to ensure that all the screws are torqued.
u. Look through the opening in the fan cover and ensure that the wires are not pinched and that they are adequately routed.
v. Install the access cover (Item 14) using four screws and washers (screws and washer are not included in the kit).
w. Assemble the strain grommet (Item 15).
x. Reconnect wires, sensors and thermistor.
y.Reassemble engine into unit.
8.10 REMOTE COMPARTMENT LSVs
8.10.1CHECKING OPERATION OF C2 LSV AND
C3 LSV AND EVXV
C2 LSV and C3 LSV are used to control the flow of refrigerant to Remote Compartments 2 and 3. Generally, when a compartment is enabled, and the box temperature is above setpoint, the controller will be calling for that compartment to operate in Cool. When either of these compartments is calling for Cool, the LSV for that compartment will be energized, allowing liquid refrigerant to flow through the valve to the evaporator.
If time permits, an easy method for checking C2 LSV and C3 LSV is to first run the unit through a defrost cycle.
Then operate Compartment 1 only with Compartment(s) 2 (and 3) turned off. After 5 to 10 minutes, visually inspect the remote evaporators. The evaporator fan motors should not be running. Inspect the condition of the evaporator coils. There should be no frost on them.
If possible, check the temperature of the suction line leaving the evaporator (without damaging the insulation on the line). Frost on either a remote compartment coil or a suction line that is colder than the compartment temperature indicates that the LSV for that compartment is leaking liquid refrigerant into the coil.
Another method of checking these components is to follow these steps: a. Connect a manifold test set to the compressor discharge and suction service valves. Connect a PC
Mode jumper to the download port, or a PC with the
ReeferManager program running, in the Monitor and
Override/ Microprocessor Monitor screen. It will be important to be able to watch the EVXV close in a later step.
b. Pump down the low side of the system per Section
8.11.1.
c. After the unit has been shut off, verify that the pressures do not equalize, and the suction pressure does not rise above 5 psig. If the suction pressure rises above 5 psig, repeat the Pumping Down the Low Side procedure.
d. When the EVXV reaches 0%, slowly open the king valve. The suction pressure should not rise. If the suction pressure rises the leakage possibilities are: the EVXV, or C2 LSV and C3 LSV (3 compartment units only). Go into each compartment and listen for any internal system leakage.
NOTE
When the suction pressure remains at 0 to 5 psig with the king valve open, C2 LSV, C3 LSV and EVXV have been tested for holding and passed.
e. To test C2 LSV for opening, use Component Test
Mode (Refer to Section 5.2.2).
f. Monitor the suction pressure when the Microprocessor = key is pressed to energize C2 LSV. The suction pressure should rapidly rise indicating that the valve opened.
g. To check C3 LSV, repeat steps b. thru f..
h. If valve leakage is detected during the low side pump down, or if either valve fails to open, repairs to the valve(s) are required. (Refer to section 8.11.1) i. Following this procedure, refill the system with the refrigerant that was removed in Step d. of Section
8.11.1
62-11039 8--18
8.11 PUMPING UNIT DOWN OR REMOVING RE-
FRIGERANT 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, U.S.A. EPA section 608.
NOTE
The unit must be in Service Mode before pumping down and/or removing the refrigeration charge. Refer to Section 5.2.3.
8.11.1 Pumping Down The Low Side
Components on the low side of the refrigeration system
(EVXV, SMV, filter drier, C2/3 LSVs, remote TXVs, and evaporators) may be tested, serviced or replaced without having to completely remove the refrigerant charge from the system by pumping down the low side, and temporarily storing the refrigerant in the condenser and receiver.
NOTE
If any leaks are suspected, do not pump the unit down below 1 psig in order to prevent contamination of the system.
a. Backseat suction and discharge service valves (turn counterclockwise) to close off gauge connection and attach manifold gauges to valves.
b. Open valves two turns (clockwise). Purge gauge line.
c. If the compressor is cold, start the unit and let it warm up for 5 to 10 minutes. If the compressor is already warmed up, skip ahead to step d..
d.
Connect a clean refrigerant reclaim bottle to the receiver king valve, and remove 6 to 7 lbs of refrigerant from the system. This will prevent a high pressure shutdown in high ambient conditions during this procedure.
e.
Front seat the king valve.
f. Watching the gauges, let the suction pressure drop to
10 to to 15” vacuum, then turn the compressor off.
g. Monitor the gauges. The suction pressure should not rise rapidly. If it does, leakage possibilities are compressor, EVXV, C2 LSV and C3 LSV (3 compartment units only). Check and repair as needed and continue with steps h. thru n. below. If there are no problems with system, continue with step i. of Section 8.10.
h. Frontseat (close by turning clockwise) suction service valve and the refrigerant will be trapped between the compressor suction service valve and the manual shut--off valve (king valve).
i. Before opening up any part of the system, a slight positive pressure should be indicated on the pressure gauge.
j. 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.
k. After making necessary repairs, leak test and evacuate the low side of the refrigeration system. (Refer to
Sections 8.12 and 8.13.) l. Backseat manual shut--off valve (king valve) and midseat suction service valve.
m. Start the unit in cooling and check for noncondensibles.
n. Check the refrigerant charge. (Refer to Table 2-1.)
NOTE
Store the refrigerant charge in an evacuated container if the system must be opened between the compressor discharge valve and receiver. Whenever the system is opened, it must be evacuated and dehydrated. (Refer to Section
8.13)
8--19 62-11039
8.11.2 Removing The Refrigerant Charge: Use
Micro “EVAC MODE”
When entering Evacuation Mode, the micro will home the valves and then open the SMV and EVXV to 100% open and energize UL1. The message center will display “ENTERING SERVICE MODE” and log an Evacuation Mode Event in the Data Recorder.
Connect a refrigerant recovery system to the unit to remove refrigerant charge. Refer to instructions provided by the manufacture of the refrigerant recovery system.
HOLD = TO EXIT.
8.12 REFRIGERANT LEAK CHECKING: Use
Micro “EVAC MODE”
a. If system was opened and repairs completed, leak check the unit.
b. The recommended procedure for finding leaks in a system is with an electronic leak detector. Testing joints with soapsuds is satisfactory only for locating large leaks, or pinpointing small leaks once a general area has been located.
c. If system is without refrigerant, charge system with refrigerant to build up pressure between 30 to 50
PSIG (2.0 to 3.4 Bar). Remove refrigerant drum and leak check all connections.
CAUTION
Only a refrigerant drum containing R404a should be connected to this refrigeration unit in order to pressurize the system. However, dry nitrogen may be used for leak checking. Any other gas or vapor will contaminate the system which will require additional purging and evacuation of the high side (discharge) of the system.
d. Remove refrigerant using a refrigerant recovery system and repair any leaks. Evacuate and dehydrate the unit. (Refer to Section 8.13) Charge unit with refrigerant. (Refer to Section 8.13.4) e. Check for proper unit operation by running Pretrip
(Refer to Section 3.5).
8.13 EVACUATION AND CHARGING: Use
Micro “EVAC MODE”
8.13.1 General
Moisture is the deadly enemy of refrigerant 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 (EVXV or TXV) by free water, and formation of acids, resulting in metal corrosion.
62-11039 8--20
8.13.2 Preparation
a. Evacuate and dehydrate only after pressure leak test. (Refer to Section 8.12) b. Essential tools to properly evacuate and dehydrate any system include a good vacuum pump (5 cfm /
8m#H volume displacement, P/N 07-00176-11) and a good vacuum indicator such as a thermocouple vacuum gauge (vacuum indicator). (07--00414--00)
NOTE
The use of a compound gauge is not recommended because of its inherent inaccuracy.
c. Keep the ambient temperature above 60_F (15.6_C) to speed evaporation of moisture. If ambient temperature is lower than 60_F (15.6_C), ice might form before moisture removal is complete. Heat lamps or alternate sources of heat may be used to raise system temperature.
8.13.3 Procedure For Evacuation
a. Remove refrigerant using a refrigerant recovery system.
b. The recommended method to evacuate and dehydrate the system is to connect three evacuation hoses (Do not use standard service hoses, as they are not suited for evacuation purposes.) as shown in
Figure 8--21 to the vacuum pump and refrigeration unit. Also, as shown, connect an evacuation manifold, with evacuation hoses only, to the vacuum pump, electronic vacuum gauge, and refrigerant recovery system.
c. With the unit service valves closed (back seated) and the vacuum pump and electronic vacuum gauge valves open, start the pump and draw a deep vacuum. Shut off the pump and check to see if the vacuum holds. This operation is to test the evacuation setup for leaks, repair if necessary.
d. Midseat the refrigerant system service valves.
e. Then 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 dry nitrogen. Raise system pressure to approximately 2 PSIG (0.1 Bar).
g. Purge nitrogen from system.
h. Repeat steps e through g one time.
i. Evacuate unit to 500 microns. Close off vacuum pump valve and stop pump. Wait five minutes to see if vacuumholds.Thischecksforresidualmoistureand/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. The correct amount of refrigerant may be added by observing the scales. Correct charge will be found in Table 2-1.
16
15
14
9
8
13
12
11
10
7
3
4
2
5
1
6
1. Refrigerant Cylinder
2. Refrigerant Recovery Unit
3. Evacuation Manifold
4. Valve
5. Vacuum Gauge
6. Vacuum Pump
7. Condenser
8. King Valve
9. Receiver
10. Suction Service Valve
11. Compressor
12. Discharge Service Valve
13. Compressor Suction Modulation Valve (SMV)
14. Evaporator
15. Compartment 2 Evaporator
16. Compartment 3 Evaporator
Figure 8--21. Vacuum Pump Connection
8--21 62-11039
8.13.4 Adding Refrigerant To System (Full Charge)
NOTE
Place unit in Service Mode before performing the following operations on the unit. Refer to
Section 5.2.3.
CAUTION
Do not vapor charge R--404A. Only liquid charging through the receiver outlet (King) valve is acceptable.
a. Dehydrate unit and leave in deep vacuum. (Refer to section 8.11) b. Place drum of refrigerant on scale and connect charging line from drum to king valve. Purge charging line at outlet valve.
c. Note weight of drum and refrigerant.
d. Open liquid valve on drum. Open king valve half way and allow the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added as indicated by scales. Correct charge will be found in
Table 2-1.
NOTE
It is possible that all liquid may not be pulled into the receiver, as outlined in step d. In this case, frontseat the receiver outlet valve (king valve) and run the unit in cooling until the correct amount of refrigerant is added.
e. When drum weight (scale) indicates that the correct charge has been added, close liquid line valve on drum and backseat the king valve.
f. Start unit in cooling mode. Run approximately ten minutes. Partially block off air flow to condenser coil so discharge pressure rises to 15.8 bars (230 psig).
Refrigerant should appear at center line of lower receiver sight glass.
8.14 ADDING REFRIGERANT TO SYSTEM
(PARTIAL CHARGE)
a. Start the unit in high speed diesel mode (ambient between 24°F (18°C) and 86°F (30°C) with a setpoint of
68°F (20°C) or lower.
b. When return air reaches 32°F (0°C), check the sight glasses.
c. If the bottom ball is floating at the top of the sightglass and the top ball is not floating, the charge is correct.
d. Liquid charge through the suction service valve.
62-11039 8--22
8.15 COMPRESSOR -- MODEL 06D
WARNING
When performing service and/or maintenance procedures, make certain the unit is disconnected from the power source and that the RS is in OFF position so that it is impossible for the unit to start up automatically during the maintenance operation.
a. The compressor should not operate in a vacuum greater than 19.6inHg (500 mm).
b. The service replacement compressor is shipped without shutoff valves (but with valve pads), and without terminal box and cover. Customer should retain all external compressor components including the original terminal box and cover for use on replacement compressor.
c. Check oil level in service replacement compressor.
(Refer to section 8.15.4)
8.15.1 Removal and Replacement of Compressor
a. Frontseat suction service valve and run unit until suction pressure equals 1 PSIG (0.1 Bar)
1 2
3
4
b. Locate the compressor junction box. Remove wiring.
Disconnect wiring from compressor terminals and remove compressor junction box.
c. Remove bolts from service valve flanges.
d. Remove compressor bolts.
e. Remove compressor. Refer to section 2.11 for weight of compressor.
f. Remove all external compressor components.
WARNING
Relieve internal pressure of replacement compressor by slightly loosening the bolts of both service valve flanges/blank valve pads and then lightly tapping the center of the valve flanges/pads with a soft mallet to break the seal.
g. Reinstall components removed in step e.
h. Install compressor in unit.
i. Connect junction box to compressor and connect all wiring per wiring diagram. Install junction box cover.
j. Install new gaskets on service valves.
14
13
12
5
6
BACK VIEW
1. Compressor discharge pressure tranducer
2. High pressure switch
3. Compressor discharge temperature sensor
4. Electrical terminal box
5. Suction valve flange
6. Motor end cover
7. Serial / Model plate
Figure 8--22 Compressor -- model 06D
7
FRONT VIEW
8
9
8. Bottom plate
9. Oil drain location
10. Crankcase heater (option)
11. Sight glass
12. Cylinder head
13. Valve plate
14. Discharge valve flange
10
11
8--23 62-11039
k. Install mounting bolts in service valves and torque according to values in Table 8-3.
l.Attach two hoses (with hand valves near vacuum pump) to the suction and discharge service valves.
Dehydrate and evacuate compressor to 500 microns
(29.90 inches Hg = 75.9 cm Hg vacuum ). Turn off
valves on both hoses to pump.
m.Fully backseat (open) both suction and discharge service valves.
n. Remove vacuum pump lines.
o. Start unit and check refrigerant charge. (Refer to section 8.11) p. Change filter-drier if necessary. (Refer to section
8.17) q. Check compressor oil level per section 8.15.4. Add oil if necessary.
8.15.2 Compressor Disassembly
a. Remove cylinder head capscrews. 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. (See
Figure 8--22 and Figure 8--23) Remove cylinder head gasket.
b. 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 capscrew as a jack screw through the tapped hole of the valve plate. Remove the valve plate gasket, see
Figure 8--23, item 7
8.15.3 Compressor Reassembly
To clean compressor parts, use a suitable solvent with proper precautions. Coat all moving parts with the proper compressor oil before assembly. Refer to Table 8-3 for applicable compressor torque values.
cross pattern in staged ten ft lb increments according to values in Table 8-3.
6
5
4
7
3
2
7
JACK HERE
1. Cylinder Head Gasket
2. Discharge valve screw and lockwasher
3. Discharge valve stop
4. Discharge valve
5. Valve plate
6. Valve plate assembly
7. Valve plate gasket
Figure 8--23 Exploded view of valve plate
1
1.
3.
2.
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 discharge valves so that they will seat properly. Any valve wear will cause leakage for this reason.
Suction valves are positioned by dowel pins (See
Figure 8--24) and will assume their original position when reinstalled. No two valves are likely to wear in exactly the same way. Never interchange used valves.
Do not omit the suction valve positioning springs. (See
Figure 8--24) 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. Torque cylinder heads in a
62-11039 8--24
1. Suction valve
2. Suction valve positioning spring
3. Valve plate dowel pin
Figure 8--24 Suction valve & positioning springs
1. Push pistons from the inside of the crankcase through the cylinders, being careful not to break the rings. Place chamfered side of connecting rod against radius of crank pins. Install the crankshaft through the pump end of the compressor. Do not damage main bearings. Install matching connecting rod caps through bottom cover plate.
8.15.4 Compressor Oil Level
CAUTION
Use only Carrier Transicold approved Polyol Ester Oil (POE). Buy quantities of one quart or less. When using this hygroscopic oil, immediately reseal. Do not leave container of oil open or contamination will occur.
2.
1.
1.
3.
4.
1. Unloaders
2. Oil fill and suction pressure transducer
3. Bearing head
4. Oil pump
Figure 8--25 Compressor oil pump end view
Checking the oil level in the compressor
a. Operate the unit in cooling mode for at least 20 minutes.
b. 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 c.
c. 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.
Adding Oil With Compressor In System
In an emergency where an oil pump is not available, oil may be drawn into the compressor through the suction service valve.
CAUTION
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 compressor.
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. 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.
Run unit for 20 minutes in cooling mode. Check oil level at the compressor sight glass.
8--25 62-11039
Adding Oil To Service Replacement Compressor
NOTE
1. Service replacement compressors are shipped without oil.
2. When first adding oil to the compressor, add only 6.3 pints (3 liters) to the compressor. Run the unit for 20 minutes in cooling mode. Check the oil level in the compressor sight glass. Add oil as necessary. This procedure is designed to compensate for excess oil that may have migrated with refrigerant to other parts of the system during unit operation.
Removing oil from the compressor
a. If the oil level recorded is above one-eighth level of the capacity of the sight glass, oil must be removed from the compressor.
b. Close (frontseat) suction service valve and pump unit down to 2 to 4 psig (0.1 to 0.3 bar). Frontseat discharge service valve and slowly bleed remaining refrigerant.
c. Remove 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 (maximum is one-eight level of the sight glass). Replace the plug securely back into the compressor. DO NOT
FORGET TO OPEN SUCTION AND DISCHARGE
SERVICE VALVES.
d. Repeat Checking The Oil Level step c. to ensure proper oil level.
-- Maximum
-- Minimum
Figure 8--26. Oil Level in Sight Glass
SIZE
DIAMETER
(INCHES)
1/4
5/16
3/8
1/2
THREADS
PER INCH
28
18
16
13
Table 8-3 Compressor Torque Values
TORQUE RANGE
FT-LB
12 -- 16
20 -- 30
40 -- 50
65--70
8.16 COMPRESSOR UNLOADER VALVE
MKG
1.66 -- 2.21
2.77 -- 4.15
5.53 -- 6.92
9.0--9.7
Unloader Valve
Discharge Valve
Cylinder Head
Suction Valve
The compressor unloaders (located on the compressor cylinder heads) are controlled by the Advance
Microprocessor. (Refer to Section 2.3.3)
Manual Checkout procedure
a. Initiate Pretrip.
b. Connect manifold gauges to the compressor suction and discharge service valves and start unit in cooling with the trailer temperature at least 5_F (2.8_C) above set point and the compressor will be fully loaded (both unloader coils are de-energized). Note suction pressure.
c. Unplug both unloader coils.
d. Using fused jumper wires energize front unloader.
Note discharge and suction pressures. A rise of approximately 3 psig (0.2 Bar) will be noted on the suction pressure gauge. Discharge pressure should drop approximately 5 to 15 psig (0.4 to 1.0 Bar).
e. Disconnect UL1 and note pressures. Suction pressure should drop and discharge pressure should rise by same amount as in step d. above.
f. Repeat steps 3 & 4 for UL2 (rear unloader). At the end of the test, plug both unloaders back in.
USAGE
NOTE
If either unloader coil energizes and the suction and discharge pressures do not change, the unloader assembly must be checked.
Replacing solenoid valve internal parts (see
Figure 8--27)
a. Put gauges on the compressor.
b. Pump down the compressor to 0--5 psig
(0 to 0.3 Bar). Frontseat both service valves to isolate compressor.
c. Equalize compressor high and low side pressures.
d. Recover refrigerant remaining in compressor.
e. Remove coil retainer and coil.
f.
Remove enclosing tube collar (Item 4, Figure 8--27) using installation/removal tool supplied with repair kit
(item 3).
g. Check plunger for restriction due to: (a) Corroded or worn parts; (b) Foreign material lodged in valve; (c) Bent or dented enclosing tube.
h. Install new parts. Do not overtighten enclosing tube assembly. Torque to a value of 100 inch pounds (1.15
kmg).
i.
Remove supplied installation/removal tool. Install coil, voltage plate, and retainer.
j.
Evacuate and dehydrate the compressor.
62-11039 8--26
k. Start unit and check unloader operation (Refer to section 8.16.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1. Retainer
2. Coil assembly
3. Installation/
Removal tool
4. Enclosing tube collar
5. O-ring
6. Enclosing tube
7. Plunger spring
8. Plunger assembly
9. Gasket
10. Valve body
11. Gasket
12. Bolt
13. Gasket, bolt
14. Piston ring
Figure 8--27 Unloader solenoid valve
Solenoid coil replacement
NOTE
The coil may be removed without pumping down the unit.
a. Disconnect leads. Remove retainer. Lift off coil.
(See Figure 8--28) b. Verify coil type, voltage and frequency of old and new coil. This information appears on the coil housing.
c. Place new coil over enclosing tube, retainer and connect wiring.
d. Check unit operation by running Pretrip (Refer to
Section 3.5).
Use tool torque
1
stem nut to 2.8 to
20-22 ft-lbs (3.0
Mkg)
3
4
5
6
7
2
Note: When installing coil, make sure roll pin is fitted into stem nut, and coil seats properly onto pin to keep it from rotating.
9
10
11
Torque 3
Bolts to
12-16 ft-lbs
12
8
1. Coil Assembly
2. Stem/Enclosing Tube
Assy
3. Installation/Removal
Tool
4. Spring, Plunger
5. Plunger Assembly
6. “O” Ring
7. Valve Body
8. Gasket, Valve Body
9. Pin, Anti-Rotation (fits into top of stem nut)
10. Bolts, Valve Body (3)
11. Washers (3)
12. Piston (use only with hot gas bypass unloaders)
Figure 8--28. Solenoid Coil Replacement
NOTE
Place unit in Service Mode before performing the following operations. Refer to Section 5.2.3
8--27 62-11039
8.17 CHECKING AND REPLACING FILTER-DRIER
To Check Filter-Drier
Check 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.
To Replace Filter-Drier
a. Pump down the unit per section 8.11.1. Remove bracket, then replace drier. Tighten inlet side fitting.
b. Slowly open king valve and purge air through the drier. Tighten drier outlet side fitting.
c. Leak test drier connections.
d. Check refrigerant level.
e. Check unit operation by running Pretrip (Refer to Section 3.5).
8.18 ELECTRONIC EXPANSION VALVE (SEE 8.19
FOR INFORMATION ON TXVs FOR REMOTE
COMPARTMENTS)
NOTE
Place unit in Service Mode before performing the following operations on the unit. Refer to
Section 5.2.3
The electronic expansion valve (EVXV) is an automatic device which maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure. The valve functions are: (a) automatic response of refrigerant flow to match the evaporator load and (b) prevention of liquid refrigerant entering the compressor. Unless the valve is defective, it seldom requires any maintenance.
Make sure the EVXV coil is snapped down fully, and the coil retention tab is properly seated in one of the valve body dimples.
1
2
FLOW
DIRECTION
1. Coil
2. Electronic expansion valve
Figure 8--29 Electronic expansion valve
8.18.1 Replacing Expansion Valve & Screen
a. Pump down the unit by closing the manual shut off per Section 8.11.1.) b. Remove coil.
c. Use a wet rag to keep valve cool whenever brazing.
Heat inlet, outlet and equalizer connection to valve body and remove valve. Clean all tube stubs so new valve fits on easily.
d. Install new valve and screen, with cone of screen pointing into liquid line at inlet to the valve by reversing steps a.through c.
e. The thermal bulb is located below the center of the suction line (See Figure 8--31). This area must be clean to ensure positive bulb contact. Firmly tighten the straps around the thermal bulb and suction line and insulate both with Presstite.
f. Evacuate by placing vacuum pump on suction service valve.
g. Open king valve and then check refrigerant level.
h. Check superheat. (Refer to Section 2.12) i. Check unit operation by running Pretrip (Refer to
Section 3.5).
62-11039 8--28
8.18.2 EVXV coil (Unipolar design)
A
A
ORN
YEL
COM (+12VDC)
GRY
RED
BLK
B
B
Figure 8--30 Electronic expansion valve
The EVXV (evaporator expansion valve) coil consists of four windings. See Figure 8--30 for labelling.
All of the windings are connected together at one end, sharing a common wire where +12V is applied from the micro.
The other end of each winding has its own wire connected back to the micro.
Looking at the 5--pin connector on the EVXV coil, the wiring is as follows:
Connector Pin
A
B
C
D
E
Wire Color
ORANGE
RED
YELLOW
BLACK
GREY
Winding
A
B
A
B
COM (+12V)
Each winding has a resistance of about 46 ohms. If the coil is good, this resistance (¦ 10 %) will be measured between the gray common wire and each of the other four wires.
Also, since the coils are all connected together at a common point, the resistance of two windings in series can be measured between any two wires other than the gray wire. This resistance will be about 92 ohms
(¦10%).
To open the valve, the micro energizes each winding of the coil in a specific sequence. Energizing the windings in the correct sequence rotates the rotor and causes the valve to open one step.
The windings are energized in the reverse sequence to close the valve one step.
8--29
If the windings are not energized in the proper sequence, the valve will chatter, but the rotor will not rotate and the valve will not open (or close).
The sequence to energize each coil is shown below:
O
P
E
N
A
A & B
B
A & B
A
A & B
B
A & B
+12 VDC on GRAY
C
L
O
S
E
D
8.19 THERMOSTATIC EXPANSION VALVES
(REMOTE COMPARTMENTS)
NOTE
Place unit in Service Mode before performing the following operations on the unit. Refer to
Section 5.2.3
The thermostatic expansion valve (TXV) is an automatic device which maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure. The valve functions are: (a) automatic response of refrigerant flow to match the evaporator load and (b) prevention of liquid refrigerant entering the compressor. Unless the valve is defective, it seldom requires any maintenance.
8.19.1 Replacing Expansion Valve & Screen
a. Pump down the unit by closing the manual shut off valve (king valve). (Refer to Section 8.11.1.) b. Remove insulation (Presstite) from expansion valve bulb and then remove bulb from suction line.
c. Remove Presstite from the expansion valve power head. Unscrew power head if only the element is being changed and replace by reversing steps a.
through c.
d. Use a wet rag to keep valve cool whenever brazing.
Heat inlet, outlet and equalizer connection to valve body and remove valve. Clean all tube stubs so new valve fits on easily.
e. Install new valve and screen, with cone of screen pointing into liquid line at inlet to the valve by reversing steps a.through c.
f. The thermal bulb is located below the center of the suction line (See Figure 8--31). This area must be clean to ensure positive bulb contact. Firmly tighten the straps around the thermal bulb and suction line and insulate both with Presstite.
g. Evacuate by placing vacuum pump on suction service valve.
h. Open king valve and then check refrigerant level.
i. Check superheat. (Refer to Section 2.12) j.Check unit operation by running Pretrip (Refer to Section 3.5).
62-11039
8.19.2 To Measure Superheat
NOTE
The expansion valve and bulb location are shown in Figure 8--31.
a. Pull loose the Presstite insulation from one end of the expansion valve bulb.
b. Loosen one TXV bulb clamp and make sure area under clamp (above TXV bulb) is clean.
c. Place thermocouple above (parallel) TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in
Figure 8--31. Use Presstite insulation to completely cover both bulbs.
3
2
1
4
5
1. Suction Line
2. TXV Bulb Clamp
3. Nut and Bolt (Clamp)
4. Thermocouple
5. TXV Bulb
Figure 8--31. Thermostatic Expansion Valve
Bulb and Thermocouple
d. Connect an accurate gauge to the 1/4” port on the suction service valve.
e. Run unit until stabilized. Set controller 10_F (5.5_C) below box temperature.
f. From the temperature/pressure chart, determine the saturation temperature corresponding to the evaporator outlet pressure.
g. Note the temperature of the suction gas at the expansion valve bulb.
h. Subtract the saturation temperature determined in
Step f. from the average temperature measured in
Step g. The difference is the superheat of the suction gas.
8.20 CHECKING AND REPLACING HIGH PRES-
SURE CUTOUT SWITCH (HPS)
8.20.1 Replacing High Pressure Switch
a. Put gauges on the compressor.
b. Pump down compressor to 0--5 psig (0 to 0.3 Bar) suction pressure.
(Refer to Section 8.11.1.)
Frontseat both suction and discharge service valves to isolate compressor.
c. Slowly equalize compressor pressure through the service valve gauge ports.
d. Recover refrigerant remaining in compressor.
e. Disconnect wiring from defective switch, and remove old switch. The HPS is located on the top cylinder head (See Figure 8--22).
f. Install new cutout switch after verifying switch settings. (Refer to Section 8.20.2) g. Evacuate and dehydrate the compressor. (Refer to
Section 8.13) h. Check unit operation by running Pretrip (Refer to Section 3.5).
62-11039 8--30
8.20.2 Checking High Pressure Switch
WARNING
Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is approximately 2350 PSIG (159.9 Bar). Do not use oxygen in or near a refrigerant system as an explosion may occur.
(See
Figure 8--32)
1
2
4
5
8.21 DISCHARGE PRESSURE TRANSDUCER
(CDP)
HIGH RANGE PRESSURE TRANSDUCER
-- CDP
3 6
PRESSURE (PSIG)
Figure 8--33. Pressure Transducer Values
1. Cylinder Valve and Gauge
2. Pressure Regulator
3. Nitrogen Cylinder
4. Pressure Gauge
[0 to 400 PSIG (0 to
27.2 Bar)]
5. Bleed-Off Valve
6. 1/4 inch Connection
Figure 8--32. Typical Setup for Testing High
Pressure Switch
a. Remove switch as outlined in Section 8.20.1
b. Connect ohmmeter or continuity light across switch terminals. Ohmmeter will indicate resistance and continuity light will be lighted if switch closed after relieving pressure.
c. Connect switch to a cylinder of dry nitrogen. (See
Figure 8--32) d. Set nitrogen pressure regulator higher than cutout point on switch being tested. Pressure switch cutout and cut-in points are shown in Section 2.12.
e. Close valve on cylinder and open bleed-off valve.
f. Open cylinder valve. Slowly close bleed-off valve and increase pressure until the switch opens. If light is used, light will go out and if an ohmmeter is used, the meter will indicate open. Open pressure on gauge.
Slowly open bleed-off valve (to decrease pressure) until switch closes (light will light or ohmmeter will move).
8--31
4.1
4.4
4.8
5.1
5.4
2.4
2.7
3.0
3.4
3.7
- 1.0
- 0.6
0
0.3
0.6
1.0
1.3
1.7
2.0
5.8
6.1
6.5
6.8
Table 8-4 Suction and discharge
Pressure Transducer Voltages
Psig Bar
Suction voltage
Discharge voltage
60
65
70
75
80
35
40
45
50
55
--14.5
--8.7
0
5
10
15
20
25
30
85
90
95
100
3.10
3.28
3.45
3.63
3.80
2.23
2.41
2.58
2.76
2.93
0.50
0.66
1.01
1.19
1.36
1.54
1.71
1.88
2.06
3.98
4.15
4.32
4.50
0.98
1.02
1.06
1.10
1.14
0.78
0.82
0.86
0.90
0.94
0.38
0.42
0.50
0.54
0.58
0.62
0.66
0.70
0.74
1.18
1.22
1.26
1.30
62-11039
8.21.1 Calibrating Compressor Discharge Pressure
Transducer
The Compressor Discharge Pressure Transducer
(CDP) has a range of 0 to 500 PSIG (0 to 34.0 Bar). With this large of a pressure range, some transducers will not read exactly the same as the next. To allow for variations in transducers and still display an accurate pressure reading in the Data List, there is a calibration feature for the CDP built into the microprocessor.
To calibrate the CDP, it must be removed from the compressor, and be exposed to 0 PSIG/Bar. During the calibration process, the microprocessor measures the difference between what the transducer is sending and what the microprocessor was expecting for a zero reading. The difference between these two is called an offset. This offset is then stored in the microprocessor’s memory, and is used in all future calculations for displaying compressor discharge pressure.
c. Press the Up Arrow until
“DISCHARGE PRESSURE:” is showing in the
MessageCenter.
d. Press and hold the Equal Key for 6 seconds. The
MessageCenter will blink 5 times. When it stops blinking, the display will either show
“DISCHARGE PRESSURE: 0.0 Bar/PSIG”, or the message “CALIBRATION UNSUCCESSFUL”.
e. When “DISCHARGE PRESSURE: 0.0 Bar/PSIG” appears, the offset has been saved into the microprocessor memory, and the calibration is complete.
f. If the calibration was unsuccessful, either there is more than 0 Bar/PSIG on the transducer, or the transducer is further away from 0 than an offset will allow.
The transducer must be replaced.
8.21.2 Testing Compressor Discharge Pressure
Transducer
30
40
50
60
70
PSIG
0
10
20
NOTE
The Compressor Discharge Pressure on the microprocessor Data List will never read less than 0 PSIG/Bar, even if it is exposed to a vacuum (such as when evacuating the system.)
Consequently, a transducer reading of 0 does not indicate accurate calibration.
Every
Discharge Transducer must be calibrated before being installed into a compressor.
a. Power up the transducer circuit. Place unit into PC
Mode (Refer to Section 5.1), or place unit in Manual
Start Mode.
b. Press the Select Key until
“PRESS "# TO VIEW DATA” appears in the
MessageCenter.
2.0
2.7
3.4
4.1
4.8
Bar
0
0.7
1.4
a. Verify that the wiring to the transducer is correct.
(See wiring diagram, Section 10.) b. Power up the transducer circuit. Place unit into PC
Mode (Refer to Section 5.1), or place unit in Manual
Start Mode.
c. Check Voltage to transducer connector. Voltage reading between A (negative) and B (positive) should be 5.0 VDC.
d. Check wire resistance between C (output to microprocessor) and 1MP5.
e. Place +5.0 VDC on transducer terminal B and --5.0
VDC on transducer terminal A. Disconnect C from the microprocessor. Test voltage between B and C.
The reading should be as shown in table below.
Table 8-5. Compressor Discharge Pressure Transducer
Voltage
0.5
PSIG
80
Bar
5.4
Voltage
1.1
PSIG
250
Bar
17.0
0.6
0.7
0.7
0.8
0.9
1.0
1.1
90
100
125
150
175
200
225
6.1
6.8
8.5
10.2
11.9
13.6
15.3
1.2
1.3
1.5
1.7
1.9
2.1
2.3
275
300
325
350
375
400
450
18.7
20.4
22.1
23.8
25.5
27.2
30.6
Voltage
2.5
2.7
2.9
3.1
3.3
3.5
3.7
4.1
CAUTION
The +5.0 VDC (terminal B) is common between the Compressor Discharge Pressure Transducer, the
Compressor Suction Pressure Transducer, and the RPM sensor. If this circuit is shorted to ground
(due to one of the mentioned components being defective, or a worn wire) the MessageCenter will show:
Suction Pressure: --14.7 psig (--1 Bar)
Discharge Pressure: 0 Bar/PSIG
Engine RPM: 0.
62-11039 8--32
8.21.3 Replacing Compressor Discharge Pressure
Transducer
a. Pump down the compressor. (Refer to Section
8.11.1.) Frontseat both suction and discharge service valves to isolate compressor.
b. Equalize compressor discharge and suction pressures through the service valve gauge set.
c. Disconnect wiring from defective transducer and remove. The CDP is located at the side of the center compressor cylinder head. (See Figure 2-2)
WARNING
The Compressor Discharge Pressure
Transducer does not have a Schrader valve in the connecting fitting. Any discharge pressure remaining in the compressor will be released when removing the CDP.
d. Calibrate new discharge transducer before installing in compressor. (Refer to Section 8.21.1) e. Install new discharge transducer, being careful to obtain the correct transducer for your unit. R-404A
CDPs have a red dot on the side.
NOTE
Place unit in Service Mode before performing the following operations on the unit. Refer to
Section 5.2
f. Evacuate and dehydrate the compressor. (Refer to
Section 8.13.) g. Check unit operation by running Pretrip (Refer to Section 3.5).
PSIG
--10
--5.0
0.0
5.0
10.0
15.0
20.0
25.0
8.22 COMPRESSOR SUCTION PRESSURE TRANSDUCER (CSP AND EVOP)
LOW RANGE PRESSURE TRANSDUCER
-- CSP/EVOP
PRESSURE (PSIG)
8.22.1 Calibrating Compressor Suction Pressure
Transducer
The Compressor Suction Pressure Transducer (CSP) has a range of --14.7 to100 PSIG (--1 to 6.8 Bar).
Because of this much smaller range, calibration of the
CSP is not required.
8.22.2 Testing Compressor Suction Pressure
Transducer
a. Verify that the wiring to the transducer is correct.
(See wiring diagram, Section 10).
b. Power up the transducer circuit. Place unit into PC
Mode (Refer to Section 5.1), or place unit in Manual
Start Mode.
c. Check Voltage to transducer. Voltage reading between A (negative) and B (positive) should be 5.0
VDC.
d. Check wire resistance between C (output to microprocessor) and 1MP6.
e. Place +5.0 VDC on transducer terminal B and --5.0
VDC on transducer terminal A. Test voltage between
B and C. The reading should be as shown in table below.
Bar
--0.7
--0.3
0.0
0.3
0.7
1.0
1.4
1.7
Table 8-6. Compressor Suction Pressure Transducer
Voltage
0.7
PSIG
30
Bar
2.0
Voltage
2.1
PSIG
70
0.8
1.0
1.2
1.4
35
40
45
50
2.4
2.7
3.1
3.4
2.2
2.4
2.6
2.8
75
80
85
90
1.5
1.7
1.9
55
60
65
3.7
4.1
4.4
2.9
3.1
3.3
95
100
Bar
4.8
5.1
5.4
5.8
6.1
6.5
6.8
Voltage
3.5
3.6
3.8
4.0
4.1
4.3
4.5
8--33 62-11039
CAUTION
The +5.0 VDC (terminal B) is common between the Compressor Discharge Pressure Transducer, the
Compressor Suction Pressure Transducer, and the RPM sensor. If this circuit is shorted to ground
(due to one of the mentioned components being defective or a worn wire) the MessageCenter will show:
Suction Pressure: --14.7 psig (--1 Bar)
Discharge Pressure: 0 PSIG/Bar
Engine RPM: 0.
8.22.3 Replacing Compressor Suction Pressure
Transducer
a. Pump down compressor until the suction pressure is approximately 0--5 PSIG (0--.4 Bar). (Refer to Section 8.11.1.) b. Disconnect wiring from defective transducer. Slowly remove the transducer. The pressure remaining in the suction line will be held in place by a Schrader valve located inside the fitting. The CSP is located on the suction line just above the Suction Service Valve.
(See Figure 2-2).
c. Install new suction transducer, being careful to obtain the correct transducer for your unit. R-404A CSPs have a blue dot on the side. Check for leaks.
d. Open the king valve and check operation.
8.24 COMPRESSOR SUCTION MODULATION
VALVE (CSMV)
The purpose of the SMV is to control suction pressure, maintain the compressor within its operating envelope, and maximize unit capacity and fuel economy.
At initial startup, the microprocessor will go through a self test.
When the test is complete, the
MessageCenter will display “SMV CLOSING”. The process of fully closing the SMV on startup is known as
“homing” the SMV. When homing is complete, the
MessageCenter will display “SETTING SMV XX%”. The
XX% will count up to a predetermined percentage depending on ambient temperature and box temperature. The unit will then go through its normal start procedure.
CSMV
e. Evacuate and dehydrate the compressor. (Refer to
Section 8.13.) f. Check unit operation by running pretrip (Refer to Section 3.5).
2-1/8 inch Nut
8.23 REPLACING RECEIVER SIGHT GLASS AS-
SEMBLY
Figure 8--34 Suction modulation valve (CSMV)
NOTE
Place unit in Service Mode before performing the following operations. Refer to Section
5.2.3.
a. Store the refrigerant in an evacuated container. (Refer to Section 8.11.1.) b. Unscrew the sight glass assembly. Wrap threads with teflon tape or spread some sealing compound on pipe threads of new sight glass assembly or plug and install. The torque value for the sight glass assembly is 37--44 ft--lbs (5.1 to 6.1 Mkg)
8.24.1 Function
The SMV coil consists of two windings labeled 1 and 2.
Each winding has two poles, labeled A and B.
Both poles of both windings have a wire connected back to the micro.
Looking at the 4--pin connector on the SMV coil, the wiring is as follow : c. Leak check receiver sight glass Section 8.12.
d. After leak checking unit, evacuate and dehydrate as outlined in Section 8.12.
e. Add refrigerant charge. (Refer to Section 8.13.4) f. Check unit operation by running Pretrip.
Table 8-7. CSMV Connections
Connector Pin Wire Color
A BLACK
Winding/Pole
1A
B
C
D
WHITE
RED
GREEN
1B
2B
2A
62-11039 8--34
O
P
E
N
1
2
3
4
Winding #1 Winding #2
1A 1B 2A 2B
+12V GRD +12V GRD
GRD +12V +12V GRD
GRD +12V GRD +12V
+12V GRD GRD +12V
C
L
O
S
E
Each winding has a resistance of about 75 Ω.
There is no common connection point between the two windings.
The reason this coil design is bipolar is that the microprocessor causes the valve to open by energizing the windings in a particular sequence and by reversing the polarity of the current through the windings in a specific sequence.
Energizing the windings with the correct polarity, in the correct sequence, rotates the rotor and causes the valve to open one step.
1A (BLK)
1
(WHT) 1B
2A (GRN)
2
(RED) 2B
Figure 8--35 CSMV Coil (Bi--Polar Design)
8.24.2 CSMV Diagnostics
If the SMV is suspected to be faulty, the first thing the operator should do is perform a unit Pretrip (Refer to
Section 3.5). Some symptoms that could indicate a faulty SMV are:
S
Unusually high suction pressure in COOL mode.
A27 -- High Suction Pressure Alarm may be generated.
S
Unusually low suction pressure
A18 -- Low Refrigerant Alarm may be generated
S
Poor temperature control
Box temperature deviates from setpoint.
If the unit fails Test 10 during pretrip,
(P180 CHECK SUCTION MOD VALVE) the SMV could be faulty. The SMV could have become mechanically jammed, or it could have failed electrically in the power head, or it may not be receiving the proper signal from the micro. There are several steps the operator should make in addition to the unit Pretrip to further diagnose the valve.
8--35 a. The SMV may be stuck in some position other than completely closed and the stepper motor cannot move the piston. To check if the valve is stuck, first start the unit and run in cool mode with manifold gauges attached to the compressor b. Allow the suction pressure to pull down to 0 PSIG/-
Bar.
WARNING
Carrier Transicold does not recommend allowing the compressor to pull less than 0
PSIG/Bar at any time.
c. Once the unit has reached suction pressure of 0
PSIG/BAR, switch the unit to OFF using the SROS.
After the engine shuts down, the microprocessor will fully close the SMV.
NOTE
Carefully listen to the valve. When the unit is off and the valve is closing, the valve will make a ratcheting noise that may be heard or felt as it is closing. If this can be heard or felt, it indicates that the microprocessor is attempting to close the valve, and may serve as a quick indication that the drive module is in working order. It is not, however, an indication that the valve piston is actually working.
d. Wait about 2 minutes after the engine stops to ensure the valve is fully shut.
e. If the SMV is fully shut, the suction pressure should still read 0 PSIG/Bar. If the valve is stuck at some position other than fully closed, or it cannot fully close for any reason, the suction pressure during this test will rise.
a. If the suction pressure holds to 0, go to Step c.
b. If the suction pressure rises, go to Step d.
c. Use the Stepper Motor Tester (CTD special tool P/N
07--00375--00) to manually open the valve. The suction pressure on the manifold gauge should go up. If the suction pressure does not go up, the SMV is stuck closed (go to Step d.) or there is something obstructing the refrigerant.
NOTE
Opening the valve can also be accomplished by using the microprocessor. Place the SROS in the Start/Run position. The microprocessor will go through its self test and the display will show
“SMV CLOSING”. The valve is obviously
closed at this point, but the microprocessor still has to “home” the SMV valve every time the mi-
croprocessor is powered up. The display will then show “SETTING SMV XX%” . Refer to
8.24 above. If the suction pressure does not go up, the SMV is stuck closed (go to Step d.) or there is something obstructing the refrigerant.
NOTE
If the valve passes steps a. through c., the valve is operating properly.
62-11039
d. If the suction pressure rises during Step e., or if the valve is determined to be stuck closed in Step c., turn the unit Off by placing the SROS in the OFF position and unplug the 4 pin connector to the SMV. With a reliable digital ohmmeter, check the winding resistance between 1A (Black) wire and the 1B (White) wire
AND between the 2A (Green) wire and the 2B (Red) wire. In normal ambient, each winding should have
72 to 84 ohms. If this resistance is confirmed, proceed to Step 8. If an infinite or zero ohm reading occurs, first check the wires at the connector for good contact. If the connector is in good condition and the resistance is still bad, one (or both) of the coils could be faulty. Replace the SMV power head assembly
P/N 14--00263--20. Refer to Section 8.24.3.
e. Locate the wires on the engine harness side of the
SMV connector. Locate the wires labeled CSMVA,
CSMVB, CSMVC and CSMVD. These will correlate to the connector pins labeled A, B, C and D. See
Table 8-7.
f. Place the SROS in the Start/Run position. DO NOT
ALLOW THE UNIT TO START. When the Message-
Center displays “SMV CLOSING”, measure the AC voltage between pins A and B and then between C and D. A reading of 10 to 16 VAC should be read by the digital voltmeter for each pair of wires. If this test passes, there is a good signal coming from the microprocessor.
g. If the reading of 10 to 16 VAC is not present on one or both of the wire pairs, check the wiring between the microprocessor and the SMV connector, or check the microprocessor for proper model number configuration.
h. If all the above tests pass, the SMV is operating properly and the abnormal unit operation can be contributed to something other than the SMV.
8.24.3
Replacing The SMV Power Head
(14--00263--20)
a.Pump the unit down at the manual shut off valve (king valve) (Refer to Section 8.11.1).
b.Unplug the SMV connector from the engine harness.
c.Loosen the 2 1/8” nut on the SMV and remove the power head assembly. (See Figure 8--34).
d.Install the new SMV power head.
e. The power head should be set to 100% (Open) when received from the warehouse. This is to ensure the
Teflon valve seal is not damaged when it is installed.
Ensure the valve is fully open by using Stepper Motor
Tester (CTD special tool P/N 07--00375--00) to manually open the valve to 100% before it is installed.
f.Torque the 2 1/8” nut to 35 to 40 ft--lbs (4.8 to 5.5 Mkg ) g.Reconnect the SMV connector to the engine harness.
NOTE
Place unit in Service Mode before pumping down and/or removing the refrigeration charge.
Refer to Section 5.2.3.
h.Evacuate the low side of the refrigeration system. (Refer to Section 8.13)
62-11039 8--36 i.Open the king valve, run the unit for approximately 10 minutes and initiate a pretrip.
Emergency repair procedures :
In the event that the SMV system has a failure, and replacement components are not readily available in an emergency. A LIMP-HOME procedure can be done as follows : a. Attach a manifold gauge set.
b. Perform a low side pump down. When the unit has reached 0 to 5 psig close the suction service valve and turn the unit OFF.
c. Remove SMV powerhead by loosening the 2-1/8 inch diameter nut (see Figure 8--34), and sliding the powerhead out.
d. Remove the piston by loosening the Allen screw and removing the piston and screw.
e. Install the powerhead assembly (without the piston), torque to 35 to 40 foot-lbs (4.8 to 5.5 Mkg).
f. Open all valves.
g. Start the unit.
3. 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.
8.25 CHECKING DEFROST OR HEATING CYCLE
NOTE
The DTT temperature for any enabled compartment must be 40°F (4.4°C) or cooler, before any checks can be made.
8.25.1 Defrost Air Switch
a. To check the Defrost Air Switch, run unit in high speed cooling and jump across the air switch terminals. This will start the defrost cycle as it simulates the action of the defrost air switch. Bypassing the switch in this manner operates all components involved in defrost.
NOTE
If none of the DTTs are below 40_F (4.4_C), the
MessageCenter will show
“CANNOT START DEFROST CYCLE”.
b. Unit should remain in defrost until all DTTs reach
55_F (12.8_C). At this point the defrost cycle will terminate, and the unit will resume automatic operation.
c. If the above test indicates satisfactory operation, test
DAS settings using a Dwyer Magnehelic gauge (P/N
07-00177) or similar instrument. (Refer to Section
8.26)
8.25.2 Electronic Defrost Timer
Refer to Section 2.12 for description.
8.26 CHECKING CALIBRATION OF
DEFROST AIR SWITCH
5
2
6
4
3
1
1. Ohmmeter or Continuity Device
2. Adjustment Screw (0.050” socket head size)
3. Low Side Connection
4. Pressure Line or Aspirator Bulb (P/N
07-00177-01)
5. Magnehelic Gauge (P/N 07-00177-00)
6. High Side Connection
Figure 8--36 Defrost Air Switch Test Setup
a. Make sure magnehelic gauge is in proper calibration.
NOTE
The Magnehelic Gauge may be used in any position, but must be re-zeroed if position of gauge is changed from vertical to horizontal or vice versa. USE ONLY IN POSITION FOR
WHICH IT IS ZEROED. The Defrost Air Switch
MUST be in the same orientation as it will be in when installed in the unit.
b. With air switch in vertical position, connect high pressure side of magnehelic gauge to high side connection of air switch. (See Figure 8--36) c. Install tee in pressure line to high side connection. Tee should be approximately half-way between gauge and air switch or an improper reading may result.
d. Attach an ohmmeter to the air switch electrical contacts to check switch action.
NOTE
Use a hand aspirator (P/N 07-00177-01), since blowing into tube by mouth may cause an incorrect reading.
e. With the gauge reading at zero, apply air pressure very slowly to the air switch. An ohmmeter will indicate continuity when switch actuates. The switch contacts should close and the ohmmeter needle move rapidly to 0. Any hesitation in the ohmmeter indicates a possible problem with the switch, and it should be replaced.
f. Refer to Section 2.12 for switch settings. If switch fails to actuate at correct gauge reading, adjust switch by
8--37 turning adjusting screw clockwise to increase setting or counterclockwise to decrease setting.
g. Repeat checkout procedure until switch actuates at correct gauge reading.
h. After switch is adjusted, place a small amount of paint or fingernail polish on the adjusting screw so that vibration will not change switch setting.
8.27 EVAPORATOR COIL
8.27.1 Cleaning
The use of recycled cardboard cartons is increasing across the country. The recycled cardboard cartons create much more fiber dust during transport than “new” cartons. The fiber dust and particles are drawn into the evaporator where they lodge between the evaporator fins. If the coil is not cleaned on a regular basis, sometimes as often as after each trip, the accumulation can be great enough to restrict air flow, cause coil icing, repetitive defrosts and loss of unit capacity. Due to the
“washing” action of normal defrost the fiber dust and particles may not be visible on the face of the coil but may accumulate deep within.
It is recommended to clean the evaporator coil on a regular basis, not only to remove cardboard dust, but to remove any grease or oil film which sometimes coats the fins and prevents water from draining into the drain pan.
Cardboard fiber particles after being wetted and dried several times can be very hard to remove. Therefore, several washings may be necessary.
a. Remove rubber check valves (Kazoo) from drain lines (front of trailer or rail car).
b. Spray coil with a mild detergent solution such as
Oakite 164 or 202) or any good commercial grade automatic dish washer detergent such as Electrosol or
Cascade and let the solution stand for a few minutes and reverse flush (opposite normal air flow) with clean water at mild pressure. A garden hose with spray nozzle is usually sufficient. Make sure drain lines are clean.
c. Run unit until defrost mode can be initiated to check for proper draining from drain pan.
8.27.2 Coil Replacement -- Compartment 1
a. Pump unit down. (Refer to section 8.11) b. With power OFF and power plug removed, remove the screws securing the panel covering the evaporator section.
c. Disconnect all heater wiring.
d. Disconnect the RAT, DTT, and SAT sensors from the coil.
e. Remove the mounting hardware from the coil.
f. Unsolder the two coil connections, one at the distributor and the other at the coil header.
g. After defective coil is removed from unit, remove heaters and install on replacement coil.
h. Install coil assembly by reversing above steps.
i. Leak check connections per section 8.12. Evacuate the unit per section 8.13 and add refrigerant charge per Section 8.13.4.
62-11039
8.28 CONDENSER COIL
8.28.1 Coil Cleaning
Remove all foreign material from the condenser coil by reversing the normal air flow. (Air is pulled in through the front and discharges over the engine.) Compressed air or water may be used as a cleaning agent. It may be necessary to use warm water mixed with any good commercial dishwasher detergent. Rinse coil with fresh water if a detergent is used.
8.28.2 Coil Replacement
a. Remove the refrigerant charge per section 8.11.
b. Drain engine coolant.
c. Remove the condenser grille.
d. Unsolder discharge line and remove the line to the receiver.
e. Remove coil mounting hardware and remove the coil.
f. Install replacement coil and solder connections.
g. Leak-check the coil per section 8.12. Evacuate the unit per section 8.13, then charge the unit with refrigerant per section 8.13.4.
h. Refill engine coolant.
8.29 CONTROLLER SENSOR CHECKOUT
An accurate ohmmeter must be used to check resistance values shown in Table 8-8.
Due to 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 bad, the resistance reading will usually be much higher or lower than the resistance values given in
Table 8-8.
Two preferred methods of determining the actual test temperature at the sensor, is an ice bath at 32_F (0_C) or a calibrated temperature tester.
°F
Table 8-8. Sensor Resistance (ATT, 1RAT, 2RAT, 3RAT, 1SAT, ENCT, EVOT, CST, 1DTT, 2DTT)
°C
Ohms
--40 --40 336,500
°F
18
°C
--7.8
Ohms
49,060
°F
76
°C
24.4
Ohms
10,250
°F
134
°C
56.7
Ohms
2,809
--38 --38.9
312,600
--36 --37.8
290,600
20
22
--6.7
--5.6
46,230
43,580
78
80
25.6
26.7
9,760
9,299
136
138
57.8
58.9
2,697
2,590
--34 --36.7
270,300
--32 --35.6
251,500
--30 --34.4
234,200
--28 --33.3
218,200
24
26
28
30
--4.4
--3.3
--2.2
--1.1
41,100
38,780
36,600
34,560
82
84
86
88
27.8
28.9
30.0
31.1
8,862
8,449
8,057
7,686
140
142
144
146
60.0
61.1
62.2
63.3
2,488
2,390
2,297
2,208
--26 --32.2
203,400
--24 --31.1
189,700
--22 --30 177,000
--20 --28.9
165,200
--18 --27.8
154,300
--16 --26.7
144,200
--14 --25.6
134,800
--12 --24.4
126,100
32
34
36
38
40
42
44
46
0
1.1
2.2
3.3
4.4
5.5
6.6
7.7
32,650
30,850
29,170
27,590
26,100
24,700
23,390
22,160
90
92
94
96
98
100
102
104
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
7,334
7,000
6,684
6,384
6,099
5,828
5,571
5,327
148
150
155
160
165
170
175
180
64.4
65.6
68.3
71.1
73.9
76.7
79.4
82.2
2,124
2,042
1,855
1,687
1,537
1,402
1,281
1,171
--10 --23.3
118,100
--8 --22.2
110,500
--6 --21.1
103,600
--4 --20 97,070
2
4
--2 --18.9
91,030
0 --17.8
85,400
6
--16.7
--15.6
--14.4
80,160
75,270
70,720
56
58
60
62
64
48
50
52
54
8.9
10
11.1
12.2
13.3
14.4
15.5
16.6
17.7
20,990
19,900
18,870
17,900
16,980
16,120
15,310
14,540
13,820
106 41.1
108 42.2
110 43.3
112 44.4
114 45.5
116 46.7
118 47.8
120 48.9
122 50.0
5,095
4,874
4,665
4,465
4,275
4,095
3,923
3,759
3,603
185 85.0
190 87.8
195 90.6
200 93.3
205 96.1
210 98.9
215 101.7
220 104.4
225 107.2
1,072
983
902
829
762
702
647
598
553
8 --13.3
66,460
10 --12.2
62,500
12 --11.1
58,790
14 --10.0
55,330
16 --8.9
52,090
66
68
70
72
74
18.9
20.0
21.1
22.2
23.3
13,130
12,490
11,880
11,310
10,760
124 51.1
126 52.2
128 53.3
130 54.4
132 55.6
3,454
3,313
3,177
3,049
2,926
230 110.0
235 112.8
240 115.6
245 118.3
250 121.1
511
473
438
406
378
62-11039 8--38
4
6
8
10
0
2
--4
--2
12
14
16
--18
--16
--14
--12
--26
--24
--22
--20
--34
--32
--30
--28
°F
--40
--38
--36
--10
--8
--6
--20
--18.9
--17.8
--16.7
--15.6
--14.4
--13.3
--12.2
--11.1
--10.0
--8.9
--32.2
--31.1
--30
--28.9
--27.8
--26.7
--25.6
--24.4
°C
--40
--38.9
--37.8
--36.7
--35.6
--34.4
--33.3
--23.3
--22.2
--21.1
Table 8-9. Sensor Resistance (CDT)
Ohms
3,360,000
°F
18
°C
--7.8
3,121,020
2,900,710
20
22
--6.7
--5.6
2,697,500
2,509,940
2,336,720
2,186,670
24
26
28
3
--4.4
--3.3
--2.2
--1.1
2,028,680
1,891,780
1,765,060
1,647,700
1,538,950
1,438,120
1,344,580
1,257,770
1,177,150
1,102,240
1,032,600
32
34
36
38
40
42
44
46
48
50
52
8.9
10
11.1
4.4
5.5
6.6
7.7
0
1.1
2.2
3.3
967,830
907,560
851,450
799,180
750,470
705,060
662,690
623,150
586,230
551,740
519,500
54
56
58
60
62
64
66
68
70
72
74
12.2
13.3
14.4
15.5
16.6
17.7
18.9
20.0
21.1
22.2
23.3
178,820
169,700
161,100
152,990
145,340
138,120
131,310
124,870
118,790
113,040
107,600
Ohms
189,690
461,170
434,790
410,080
386,940
365,260
344,930
325,860
307,970
291,180
275,410
260,590
246,670
233,570
221,260
209,670
198,760
188,490
8--39 62-11039
50.0
51.1
52.2
53.3
54.4
55.6
45.5
46.7
47.8
48.9
41.1
42.2
43.3
44.4
36.7
37.8
38.9
40.0
32.2
33.3
34.4
35.6
27.8
28.9
30.0
31.1
°C
24.4
25.6
26.7
122
124
126
128
130
132
114
116
118
120
106
108
110
112
98
100
102
104
90
92
94
96
82
84
86
88
°F
76
78
80
36,100
34,610
33,200
31,850
30,560
29,330
51,010
48,800
46,710
44,710
42,820
41,010
39,290
37,660
73,380
70,040
66,880
63,880
61,040
58,330
55,770
53,330
Ohms
102,460
Sensor Resistance (CDT) Continued
°F °C
Ohms
134 56.7
28,160
°F °C
260 126.7
97,600
92,990
136
138
57.8
58.9
27,040
25,970
270
280
132.2
137.8
88,630
84,510
80,600
76,890
140
142
144
146
60.0
61.1
62.2
63.3
24,960
23,980
23,050
22,160
290
300
310
320
143.3
148.9
154.4
160.0
148
150
155
160
165
170
175
180
64.4
65.6
68.3
71.1
73.9
76.7
79.4
82.2
21,310
20,500
18,980
16,940
15,450
14,070
12,870
11,750
330
340
350
360
370
380
390
400
165.5
171.1
176.7
182.2
187.8
193.3
198.9
204.4
185
190
195
200
205
210
215
220
85.0
87.8
90.6
93.3
96.1
98.9
101.7
104.4
225 107.2
230 110.0
235 112.8
240 115.6
245 118.3
250 121.1
10,750
9,870
9,050
8,320
7,650
7,050
6,510
6,000
5,540
5,130
4,760
4,410
4,090
3,800
410 210.0
420 215.6
430 221.1
440 226.7
450 232.2
460 237.8
470 243.3
480 248.9
490 254.4
500 260.0
830
740
670
600
1,310
1,160
1,040
920
Ohms
3,290
2,850
2,490
2,170
1,910
1,680
1,480
370
340
310
280
540
490
450
410
260
240
62-11039 8--40
Temperature Pressure
_
C
_
F Bar PSIG
--40 --40 0.3
4.5
--37 --35
--34 --30
--32 --25
--29 --20
--28 --18
--27 --16
0.5
0.7
0.9
1.1
1.2
1.3
7.1
9.9
12.9
16.3
17.7
19.2
--26 --14
--24 --12
1.4
20.7
1.5
22.3
--23 --10
--22 --8
1.7
1.8
23.9
25.6
--21 --6 1.88
27.3
--20 --4
--19 --2
--18
--17
--16 4
0
2
2.0
2.1
2.3
2.4
2.5
29.1
30.9
32.8
34.8
36.8
--14
--13
--12 10
--11 12
6
8
--10 14
--9 16
--8 18
--7 20
--6 22
--4 24
--3 26
--2 28
2.7
38.9
2.8
41.1
3.0
43.3
3.1
45.6
3.3
48.0
3.5
50.4
3.7
52.9
3.8
55.5
4.0
58.1
4.2
60.9
4.4
63.7
4.6
66.5
--1 30 4.8
69.5
Temperature Pressure
_
C
_
F Bar PSIG
0 32 5.0
72.5
1 34
2 36
3 38
4 40
6 42
7 44
5.2
5.4
5.7
5.9
6.1
6.4
75.6
78.8
82.1
85.5
89.0
92.5
8 46
9 48
6.6
6.9
96.2
99.9
10 50
13 55
16 60
7.2 103.7
8.0 115.4
8.7 126.1
18 65 9.5 137.4
21 70 10.3 149.4
24 75 11.2 162.1
27 80 12.1 175.5
29 85 13.1 189.6
32 90 14.1 204.5
35 95 15.2 220.2
38 100 16.3 236.8
41 105 17.5 254.2
43 110 18.8 272.4
46 115 20.1 291.6
49 120 21.5 311.8
52 125 23.0 332.9
54 130 24.5 355.0
57 135 26.1 378.1
60 140 27.7 402.3
63 145 29.5 427.6
66 150 31.3 454.0
Table 8-10. Temperature Pressure Chart
8--41 62-11039
SECTION 9
MICROPROCESSOR AND UNIT TROUBLESHOOTING
9.1 MICROPROCESSOR TROUBLESHOOTING
CAUTION
Under no circumstances should anyone attempt to service the Advance Microprocessor. Should a problem develop with the Advance Microprocessor, contact your nearest Carrier Transicold dealer for replacement.
INDICATION/
TROUBLE
DIESEL ENGINE
9.1.1 Engine Will Not Start
POSSIBLE CAUSES
REFERENCE
SECTION
Starter motor will not crank or low cranking speed
Starter motor cranks but engine fails to start
Starter cranks, engages, but dies after a few seconds
Battery insufficiently charged
Battery terminal post dirty or defective
Bad electrical connections at starter
Starter motor malfunctions
Starter motor solenoid defective
Open starting circuit
Incorrect grade of lubricating oil
Worn generator bearings
No fuel in tank
Air in fuel system
Water in fuel system
Plugged fuel filter(s)
Plugged fuel lines to injector(s)
Fuel control operation erratic
Glow plug(s) defective
Fuel solenoid defective
Optional fuel pump (FP) malfunction
Engine lube oil too heavy
Voltage drop in battery cable(s)
Check
Check
Check
9.1.4
Engine Manual
9.1.5
2.9
replace
Check
8.3
Drain Sump
Replace
Check
Engine Manual
8.6.8
Engine Manual
8.3
2.9
Check
9--1
62-11039
INDICATION/
TROUBLE
9.1.2 Engine Starts Then Stops
Engine stops after several rotations
POSSIBLE CAUSES
Fuel supply restricted
No fuel in tank
Leak in fuel system
Faulty fuel control operation
Fuel filter restricted
Injector nozzle(s) defective
Injection pump defective
Air cleaner or hose restricted
Safety device open
Fuel solenoid defective
Optional fuel pump (FP) malfunction
Open wiring to fuel solenoid
Mechanical lift fuel pump malfunction
Oil pressure switch defective
9.1.3 Engine Will Not Shut Off
Loose ground connection
Engine will not shut off
Improperly seated fuel solenoid
9.1.4 Starter Motor Malfunction
Starter motor will not crank or turns slowly
Starter motor turns but pinion does not engage
Battery insufficiently charged
Battery cable connections loose or oxidized
Battery cables defective
Starter brushes shorted out
Starter brushes hang up or have no contact
Starter solenoid damaged
Glow/Crank switch defective
Engine lube oil too heavy
Pinion or ring gear obstructed or worn
Starter motor does not disengage after switch has been released
Pinion does not disengage after switch is released
Glow/Crank switch defective
Starter motor solenoid defective
Defective starter
9.1.5 Malfunction In The Engine Starting Circuit
No power to starter solenoid (SS)
Battery defective
Loose electrical connections
Fuel solenoid does not energize or does not remain energized
Battery defective
Loose electrical connections
Oil pressure safety switch (ENOPS) defective
Run relay (RR) defective
Engine coolant temp. (ENCT) defective
Fuel solenoid defective
62-11039
9--2
REFERENCE
SECTION
Check
Check
Check
Engine
Replace
Engine Manual
Engine Manual
8.6.6
2.15
Engine Manual
8.3
Check
Engine Manual
Replace
Clean & Tighten
Correct
Check
Check
Replace
Engine Manual
Engine Manual
Engine Manual
Replace
2.9
Clean both, remove burrs, or replace; apply grease
Replace
Engine Manual
Engine Manual
Check
Tighten
Check
Tighten
Replace
Replace
Replace
Engine Manual
INDICATION/
TROUBLE
POSSIBLE CAUSES
9.1.6 Miscellaneous Engine Troubleshooting
Restriction in air cleaner
Air in fuel system
Loss of power
Air vent restricted
Restricted fuel lines
Defective fuel injection pump
Defective injector(s) or incorrect type
Incorrect fuel injection pump timing
Vibration
Overheating
Excessive crankcase pressure
Incorrect valve timing
Poor compression
Engine shockmounts defective
Poor compression
Restriction in air cleaner
Exhaust pipe restriction
Restriction in water jacket
Restriction in radiator
Coolant level too low
Loose water pump
Defective thermostat
Defective water pump
Plugged crankcase breather line
REFERENCE
SECTION
8.6.6
8.3.1
Clean
Engine Manual
Engine Manuall
Engine Manual
Engine Manuall
Engine Manual
Engine Manual
Replace
Engine Manual
8.6.6
Removel
Engine Manual
8.6.2
8.5.1l
replace
Engine Manual
Engine Manual
8.6.7
9--3
62-11039
INDICATION/
TROUBLE
9.2 BATTERY CHARGER
Input fuse blows when charger is turned on
Input fuse blows repeatedly, even when not connected
POSSIBLE CAUSES
Short in 12 volt wiring causing overload of charger
Internal short
Bad cell in battery
Charger does not taper back after charging for a few minutes
Defective charger
Open input fuse
Charger is not receiving AC input
Charger does not charge
Low output voltage measured across charger output
Reverse polarity connection to battery has caused charger to stop charging
Charger output is not connected to 12 volt battery
Defective charger
Battery not connected to charger. It is normal to measure 12 volts or less across charger output with no battery connected
Internal DC fuse blown and possible damage to current carrying components
REFERENCE
SECTION
Locate and remove short
Replace
Test battery for defect according to battery manufacturer’s instructions
Replace
Replace.
Using a voltmeter, confirm charger is receiving correct
(460v) AC voltage. If not check input connections.
Check output wiring connections to battery.
Replace
Check charging leads from charger to battery
Replace
62-11039
9--4
INDICATION/
TROUBLE
9.3 ALTERNATING CURRENT GENERATOR
No voltage
POSSIBLE CAUSES
Loss of residual magnetism in exciter field
Circuit breaker tripped
Open or short in stator windings
Low voltage
Short circuited
Low engine speed
Excessive load
High resistance connections -- connections warm or hot
Fluctuating voltage
High voltage
Overheating
Mechanical Noise
Generator frame produces shock when touched
Fluctuating speed
Irregular speed of engine
Loose terminal or load connections
Excessive engine speed
Generator overloaded
Clogged ventilation openings
Insufficient circulation
Unbalanced load
Loose laminations
Static charge
REFERENCE
SECTION
8.9
Check
Check
Repair
Correct
Check
Clean and
Tighten
Correct
Engine Manual
Tighten
Correct
Check
Clean
Check Fan
Balance
8.9.2
Check ground to frame
9--5
62-11039
INDICATION/
TROUBLE
9.4 REFRIGERATION
9.4.1 Unit Will Not Cool
POSSIBLE CAUSES
REFERENCE
SECTION
Compressor malfunction
Compressor contactor defective
Compressor defective check
8.15
Refrigeration system
A defrost cycle did not terminate
Abnormal pressure
Liquid line solenoid valve (LSV2/3) malfunction
8.25
9.4.7
9.4.12
9.4.2 Unit Runs But Has Insufficient Cooling
Compressor
Compressor valves defective
Unloader malfunction
Abnormal pressure
Unloader malfunction
Refrigeration system
Expansion valve malfunction
No or restricted evaporator airflow
Suction Modulation Valve malfunction
9.4.3 Unit Operates Long Or Continuously In Cooling
Hot Load
Trailer
Refrigeration system
Compressor
Defective box insulation or air leak
Abnormal pressure
Temperature controller malfunction
Defective
8.15
8.16
9.4.7
8.16
9.4.11
9.4.10
8.24
Allow time to pull down
Correct
9.4.7
9.4.9
8.15
9.4.4 Unit Will Not Heat Or Has Insufficient Heating
Unit will not heat or has insufficient heat
Evaporator fan internal motor protector open
Heat relay defective
Heater(s) defective
8.7.3
Check
8.7
Heater contactor or coil defective Replace
Evaporator fan motor(s) defective or rotating backwards 8.7.3
Evaporator fan motor contactor defective Replace
Controller malfunction
Defective wiring
Loose terminal connections
Low voltage
9.4.9
Replace
Tighten
9.3
62-11039
9--6
INDICATION/
TROUBLE
REFRIGERATION (Continued)
POSSIBLE CAUSES
9.4.5 Unit Will Not Terminate Heating
Controller improperly set
Unit fails to stop heating
Controller malfunction
Heater termination thermostat remains closed along with the heat relay
9.4.6 Defrost Cycle Malfunction
Will not initiate defrost automatically
Will not initiate defrost manually
Initiates but does not defrost
Frequent defrost
Defrost air switch (DAS) out of calibration
A DTT is above 40_F (4.4_C)
Defrost air switch (DAS) defective
Loose terminal connections
Air sensing tubes defective or disconnected
Microprocessor defective
Loose terminal connections
DTT2 is above 40_F (4.4_C)
Unit has been running less than 15 seconds
Heater contactor or coil defective
Heater(s) burned out
Defrost air switch (DAS) out of adjustment
Wet load
REFERENCE
SECTION
Reset
9.4.9
Repair
8.26
Cool Box Down
8.25 & 8.26
Tighten
Check
Replace
Tighten
Cool Box Down
Try again
Replace
8.7
8.25 & 8.26
Normal
9--7
62-11039
INDICATION/
TROUBLE
9.4.7 Abnormal Pressure
POSSIBLE CAUSES
High discharge pressure
Low discharge pressure
Low suction pressure
High suction pressure
Suction and discharge pressures tend to equalize when unit is operating
Condenser coil dirty
Condenser fan rotating backwards
Condenser fan inoperative
Refrigerant overcharge or noncondensibles
Discharge service valve partially closed
Suction modulation valve malfunction
Compressor valves(s) worn or broken
Suction service valve partially closed
Filter-drier partially plugged
Low refrigerant charge
Expansion valve defective
No evaporator air flow or restricted air flow
Excessive frost on evaporator coil
Evaporator fan(s) rotating backwards
Discharge pressure regulator valve defective
Suction modulation valve malfunction
King valve partially closed
Compressor valves(s) worn or broken
Compressor gasket(s) defective
Compressor valves defective
Compressor gasket(s) defective
9.4.8 Abnormal Noise
Compressor
Condenser or evaporator fan
Loose mounting bolts
Worn bearings
Worn or broken valves
Liquid slugging
Insufficient oil
Loose or striking shroud
Bearings defective
Bent shaft
Cracked or worn V-belt
9.4.9 Control System Malfunction
Sensor defective
Will not control
Relay(s) defective
Microprocessor controller malfunction
Tighten
8.15
8.15
9.4.11
8.15.4
Check
8.7.3
8.7.3
replace
8.29
Check
Check
REFERENCE
SECTION
8.28
Check Wiring
Check
8.11
Open
8.24
8.15
Open
8.17
8.13
9.4.11
9.4.10
9.4.6
8.7.3
Replace
8.24
Open
8.15
8.15
8.15
8.15
62-11039
9--8
INDICATION/
TROUBLE
POSSIBLE CAUSES
9.4.10 No Evaporator Air Flow Or Restricted Air Flow
Frost on coil
Evaporator coil blocked Dirty coil
No or partial evaporator air flow
Evaporator fan loose or defective
Evaporator fan rotating backwards
Evaporator air flow blocked in trailer (box)
9.4.11Expansion Valve Malfunction
Low refrigerant charge
Low suction pressure with high superheat
External equalizer line plugged
Ice formation at valve seat
Wax, oil or dirt plugging valve or orifice
Broken capillary
Power assembly failure or partial Loss of element/bulb charge
Superheat setting too high
Superheat setting too low
Low superheat and liquid slugging in compressor
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
Fluctuating suction pressure
Improper bulb location or installation
Low superheat setting
High superheat Broken capillary
9.4.12Solenoid Valve Malfunction
No power to valve
Solenoid valve does not function properly
Improper wiring or loose connections
Coil defective
Valve improperly assembled
Coil or coil sleeve improperly assembled
Movement of plunger restricted due to: a. Corroded or worn parts b. Foreign material lodged in valve c. Bent or dented enclosing tub
Foreign material lodged under seat
Solenoid valve closes but refrigerant continues to flow
Defective seat
REFERENCE
SECTION
8.25
8.27
8.7.3
8.7.3
Check
8.12/8.13.4
Clean
8.13
8.18
8.18
Replace
8.18
8.18
Open
8.13
Clean
8.18
8.18
8.18
8.18
Check
Check
8.16
8.15
8.15
8.15
Clean
Replace
9--9
62-11039
SECTION 10
WIRING
Plugs used with Schematic 62--60926--07 Rev H
1MP -- NATURAL
1
12
24
35
Component
3DTT
3RAT
CDP (C)
EVOP (C)
ENCT
CDT
CST
AAT
1RAT
CSP (A)
HC1
CDP (A)
EVOP (A)
ENCT
CST
EVOT
CDT
1DTT
2DTT
3DTT
2SAT
20 (9)
21 (34)
21 (8)
21 (3)
21 (31)
AAT
1SAT
1RAT
2RAT
3RAT
CSP (C)
CSP (B)
CDP (B)
EVOP (B)
2SAT
22 (11)
23 (35)
23 (12)
23 (33)
23 (4)
29 (15 (30)
30 (25) (29)
30 (5) (16)
30 (6) (17)
31 (21)
EVOT
2RAT
1DTT
1SAT
32 (19)
33 (23)
34 (21)
35 (23)
Unused terminals: 1, 2, 13, 14, 24,
25, 26, 27 & 28
Terminal
3 (21)
4 (23)
5 (16) (30)
6 (17) (30)
7 (18)
9 (20)
10 (19)
11 (22)
12 (23)
15 (29) (30)
15 (SP16)
16 (5) (30)
17 (6) (30)
18 (7) (SP2)
19 (10)
19
(SP14)
(32)
10--1
62-11039
2 MP -- Black
1 24
3 MP -- Grey
1 24
12 35
12 35
Component
HC9
OCC
SP46
SP45
DAS
ENRPM--C
CSMV--D
EVXV--B
EVXV--E
OCD
ENCLS--C
OCE
ENOPS
ENRPM--B
CSMV--C
CSMV--A
4
5
2
3
Terminal Component
SLP2--C
SLP (C)
6
7 (18) (31)
2HTCON2
3HTCON2
3EVCON
8 (19) (20) (32) 3LSV
11 (12) (22)
(23) (35)
UL1
12 (11) (22)
(23) (35)
SLP2--B
13
15
16
17
18 (7) (31)
SLP --B
2LSV
FL
DL
19 (8) (20) (32) UL2
20 (8) (19) (32)
SLP2--A
SLP--A
EVXV--D
EVXV--A
22 (11) (12)
(23) (35)
23 (11) (12)
(22) (35)
HC19
ENOLS--B
SP15
ENRPM--A
CSMV--B
26
28
29
31 (7) (18)
EVXV--C
32 (8) (19) (20)
35 (11) (12)
(22) (23)
Unused terminals: 1, 9, 10, 14, 21, 24,
25, 27, 30, 33 & 34
2EVCON
ARL
3HTCON1
2HTCON1
6
7
8
9
12
18
19
20
23
27 (3) (15)
29 (5) (17)
33
34
Terminal
3 (15) (27)
5 (17) (29)
15 (3) (27)
17 (5) (29)
30
32
Unused terminals: 1, 2, 4, 10, 11, 13,
14, 16, 21, 22, 24, 25, 26, 28, 31 & 35
62-11039
10--2
4 MP 5 MP 6 MP
Component
CCONR--2
CDCON--A2
1EVCON--A2
HTCON1R--2
CCONR--2
CDCON--A1
GENCONR--2
CT2/OGF
CT3/CT4/OGF
CT3/OGF
HTCON1R--2
HTCON2--A1
1EVCON--A1
Terminal
1 (5)
2 (6)
3 (15)
4 (13) (14)
(SP14)
7
8
5 (1)
6 (2)
9
10
13 (4) (14)
14 (4) (13)
15 (3)
Component
MPQCC9/SPK2
SP20/DES
PRM--OUT+
GCS--2
GCS--3
PSCONR2
SPK2
GPR
SSR
Unused terminals: 11 & 12.
Terminal
1
2
4
5 (6)
8
9
6 (5)
7
10
Unused terminals: 3, 11 & 12
Component
DISP/KEY1 -- BLK 1
DISP/KEY1 -- WHT 2
DISP/KEY1 -- RED 3
DISP/KEY1 -- GRN 4
Terminal
DISP/KEY1 -- BRN 5
DISP/KEY1 -- BLU 6
DISP/KEY1 -- ORG 7
DISP/KEY1 -- YEL 8
Unused terminals: None
10--3
62-11039
HC Plug
17
16
18
19
7
6
5
1
8
2
4
3
15
14
9
10
13
11
12
Component
OGF--OV/HC--1
HC--2/MPQC--3
MPQC--1/HC--3
MPQC--1/HC--4
RCR--2/HC--7
HC--8/SSR--87
HC--9/C2--1
HC--12/F5--B
GPR--87/HC--14
GRD/HC--15
SP1/HC--16
RCR--3/HC17
SPK2/HC--18
GENCONR--1/HC--19
Unused terminals: 5, 6, 10, 11 & 13
Terminal
1
2
12
14
15
16
17
18
19
7
8
9
3
4
62-11039
10--4
ADVANCE MICRO DISPLAY HARNESS CONNECTIONS
Test Point
TP14
TP13
TP13
TP12
TP11
TP10
TP9
TP8
Pin
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Color
Black
White
Red
Green
Brown
Orange
Blue
Yellow
Description
+12 Vdc for Display backlighting and indicator LED s
Ground for Backlighting and indicator LEDs
Ground for Backlighting and indicator LEDs
+5 Vdc for Display processor and LCD
Display ground
TX the serial communications from the control to the display
RX the serial communications from the display to the control
Display ground
VOLTAGE TESTS:
Negative Test Lead
TP13
TP13
TP13
TP13
TP11
TP11
TP8
Positive Test Lead
TP14
TP12
TP11
TP8
TP14
TP8
TP14
Voltage Reading
12
5
0
0
12
0
12
10--5
62-11039
0--
0--
A
Air Switch, 8--37
Ambient Air Temperature Sensor, 2--10
B
Battery Charger, 8--12
C
Calibrating Compressor Discharge Pressure Transducer, 8--32
Changing IntelliSets, 3--34, 3--35
Changing Setpoint, 3--9
Changing Setpoint with Auxiliary Control Panel, 3--38
Charging Amps, 4--4
Checking Operation Of C2 Lsv And C3 Lsv, 8--18
Compartment One Evaporator Fan and Motor, 8--11
Component Test Mode, 5--12
Compressor, 2--7
Compressor -- Model 06D, 8--23
Compressor Data, 2--21
Compressor Disassembly, 8--24
Compressor Discharge Pressure Transducer, 2--10
Compressor Discharge Temperature Transducer,
2--10
Compressor Reassembly, 8--24
Compressor Suction Modulation Valve , 2--10
Compressor Suction Pressure, 2--10
Compressor Suction Pressure Transducer, 2--10,
8--33
Compressor Unloader, 2--7, 8--26
INDEX
Condenser Coil, 8--38
Condenser Fan And Motor Assemblies, 8--12
Condenser/Subcooler, 2--7
Config. and Tech. Test Modes, 5--2
Configuration Mode, 5--3
Continuous Run Operation, 3--11, 4--4
Controller Sensor, 8--38
Cool Mode, 4--4
D
Data Ohms And Amps, 2--23
Data Recording, 3--31
Default Mode, 4--8
Defrost Air Switch, 8--37
Defrost Cycle, 8--36
Defrost Initiation And Start, 4--9
Defrost Modes, 4--8
Defrost Operation, 4--8
Defrost Safety, 2--21
Defrost Temperature Sensor, 2--10
Defrost Termination, 4--9
Defrost Termination Thermistor , 2--21
Defrost Timer, 2--21
Dehydration, 8--20
Discharge Pressure Transducer (Cdp), 8--31
Display, 2--16
Door Switches & Remote Switches, 2--18, 2--19
Download Port, 5--1
Downloading Data With The Pc Card, 5--15
Index--1 62--11039
E
Electrical Data, 2--22
Electronic Expansion Valve , 8--28
Electronic Modules, 2--18
Engine Air Cleaner, 8--9
Engine Air System, 2--20
Engine Coolant Level Sensor, 2--7
Engine Coolant Temperature, 4--3
Engine Coolant Temperature Sensor, 2--7
Engine Cooling System, 8--7
Engine Crankcase Breather, 8--9
Engine Data, 2--20
Engine Oil, 2--20
Engine Oil Level Switch, 2--7
Engine Oil Pressure Switch, 2--7
Engine Rpm Sensor , 2--7
Engine/Standby Switch, 2--16
Evacuation, 8--20
Evaporator Coil, 8--37
Evaporator Heaters, 8--11
Evaporator Outlet Temperature, 2--10
Expansion Valve, 8--28
F
Failed To Start -- Auto Mode, 4--3
Filter--Drier, 8--28
Fuel Level Sensor, 8--5
Functional Change (Parameters), 3--24
G
Generator, 8--13
Generator Assembly Procedure, 8--16
Glow Plugs, 8--10
INDEX
H
Heat Mode, 4--7
Heating Cycle, 8--36
High Pressure Switch, 2--21, 8--30
I
Indicator Leds, 2--16
Installing New Software, 5--16
Intelliset, 3--33
K
Key Descriptions, 2--17
L
Language Selection, 3--29
Lock/Unlocking The Remote Control Panel, 3--38
Lube Oil And Flow Diagrams, 8--8
Lube Oil Filter, 8--8
Lubrication System, 2--20
M
Maintenance Schedule, 8--1
Manual Defrost, 3--15
Messagecenter, 2--16
Messagecenter , 6--1
Microprocessor Replacement, 5--19
N
Null Mode, 4--7
O
Output Overrides, 4--16
Overload Ground Fault Module (Ogf), 2--18
62--11039
Index--2
P
Pc Mode, 5--1
Pre--Setting Setpoints With Remote Control Panel,
3--39
Pretrip, 3--6
Pretrip Inspection, 8--3
Priming Fuel System, 8--4
Priority Modes, 4--5
Productshield, 4--12
Pulse Cool Mode, 4--5
Pumping Down The Unit, 8--19
Pumping Unit Down, 8--19
INDEX
Speed Control Solenoid, 8--9
Speed Control Solenoid (Scs) Overrides, 4--16
Start--Run/Off Switch, 2--16
Start--Stop Indicator, 4--3
Start--Stop Operation, 3--10, 4--2
Starting Unit With Remote Control Panel, 3--37
Stopping Unit, 3--30
Suction Pressure Operation , 4--19
Supply Air Limit Control , 4--6
Supply Air Temperature Sensor , 2--11
Switch Descriptions, 2--16
System Start--Up, 4--1
R
Receiver Sight Glass, 8--34
Refrigerant Charge, 8--19, 8--22
Refrigerant Circuit -- Cooling, 2--24
Refrigerant Circuit -- Heating & Defrosting, 2--24
Refrigerant Leak Checking, 8--20
Refrigeration System Data , 2--21
Relief Valve Setting, 2--21
Remote Control Panel, 2--19, 3--36
Remote Control Panel Display, 3--37
Remove Jumper Mode, 5--2
Removing Pre--Set Setpoints With Remote Control
Panel, 3--39
Restart Voltage, 4--4
Return Air Temperature Sensor, 2--10
Rpm Sensor, 8--8
T
Temperature Control, 4--4
Temperature Range Lock 1 & 2, 4--10
Thermostatic Expansion Valves, 8--29
Trip Start, 3--16
Troubleshooting, 7--1
Troubleshooting Software Loading, 5--17
U
Unit Data, 3--19
Unit Startup -- Engine/Road And Electric Standby, 3--5
Unloader, 2--7, 8--26
Unloader Control Overrides, 4--17
Unloaders, 4--7
Using Microprogrammer, 5--17
Using The Datashare Program Pc Card, 5--16
S
Safety Decals, 1--5
Safety Devices, 2--23
Safety Precautions, 1--1
Service Mode, 5--14
Servicing Fuel Pump, 8--5
Setting Pm Hourmeters, 5--18
Sleep Mode On, 3--12, 3--13
Speed Control, 4--8
V
Variable Glow Time, 4--2
View Active Alarms, 3--17
View Hourmeters, 3--23
View Inactive Alarms, 3--18
W
Water Pump V--Belt, 8--10
Index--3 62--11039
North America
Carrier Transicold
700 Olympic Drive
Athens, GA 30601 USA
Tel: 1--706--357--7223
Fax: 1--706--355--5435
Central America and Mexico
Ejercito Nacional No. 418
Piso 9, Torre Yumal
Col. Chapultepec Morales
11570 Mexico, D.F.
Tel: (5255) 9126.0300
Fax: (5255) 9126.0373
A member of the United Technologies Corporation family. Stock symbol UTX
©2007 Carrier Corporation D Printed in U. S. A. 1107
Carrier Transicold Division,
Carrier Corporation
Truck/Trailer Products Group
P.O. Box 4805
Syracuse, N.Y. 13221 U.S A www.carrier.transicold.com

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Key features
- Multi-temperature control
- Powerful engine and compressor
- Microprocessor control
- User-friendly keypad
- Multiple compartments
- Temperature control modes (cool, pulse cool, heat, defrost)
- ProductShield
- Safety features
- Sensors