Carrier X Series Trailer Refrigeration Unit Operation & Service Manual
X SERIES is a trailer and rail refrigeration unit equipped with the Advance microprocessor. This unit is designed to keep your perishables and frozen goods at the desired temperature during transport. The Advance microprocessor features a user-friendly interface and offers various options for temperature control, including IntelliSet and DataTrakt.
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R
Trailer & Rail Refrigeration
EVAPORATOR
CONDENSER
TXV
TXV BULB
RECEIVER
OPERATION & SERVICE
for
X SERIES
Trailer and Rail Refrigeration Units
With Advancet Microprocessor
62--10683 Rev C Change 09/11
OPERATION AND
SERVICE MANUAL
NOSEMOUNT
TRAILER AND RAIL
REFRIGERATION UNITS
WITH ADVANCE MICROPROCESSOR
How to use this manual
Please take a few minutes to read this page. It explains the content and structure of this manual.
This will make it easier for you to find the information that you need.
Section 1 -- Safety Precautions
This section contains the Safety Precautions, Safety Decals, and Microprocessor cautions. Read this section before working on the unit.
Section 2 -- Unit Description
This section describes the unit listed in the Model Chart Table 2-1.
Section 3 -- Operation
This section shows you how to configure and operate the Carrier Advance
Microprocessor.
Section 4 -- Engine and Standby Motor
This section describes operation of the engine and the standby motor.
Section 5 --Temperature Control
This section describes the temperature control.
Section 6 -- Technician Interface
This section describes various testing and downloading functions available to a technician.
Section 7 -- Message Center
This section describes all the messages and alarms which can be displayed on the
MessageCenter.
Section 8 -- Alarm Troubleshooting
This section provides information on the probable causes of the alarm codes given by the microprocessor controller.
Section 9 -- Service
This section describes the service procedures for the unit .
Section 10 -- Unit Troubleshooting
This section provides information on the probable causes for unit troubleshooting.
Section 11 -- Wiring
This section contains Electrical Schematics and Plug Information the model covered in this book.
62--10683
TABLE OF CONTENTS
PARAGRAPH NUMBER
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
SPECIFIC WARNING AND CAUTION STATEMENTS
1.3
SAFETY DECALS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
1-1
1--1
1--1
1--5
UNIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
CONDENSING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1 Condenser Coil
2.3.2 Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3 Alternator/Regulator
2.3.4 Compressor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.5 Compressor Unloaders
2.3.6 Filter Drier
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.7 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.8 Compressor Transducers and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4
EVAPORATOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Thermal Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Heat Exchanger
2.4.3 Evaporator Coil
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.4 Evaporator Transducers and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5
SYSTEM OPERATING CONTROLS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.1 Multiple Languages
2.5.2 Special Features
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.3 Component Description And Location
2.5.4 Handling of PC Cards
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.1 Light Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2 Door and Remote Switches
2.6.3 Out of Range Alarm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7
ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8
ENGINE SCREW THREADS
2.9
ENGINE AIR SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10 COMPRESSOR DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11 REFRIGERATION SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.13 COMPONENT RESISTANCE AND CURRENT DRAW
2.14 REFRIGERANT CIRCUIT DURING COOLING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.15 REFRIGERANT CIRCUIT -- HEATING AND DEFROSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--23
2--24
2--25
2--25
2--26
2--26
2--26
2--26
2--27
2--15
2--15
2--15
2--15
2--16
2--22
2--22
2--22
2--28
2--29
2--30
2--12
2--13
2--13
2--14
2--14
2--14
2--14
2--14
2-1
2--1
2--2
2--10
2--10
2--10
2--11
2--12 i 62--10683
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
STARTING UNIT -- AUTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
MANUAL START -- GLOW AND CRANK -- IF EQUIPPED* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Unit Startup -- Self Test
3.4
PRETRIP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5
CHANGING SET POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6
START-STOP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7
CONTINUOUS RUN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8
SLEEP MODE ON
3.9
SLEEP MODE OFF
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.1 Manual Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11 TRIP START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.12 VIEW ACTIVE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.13 VIEW INACTIVE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.14 UNIT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.15 VIEW HOURMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.16 FUNCTIONAL CHANGE (PARAMETERS)
3.17 LANGUAGE SELECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.18 STOPPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.19 DATA RECORDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.19.1 Microprocessor Information
3.19.2 Data Recording
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.19.3 Sensor and Event Data
3.19.4 Data Downloading
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.19.5 DataRecorder Power-Up
3.20 OPTIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.20.1 IntelliSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.20.2 DataTrakt for Advance Microprocessors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.20.3 Two-Way Remote Communication
3.20.4 AutoFresh Air Exchange
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--25
3--31
3--32
3--33
3--33
3--33
3--33
3--34
3--34
3--35
3--12
3--13
3--15
3--15
3--16
3--17
3--18
3--20
3--24
3--35
3--37
3--37
3--38
Page
3--1
3--1
3--2
3--3
3--4
3--8
3--9
3--11
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2
ENGINE START--UP
4.2.1 Engine Cranking
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Variable Glow Time
4.2.3 Engine Running
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.4 Initial Engine Operation
4.3
RUNNING MODES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Start--Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 CONTINUOUS RUN MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4
SPEED CONTROL OVERRIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--1
4--3
4--3
4--3
4-1
4--1
4--1
4--1
4--3
4--5
4--6
62--10683 ii
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
TEMPERATURE CONTROL
5.1
INTRODUCTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2
PERISHABLE AND FROZEN SET POINT RANGES
5.3
PULLDOWN / PULL-UP MODE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4
HEAT MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5
COOL MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6
UltraFresh 3 TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.1 Heat/Cool/Null Switching Operation
5.6.2 Null Mode Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7
UltraFreeze TEMPERATURE CONTROL
5.7.1 UltraFreeze Offset
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.2 UltraFreeze Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8
FreshProtectt SUPPLY AIR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9
CARGO PROTECT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10 ENGINE SPEED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11 DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.1 Evaporator Temperature Criteria For Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.2 Defrost Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.3 Normal Defrost Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.4 Normal Defrost Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.5 Normal Defrost Termination Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.6 High Ambient Defrost Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.7 High Ambient Defrost Termination Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.8 High Ambient Defrost Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.9 High Ambient Defrost Termination Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.12 UNLOADER CONTROL OPERATION
5.13 SV1 OPERATION :
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.14 SV2 OPERATION : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.15 TEMPERATURE RANGE LOCK 1 & 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.16 ProductShield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.16.1 ProductShield Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.17 UNLOADER CONTROL OVERRIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.18 MAXIMUM SUCTION OPERATING PRESSURE (COOL ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.19 MAXIMUM OPERATING PRESSURE (MOP) OVERRIDE (HEAT AND DEFROST ONLY) . . . . . .
5.20 SUCTION PRESSURE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--10
5--10
5--11
5--11
5--11
5--11
5--11
5--12
5--8
5--9
5--9
5--9
5--5
5--8
5--8
5--8
5--14
5--14
5--18
5--19
5--19
5--20
5--4
5--4
5--4
5--5
5--2
5--3
5--3
5--4
Page
5-1
5--1
5--1
5--2
5--2 iii 62--10683
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
TECHNICIAN INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
PC MODE/DOWNLOAD PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2
MICROPROCESSOR CONFIGURATION AND TECHNICIAN TEST MODES
6.2.1 Configuration Mode
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2 Component Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.3 Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3
PC SUPPORT SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.1 ReeferManager And Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4
DOWNLOADING DATA WITH THE PC CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5
INSTALLING NEW SOFTWARE
6.5.1 Software Version Numbers
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.2 Using The Program PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.3 Using ReeferManager to Install Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.4 Troubleshooting Software Loading Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6
RE-SETTING PM (PREVENTATIVE MAINTENANCE) HOURMETERS . . . . . . . . . . . . . . . . . . . . . .
6.7
ADVANCE MICROPROCESSOR REPLACEMENT & CONFIGURATION SETUP
6.7.1 Microprocessor Replacement
. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.2 Microprocessor Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.3 Configurations Via Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.4 Functional Parameters via Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.5 DataRecorder Via ReeferManager PC Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.6 Engine And Switch-on Hourmeters Via ReeferManager PC Program
6.7.7 Configuration/IntelliSet PC Card
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.8 Microprocessor Final Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.9 Replacing Display Bezel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MESAGECENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1
MessageCenter MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALARM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1
INTRODUCTION TO ALARM TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3
DRIVER/OPERATOR ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 LOW FUEL LEVEL WARNING
(for units with Low Fuel Level 0% to 100% Sensor / fuel level is displayed in Data list) . . . . . . . . . .
1
2
3
LOW FUEL LEVEL WARNING
(for units with Low Fuel Level switch/no fuel level display in Data list . . . . . . . . . . . . . . . . . . . . . . . . .
LOW ENGINE OIL LEVEL
LOW COOLANT LEVEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--26
6--26
6--26
6--27
7-1
7--1
8-1
8--1
8--2
8--3
6--19
6--20
6--22
6--23
6--24
6--25
6--25
6--25
6--13
6--14
6--14
6--16
6--17
6--17
6--18
6--19
Page
6-1
6--1
6--2
6--3
6--12
8--3
8--4
8--5
8--6
62--10683 iv
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
ALARM TROUBLESHOOTING (Cont)
8.4 SHUTDOWN ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 LOW ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 HIGH COOLANT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 HIGH DISCHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 HIGH DISCHARGE PRESSURE (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 BATTERY VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 BATTERY VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 HIGH COMP DISCHARGE TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 HIGH COMP DISCHARGE TEMP (Continued)
18 LOW REFRIGERANT PRESSURE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 LOW FUEL SHUTDOWN
(for units with Low Fuel Level 0% to 100% Sensor / fuel level is dsplayed in Data list)
19 LOW FUEL SHUTDOWN
(for units with Low Fuel Level Switch / no fuel level display in Data list)
. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
20 MAXIMUM COMPRESSOR ALARMS
21 TECHNICIAN RESET REQUIRED
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 HIGH SUCTION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 CHECK REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 CHECK HEAT CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 START UP ENGINE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 FAILED TO RUN MINIMUM TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 FAILED TO START -- AUTO MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 FAILED TO START -- MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 ENGINE FAILED TO STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 CHECK STARTER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 CHECK COOLANT TEMPERATURE
37 CHECK LOW SPEED RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 CHECK HIGH SPEED RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 CHECK ENGINE RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 CHECK GLOW PLUGS
41 ENGINE STALLED
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6 WARNING / STATUS ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51 ALTERNATOR NOT CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53 BOX TEMP OUT-OF-RANGE
54 DEFROST NOT COMPLETE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55 CHECK DEFROST AIR SWITCH
56 CHECK EVAPORATOR AIRFLOW
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57 CHECK REMOTE SWITCH 1
58 CHECK REMOTE SWITCH 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59 DATALOGGER NOT RECORDING
60 DATALOGGER TIME WRONG
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61 DOOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
8--15
8--7
8--7
8--8
8--9
8--10
8--11
8--11
8--12
8--13
8--14
8--41
8--42
8--43
8--44
8--45
8--46
8--47
8--32
8--34
8--35
8--37
8--37
8--38
8--40
8--22
8--24
8--25
8--27
8--28
8--30
8--15
8--16
8--16
8--17
8--18
8--18
8--19
8--19
8--20
Change 09/11 v 62--10683
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
ALARM TROUBLESHOOTING (Cont)
8.7 ELECTRICAL ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71 BAD F2 OR F3 FUSE
72 BAD F4 OR F6 FUSE
78 CHECK SV1 CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79 CHECK SV4 CIRCUIT
81 CHECK FHR CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82 CHECK REMOTE OUT-RANGE LIGHT
83 CHECK REMOTE DEFROST LIGHT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84 CHECK REMOTE ALARM LIGHT
85 CHECK UL1 CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86 CHECK UL2 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87 CHECK REMOTE HEAT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88 CHECK REMOTE COOL LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89 CHECK REMOTE AUTO LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90 AUTOFRESH AIR EXCHANGE RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93 CHECK START UP BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97 CHECK SV2 CIRCUIT
8.8 SENSOR ALARMS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
121 CHECK AMBIENT AIR SENSOR
122 CHECK RETURN AIR SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
123 CHECK SUPPLY AIR SENSOR
125 CHECK COMP DISCH SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
126 CHECK FUEL SENSOR CIRCUIT
129 CHECK ENG COOLANT SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
130 CHECK ENGINE RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132 CHECK DEFROST TERM 2 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
133 CHECK REMOTE TEMP SENSOR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 CHECK REMOTE TEMP SENSOR 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
135 CHECK REMOTE TEMP SENSOR 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
8--55
8--56
8--56
8--57
8--58
8--59
8--60
8--61
8--62
8--64
8--65
8--66
8--67
8--51
8--52
8--52
8--53
8--53
8--54
8--54
8--55
8--48
8--48
8--48
8--49
8--49
8--50
8--50
8--51
62--10683 vi
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
ALARM TROUBLESHOOTING (Cont)
8.9 PRETRIP ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P141 PRETRIP STOPPED BY USER
P143 CHECK CLUTCH CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P144 CHECK UL1 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P145 CHECK SPEED SOL CIRCUIT
P148 CHECK SV1 CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P150 CHECK SV4 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P151 CHECK GLOW PLUG CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P152 CHECK FUEL SOLENOID CIRC
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
P160 CHECK DISCH TEMP SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P162 CHECK AUTO FRESH AIR EXCHANGE SOLENOID (AFAS) CIRCUIT
P164 CHECK UL2 CIRCUIT
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P165 CANNOT PUMP DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P174 CHECK LOW SPEED RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P175 CHECK HIGH SPEED RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P175 CHECK HIGH SPEED RPM (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P178 CHECK UL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P180 CHECK SUCTION MOD VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P181 CHECK SV4 VALVE
P182 CHECK SV1 VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P191 CHECK UL2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P192 CHECK SV2 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P194 HIGH SUCTION PRESSURE
P195 LOW SUCTION PRESSURE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P196 HIGH DISCHARGE PRESSURE
P198 LOW DISCHARGE PRESSURE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P200 CHECK UL1 CYLINDERS
P201 CHECK UL2 CYLINDERS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P202 HIGH SIDE LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P203 CHK DISCHARGE CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P204 LOW SUCTION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P205 CHK DEFROST TERM 2 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
8--98
8--99
8--99
8--100
8--101
8--102
8--89
8--90
8--91
8--92
8--93
8--94
8--96
8--97
8--81
8--82
8--83
8--84
8--85
8--86
8--87
8--88
8--74
8--75
8--76
8--77
8--77
8--78
8--79
8--80
8--68
8--68
8--68
8--69
8--70
8--71
8--72
8--73 vii 62--10683
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
ALARM TROUBLESHOOTING (Cont)
8.10 MAINTENANCE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
223 ENGINE MAINTENANCE DUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
225 GENERAL MAINTENANCE DUE
226 SERVICE SOON -- PM #1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11 MICROPROCESSOR ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
232 SETPOINT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
233 MODEL # ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
237 FUNCTIONAL PARAMETERS ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
238 CONFIGURATIONS 1 ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
242 DIS PRESS CALIBRATE ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
243 SUCT/EVAP CALIBRATE ERROR
246 EEPROM WRITE FAILURE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
248 CONF MODE / HP2 ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
249 MICROPROCESSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
8--106
8--107
8--107
8--107
8--108
8--109
8--110
8--110
8--111
8--103
8--103
8--103
8--104
8--104
8--105
8--105
8--111
8--112
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2
PRETRIP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3
GRILLE INSERT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4
SURROUND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5
DOOR LATCH MAINTENANCE AND REPLACEMENT
9.5.1 Front Door Latch Cable Replacement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.2 Side Door Latch Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6
PRIMING FUEL SYSTEM
9.6.1 Mechanical Fuel Pump
9.7
SERVICING FUEL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7.1 Mechanical Pump (See Figure 9--2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8
ENGINE SERVICE AND COMPONENTS
9.8.1 Cooling System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8.2 Fuel Level Sensor
9.8.3 The RPM Sensor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8.4 Engine Oil And Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8.5 Lube Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8.6 Speed Control Solenoid And Linkage.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8.7 Electronic Speed Control (ESC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8.8 Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8.9 Engine Crankcase Breather
9.8.10 Glow Plugs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9--12
9--12
9--12
9--13
9--13
9--14
9--14
9--15
9--16
9--16
9--17
9--17
9-1
9--10
9--10
9--10
9--11
9--1
9--4
9--8
9--9
9--11
9--12
62--10683 viii
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
SERVICE (Cont)
9.9
SERVICING AND ADJUSTING V-BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.9.1 Belt Tension Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.9.2 Water Pump/Alternator/Crankshaft V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.10 FANSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.10.1 Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.10.2 Blower Wheel And Fanshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.10.3 Fanshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.10.4 Blower Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.10.5 Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.11 THERMOSTATIC EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.11.1 Replacing Expansion Valve & Screen
9.11.2 Checking Superheat
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.11.3 Measuring Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.11.4 Checking The Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.11.5 Partial Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.11.6 Adding Full Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12 REPLACING THE COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12.1 Removal and Replacement of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.13 CHECKING COMPRESSOR OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.13.1 To Check The Oil Level In The Compressor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.13.2 Adding Oil With Compressor In System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.13.3 Adding Oil To Service Replacement Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.13.4 To Remove Oil From The Compressor:
9.14 COMPRESSOR UNLOADER VALVE
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9.14.1 Unloader Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.14.2 Replacing Unloader Valve Internal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.14.3 Unloader Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.15 REPLACING OR SERVICING CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.15.1 To Service Check Valve
9.15.2 To Replace Check Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.16 CHECKING AND REPLACING FILTER-DRIER
9.16.1 To Check Filter-Drier
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.17 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCH (HPS) . . . . . . . . . . . . . . . . .
9.17.1 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.17.2 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.18 COMPRESSOR DISCHARGE PRESSURE TRANSDUCER (CDP) . . . . . . . . . . . . . . . . . . . . . . . . . .
9.18.1 Testing Compressor Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.18.2 Calibrating Compressor Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . .
9.18.3 Replacing Compressor Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . .
Page
9--31
9--31
9--32
9--32
9--33
9--33
9--33
9--33
9--28
9--28
9--30
9--30
9--30
9--30
9--31
9--31
9--33
9--33
9--34
9--35
9--35
9--35
9--36
9--24
9--24
9--24
9--25
9--25
9--27
9--27
9--28
9--17
9--17
9--18
9--21
9--21
9--21
9--22
9--23 ix 62--10683
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
SERVICE (Cont)
9.19 COMPRESSOR SUCTION PRESSURE TRANSDUCER (CSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.19.1 Testing Compressor Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.19.2 Calibrating Compressor Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.19.3 Replacing Compressor Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.20
Replacing Receiver Sight Glass Assembly Or Fusible Plug
9.21 SERVICING SOLENOID VALVES
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9.21.1 Solenoid Valve -- SV2/SV4
9.21.2 Solenoid Valve -- SV1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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9.22 COMPRESSOR SUCTION MODULATION VALVE (CSMV)
9.22.1 Function
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9.22.2 CSMV Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.22.3 Replacing The CSMV Power Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.23 2 LIGHT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.23.1 Light Bar Operation and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.24 CHECKING DEFROST OR HEATING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.24.1 Hot Gas Solenoid Valve (SV1 & SV4) Heating and Defrosting . . . . . . . . . . . . . . . . . . . .
9.25 DEFROST AIR SWITCH (DAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.25.1 Testing The Defrost Air Switch And Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.25.2 Checking Calibration Of Defrost Air Switch
9.26 EVAPORATOR COIL CLEANING
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.27 CONDENSER COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.28 MICROPROCESSOR SENSOR CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.29 UNIDRIVE TORQUE REQUIREMENTS
9.29.1 Drive Gear
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT TROUBLESHOOTING
10.1 DIESEL ENGINE
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10.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.3 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.4 Malfunction In The Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.5 Miscellaneous Engine Troubleshooting
10.2 ALTERNATOR (12 Volt DC)
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Page
10-1
10--1
10--1
10--1
10--2
10--2
10--3
10--3
9--43
9--43
9--44
9--44
9--45
9--45
9--47
9--47
9--41
9--41
9--41
9--42
9--43
9--43
9--43
9--43
9--37
9--37
9--37
9--37
9--38
9--38
9--38
9--39
62--10683 x
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER Page
UNIT TROUBLESHOOTING (Cont)
10.3 REFRIGERATION / TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.1 Unit Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.3 System Will Not Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.4 Unit Operates Long Or Continuously In Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.5 Unit Will Not Terminate Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.6 Unit Will Not Heat Or Has Insufficient Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.7 Unit Will Not Terminate Heating
10.3.8 Defrost Cycle Malfunction
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.9 Abnormal Pressure a. Cooling
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b. Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.10 Abnormal Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.11 Control System Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.12 No Evaporator Air Flow Or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.13 Expansion Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.14 Compressor Suction Modulation Valve (CSMV) Malfunction . . . . . . . . . . . . . . . . . . . . .
10.3.15 Solenoid Valve Malfunction (SV1, 2 OR 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 ELECTRONIC SPEED CONTROL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4.1 Advance Microprocessor Troubleshooting Guide
10.5 COMPRESSOR TROUBLESHOOTING GUIDE
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10--7
10--8
10--8
10--8
10--13
10--23
10--5
10--5
10--6
10--6
10--6
10--7
10--7
10--7
10--4
10--4
10--4
10--4
10--4
10--5
10--5
WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLUGS USED WITH SCHEMATIC 62--10499 REV V (STANDARD ENGINE) . . . . . . . . . . . . . . . . . . . . . . .
PLUGS USED WITH SCHEMATIC 62--04102 REV -- (ESC ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLUGS USED WITH SCHEMATIC 62--10300 REV A (ESC ENGINE)
HC PLUG FOR ALL UNITS
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ADVANCE MICRO DISPLAY HARNESS CONNECTIONS
VOLTAGE TESTS
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11-1
11--1
11--2
11--2
10--3
10--4
10--4
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 1
xi 62--10683
LIST OF ILLUSTRATIONS
FIGURE NUMBER
Figure 2-1. Front View Of Unit With Non ESC Engine
Figure 2-2. Curbside (Non ESC Engine)
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Figure 2-3. Roadside (Non ESC Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-4. Front View Of Unit With Electronic Speed Control (Electronic Speed Control)
Figure 2-5. Curbside (Electronic Speed Control)
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Figure 2-6. Roadside (Electronic Speed Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-7. Evaporator Section -- Panels and Grille Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-8. Control Box (Short Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-9. Control Box (Redesigned Tall Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-10. Engine Speed Control Unit (ENSCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-11. Alternator and Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-12. Compressor Cylinder Head Unloaded
Figure 2-13. Compressor Cylinder Head Loaded
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-14. Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-15 Display and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-16. Refrigerant Circuit During Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-17. Refrigerant Circuit During Heating And Defrost
Figure 3--1. AutoFresh Air Exchange
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Figure 3--2. AutoFresh in Closed Position
Figure 3--3. AutoFresh in Open Position
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Figure 4--1. Auto Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5--1. Continuous Run Temperature Control Operating Sequence -- Perishable Range . . . . . . . . . . . .
Figure 5--2. Continuous Run Temperature Control Operating Sequence -- Frozen Range . . . . . . . . . . . . . . .
Figure 5--3. Start-Stop -- Temperature Control Operating Sequence -- Perishable Range
Figure 5--4. Start-Stop -- Temperature Control Operating Sequence -- Frozen Range
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Figure 5--5. Range Lock 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5--6. Range Lock 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6 --1. Display Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--1 Grille Insert Removal And Door Latch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--2 Surround Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--3 Side Door Latch Lower Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--1. Priming Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--2. Mechanical Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--3. Fuel Level Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--4. Fuel System Diagram
Figure 9--5. Lube Oil Flow Diagram
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Figure 9--6. Speed Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--7. Electronic Speed Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--8. Frame Mounted Engine Speed Control Unit (ENSCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--9. DI -- Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--10 Belt Tension Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--11. V-Belt Arrangement None ESC Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--12. V-Belt Arrangement Electronic Speed Control Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--13. Removing V-Belt from Engine Adapter Drive Sheave
Figure 9--14. Fanshaft Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9--14
9--15
9--15
9--16
9--16
9--17
9--18
9--18
9--19
9--20
9--22
5--7
5--7
5--13
5--13
6--27
9--8
9--9
9--10
9--11
9--12
9--13
2--12
2--13
2--16
2--18
2--29
2--30
3--38
3--39
3--39
4--2
5--6
5--6
2--6
2--7
2--8
2--9
2--10
2--11
Page
2--3
2--4
2--4
2--5
2--6
62--10683 xii
LIST OF ILLUSTRATIONS (Continued)
FIGURE NUMBER
Figure 9--15. Blower Wheel And Nozzle Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--16. Thermostatic Expansion Valve Bulb and Thermocouple
Figure 9--17. Vacuum Pump Connection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--18. Pressure Switch and Sensor
Figure 9--19. Compressor Drive Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--20. Oil Level in Sight Glass
Figure 9--21. Compressor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--22. Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--23. Discharge Check Valve (Serviceable) Prior to S/N JAW90756460 . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--24. Discharge Check Valve (Non-Serviceable) Beginning With S/N JAW90756460
Figure 9--25. Hot Gas Check Valve (Non-Serviceable)
. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--26. Typical Setup for Testing High Pressure Switch
Figure 9--27 Discharge Pressure Transducer Values
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--28 Suction Pressure Transducer Values
Figure 9--29. SV2/SV4 Solenoid Valves
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--30. SV-2/SV-4 MARKING
Figure 9--31. SV1 Solenoid Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--32 Suction modulation valve (CSMV)
Figure 9--33 CSMV Coil
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--34. Defrost Air Switch Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--35. Unidrive Torque Requirements -- Non ESC Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9--36. Unidrive Torque Requirements -- Electronic Speed Control Engine . . . . . . . . . . . . . . . . . . . . . . .
Figure 10--1. ESC Diagnostic Tree -- 1 Long, 1 Short LED Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10--2. ESC Diagnostic Tree -- 2 Long, 1 Short LED Code
Figure 10--3. ESC Diagnostic Tree -- 2 Long, 3 Short LED Code
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10--4. ESC Diagnostic Tree -- 2 Long, 7 Short LED Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10--5. Micro Diagnostic Tree -- Cond. 1 -- Start/Run-Off Switch On -- Unit Does Not Operate . . . . . .
Figure 10--12. Micro Diagnostic Tree -- Cond. 8 -- Programming Problems With PC Cards
Figure 10--13. Micro Diagnostic Tree -- Cond. 9 -- Programming Problems With MicroProgrammer
Figure 10--14 Compressor Diagnostics
. . . . . . . . . . . . . .
. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10--10
10--11
10--12
10--14
Figure 10--6. Micro Diagnostic Tree -- Cond. 2 -- Start/Run-Off Switch On -- Unit Operates But Not Properly 10--15
Figure 10--7. Micro Diagnostic Tree -- Cond. 3 -- Start/Run-Off Switch Off -- Unit Fails To Stop . . . . . . . . . .
10--16
Figure 10--8. Micro Diagnostic Tree -- Cond. 4 -- Unit Will Not Run In High Speed
Figure 10--9. Micro Diagnostic Tree -- Cond. 5 -- Unit Will Not Run In Low Speed
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
10--17
10--18
Figure 10--10. Micro Diagnostic Tree -- Cond. 6 -- Data Recorder Data Download Problems
When Using ReeferManager and a Download Cable. Data File Analysis
Problems Using Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10--11. Microprocessor Diagnostic Tree -- PC Card Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10--19
10--20
10--21
10--22
10--26
9--39
9--40
9--41
9--42
9--44
9--48
9--49
10--9
9--32
9--32
9--32
9--33
9--34
9--35
9--37
9--38
Page
9--23
9--25
9--26
9--28
9--29
9--30
9--31 xiii 62--10683
LIST OF TABLES
TABLE NUMBER Page
Table 2-1.
Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-2.
Additional Support Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-3.
Field Effect Transistors
Table 2-4 .Engine Data
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-5.
Compressor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-6.
Refrigeration System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-8.
Component Resistance and Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3-1.
Shutdown Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3-3.
Functional Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-1.
Glow Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-3 Suction MOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 6-1 Connection Point Voltage
Table 9-1.
Maintenance Schedule
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9-3.
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9-4.
Compressor Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9-5.
Compressor Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9-6 CSMV Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9-7.
Sensor Resistance (ENCT, RAT, SAT, ATT, DTT)
Table 9-8.
Sensor Resistance (CDT)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9-9.
R404A Temperature-Pressure Chart
Table 10-1. ENSCU LED Fault Chart
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--1
5--19
6--22
9--2
9--18
9--36
9--36
9--41
2--1
2--1
2--21
2--25
2--26
2--26
2--28
3--19
3--26
9--45
9--46
9--50
10--8
62--10683 xiv
SECTION 1
SAFETY PRECAUTIONS
PARAGRAPH NUMBER
1.1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
SPECIFIC WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
1--1
1--1
1--5
1
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.
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.
CAUTION
SECTION 1
SAFETY PRECAUTIONS
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.
Engine Coolant
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.
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.
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.
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 five 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.
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.
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 62-10683
WARNING
Beware of V-belts and belt driven components as the unit may start automatically.
Before servicing unit, make sure the
START/RUN-OFF switch is in the OFF position or the unit is in Maintenance mode.
Also disconnect the negative battery cable.
WARNING
UNITS EQUIPPED WITH STAR-TRAK TWO
WAY COMMUNICATION CAPABILITIES MAY
HAVE THE ABILITY TO BE STARTED OR
TURNED OFF REMOTELY REGARDLESS OF
THE SETTING OF THE START/RUN-OFF
SWITCH.
The unit is controlled locally and there can be no two-way communication when the
Mode switch on the Remote Monitoring
Control Box is in MAINTENANCE MODE.
Therefore, when performing maintenance on the unit, place the Mode switch in MAIN-
TENANCE MODE. After the unit is serviced, return the Mode switch to REMOTE ON. (Refer to Section 3.20.3 for more detailed information on two-way communication.)
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.
WARNING
Under no circumstances should ether or any other starting aids be used to start engine.
WARNING
Do Not Allow Configuration Jumper Wire
To Touch Any Ground.
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:
S
Suction Pressure: -14.7 PSIG (-1 Bar)
S
Discharge Pressure: 0 PSIG/Bar
S
Engine RPM: 0.
WARNING
Keep hands and arms away from unit when operating without belt guard in place. Never release a unit for service without the belt guard securely tightened in place
WARNING
Do not start unit without installing the evaporator panels as unit damage or body harm may result.
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.
Figure 9--26)
(See
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
PSIG/Bar at any time.
62-10683 1--2
CAUTION
Observe proper polarity when installing battery, negative battery terminal must be grounded. Reverse polarity will destroy the rectifier diodes in alternator. As a precautionary measure, disconnect positive battery terminal when charging battery in unit.
Connecting charger in reverse will destroy the rectifier diodes in alternator.
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
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, and is showing the correct time.
Also, some customers are located in different time zones from where the repair is being made. If you know what time zone they use, enter that time. If you don’t, then enter the current time where you are located.
CAUTION
Do not over--torque display screws. Torque all screws to 11in--lbs (1.2 Nm).
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
CAUTION
Do not get anti-seize oil/compound onto clutch contact surfaces. Thoroughly clean off oil/compound with contact or brake cleaner if this occurs.
1--3 62-10683
CAUTION
Only a refrigerant drum containing R404a should be connected to units covered by this manual in order to pressurize the system. Any other gas or vapor will contaminate the system, which will require additional purging and evacuation of the high side (discharge) of the system.
CAUTION
Do not vapor charge R404A systems. Only liquid charging through the receiver outlet
(King) valve is acceptable.
CAUTION
Do not over tighten or damage the SV2 or
SV4 enclosing tube assembly. Torque to
17-ft pounds (2.4 Mkg). Also make sure all parts are placed on the enclosing tube in proper sequence to avoid premature coil burnout.
CAUTION
When adding oil to the compressor, extreme care must be taken to ensure the hose is immersed in the oil at all times. Otherwise air and moisture will be drawn into the compressor.
CAUTION
When removing the compressor cylinder head leave two cylinder head bolts loose with threads engaged in the crankcase until cylinder head is completely loosened to prevent any residual crankcase pressure.
62-10683 1--4
1.3 SAFETY DECALS
62-03958-00 Heat Warning
ONLY USED ON UNITS WITH TWO-WAY
COMMUNICATION CAPABILITIES
1--5 62-10683
62-10683 1--6
OR
1--7 62-10683
SECTION 2
UNIT DESCRIPTION
PARAGRAPH NUMBER
2.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
CONDENSING SECTION
2.3.1 Condenser Coil
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3 Alternator/Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.4 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.5 Compressor Unloaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.6 Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.7 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.8 Compressor Transducers and Sensors
2.4
EVAPORATOR SECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Thermal Expansion Valve
2.4.2 Heat Exchanger
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3 Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.4 Evaporator Transducers and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5
SYSTEM OPERATING CONTROLS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.1 Multiple Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.2 Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.3 Component Description And Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.4 Handling of PC Cards
2.6
OPTIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.1 Light Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2 Door and Remote Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.3 Out of Range Alarm
2.7
ENGINE DATA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8
ENGINE SCREW THREADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9
ENGINE AIR SYSTEM
2.10 COMPRESSOR DATA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11 REFRIGERATION SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.13 COMPONENT RESISTANCE AND CURRENT DRAW
2.14 REFRIGERANT CIRCUIT DURING COOLING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.15 REFRIGERANT CIRCUIT -- HEATING AND DEFROSTING . . . . . . . . . . . . . . . . . . . . . . . . .
Page
2--24
2--25
2--25
2--26
2--26
2--26
2--26
2--27
2--15
2--15
2--15
2--16
2--22
2--22
2--22
2--23
2--28
2--29
2--30
2--13
2--13
2--14
2--14
2--14
2--14
2--14
2--15
2--1
2--2
2--10
2--10
2--10
2--11
2--12
2--12
1
9
SECTION 2
UNIT DESCRIPTION
2.1 INTRODUCTION
WARNING
WARNING
Beware of V-belts and belt driven components as the unit may start automatically.
Before servicing unit, make sure the Start/
Run--Off switch is in the OFF position or the unit is in Maintenance mode. Also disconnect the negative battery cable.
UNITS EQUIPPED WITH REMOTE TWO WAY
COMMUNICATION CAPABILITIES HAVE THE
ABILITY TO BE STARTED OR TURNED OFF
REMOTELY REGARDLESS OF THE SETTING
OF THE START / RUN-OFF SWITCH.
The unit is controlled locally and there can be no two-way communication when the
Mode Switch on the Remote Monitoring
Control Box is in MAINTENANCE MODE.
Therefore, when performing any work on the unit place the mode switch in MAINTE-
NANCE MODE. After the unit is serviced, return the mode switch to REMOTE ON.
This manual contains Operating Data, Electrical Data and Service Instructions for the refrigeration units listed in
Table 2-1.
Additional support manuals are listed in Table 2-2.
The model/serial number plate is located inside the unit on the frame as shown in Figure 2-3.
Table 2-1. Model Chart
Advance Models
R-404A
KG LB
Compressor Engine
Engine Speed
High Low
Ultra XTC NDL-93NN
Ultra XTC Rail Edition NDL-93NR
Ultra XTC with Tier 2 Engine NDL-93VN
Ultima XTC NDL-93PN
Ultima XTC Rail Edition NDX-93PR
Ultima XTC with Tier 2 Engine NDL-93RN
X2 2100A and R NDL93S
X2 2500A and R NDL93U
9.1
20
9.5
21
05G 41cfm
CT4-134-DI
V2203-DI
ESC
1700
2200
1700
2200
1350
1475
1350
1450
Manual Number
62-10671
62-11171
62-10646
62-10682
62-10295
62-10863
62-11168
62-10301
62-10865
62-11167
62-10299
62-11053
62-02756
62-11052
Table 2-2. Additional Support Manuals
Equipment Covered
Ultra/Ultima XTC
X2 2100/2500 A AND R
Units With Advance Microprocessor
Units With Advance Microprocessor
Engine V2203-DI
Engine (Tier 2)
Engine (Electronic Speed Control)
Engine V2203-DI
Engine (Tier 2)
Engine (Electronic Speed Control)
Compressor
Compressor (05G TWINPORT))
Compressor
Compressor (05G TWINPORT)
Type of Manual
Parts List
Parts List
Operator’s Manual
Easy To Run
Parts List
Parts List
Parts List
Workshop
Workshop
Workshop
Parts List
Parts List
Service
Service
2--1 62-10683
2.2 GENERAL DESCRIPTION
The refrigeration units described in this manual are one-piece, self-contained, fully charged, pre-wired, refrigeration/heating nosemount diesel powered units for use on insulated trailers or rail cars to maintain cargo temperatures within very close limits.
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.
The control box includes manual switches, microprocessor, fuses, and associated wiring. The unit can be equipped with an optional remote light bar which mounts separately on the front roadside corner of the refrigerated compartment.
The temperature controller is a solid state microprocessor (Refer to Section 2.5). Once the microprocessor is set at the desired temperature, the unit will operate automatically to maintain the desired temperature within very close limits. The control system automatically selects high and low speed cooling or high and low speed heating as necessary to maintain the desired temperature within the refrigerated compartment.
The auto Start--Stop operation 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). The auto
Start--Stop feature is standard equipment.
62-10683 2--2
9
22
1
2
3
4
6
5
21
20
18
17
19
7
8
9
10
11
12 13
14
15
16
1. Liquid line service valve
2. Hot Gas Solenoid Valve (SV4)
3. Suction Modulation Valve (CSMV)
4. High Pressure Cutout Switch (HPS)
5. Discharge service valve
6. Unloader solenoid valve
7. Compressor Discharge Transducer (CDT)
8. Compressor -- 05G
9. Compressor sight glass
10. Suction Pressure Transducer (CSP)
11. Suction service valve
12. Fuel filter
13. Engine oil drain
14. Starter motor
15. Lube oil fill and dipstick
16. Lube oil filter
17. Oil Pressure Switch (OP)
18. Mechanical fuel pump
19. Fuel bleed valve
20. Speed Control Solenoid (SCS)
21. Water Temperature Sensor (WTS)
22. Ambient Temperature Sensor (ATS)
Figure 2-1. Front View Of Unit With Non ESC Engine
2--3 62-10683
1
2
3
3
4
5
6
1
2
7
1.
Condenser Pressure Control
Solenoid Valve (SV1)
2.
Defrost Air Switch (DAS)
3.
Filter Drier
4.
Receiver
5.
Receiver sight glass
6.
Liquid Line Solenoid Valve (SV2)
7.
Battery location
Figure 2-2. Curbside (Non ESC Engine)
62-10683 2--4
1.
Condenser / Radiator
2.
Radiator fill neck
3.
Radiator overflow reservoir
4.
Engine air cleaner
5.
Alternator -- See Figure 2-11
6.
Model / Serial No. Location
7.
Control box -- See Figure 2-8
Figure 2-3. Roadside (Non ESC Engine)
4
5
6
7
9
1
2
3
4
5
6
7 8
9
10
11
12
13
14
15
23
22
21
20
19
18
17
16
1. Liquid line service valve
2. Hot Gas Solenoid Valve (SV4)
3. Suction Modulation Valve (CSMV)
4. High Pressure Cutout Switch (HPS), Compres-sor Discharge Transducer (CDT) and Unloader
Solenoid Valve
5. Discharge service valve
6. Compressor -- 05G
7. Compressor sight glass
8. Suction Pressure Transducer (CSP)
9. Suction service valve
10. Engine oil drain
11. Starter motor
12. Lube oil fill and dipstick
13. Lube oil filter
14. Mechanical fuel pump
15. Engine Oil Pressure Switch (ENOPS)
16. Engine Speed Sensor (ENSSN)
17. Fuel and Speed Actuator (FSA) and Alternator
18. Fuel bleed valve
19. Engine air cleaner
20. Fuel filter
21. Engine Speed Control Unit (ENSCU)
22 Water Temperature Sensor (WTS
23. Ambient Temperature Sensor (AAT)
Figure 2-4. Front View Of Unit With Electronic Speed Control (Electronic Speed Control)
2--5 62-10683
2
3
2
1
4
5
6
1
3
7
4
5
1.
Condenser Pressure Control
Solenoid Valve (SV1)
2.
Defrost Air Switch (DAS)
3.
Filter Drier
4.
Receiver sight glass
5.
Receiver
6.
Liquid Line Solenoid Valve (SV2)
7.
Battery location
Figure 2-5. Curbside (Electronic Speed Control)
62-10683 2--6
1.
Condenser/Radiator
2.
Pressurized coolant system
3.
Control box -- See Figure 2-8
4.
Serial Port/Download Plug (SLP)
5.
Model/Serial No. Location
Figure 2-6. Roadside (Electronic Speed Control)
9
8
7
6
5
1
2
3
9
CURBSIDE
4
1.
Evaporator fan
2.
Expansion valve
3.
Heat exchanger
4.
Return Air Thermistor (RAT)
5.
Evaporator coil
6.
7.
8.
9.
Defrost Termination Thermostat (DTT)
Supply Air Thermistor (SAT)
Nozzle cover
AutoFresht Air Exchange (See Sections
2.4.3 and 3.20.4
Figure 2-7. Evaporator Section -- Panels and Grille Removed
2--7 62-10683
12
11
10
9
8
7
6
4
5
1
2
3
1.
Serial Port / Download Plug (SLP)
2.
Control module (Microprocessor)
Refer to Section 2.5.3
3.
Fuse (F1) 7.5 Amp
4 Fuse (F10) 40 Amp -- Optional Auto Fresh Air
Exchange
5.
Fuse (F7) 5 Amp
6.
7.
8.
9.
Fuse (F6) 15 Amp (Fuel Pump)
Fuse (F8) 20 Amp (Optional Fuel Heater)
AutoFresh Relay (AFAR)
Fuse (F5) 80 Amp
10. Fuel Heater Relay (FHR)
11. Starter Solenoid Relay (SSR)
12. Glow Plug Relay (GPR)
Figure 2-8. Control Box (Short Box)
62-10683 2--8
11
9
10
9
8
7
6
5
4
3
2
12
1
1.
Control Module (Microprocessor)
Refer to Section 2.5.3
2.
Fuse (F1) 7.5 Amp -- Located next to control module
3 Fuse (F10) 40 Amp -- Optional Auto Fresh Air
Exchange -- Location Only
4.
Fuse (F6) 15 Amp
5.
Fuse (F8) 20 Amp (Optional Fuel Heater)
6.
Fuse (F7) 5 Amp
7.
8.
9.
AutoFresh Relay (AFAR) -- Location Only
Fuse (F5) 80 Amp
Fuel Heater Relay (FHR) -- Location Only
10. Starter Solenoid Relay (SSR)
11. Glow Plug Relay (GPR)
12. Glow Crank Switch (GCS) -- on side of box If equipped
Figure 2-9. Control Box (Redesigned Tall Box)
2--9 62-10683
2.3 CONDENSING SECTION
The condensing section consists of an engine-compressor drive package, condenser fan, condenser/radiator coil, refrigerant controls, piping, wiring.
The drive equipment includes the engine, clutch, 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 a tube in fin type and acts as a heat exchanger in which the compressed refrigerant gas is lowered in temperature and condensed into a liquid. Air movement over the condenser is provided by an electric motor driven fan mounted in the condensing section.
2.3.2 Engine
The diesel engine drives the compressor directly through a nylon drive gear and adapter. The adapter also includes a V-belt sheave which drives the gearbox.
The condenser/evaporator fan shaft is driven with a
V-belt from the gearbox. The water pump V-belt drives the alternator.
a. Engine Transducers and Sensors:
1) Engine RPM Sensor (ENRPM) (Non ESC engines only)
Non ESC Engines: Provides microprocessor with engine RPM information to be displayed and recorded in the DataRecorder. It is located on the rear of the engine in the flywheel housing.
ESC Engines: Provides the ENSCU with the engine
RPM information for speed control of the engine. The
ENSCU then sends the information to the microprocessor to be displayed in the unit Data List and then to be recorded in the Data Recorder. It is located in the timing case cover of the engine above the oil filter.
2) Engine Oil Pressure Switch (ENOPS)
This normally open switch allows the engine to operate when oil pressure is above 15 ¦ 2 PSIG (1.02 ¦ 0.1
Bars). The switch will open and automatically stop the engine 5 seconds after pressure drops below 15 ¦ 2
PSIG (1.02 ¦ 0.1 Bars). 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.
3) 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.
4) Engine Coolant Temperature Sensor (ENCT)
Provides microprocessor with engine coolant temperature information to be displayed and recorded in the DataRecorder . The sensor is located on the starter side of the engine near the #4 Injector.
5) Engine Coolant Level Sensor (ENCLS)
(Optional)
Sets off alarm when coolant level is more than 1 quart low. Located in the coolant bottle.
6) Engine Speed Control Unit (ENSCU) (ESC only)
(See Figure 2-10)
The ENSCU is mounted on the roadside frame behind the upper door. (See Figure 2-4). It provides the RPM signal to the microprocessor. The unit has an alarm LED incorporated within it which is used to diagnose failures within the ESC system. See Section 10.4 for information on diagnosing failures.
LED
Figure 2-10. Engine Speed Control Unit (ENSCU)
7) Fuel and Speed Actuator (FSA) (ESC only)
The FSA combines the fuel shutoff solenoid and speed control solenoid into one component. Engine speed is controlled by varying rod position.
8) Engine Speed Sensor (ENSSN) (ESC only)
The ENSSN provides the RPM signal to the ENSCU for speed control. It is located on the front of the engine in the gear case cover.
62-10683 2--10
2.3.3 Alternator/Regulator
Electrical power for the control system and for charging the battery is provided by the 12 VDC alternator.
a. Alternator Operation
CAUTION
Observe proper polarity when installing battery. Negative battery terminal must be grounded. Reverse polarity will destroy the rectifier diodes in alternator. As a precautionary measure, disconnect positive battery terminal when charging battery in unit.
Connecting charger in reverse will destroy the rectifier diodes in alternator.
9
The alternator converts mechanical and magnetic energy to alternating current (AC) and voltage, by the rotation of an electromagnetic field (rotor) inside a threephase stator assembly. The alternating current and voltage is changed to direct current and voltage by passing AC energy through a three-phase, full-wave rectifier system. Six silicon rectifier diodes are used.
The regulator is an electronic switching device. It senses the system voltage level and switches the voltage applied to the field in order to maintain proper system voltage.
b. Integral Voltage Regulator Operation (12 VDC)
The regulator is an all-electronic, transistorized device.
No mechanical contacts or relays are used to perform the voltage regulation of the alternator system. The electronic circuitry should never require adjustment and the solid state active elements used have proved reliable enough to warrant a sealed unit. The system is temperature compensated to permit the ideal charging rate at all temperatures.
Yellow
1
Yellow
2
Red
4
2
Black
3
1.
D+ Emulation (Orange) -- Not Used on Advance
2.
#10-24 AC Terminal
3.
#10-24 Ground Screw
4.
1/4-20 Positive Output Cable
Figure 2-11. Alternator and Regulator
2--11 62-10683
2.3.4 Compressor
The compressor assembly includes the refrigerant compressor, suction and discharge service valves, high pressure switch, and the suction and discharge pressure transducers. The compressor draws refrigerant gas from the evaporator and delivers it to the condenser at an increased pressure. The pressure is such that refrigerant heat can be absorbed by the surrounding air at ordinary temperatures.
2.3.5 Compressor Unloaders
The refrigeration compressor used is a 41 cfm model
05G, 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 and reduces power required to operate the compressor; thus reducing fuel consumption.
a. Major Working Parts
S
Solenoid and valve system
S
Spring loaded piston type bypass control valve
S
Spring loaded discharge check valve
4
5
6 b. Unloaded Operation (Figure 2-12)
Pressure from the discharge manifold (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.
7
11
2 3
1
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 2-12. Compressor Cylinder Head Unloaded
62-10683 2--12
c. Loaded Operation (Figure 2-13)
Discharge pressure bleeds from the discharge manifold
(Item 15) through the strainer (9) and (8) bleed orifice to the solenoid valve stem (2) chamber and then 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
4
5
6
9
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 5.12 for more information on Loaded Operation.
2
3
7
11
1
10
9
14
15
8
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
2.3.6 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.
Figure 2-13. Compressor Cylinder Head Loaded
2.3.7 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 sight glasses for the observation of liquid level and a fusible plug.
2--13 62-10683
2.3.8 Compressor Transducers and Sensors a. Compressor Suction Pressure Transducer (CSP)
Provides microprocessor with suction pressure information to be displayed, recorded in the
DataRecorder 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 microprocessor with discharge pressure information to be displayed, recorded in the
DataRecorder 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 microprocessor with compressor discharge temperature information to be displayed, recorded in the DataRecorder and used to control the refrigeration system. It is located on the center cylinder head of the compressor.
It will shut the unit down if center compressor head discharge temperature reaches 310°F (154°C) for three minutes or 350°F (177°C). If ambient temperature sensor (AAT) is at 120°F (49°C) or higher, the CDT limits are increased to 340°F (171°C) for three minutes.
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. Ambient Air Temperature Sensor (AAT)
AAT is a temperature control probe which provides the microprocessor with ambient air temperature information to be displayed, recorded in the DataRecorder and used to control the refrigeration system. It is located behind the condenser grille.
2.4 EVAPORATOR SECTION
The evaporator fits into a rectangular opening in the upper portion of the front wall of the refrigerated compartment front wall. When installed, the evaporator section is located inside this compartment, and the condensing section is outside.
The evaporator assembly consists of an evaporator coil, an evaporator fan motor, a thermal expansion valve, a heat exchanger, a defrost termination sensor (DTT), supply (SAT) and return (RAT) air sensors (See
Figure 2-7.
2.4.1 Thermal Expansion Valve
The thermal expansion valve is an automatic device which controls the flow of liquid to the evaporator according to changes in superheat to the refrigerant leaving the evaporator. The thermal expansion valve maintains a relatively constant degree of superheat in the gas leaving the evaporator regardless of suction pressure.
Thus, 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 the tube in tube type and is connected in the main suction line and liquid line. The cold suction gas is used to cool the warm liquid refrigerant within the heat exchanger. This results in greater system capacity and efficiency.
2.4.3 Evaporator Coil
The unit evaporator is a tube and 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.
Heating is accomplished by circulating hot gas directly from the compressor to the evaporator coil. Solenoid valves control the refrigerant circuit to operate the heating/cooling system.
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.
As perishable products respire, they consume oxygen
(O
2
) and give off carbon dioxide (CO
2
). This will eventually cause the atmosphere within a refrigerated compartment to have higher levels of CO levels of O
2.
2 and lower
This may adversely affect the shelf life of some sensitive perishable products. When transporting these products, it may be desirable to maintain normal atmospheric conditions (prevent the build up of CO
2 the depletion of O
2 and
) by using fresh air exchange, in addition to accurate temperature control. AutoFresh Air
Exchange provides the ability to control the amount of fresh air without the need for manual intervention while in transit. AutoFresh Air Exchange can also be used to lower the humidity level within a refrigerated compartment IF the ambient air has a lower humidity level.
AutoFresh Air Exchange is a factory-installed option, as it requires a modified evaporator pod. (See Figure 2-7)
When AutoFresh Air Exchange is operational and “ON”, two air ports open. The upper port allows fresh ambient air to enter while stale air exits through the lower port.
AutoFresh Air Exchange is available for all setpoints at or above +28°F (-2.2°C). AutoFresh Air Exchange is not operational when the setpoint is set below +28°F
(-2.2°C) or when the unit is in Defrost, or when the unit has cycled off in Auto Start-Stop. (Refer to Section
3.20.4 for more information on AutoFresh Air
Exchange.)
62-10683 2--14
2.4.4 Evaporator Transducers and Sensors a. Defrost Termination Temperature Sensor (DTT)
The DTT is located on the curbside evaporator support bracket above the coil. It senses the temperature of the evaporator and allows defrost initiation once the temperature falls below 40°F (4.4°C)
b. Return Air Temperature Sensor (RAT)
The RAT is a temperature control probe which provides microprocessor with return air temperature information to be displayed, recorded in the data recorder and used to control the refrigeration system. It is located in the center of the return air grille.
c. Supply Air Temperature Sensor (SAT)
The SAT is a temperature control probe which provides microprocessor with supply air temperature information to be displayed, recorded in the data recorder and used to control the refrigeration system. It is located in the supply air nozzle.
2.5 SYSTEM OPERATING CONTROLS AND
COMPONENTS
The temperature controller is a Carrier Transicold
Advance Microprocessor (Refer to Section 2.5.3 and 3).
Once the microprocessor is set at the desired temperature, the unit will operate automatically to maintain the desired temperature within very close limits.
The microprocessor consists of two modules -- the control module (See Figure 2-14) and the display and keypad module (See Figure 2-15). The control box includes manual switches, a 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
2.5.1 Multiple Languages
Messages in the MessageCenter can be displayed in
English, French, Portuguese or Spanish.
Press and hold the Select Key for 6 seconds to view or change the current language selection. See Section
3.16 for more information on Language Selection.
2.5.2 Special Features
The following special features are incorporated into the
Carrier Transicold Advance Microprocessor:
S
A MessageCenter which clearly displays all information in dot matrix form.
S
Unit Operation and Alarms are displayed in English
(not in codes)
S
UltraFresh 3
S
Large LCD display
S
Unit Data and Functional Parameters
S
Programmable Maintenance hourmeters
S
PM Hourmeters are resettable from the keypad
S
Bright LED alarm light
S
Bright LED mode lights
S
Fully automated Pretrip
S
Automated microprocessor Self-test
S
DataRecorder
S
DataRecorder date and time can be set from the keypad
S
Auto Start-Stop
S
Trip Start to record date/time of trip in
DataRecorder memory
S
PC card functionality for downloading data, upgrading programming and setting up
Configurations. (Refer to Section 2.5.4.)
S
FETs (Field Effect Transistors) for switching components on and off, and checking circuit current
S
Automatic Engine Starting. Manual engine starting exists in units built before April 2007.
S
Functional Parameter locks
S
Alarms are stored in microprocessor memory for future reference
S
New menu system to simplify keyboard and enhance functionality
2--15 62-10683
2.5.3 Component Description And Location a. Control Module
The control module is housed in the control box on the lower roadside (right) corner of the unit, just inside the lower roadside door. The control module contains replaceable relays and fuses which are externally accessible. LEDs are located next to the three relays plugged into the control module to indicate relay operation. Additional LEDs indicate operation of the
FETs (Field Effect Transistors).
The control module includes the logic board, program memory, FETs, PC card slot, and necessary input/output circuitry to interface with the unit.
The logic board is located within the control module, and does not contain any serviceable components.
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.
CLUTCH RELAY (K3)
GROUND STRAP
PC CARD FAULT LED
(RED)
1MP (WHITE)
PC
CARD SLOT
2MP (BLACK)
PC CARD STATUS
LED (GREEN)
MICROPROCESSOR
STATUS LED
(GREEN)
3MP (GREY)
QC5
LED29
F4 (7.5A)
RUN RELAY (K2)
QC4
LED28
F3 (7.5A)
SPEED RELAY (K1)
QC3
LED27
F2 (10A)
RELAY POWER
QC8 (12+ VDC
AUTOFRESH AIR RELAY
DC CURRENT
SENSOR
LED30 (GPR)
LED31 (SSR)
6MP (DISPLAY KEYPAD
CIRCUIT)
5MP ( START/CRANK/
GLOW CIRCUIT)
4MP (NOT USED)
QC2 (MICROPROCESSOR
GROUND)
QC1 (SYSTEM POWER
12+VDC)
FET LEDs
F1 (7.5A)
Figure 2-14. Control Module
62-10683 2--16
Figure 2-14 shows the control module. The control module has three relays and four fuses that are user accessible. There are three 7.5 amp fuses and one 10 amp fuse.
The PC card slot is also shown in Figure 2-14. This card slot is used with all Carrier Transicold PC cards. The microprocessor automatically detects the presence and type of PC card inserted and responds accordingly. The different types of PC cards are:
S
Download PC card for downloading unit data
S
Option PC card for installing optional software programs
S
Configuration PC card for setting the microprocessor functions, configurations, and
DataRecorder 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 Microprocessor 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.
9
• 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. The
LED will blink every 0.5 seconds during a software change -- either an upgrade or downgrade. It will blink every 1.0 seconds during data download to PC card. It will blink every 2.0 seconds when either the Program or
Configuration or Option cards is inserted and no action is taken. Check the MessageCenter for description of error.
2--17 62-10683
b. Display and Keypad
MODE LIGHTS
DISPLAY
-20
+34.1°F
MessageCenter
DOOR
DEFAULT MESSAGE
MAY BE REPLACED BY
USER DEFINED
MESSAGE
-20
STATUS OK
DISPLAY and KEYPAD MODULE
Figure 2-15 Display and Keypad
2--18 62-10683
+34.1°F
The Display and Keypad module is located for operator access at the lower roadside corner of the unit.
The display board is mounted in the Keypad and Display module. The display board includes the LCD display, keypad, and keypad interface.
The Display and Keypad 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. The previous figure shows the Display and
Keypad module.
Display
The main display has nine characters (seven seven-segment characters and two nine-segment characters), two decimal points, two commas, and a degree symbol. The display is used to provide the user a setpoint and refrigerated compartment temperature -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 refrigerated compartment temperatures below
Zero. A positive sign will be displayed for all setpoint and refrigerated compartment temperatures above
0° which will not have a sign in front of it. The resolution for refrigerated compartment temperature in both
Centigrade and Fahrenheit is one-tenth degree.
The user has the option as to whether to have the setpoint displayed with a decimal or comma. Only setpoint is affected by this selection. All other temperatures and pressures will continue to be displayed with either a decimal or comma. Refer to
Configurations Section 6.2.
9
Indicator LEDs
The display has six LEDs across the top to indicate operation status. These indicators are:
S
Cool Indicator (Green) -- Turned on when the unit is in Cool mode.
S
Heat Indicator (Amber) -- Turned on when the unit is in Heat mode.
S
Defrost Indicator (Amber) -- Turned on when the unit is in Defrost mode.
S
Start-Stop Indicator (Green) -- Turned on when the
Start-Stop mode has been selected.
S
Continuous Indicator (Green) -- Turned on when the Continuous mode has been selected.
S
Alarm Indicator (Red) -- Off or flashes at a rate of
0.5 seconds.
NOTE
When the unit is in PULSED 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.
2--19 62-10683
MessageCenter
The MessageCenter is used to show messages. Details of the messages are described in Section 7.1
MessageCenter.
Switch Descriptions
START / RUN--OFF Switch (SROS)
START/RUN-OFF Switch
The START/RUN-OFF switch is a 12 VDC input to the microprocessor. When placed in the START/RUN position, this switch provides power to the microprocessor. The microprocessor performs a self-test (all segments of display are illuminated). Then set point and refrigerated compartment temperature are displayed. To stop the unit or remove power from the microprocessor, place the SR0S to the OFF position.
GLOW/CRANK Switch (GCS) (Removed from units built after April 2007)
The GLOW/CRANK switch is located on the back of the control box and is easily reachable from under the control box.
GLOW
NOTE
CRANK
The GLOW/CRANK switch will energize the glow and crank circuits only when the
START/RUN-OFF switch is in the RUN position, and after the microprocessor has gone through the self-test.
Key Descriptions
MANUAL
DEFROST
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
The MANUAL DEFROST key is used to initiate a defrost cycle when the proper conditions are met.
ALARM LIST
START--STOP/
CONTINUOUS
SELECT
ALARM LIST Key
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 3.13.
START-STOP/CONTINUOUS Key
This key allows you to change from
Start-Stop operation to Continuous Run operation. In Start-Stop operation, when the microprocessor is in Off-Cycle mode, the unit will not be running. During Off-Cycle mode, the microprocessor monitors refrigerated compartment temperature, battery voltage and engine coolant temperature and will restart the unit when needed.
SELECT Key
Press the SELECT key to scroll through the menu selections. One of the five standard and one optional menu selections will appear in the MessageCenter when the
SELECT key is pressed.
The five standard selections are:
•PRESS
↑↓
TO VIEW HOURMETERS--
Displays the hours for individual hour meters. Refer to Section 3.15.
•
PRESS
↑↓
TO START PRETRIP -- Used to initiate a pretrip. Refer to Section 3.4.
•
PRESS
↑↓
TO VIEW DATA -- Displays
Unit Data. Refer to Section 3.14.
•
PRESS
↑↓
TO VIEW SETTINGS -- Displays unit Functional Parameter settings.
Refer to Section 3.16.
•
PRESS
↑↓
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 3.11.
•
PRESS
↑↓
TO VIEW PRINT MENU -- Enables the user to use hand--held Strip Print printer kit P/N 12--00543--10.
The optional selection is:
•
PRESS
↑↓
TO VIEW INTELLISETS -- Refer to Section 3.20.1.
62-10683 2--20
9
FET
FET6
FET7
FET8
FET9
FET10
FET12
FET14
FET15
FET16
FET17
FET18
FET21
FET22
FET23
Table 2-3. FIELD EFFECT TRANSISTORS (Transistors not listed are spares)
FET
FET14
FET15
STANDARD
DESIGNATION
Auto Fresh Air Relay
Auto Restart Light
Heat Light
SV4
SV1
Fuel Heater Relay (FHR)
Fault Light
Out of Range Light
Defrost Light
Cool Light
Buzzer (B)
SV2
Rear unloader (UL2)
Front unloader (UL1)
LED LIGHT BAR OPTIONS
DESIGNATION
Fault Light
Out--Of--Range Light
2--21 62-10683
2.5.4 Handling of PC Cards
PC cards can be used to upgrade software (Section
6.5.2), download recorder data (Section 6.7.1, set configurations (Section 6.2.1) and Functional
Parameters (Section 6.7.7) and install optional features.
While these cards are constructed for a rugged environment, they are not intended to be stored in a technician’s toolbox.
The label on each card clearly states that the card is to be handled with care -- not to be bent, dropped or exposed to impact. Heat, moisture and direct sunlight should be avoided.
PC cards are designed to be used in a wide temperature range of --40 to +185°F (--40 to +85°C). When a PC card is connected to an Advance microprocessor or computer at temperatures outside this range, data transmission between the card and the other device may not be performed correctly.
Retention of programmed data for extended periods of time requires a temperature range of --4 to +149°F (--20 to +65° C). When PC cards are exposed to temperatures outside of this range for several days data contained on the card may be damaged.
PC cards should never be:
• Dropped
•
Bent
• Twisted
• Squeezed
• Submersed in any liquid
• Exposed to electrostatic discharge
• Exposed to intense ultraviolet light
• Exposed to nearby magnetic or electromagnetic fields
Low X--Ray exposure, i.e. that experienced while passing through a security screen, should not harm the card data. High X--Ray exposure, i.e. that experienced in a medical or dental environment may damage the card data. PC cards should not be kept in a shirt pocket contained a pocket screwdriver with a magnetic end.
PC cards should be kept in a hard plastic jewel case when not in use. Replacement cases P/N 58--50109--00 are available from Carrier Transicold’s Performance
Parts Group.
2.6
OPTIONS
2.6.1 Light Bar
The Light Bar is an external set of indicator lights that can be seen in the mirror from the cab of a truck or on the front of a rail car. They are controlled by the microprocessor.
a. Eight--Light Light Bar
These lights correspond to the microprocessor LEDs --
HEAT, COOL, DEFROST, START-STOP, and ALARM.
The ENGINE-AUTO-START light is only illuminated when the unit is operating in Start-Stop. The
OUT-OF-RANGE light is illuminated when the
Out-of-Range Alarm is active.
b. Two--Light Light Bar
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 microprocessor display.
62-10683 2--22
2.6.2 Door and Remote Switches
A unit has provisions to connect a Door Switch (DS) and/or two remote switches (REMS1 and 2) directly to the microprocessor.
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
9 no alarm and only record door openings and closings in the Data Recorder.
If the door or remote switch is configured to shut the unit down when the door is open, the unit will shut down for a minimum of three minutes. Additionally, there is an
Override Door/Remote Switch in the Functional Parameters (Refer to Functional Parameter List, Section
3.16.) When this parameter is set to YES, the Door/Remote 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.
EIGHT--LIGHT BAR
TWO--LIGHT LED LIGHT BAR
2--23 62-10683
2.6.3 Out of Range Alarm
The Out Of Range Alarm is intended to notify the driver when the refrigerated compartment temperature has moved away from set point or when the unit is operating at low cooling capacity, and the compartment temperature is not pulling down toward set point. The Out Of
Range Alarm may be configured as an Alarm Only, or as an Alarm and Unit Shutdown. (Refer to Section 6.2 Configuration Mode).
If the unit shuts down due to a shutdown alarm, the Out
Of Range Alarm will come on when the refrigerated compartment temperature has been out of range for 30 to 45 minutes regardless if the refrigerated compartment temperature was ever within set point range or not.
Generally, when the unit is running, the refrigerated compartment temperature must have first been In
Range before the Out of Range Alarm can be triggered.
In Range is defined as the temperature of the refrigerated compartment having been within ± 2.7°F
(1.5°C) of set point in the Perishable Range, or within +
2.7°F (1.5°C) of set point in the Frozen Range.
The point at which the actual Out of Range Alarm comes on is determined by the Out of Range 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 set point the refrigerated compartment temperature will move before turning on the Alarm. The alarm will be activated after 30 minutes if the unit is still more than the number of degrees selected in the Functional Parameter list away from set point if the alarm is configured for Alarm Only.
The alarm will be activated and the unit will shutdown after 45 minutes if the alarm is configured for Alarm and
Shutdown.
In Sleep Mode, Pretrip, Component Test Mode, or if the unit has a Door Switch or Remote Switch configured as a Door Switch, and the door has been opened, the Out of Range Alarm is disabled and will not come on. After exiting any of these modes, or closing the refrigerated compartment door, the refrigerated compartment temperature must again come In Range of the set point before the Out of Range Alarm can be activated.
The internal timer is inactive in Defrost or in a Start--Stop
Off Cycle. Once the unit leaves these modes, and goes into a temperature control mode (HEAT, COOL, or
PULSED NULL), the Out of Range internal timer not start until the temperature is out of range of set point.
Once the compartment temperature is out of range, the timer will start, allowing the unit time to bring the refrigerated compartment temperature into range before the
Out of Range Alarm can be activated.
If the unit is not heating or cooling correctly, the Out of
Range alarm may come on when:
S
The unit is in cool and in pulldown mode (RAT is still far away from set point) and if the Delta--T (SAT minus RAT) is not at least --1.0°F (0.56°C) for 30 minutes OR
S
The unit is in pullup mode (RAT is still far away from set point) and the unit is operating in heat and the
SAT is the same temperature or colder than RAT.
62-10683 2--24
9
2.7 ENGINE DATA
Table 2-4. Engine Data
Engine Model
Displacement
No. Cylinders
Weight
Coolant Capacity
Oil Capacity with Filter
Fuel
Glow Plug Amperage
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
CT4-134DI (V2203-DI-E2B)
V2203-DI-ESC
134 in
3 (
2.2 liters)
4
417.8 lbs (189.5 kg)
2 gallons (7.6 liters) (50/50 mix -- never to exceed 60/40)
15 quarts (14 liters)
Winter: Diesel No. 1 Summer: Diesel No. 2
7.0 amps per plug at 10.5 VDC (nominal)
2.7.1 Lubrication System a.Oil Pressure
40 to 60 PSIG (2.7 To 4.1 Bars)
(Engine in high speed)
b.Oil Pressure Safety Switch Setting Closes
15 ( ¦ 3) PSIG [1.02(¦.2) Bars]
c.Lube Oil Viscosity:
Outdoor Temperature
Fahrenheit
Below 32_
Above 32_
Centigrade
Below 0°
Above 0_
SAE
10W30 or
Mobil Delvac 1
(5W 40)
10W 30 or
Mobil Delvac 1
(5W 40or 15W40)
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.
Extended Service Interval (ESI) packages are standard on X units beginning with S/N JAB90602792. The ESI package reduces the frequency of scheduled service intervals. Refer to Section 9.1 for instructions on service intervals.
Change 09/11 2--25 62-10683
2.8 ENGINE SCREW THREADS
All threads used on the diesel engine are metric.
2.9 ENGINE AIR SYSTEM
The air cleaner is installed on the engine to prolong its life and performance by preventing dirt and grit from getting into the engine 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 9.8.8)
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.
2.10 COMPRESSOR DATA
Table 2-5. Compressor Data
Compressor Model
No. Cylinders
No. Unloaders
Weight
Oil Charge
Approved OIl
05G
6
2
137 lbs (62 kg)
5.5 pints (2.8 L)
Mobil Arctic EAL 68
2.11 REFRIGERATION SYSTEM DATA
Table 2-6. Refrigeration System Data
Gearbox Oil
Fanshaft Oil
Mobil SHC 75-90W: 15oz
(0.43 kg)
Mobil SHC 630: 3.2oz (0.09
kg)
a. Compressor Discharge Pressure Transducer
(CDP)
Range: 0 to 500 psig (0 to 34 bar)
b. Compressor Suction Pressure Transducer
(CSP)
Range: --29.93 inHg/--14.7 psig to 100 psig
(1 to 6.9 bar)
c. Defrost Air Switch (DAS)
Initiates Defrost:
1.40 ¦ .07 inch (35 ¦ 1.8 mm) WG
d. Defrost Timer (microprocessor controlled)
1.5h, 3h, 6h, or 12 hours
e. Defrost Termination Thermistor (DTT)
(4.4
Allows defrost initiation at temperatures below 40°F
°
°C)
Terminates defrost cycle at 55
°
(12.8
°
C)
f. Receiver Fusible Plug Setting
430°F (221°C) Melting Point
g. High Pressure Switch (HPS)
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)
h. Unit Dry Weight: (Approximate) 1600 lb. (725 kg)
i. Expansion Valve MOP
Ultima and X2 2500 -- 105 PSIG (7.1 Bars)
Ultra and X2 2100 -- 55 PSIG (3.7 Bars)
j. Expansion Valve Superheat Setting
8 to 10_F (4.4 to 5.6_C) at 0_F (-17.8_C) refrigerated compartment temperature
62-10683 2--26 Change 09/11
9
2.12 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 2-7.
Unsafe Conditions
High engine cooling water temperature
Table 2-7. Safety Devices
Unit Shutdown Safety Devices
Safety Device
Engine coolant temp. (ENCT)
(microprocessor reset)
Excessive current draw by microprocessor Fuse (F1)
Excessive current draw by speed relay Fuse (F2)
Excessive current draw by run relay
Excessive current draw by clutch relay
Fuse (F3)
Fuse (F4)
Excessive current draw by glow plug circuit, control circuit or starter solenoid (SS)
Excessive current draw by all solenoid valves and unloaders and light bar
Fuse (F5)
Fuse (F6)
Excessive current draw by glow/crank switch and START/RUN-OFF switch (Glow/
Crank switch removed in units built after
April 2007)
Excessive current draw by fuel heater
Excessive current draw by light bar
Fuse (F8) -- Optional
Fuse (F9)
Excessive current draw by Fresh Air Relay Fuse (F10) -- Optional
Excessive compressor discharge pressure High pressure cutout switch
(HPS) automatic reset
Unsafe Conditions
Low Engine Oil Level
(May be configured for alarm only or alarm and shutdown)
Low Fuel Level
(May be configured for alarm only or alarm and shutdown)
Fuse (F7)
Other Safety Devices
Safety Device
Low Engine Oil Level Switch
(ENOLS)
Low Fuel Level Switch, or
Low Fuel Level Sensor
Device Setting
Refer to section 2.7
Opens at 7 1/2 amps
Opens at 10 amps
Opens at 7 1/2 amps
Opens at 7 1/2 amps
Opens at 80 amps
Opens at 15 amps
Opens at 5 amps
Opens at 20 amps
Opens at 3 amps
Opens at 40 amps
Refer to section 2.3.8
Device Setting
Engine oil level is more than 7 quarts low.
See Trigger On criteria for alarms 1 and 19 in Section 8
2--27 62-10683
2.13 COMPONENT RESISTANCE AND CURRENT DRAW
Table 2-8. Component Resistance and Current Draw
SV1
Component
SV2 and 4
AFAS (Auto Fresh Air
Solenoid)
Compressor Suction Modulation Valve
Ohms
7.8 ± 0.3 Ohms
10.6 ± 0.3 Ohms
Pull in -- 0.36 Ohms ± 10%
Hold -- 14.4 Ohms ± 10%
Unloader
Clutch
Speed solenoid (Units without ESC)
Fuel solenoid
Red--Black wires:
10.6 ± 0.3 Ohms
2.5 ± 0.2 Ohms
1.5 to 2.5 Ohms
11.1 Ohms to 13.4 Ohms
White--Black wires: Can not be accurately measured with Coil
Commander in circuit.
Engine Speed Sensor (Units with ESC)
12VDC Relay
(GPR, SSR, FHR)
12VDC Relay
(RCR)
72 Ohms ±10%
80 Ohms ±15%
Indicator lights (8 Light Bar
Only)
4.8 ± 0.2 Ohms
Unit non-running amps (See Note 2 in Section 8.2)
Glow Plug Amps Each Plug
Glow Plug Total Circuit
Starter Amps NA
Resistance
Amps
0.10 to 2.0 Amps
0.75 to 2.0 Amps
Pull in -- 29 Amps
Hold -- 0.83 Amps
1.0 to 2.0 Amps
3.0 to 5.0 Amps
3.0 -- 8.0 Amps
0.25 to 2.0 Amps
30.0 to 40.0 Amps
22 mAmps Max
0.14 -- 0.18 Amps
0.12 -- 0.17 Amps
NA
6 -- 9 Amps
6 -- 9 Amps
24 -- 36 Amps
270 -- 380 amps
72 to 84 ohms per winding
92 ohms (¦ 10 %) for any two windings.
62-10683 2--28
9
2.14 REFRIGERANT CIRCUIT DURING COOLING (See Figure 2-16)
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) expansion valve, and (4) direct expansion evaporator.
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 compressor raises the pressure and the temperature of the refrigerant and forces it through the discharge check valve and 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 through the solenoid valve SV1
(normally open) and to the receiver.
The receiver stores the additional charge necessary for low ambient operation and for the heating and defrost modes. The receiver is equipped with a fusible plug, which melts if the refrigerant temperature is abnormally high and releases the refrigerant charge.
The liquid then flows to an externally equalized thermostatic expansion valve, which reduces the 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 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 refrigerated compartment to maintain the cargo at the desired temperature.
The refrigerant leaves the receiver and flows through the manual liquid line service 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; and the electrically controlled liquid line solenoid valve, SV2
(normally closed), which starts or stops the flow of liquid refrigerant.
The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize.
This low temperature, low pressure vapor 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 Suction Modulation Valve (CSMV). The
CSMV controls the compressor suction pressure thereby matching the compressor capacity to the load.
FUSIBLE PLUG
EXTERNAL
EQUALIZER
CSMV
TXV
BULB
EVAPORATOR
HEAT EXCHANGER
LIQUID LINE
VIBRASORBER
CDP HPS
CSP
SV4
N/C
COMPRESSOR
TXV
LIQUID LINE
SERVICE VALVE
BYPASS
CHECK
VALVE
SUBCOOLER
RECEIVER
FILTER
DRYER
SV2
N/C
SV1
N/O
DISCHARGE
CHECK VALVE
CONDENSER
VIBRASORBER
Figure 2-16. Refrigerant Circuit During Cooling
2--29 62-10683
2.15 REFRIGERANT CIRCUIT -- HEATING AND DEFROSTING (See Figure 2-17)
When vapor refrigerant is compressed to a high pressure and temperature in a reciprocating compressor, the mechanical energy necessary to operate the compressor is transferred to the gas as it is being compressed. This energy is referred to as the “heat of compression” and is used as the source of heat during the heating cycle.
When additional heating capacity is required the microprocessor opens the Liquid Line Solenoid valve
(SV2) to allow additional refrigerant to be metered into the hot gas cycle (through the expansion valve).
When in engine operation and the discharge pressure exceeds pressure settings detailed in Section 2.11, the pressure cutout switch (HPS) opens to de-energize the run relay coil (RR). When the RR coil is de-energized, the RR contacts open stopping the engine.
When the microprocessor calls for heating, the hot gas solenoid valve (SV4) opens and the condenser pressure control solenoid valve (SV1) closes. The condenser coil then fills with refrigerant, and hot gas from the compressor enters the evaporator. Also the liquid line solenoid valve (SV2) will remain energized
(valve open) until the compressor discharge pressure increases to a predetermined setting in the microprocessor.
The microprocessor de-energizes the liquid line solenoid valve (SV2) and the valve closes to stop the flow of refrigerant to the expansion valve.
The function of the hot gas bypass line is to raise the receiver pressure when the ambient temperature is low
(below -17.8_C/ 0_F ) so that refrigerant flows from the receiver to the evaporator when needed.
EXTERNAL
EQUALIZER
CSMV
TXV
BULB
EVAPORATOR
HEAT EXCHANGER
LIQUID LINE
VIBRASORBER
CDP HPS
CSP
SV4
N/C
COMPRESSOR
TXV
BYPASS
CHECK
VALVE
FUSIBLE PLUG
RECEIVER
LIQUID LINE
SERVICE VALVE
SUBCOOLER
FILTER
DRYER
SV2
N/C
SV1
N/O
DISCHARGE
CHECK VALVE
CONDENSER
VIBRASORBER
Figure 2-17. Refrigerant Circuit During Heating And Defrost
62-10683 2--30
SECTION 3
OPERATION
PARAGRAPH NUMBER
3.1
STARTING UNIT -- AUTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
MANUAL START -- GLOW AND CRANK -- IF EQUIPPED . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Unit Startup -- Self Test
3.4
PRETRIP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5
CHANGING SET POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6
START-STOP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7
CONTINUOUS RUN OPERATION
3.8
SLEEP MODE ON
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9
SLEEP MODE OFF
3.10 DEFROST
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.1 Manual Defrost
3.11 TRIP START
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.12 VIEW ACTIVE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.13 VIEW INACTIVE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.14 UNIT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.15 VIEW HOURMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.16 FUNCTIONAL CHANGE (PARAMETERS)
3.17 LANGUAGE SELECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.18 STOPPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.19 DATA RECORDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.19.1 Microprocessor Information
3.19.2 Data Recording
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.19.3 Sensor and Event Data
3.19.4 Data Downloading
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.19.5 DataRecorder Power-Up
3.20 OPTIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.20.1 IntelliSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.20.2 DataTrakt for Advance Microprocessors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.20.3 Two-Way Remote Communication
3.20.4 AutoFresh Air Exchange
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
3--34
3--35
3--35
3--37
3--37
3--38
3--25
3--31
3--32
3--33
3--33
3--33
3--33
3--34
3--13
3--15
3--15
3--16
3--17
3--18
3--20
3--24
3--8
3--9
3--11
3--12
3--1
3--2
3--3
3--4
1
SECTION 3
OPERATION
3.1 STARTING UNIT -- AUTO
WARNING
Under no circumstances should ether or any other starting aids be used to start engine.
MODE LIGHTS DISPLAY
-20
+34.1° F
MessageCenter
DOOR
1. Place the START/RUN-OFF switch
to START/RUN position.
3--1 62-10683
3.2 MANUAL START -- GLOW AND CRANK -- IF EQUIPPED*
WARNING
Under no circumstances should ether or any other starting aids be used to start engine.
-20
+34.°F
1. Hold GLOW/CRANK switch in the GLOW
position.
2. Place START/RUN-OFF switch to the
START/RUN position.
GLOW CRANK
3. Continue to hold GLOW/CRANK switch in the GLOW
position for up to 15 seconds.
Back of Control Box
4. Then crank the engine by holding the GLOW/CRANK switch
in the CRANK position until the engine starts. This may take up to 10 seconds.
*NOTE
The GLOW/CRANK switch was removed from units built after April 2007.
When the micro powers up, “MANUAL START MODE
SELECTED” will appear in the MessageCenter and the
Alarm LED will blink for five seconds.
If the GLOW/CRANK switch is held in the GLOW position before the START/RUN-OFF switch is placed in the START/RUN position, when the
START/RUN-OFF switch is in the START/RUN position, the unit Start mode is changed to MANUAL
START, and the unit operation mode is set to
CONTINUOUS RUN. When the engine is running, this switch is disabled.
62-10683 3--2
The GLOW/CRANK switch, when held in the GLOW position, tells the microprocessor to energize the glow plug relay, which powers the glow plugs in the engine to preheat the combustion chamber. The CRANK position of the switch tells the microprocessor to engage the engine starter. If the switch is held in the CRANK position, the starter will engage after a short delay of up to one second, for a maximum 10 seconds.
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.
Refer to Section 4.2.2 for glow times.
3.3
U
NIT
S
TARTUP --
S
ELF
T
EST
STANDBY
ENGINE
SELF TEST
When first powered up:
•
The microprocessor 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 set point temperature in the left four characters and the refrigerated compartment temperature in the right four characters. The last character (after the degree symbol) shows the temperature units as “C” Centigrade or “F”
Fahrenheit. When set for °F, there is a decimal in the compartment Temperature. When set for °C, there is a comma in the compartment Temperature.
• The MessageCenter will display the default message, unless there is an alarm(s) stored in the microprocessor. If there is an alarm(s) stored in the microprocessor,
“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. Any hourmeters that are configured
ON will also be displayed.
• The MessageCenter will show “STATUS OK” as the microprocessor begins to position the CSMV to unit starting positions.
• In engine operation, after the refrigeration valves open the intake air heater will energize (as required), the buzzer will sound, and the diesel engine will start.
• The suction modulation valve (CSMV) will go through a procedure to close itself. The microprocessor starts out giving the CSMV the command to close completely. The display will show
“SMV CLOSING: WAIT XX SECONDS” where xx is the number of seconds until the valve is fully closed.
The CSMV will then open to a predetermined position according to the ambient and compartment temperatures. The display will show “SETTING SMV
XX%.” The start sequence will start at 30%.
•
After the CSMV reaches 30%, the glow plugs will energize (as required), the buzzer will sound, and the diesel engine will start.
NOTE
Placing the unit in either Continuous Run or-
Start-Stop will automatically put the unit into
Auto Start operation.
3--3 62-10683
3.4 PRETRIP
HEAT COOL DEFROST
PPPP
SETPOINT
TEST #1
ALARM START-STOP CONTINUOUS
BOX TEMPERATURE
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the SELECT key until the MessageCenter
displays “PRESS THE = KEY TO START PRETRIP.”
2. Press the = key to start PRETRIP.
3. 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.
4. 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
A Pretrip can be started when the refrigerated compartment is at any 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:
• “PRETRIP PASS” OR
• “PRETRIP FAIL IN TEST X” OR
•
“PRETRIP FAILED & COMPLETE”. Alarm light will be on.
Press the ALARM LIST key to review the alarms triggered by the Pretrip tests.
62-10683 3--4
TIP
The Pretrip test “PASS” results message will stay displayed until a key is pressed, or until the
Start/Run--Off switch is placed 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.
TIP
If “CAN NOT START PRETRIP” is displayed in the MessageCenter, check to see if the unit is in
PC mode, Defrost (Refer to Section 6.1) or check the alarm list (Section 3.12) for active shutdown alarms.
PRETRIP (Continued)
NOTES
NOTE 1: Pretrip may be initiated any time the unit is running, or when the unit is off but the
START/RUN-OFF switch is in the
START/RUN position. Pretrip will not start if there is an active shutdown alarm, or if the unit is in PC mode or in defrost.
NOTE 2: 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 five 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.
If the unit is not running and the suction modulation valve (CSMV) has reached its fully closed position,
Pretrip will begin.
NOTE
Before completing PreTrip, the microprocessor 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.
LED display.
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
Test 1 -- Display And Sound Test
The microprocessor activates the LCD/LED display, and all lights on the Light Bar. This test will last five 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 Electrical Components
Check the amperage (current) draw of the following components:
•
Battery DC Current (All Components Turned
Off)
•
•
•
•
•
•
•
•
Auto Fresh Air Solenoid
Auto Fresh Air Solenoid
Evap/Cond Fan Clutch
UL1 Front Unloader
UL2 Rear Unloader
Speed Solenoid (or ESC module)
SV1
SV2
•
SV4
•
Glow Plugs
•
Fuel Solenoid (or ESC module)
3--5
Most components will be energized for four seconds at which time the amperage reading is taken. There is a two second rest period between each component. The glow plugs will be energized for 15 seconds, at which time the amperage reading is taken. Test 2 will last approximately two minutes. If a problem is detected with any of the listed components, the corresponding alarm will be displayed.
Test 3 -- Temperature and Pressure Sensor Check
Check the condition of the following sensors:
•
Return Air Sensor
•
Supply Air Sensor
•
Engine Coolant Sensor
•
Battery Voltage Sensor
•
Ambient Air Sensor
•
Defrost Termination Sensor
•
Compressor Discharge Sensor
Test 3 will last approximately five seconds. If a problem is detected with any of the listed components, the corresponding alarm will be displayed.
62-10683
PRETRIP (Continued)
Test 4 -- Warm Up
The engine is started automatically and the ambient air sensor is read.
The Pretrip splits into two modes at this point as the engine and compressor are allowed to run and be warmed up. If the ambient temperature is above +32°F
(0°C), the unit will operate in the “Cool Pretrip” mode. If the ambient temperature is at or below +32°F (0°C), the unit will operate in the “Heat Pretrip” mode.
In the Cool Pretrip mode, the unit will operate in two cylinder Low Speed Cool. The compressor suction and discharge pressures will be tested. Appropriate alarms will be displayed if any problem is detected. Test 4 in
Cool Pretrip will last approximately 60 seconds.
In the Heat Pretrip mode, the unit will operate in four cylinder Low Speed Heat. The micro will check for a rise in compressor discharge pressure, fan clutch operation, and SV1 operation. Appropriate alarms will be displayed if any problem is detected. Test 4 in Heat Pretrip may last up to 12 minutes depending on ambient and compartment temperatures and unit condition. For very low compartment temperature, the unit may operate in six cylinder low speed heat.
Test 5 -- UL2 (Rear) Unloader
With the unit still running the same as it was in Test 4, the operation of UL2 Unloader is tested. If suction and discharge pressures do not change when UL2 is energized and de-energized, the “CHECK UL2” alarm will be displayed. Test 5 will last about 20 seconds.
Test 6 -- UL1 (Front) Unloader
With the unit still running the same as it was in Test 5, the operation of UL1 is tested. If suction and discharge pressures do not change when UL1, the “CHECK UL1” alarm will be displayed. Test 6 will last about 20 seconds.
Test 7, 8, and 9 -- Engine High and Low Speeds
The engine will go from Low Speed to High Speed, then back to Low Speed during these tests. Engine RPM will be checked. If the engine is not operating within the operating range, either the “CHECK LOW SPEED
RPM,” or “CHECK HIGH SPEED RPM” alarm will be displayed. Tests 7, 8, and 9 will last about 30 seconds.
Test 10 -- Check 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 11 -- SV1 (Cool Pretrip Only)
With the unit running in two cylinder Low Speed Cool, the operation of SV1 will be tested for opening and closing. If the valve does not operate correctly, the
“CHECK SV1 VALVE” alarm will be displayed. This test may last up to three minutes.
Test 12 -- Check SV4
NOTE
The Cool and Heat Pretrip modes will merge together at this step.
With the unit running in two cylinder, Low Speed Heat,
SV4 is tested for opening and closing. If the valve does not operate correctly, the “CHECK SV4” VALVE alarm will be displayed. This test may last up to eight minutes.
Test 13 -- Low Side Pump Down
With the unit running in two cylinder Low Speed, SV2 and SV4 will all be closed to pump the low side of the unit down. If a problem is detected, the alarm “CANNOT
PUMP DOWN LOW SIDE” will be displayed. Test 13 may last up to eight minutes.
Test 14 -- High to Low Side Leakage
The unit will shut down, and check for pressure equalization between the high and low sides. If any leakage is detected, the HIGH SIDE LEAK alarm will be displayed. This test will last one minute.
Test 15 -- Check Discharge Check Valve
With the unit off, the discharge check valve is checked for leakage. If any leakage is detected, the “CHECK
DISCHARGE CHECK VALVE” alarm will be displayed.
Test 15 will last 40 seconds.
Test 16 -- Check for Other Alarms
The alarm list is checked for any non-pretrip alarms that may have occurred during the Pretrip test. If any operational alarms occurred, Pretrip will show FAIL, and the technician will need to review the Alarm List and take necessary and appropriate action to clear them (see list below). Test 16 will last about five seconds.
62-10683 3--6
Test 16 -- Check For Other Alarms That May Be Present:
Check for the following alarms:
Alarm
No.
Alarm Description
1
LOW FUEL LEVEL WARNING (for units with Low Fuel Level switch/no fuel level display in Data List)
LOW FUEL LEVEL WARNING (for units with Low Fuel Level 0% to 100% Sensor / fuel level is displayed in Data List)
2 LOW ENGINE OIL LEVEL
3 LOW COOLANT LEVEL
18 LOW REFRIGERANT PRESSURE
27 HIGH SUCTION PRESSURE
28 CHECK REFRIGERATION SYSTEM
34 ENGINE FAILED TO STOP
36 CHECK COOLANT TEMPERATURE
51 ALTERNATOR NOT CHARGING
54 DEFROST NOT COMPLETE
55 CHECK DEFROST AIR SWITCH
59 DATALOGGER NOT RECORDING
60 DATALOGGER TIME WRONG
71 BAD F2 OR F3 FUSE
81 CHECK FHR CIRCUIT
82 CHECK REMOTE OUT-RANGE LIGHT
223 thru
230
If any Maintenance alarms are active, Pretrip will not pass.
232 thru
249
If any Microprocessor alarms are active, Pretrip will not pass.
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 and COMPLETE” (if the entire Pretrip cycle was completed), or “PRETRIP FAIL IN TEST–––,” (if the Pretrip cycle was aborted by an alarm before it was completed).
3--7 62-10683
3.5 CHANGING SET POINT
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. With the setpoint 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.”
2. Press the = key to save the
new setpoint.
Set points of --22°F to +89.6°F (--30°C to +32°C) may be entered via the keypad. The microprocessor always retains the last entered set point in memory. Depending on microprocessor set--up, the set point 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
The microprocessor Configurations allow a minimum and maximum setpoint to be entered so that only set points within that range may be selected. “MAX SETPOINT HAS BEEN
REACHED” or “MIN SETPOINT HAS BEEN
REACHED” will appear in the MessageCenter when either of these conditions are met.
62-10683 3--8
Set point may be changed any time the Start/Stop--Off switch is in the START/RUN position, or when the unit in
PC Mode EXCEPT when:
• Viewing the Alarm List, Data List or Functional Parameters OR
• When the unit is in PreTrip OR
• When the unit is in Sleep Mode
Pressing the = key will cause the new displayed set point value to become active and “SETPOINT
CHANGED” will be displayed. If the = key is not pressed and there is no keyboard activity for 5 seconds the entire display and Light Bar will flash for 15 seconds and
“SETPOINT NOT CHANGED” will be displayed. The microprocessor setting will then revert back to the last entered set point. All other keys are active while the display is flashing and if pushed while the display is flashing, will cause the flashing to stop and perform the requested function.
TIP
The set point may be changed quickly by pressing and holding the UP ARROW or DOWN AR-
ROW key. The longer the key is held, the faster the setting will change.
3.6 START-STOP OPERATION
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 refrigerated compartment temperature, battery charging amps, battery voltage and engine coolant temperature (Engine/Road only). The main function of automatic cycling is to turn off the refrigeration system near set point to provide an 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 4.3.1 for more detailed information on Start--Stop Mode.
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, 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 unit cycles off normally.
NOTE
FreshProtect is not enabled in Start-Stop mode. See Functional Parameters List --
Table 3-3.
3--9 62-10683
3.6.1 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 set point, or
• The settings can be specified to be different, depending on whether the set point is in the perishable range or in the frozen range.
The decision as to whether the same settings will be used together for all set points or if they will be separated between Perishable and Frozen is made in the Configuration List. (Refer to Section 6.2.)
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
NOTE
In the event that the Configuration is changed from Separate to Together, the values from the
Perishable Functional Parameters are the ones that will be used.
3.6.2 Charging Amps
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 recharging 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.)
3.6.3 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 12.0 to 12.8 Volts in
0.1V increments. The factory setting for this configuration is 12.2V.
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.
62-10683 3--10
3.7 CONTINUOUS RUN OPERATION
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 microprocessor 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 4.3.2 for more detailed information on
Continuous Run operation.
Start-Stop and Continuous operation may be tied to the set point 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 6.2.
If the unit fails to start after three start attempts, Alarm
31 -- “FAILED TO START--AUTO MODE” will be activated. While running, if the unit shuts down, an internal counter keeps track of the shutdowns. Should the unit shut down three consecutive times without running a minimum of 15 minutes between shutdowns, the
Alarm 30 “FAILED TO RUN MINIMUM TIME” Alarm will be activated. The shutdown counter is cleared when the unit has run for 15 minutes.
NOTE
FreshProtect is enabled in Continuous Run mode. See Functional Parameters List --
Table 3-3.
3--11 62-10683
3.8 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 UP or
DOWN ARROW key to change the Sleep Mode to “YES”.
62-10683 3--12
3.9 SLEEP MODE OFF
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 “NO”.
OR
Sleep Mode OFF
1. To take the unit out of Sleep Mode, place the START/RUN - OFF switch to the OFF position, then back to Start/Run.
NOTE
If IntelliSleep is active the only way to exit Sleep
Mode is to activate another IntelliSet.
3--13 62-10683
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 3.9
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 four 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 (set point and compartment temperature) will be turned off.
This is because the refrigerated compartment temperature does not have to be at set point 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.
62-10683 3--14
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 five minutes. Sleep Mode may be exited by either turning the Start/Run-Off switch to the OFF position, then back to the START/RUN position, or by accessing the Functional Parameter list, and selecting “SLEEP
MODE: OFF”.
While in Sleep mode, the 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 set point 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 6.2.1)
Sleep mode is generally used in cold ambients when the trailer or rail car may be parked or not used and the unit is OFF for an extended period of time (one 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 the unit will “Wake Up” periodically and run to keep the battery charged and the engine warm.
In Sleep Mode the unit will “Wake Up” periodically and run to keep the battery charged and the engine warm.
NOTE
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 3.20.1).
IntelliSleep can ONLY be exited by selecting a different IntelliSet.
3.10 DEFROST
3.10.1 Manual Defrost
DEFROST LIGHT
HEAT COOL DEFROST
+34
ALARM
d
F
START-STOP
SETPOINT
DEFROST CYCLE STARTED
BOX TEMPERATURE
CONTINUOUS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the MANUAL DEFROST key. The DEFROST light will come on and the Messa-
geCenter will display “DEFROST CYCLE STARTED” for five seconds, or flash “CAN-
NOT START DEFROST CYCLE” for five seconds.
When Defrost mode CANNOT be manually initiated
“CANNOT START DEFROST CYCLE” is displayed in the MessageCenter. This will occur when:
•
DTT2 is above 40°F (4.4°C), and SAT is above 45°F (7.2°C), OR
•
The engine has not run a minimum of15 seconds after starting OR
•
The unit is in PC mode OR
•
The unit is in Pretrip OR
•
There is an active shutdown Alarm.
NOTE
Refer to Section 5.11 for more detailed information on manual and automatic defrost initiation and termination.
TIP
The Manual Defrost Key can be used at any time to start a Defrost Cycle.
3--15 62-10683
3.11 TRIP START
HEAT COOL DEFROST
-20
SETPOINT
TRIP START ENTERED
ALARM START-STOP CONTINUOUS
+34.5° F
BOX TEMPERATURE
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 ENTER TRIP START.”
2. Press the = key.
3. If trip start is acknowledged by the data recorder, “TRIP START ENTERED” will be dis-
played for five 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 stamped events 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.
62-10683 3--16
3.12 VIEW ACTIVE ALARMS
ALARM LIGHT
HEAT COOL DEFROST
-20
SETPOINT
NO ACTIVE ALARMS
ALARM START-STOP CONTINUOUS
+34.5° F
BOX TEMPERATURE
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 five 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 five seconds.
5. To clear the active alarm list, press the = key while “LIST END, = TO CLEAR ALARMS” is be-
ing displayed. “ACTIVE ALARMS LIST CLEAR” is displayed. This will move all Alarms to the
Inactive Alarm list.
Alarms are stored in the Alarm list in the microprocessor. Stored alarms may be viewed on the
MessageCenter.
For a complete list of alarms, their meanings, and troubleshooting refer to Section 8.1.
TIP
Another way to clear active alarms is to turn the microprocessor OFF and then back ON using the START/RUN-OFF switch.
TIP
The message “CHECK MICROPROCESSOR”
(on earlier microprocessors) or “CHK WIRES
FROM MICRO TO KEYPAD” (on newer microprocessors) means there is a wiring problem between the microprocessor and the display module.
3--17 62-10683
3.13 VIEW INACTIVE ALARMS
HEAT COOL DEFROST
-20
SETPOINT
NO INACTIVE ALARMS
ALARM START-STOP CONTINUOUS
+34.5° F
BOX TEMPERATURE
MANUAL
DEFROST
ALARM LIST START-STOP/
CONTINUOUS
SELECT
1. Press and hold both the ALARM LIST key and the UP ARROW key for six
seconds. If there are no inactive alarms, the display will read
“NO INACTIVE ALARMS” for five 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 five 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 in the combined Active and Inactive Alarm lists. The lists can be read via the MessageCenter or using the
ReeferManager PC program. There are two 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 to the Active Alarm list.
As additional alarms occur, they will be placed first in the
Active Alarm list. Each alarm can only be present in either the Active or Inactive Alarm List at any given time.
As conditions change, 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.
For a complete list of alarms and troubleshooting information refer to Section 8.1.
62-10683 3--18
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. Pressing the Alarm List key will bring any Active
Alarms into the MessageCenter. Refer to Section 8 for a complete list of Alarms and their descriptions.
NOTE
The Inactive Alarm list is also called the Technicians List. Only qualified refrigeration technicians should access the inactive list. It is not intended for the use of drivers or operators.
Table 3-1. Shutdown Alarms
♦122
♦123
204
232
233
237
238
242
243
246
248
249
41
51
53
56
31
32
35
39
57
58
61
72
20
27
28
29
30
2
11
12
13
15
16
17
18
19
SHUTDOWN ALARMS
Low Oil Level
Low Engine Oil Pressure
High Coolant Temperature
High Discharge Pressure
Battery Voltage Too High
Battery Voltage Too Low
High Comp Discharge Temp
Low Refrigerant Pressure
Low Fuel Shutdown
Maximum Compressor Alarms (Optional)
High Suction Pressure
Check Refrigeration System
Check Heat Cycle
Failed To Run Minimum Time
Failed to Start -- Auto Mode
Failed to Start -- Manual
Check Starter Circuit
Check Engine RPM
Engine Stalled
Alternator Not Charging
Compartment Temp Out-of-Range
Check Evaporator Airflow
Check Remote Switch 1
Check Remote Switch 2
Door Open
Bad F4 or F6 Fuse
Check Return Air Sensor
Check Supply Air Sensor
Low Suction Pressure
Setpoint Error
Model # Error
Function Parameter Error
Configurations 1 Error
DIS PRESS Calibrate Error
SUCT/EVAP Calibrate Error
EEPROM Write Failure
Config Mode/HP2 Error
Microprocessor Error
SHUTDOWN
X
X
X
X
X
X
X
X
♦
X
X
X
X
X
X
X
X
♦
X
X
X
X
X
X
X
X
X
ALARM ONLY
or may be configured as
SHUTDOWN
(see configuration list
Section 6.2.1)
X
X
X
X
X
X
X
X
X
X
X
♦If Alarms 122 and 123 are both active and setpoint is in the perishable range [10.4°F(-12°C)] and higher -- the unit will shut down. Otherwise, alarm only.
3--19 62-10683
3.14 UNIT DATA
HEAT COOL DEFROST
-20
SETPOINT
PRESS ↑ ↓ TO VIEW DATA
ALARM START-STOP CONTINUOUS
+34.5° F
BOX TEMPERATURE
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. The selected Data Item will remain in the
MessageCenter for ten seconds, then the default message (“STATUS OK” or other customer specified message) will appear.
4. To lock an item in the MessageCenter for continuous viewing, press the =
key. The Data item will flash continuously to indicate it is locked.
5. Pressing the UP or DOWN ARROW key will unlock that item and move
to the next data item. Pressing the = key will unlock the item. After ten seconds the default message will be displayed.
62-10683 3--20
Table 3-2. UNIT DATA
* Also appear in Configurations
+ May or may not be displayed depending on functional parameter settings
SUCTION PRESSURE Compressor suction pressure
DISCHARGE PRESSURE Compressor discharge pressure
ENGINE COOLANT TEMP Engine coolant temperature
RETURN AIR TEMP
SUPPLY AIR TEMP
Return (air entering evaporator) air temperature
Supply (air leaving evaporator) air temperature
DELTA-T
AMBIENT AIR TEMP
Supply air temperature minus Return air temperature.
Ambient (air entering condenser) air temperature
DEFROST TERM TEMP 2
Defrost termination temperature
EVAP OUTLET TEMP Suction line temperature at the evaporator outlet
BATTERY
CURRENT DRAW
Battery voltage
Battery charging or discharging amps
ENGINE RPM
FUEL LEVEL
SUCTION MOD VALVE
START MODE
Engine revolutions per minute
% of fuel in tank. (This is only shown when 0%-100% sensor is configured ON.)
% open of CSMV
AUTO if the engine will start automatically
MANUAL if the engine must be started manually
Applies only if unit has any one or more of these options installed INSTALLED OPTIONS
INTELLISET INSTALLED
DATATRAK INSTALLED
COMPRESSOR ALARM
SHUTDOWN
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 #
*
ID #
*
UNIT SERIAL #
*
UNIT MODEL #
Serial Number of the microprocessor
ID (as entered by the user) -- Trailer, Car or Asset ID
Unit serial number
Unit model number (selected through configurations)
Number of engine hours until the next programmed engine maintenance
3--21 62-10683
*
+
*
+
+
*
+
*
+
Table 3-2. UNIT DATA
* Also appear in Configurations
+ May or may not be displayed depending on functional parameter settings
+ HOURS TO UNIT MAINT
Number of switch-on hours until the next programmed general unit maintenance
+ TIME LEFT TO PM (1-5)
Number of hours until the next programmed maintenance
*
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
PRODUCTSHIELD HIGH
AIR:
Delta-T value for activation of ProductShield Econo (Will only be displayed if Econo is NOT OFF)
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
CONTINUOUS -- The unit is set to operate only in Continuous Run when the set point is set between Range 1 Minimum and Maximum Temperatures
START-STOP -- The unit is set to operate only in Start-Stop when the set point is set between Range 1 Minimum and Maximum Temperatures
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
RANGE 2 MIN. TEMP
OFF -- Temperature Range 2 Lock is turned off.
CONTINUOUS -- The unit is set to operate only in Continuous Run when the setpoint is set between Range 2 Minimum and Maximum Temperatures
START-STOP -- The unit is set to operate only in Start-Stop when the setpoint is set between Range 2 Minimum and Maximum Temperatures
This is the lower limit for Range 2.
RANGE 2 MAX. TEMP This is the upper limit for Range 2.
62-10683 3--22
Table 3-2. 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 three remote sensors may be listed.)
*
DATALOGGER This is the current Date and Time that the DataRecorder 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
3--23 62-10683
3.15 VIEW HOURMETERS
ALARM HEAT
-20
COOL DEFROST
SETPOINT BOX TEMPERATURE
TOTAL ENGINE HOURS: 0 HRS
START-STOP CONTINUOUS
+34.5° F
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 6.2.1). Typical
displayed meters are: “TOTAL ENGINE HOURS” and “TOTAL SWITCH ON HOURS.”
4. Pressing the = key will access all other meters and display
“OTHER METERS AND COUNTERS”
5. The selected hourmeter will remain in the
MessageCenter for 10 seconds and then the default message (“STATUS
OK” or other customer specified message) will appear.
6. To lock an hourmeter in the MessageCenter for continuous viewing, press
the = key. The hourmeter 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:
•
Meters listed in Step 3 above that were not previously displayed.
•
Engine Protect Hours
•
Switch On Protect Hours
•
Engine Sleep Hours
•
High Speed Hours
•
Clutch Cycles
•
Start Cycles
62-10683 3--24
3.16 FUNCTIONAL CHANGE (PARAMETERS)
HEAT COOL DEFROST ALARM START-STOP
-20
SETPOINT BOX TEMPERATURE
PRESS ↑ ↓ TO VIEW SETTINGS
CONTINUOUS
+34.5° F
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 = key. “↑ ↓ TO SCROLL, THEN = TO SAVE” will show in the MessageCenter. Pressing either the 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 the UP or DOWN ARROW key until the desired value is displayed, 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 five seconds, then return to the last
Functional Parameter displayed. If no further keys are pressed, the default message will be displayed after 10 seconds.
NOTE
Any function that is shown with a padlock symbol cannot be changed from the keypad.
3--25 62-10683
Table 3-3. Functional Parameters
FUNCTIONAL
PARAMETER
DEFROST TIMER
SET FOR
SELECTIONS
1.5HRS
3HRS
6HRS
12HRS
DESCRIPTION
The defrost timer will automatically put the unit into the defrost cycle at the interval selected if evaporator 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 one minute increments)
10MINS
TO
90MINS
20MINS
S
(PERISH /
FROZEN)
OVERRIDE
TEMP:
(in one minute increments)
3.6
TO
18
°
F (2
°
C)
°
F (10
°
C)
11
°
F (6
°
C)
(in 0.5°F or C 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 restart 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 set point in the Frozen Range, the unit will override the Minimum Off Time, and restart.
OFF
OFF -- There is no maximum off time.
S
(PERISH /
FROZEN)
MAX OFF
TIME:
10MINS
TO
255MINS
(in one minute increments)
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.
FROZEN SHUT-
DOWN OFFSET
0
°
TO
F (0
3.6
°
°
C)
F (2
°
C)
This only applies to Frozen set points in Start-Stop operation.
This offset is the number of degrees below set point 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.
The unit has both a Return Air Sensor and a Supply Air Sensor. This selection determines which sensor temperature will be used for set point selections above 10.4°F (-12°C) to determine when set point is reached.
TEMP CONTROL:
RETURN AIR /
SUPPLY AIR
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.
NOTE: Whenever the setpoint is below +10.4°F(-12°C), the unit will ALWAYS be controlled by the Return Air
Sensor, regardless of the selection made here.
62-10683 3--26
FUNCTIONAL
PARAMETER
SELECTIONS
DISPLAY TEMPS
IN
FAHRENHEIT/CEL
CIUS
DISPLAY
PRESSURE IN
PSIG/BAR
ENGLISH UNITS
METRIC UNITS
ENGLISH UNITS
METRIC UNITS
*RESET PM HOURMETERS
S
ENGINE
S
SWITCH ON
RESET
S
PM 1 Thru 5
OUT OF RANGE
ALARM:
English Metric
OFF
4°F
5°F
7°F
OFF
2°C
3°C
4°C
DESCRIPTION
Temperatures will display in either English (°F ) or Metric (°C )
Pressures will display in either English ( psig) or Metric (bar)
Maintenance hourmeters that have expired will appear in this list.
If there are no active maintenance hourmeters, this menu item will not appear in the Functional Parameters.
If there are active maintenance hourmeters and none have expired and turned the alarm on, the MessageCenter will display
“NO HOURMETERS TO RESET.”
When any maintenance hourmeter has timed out, and preventative maintenance has been performed, selecting RESET and pressing the
= key will de-activate the alarm, and reset the hourmeter for the next service interval.
Once the unit is at set point, then drifted away for more than 15 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 set point the temperature must move before the timer is started. 4°F may be used for very critical temperature products, 7°F may be used for less critical products. The alarm may be turned off by selecting the OFF setting.
3--27 62-10683
FUNCTIONAL
PARAMETER
AIR FLOW
AIR FLOW
FRESH PROTECT
AUTO FRESH AIR
AUTO FRESH AIR
CONTROL
SELECTIONS
DESCRIPTION
NORMAL
HIGH
The NORMAL selection allows the unit to cycle from High Speed to
Low Speed, depending on how close the compartment temperature is to setpoint. Some products generate a considerable amount of heat
(heat of respiration) during transportation. This frequently occurs with produce.
The HIGH selection can be used for these loads, since continuous high air flow may be required to keep the entire load at a constant temperature. The engine will remain in High Speed when High is selected.
NOTE: HIGH AIR FLOW does not work with set points below +10.4°F (-12.0°C).
OFF
OFF -- Fresh Protect is turned off
A = 2 TO 5°F (1.1 TO
2.8°C)
B = 4 TO 7°F (2.2 TO
3.9°C)
C = 6 to 9°F (3.3 TO
5.0° C)
D = 8 to 11°F (4.4 TO
6.1 ° C)
E = 10 to 13°F (5.6 TO
7.2° C)
A thru E determines the allowable temperature SAT can go below setpoint when the unit is operating in Continuous Run Cool. FreshProtect does not operate in Start-Stop. (See Section 5.8.)
CLOSED -- AutoFresh Air Exchange assembly will be closed except for pretrip and component test mode.
0 = CLOSED
1 = OPEN
2 = CFM CONTROL
5 TO 50 CFM IN 5
CFM INCREMENTS
25 CFM
OPEN -- Assembly will be open if the engine is running and the setpoint is greater than 28°F (-2.2°C) and the unit is not defrosting
CFM CONTROL -- Assembly will be cycled open and closed over a 20 minute time period. The length of time the assembly is opened or closed is based on the Auto Fresh Air Control Functional Parameter.
The CFM CONTROL will only be active for setpoints greater than 28°F
(-2.2°C) and in Continuous Run mode or Auto Start-Stop mode when the engine is running. The assembly will be closed when the setpoint is less than 28°F (-2.2°C) or during defrost or during the off cycle of
Start-Stop mode.
When CFM CONTROL is selected, this parameter is visible. When
CFM CONTROL is used, the solenoid will open and close in 20-minute time blocks to control the amount of air being exchanged, so that the amount of air exchanged averages the CFM setting. During the first portion of the 20-minute block, the solenoid will be open, allowing fresh air in and exhausting stale air. Once sufficient air has been exchanged, the solenoid will close until the beginning of the next 20-minute block.
62-10683 3--28
FUNCTIONAL
PARAMETER
LOW SPEED
START-UP
MINUTES
--CONTINUOUS:
SELECTIONS
DESCRIPTION
--START-STOP
OFF or
1 to 255 minutes
OFF or
1 to 255 minutes (10
min)
Allows user to set the number of minutes the unit will run in low speed every time the engine starts.
UNLOADER
PRESSURE
CONTROL
Std
-5
+5
The recommended setting for this is Std. This setting should not be changed unless discussed with a Carrier Transicold Factory Service
Engineer or Field Service Engineer.
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
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.
S
WAKE UP TIME
• MONTH
•DAY
•YEAR
•HOURS
•MINUTES
The following Sleep Mode parameters were added in Software Version 04.07.00
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 START / RUN--OFF switch to OFF and then back to
START/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--29 62-10683
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 set point. The Pretrip Pass/Fail message will remain in the MessageCenter until the message is manually cleared.
* OVERRIDE
DOOR
SHUTDOWN
This will only appear when a compartment door switch is configured “ON” in the Configuration
List.
NO
YES
NO -- Allows the door switch to shut the unit down whenever the compartment door is opened and the door switch is configured for shutdown.
YES -- Allows operator to over-ride the compartment door shutdown switch, and allow the unit to continue to run, even with the compartment door open.
NOTE: This will only appear when a remote switch (REMS1 or REMS2) is configured “ON” in the Configuration List.
* OVERRIDE
REMS (1-2)
SHUTDOWN
LANGUAGE:**
IDIOMAS:
LANGUE:
LINGUAGEM:
NO
YES
ENGLISH
FRANÇAIS
ESPAÑOL
PORTUGUÊS
NO -- Allows remote switch (1 and/or 2) to shut the unit down whenever door is open or the switch is turned ON.
YES -- Allows operator to override remote switch (1 and/or 2), and allow the unit to continue to run, even with the remote switch in the ON position or the door is open.
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 six seconds.
Selections in BOLD are the factory settings.
* This Functional Parameter may not appear in the list for your unit, depending on how the microprocessor has been configured.
NOTE
**If the padlock is visible when accessing language from the Functional Parameter List, the language cannot be changed. However, when accessing the language using the “hot key” (press and hold the Select Key for 6 seconds) the language can be changed regardless if the padlock is shown or not.
62-10683 3--30
3.17 LANGUAGE SELECTION
HEAT
-20
COOL DEFROST
SETPOINT
ESPAÑOL
ALARM START-STOP
+34.5° F
CONTINUOUS
BOX TEMPERATURE
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press and hold the SELECT key for six 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 five seconds, then return to the current language. If no further keys are pressed, the default display will return in another 10 seconds.
TIP
If the language is set to one that the user does not understand, press and hold the
“SELECT” key for 6 seconds to bring up the Language Parameter so that it can be changed.
3--31 62-10683
3.18 STOPPING UNIT
1. To stop the unit, place the START/RUN -
OFF switch in the OFF position.
The diesel engine will stop and the microprocessor 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 START/RUN-OFF switch 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.
NOTE
The CSMV will close to 0% when START/
RUN-OFF switch is switched to OFF.
62-10683 3--32
3.19 DATA RECORDING
The Advance microprocessor contains a built-in
DataRecorder with 512K of memory. The recorded data can be downloaded from the DataRecorder using either
ReeferManager, a PC software program, or a Download
PC card.
The DataRecorder reads the same input information as the microprocessor (Functional Parameters,
Configurations, and Unit Data) at all times. The
DataRecorder records events as they occur, such as set point 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.
3.19.1 Microprocessor Information
The microprocessor Information that is available to be recorded is as follows:
•
DataRecorder Setup Sensor Being Recorded
(Logging Intervals, Events and Sensors)
•
DataRecorder Time Clock Date / Time
•
Setpoints (And all setpoint changes.)
•
ID Number
•
Unit Serial Number
•
Unit Model Number
•
Current System Mode
•
Functional Parameters
•
Microprocessor Configurations
3.19.2 Data Recording
The DataRecorder data comes from four general categories of information: a. Microprocessor Information as described in Section
3.19.1 above.
b.Sensor Data
This information is recorded at predetermined 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 intervals, and whether snapshot or averaged readings are preferred. Snapshot readings of sensors are also taken at the time of a shutdown alarm.
c.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. set point 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.
d.User Area Data
The user or service technician is able to enter a comment into the DataRecorder using the
ReeferManager program.
3.19.3 Sensor and Event Data
Sensors
The following sensors may be recorded either with an averaged reading, or snapshot or may not be recorded at all.
3--33
•
Return Air Temperature
•
Supply Air Temperature
•
Ambient Air Temperature
•
Compressor Discharge Temperature
•
Engine Coolant Temperature
•
Compressor Discharge Pressure
•
Compressor Suction Pressure
•
Battery Voltage
•
Battery DC Current
•
Engine RPM
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
•
Transducer Calibration
Optional Sensors and Events
In addition to the above Sensors and Events, the
DataRecorder also has the capabilities to record the following:
•
Remote Temperature Sensor 1
•
Remote Temperature Sensor 2
•
Remote Temperature Sensor 3
•
Remote Switch 1
•
Remote Switch 2
•
Door Switch
•
Fuel Tank % Level
62-10683
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
3.19.4 Data Downloading
The data within the DataRecorder can be downloaded from the DataRecorder by using either the
ReeferManager, (a PC software program) and a download cable connected to the download port (refer to
Section 6.1) or with a Download PC card (refer to
Section 6.4) If a PC card is used, the ReeferManager program is then used to extract the data from the PC card, and place it on the computer hard disk.
3.19.5 DataRecorder Power-Up
The DataRecorder 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 eight hours of data to be recorded after the START/RUN-OFF switch is placed in the OFF position, or to stop recording at the same time the
START/RUN-OFF switch is turned to the Off position.
The factory setting is to include the additional 8 hours of data. (See Configuration List Section 6.2.1.)
62-10683 3--34
3.20 OPTIONS
3.20.1 IntelliSet
HEAT
+34
COOL DEFROST
SETPOINT
APPLES
ALARM START-STOP
+34.5° F
CONTINUOUS
BOX TEMPERATURE
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 MOD-
IFIED after it. MODIFIED indicates that one or more of the IntelliSet settings
(other than set point) have been changed. To change MODIFIED to AC-
TIVE, 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 set points 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 set points may be locked, leaving the operator the ability to change the set point within the locked range.
When a load of apples is going to be picked up, the operator simply selects “APPLES” from the IntelliSet 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 3.8) to be entered by simply changing to that IntelliSet.
The ONLY way to exit from IntelliSleep is to select a different IntelliSet.
NOTE
The above settings are examples of possible settings. Factory IntelliSets are available from the Information Website through your authorized Truck/Trailer dealer.
3--35 62-10683
a. Changing IntelliSets
HEAT COOL DEFROST
-20
ALARM START-STOP CONTINUOUS
+34.5° F
SETPOINT BOX TEMPERATURE
PRESS ↑ ↓ TO VIEW INTELLISETS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. PRESS = Key to display current IntelliSet. (Enable IntelliSet at =
Key must configured ON. See Section 6.2.1.) If the = Key is not enabled, press the Select Key until the MessageCenter shows
PRESS
↑ ↓
TO VIEW INTELLISETS.
2. Press 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 or to change the current IntelliSet from
“MODIFIED to “ACTIVE,” bring the IntelliSet you wish to use into the
MessageCenter and press = Key.
62-10683 3--36
3.20.2 DataTrak
t
for Advance Microprocessors
DataTrak allows remote communication providers
(cellular, satellite, etc) to request data from the Advance microprocessor and have it transmitted via their equipment to another location. This is typically done via the internet to any destination in the world. Some providers can also send commands via their equipment to the Advance microprocessor to change settings and the way the controller is operating the unit.
DataTrak is an optional feature. The DataTrak option is installed by inserting a DataTrak PC Card into the PC
Card slot of the microprocessor and following the on--screen instructions on the keypad.
The DataTrak Option installation can be confirmed by scrolling through the Unit Data List (see Section 3.14).
DataTrak will be listed under the Installed Options heading if it is installed.
Once DataTrak is installed, the Advance
Microprocessor must be properly configured for the provider that will be connecting to it. This is done in the configuration list (see section 6.2.1.) The Satellite Com configuration can be set for “Qualcomm” or “Other”. If the provider is “Qualcomm” then this selection must be made. All other communications providers use the
“Other” selection.
Carrier Transicold has worked with approved communication providers with recommended installation locations, and wiring connections to Carrier units. Instructions for installing this equipment is supplied by individual providers, and not by Carrier
Transicold. Communications electrical harnesses and serial port splitters are available from Carrier Transicold
Performance Parts Group (PPG).
Communication Providers will connect into the wiring harness at the SATCOM port, and possibly at the J1 connector. Testing the SATCOM port may be done using a serial port to PC cable (22--01690--00) and the
ReeferManager program. If ReeferManager can communicate with the microprocessor the unit wiring and microprocessor are performing normally and any communication problem is with the provider’s equipment.
3.20.3 Two-Way Remote Communication
There are several different Telematics providers whose systems are approved for one-way or possibly two-way communications with Carrier Transicold
Truck/Trailer/Rail refrigeration equipment. Current information on each of these systems is available on the
Carrier Transicold TransCentral Information Center.
Please visit www.transcentral.carrier.com.
3--37 62-10683
3.20.4 AutoFresh Air Exchange
To activate AutoFresh operation, the AutoFresh Air
Exchange configuration needs to be set (See Section
6.2.1). A second configuration, AutoFresh Air Delay, can be used to delay the start of AutoFresh operation by up to 48 hours after engine start-up.
Two functional parameters (See Table 3-3) are used to choose the type of fresh air exchange. The AutoFresh
Air Exchange parameter is used to choose the type of fresh air control. The AutoFresh Air Control parameter is used to select the cycling of the assembly if CFM
CONTROL has been set.
The air exchange rate can be adjusted from zero to the maximum at the microprocessor. Maximum rate is 50
CFM.
AutoFresh Air Exchange controls the amount of CFM exchanged based on a 20-minute duty cycle. The duty cycle timer is reset whenever the START/RUN-OFF switch is turned OFF, then back ON, or if the unit is shut down by either a Door or Remote switch shutdown.
When the ambient air temperature is below 36°F (2.2°C) and the AutoFresh Air Exchange functional parameter is set for OPEN, the AutoFresh Solenoid (AFAS) will always be closed for the last 15 seconds of each 20minute time block and then reopen. Closing and opening the vent periodically prevents ice buildup from freezing the solenoid or air door into the open position.
The AutoFresh solenoid current draw is tested during
Pretrip Test #2; however, it is a good idea for the technician to visually verify that the solenoid actually pushes the air assembly open, then closed again. This operation is visible from ground level, by looking up at the curbside of the unit. See Figure 3--2 and Figure 3--3.
With the introduction of unfiltered air into the refrigerated compartment, “dirty” air may be drawn into the air stream and be deposited onto the fan blades, reducing the airflow and ventilation. Periodically, the fan blades must be inspected and cleaned, if necessary, to maintain optimum air flow and air exchange performance.
ITEMS 6, 7 AND 8 ARE NOT ACTUALLY
SHOWN . ONLY LOCATIONS ARE INDICATED.
5
9
11
6
7
1. Solenoid
2. Jam Nut
3. Washer
4. Cap Screw
5. Gasket
6. Hose Clamp
7. Inlet Hose
3
2
9
4
10
8. Outlet Hose
9. Sleeve
12
10. Push-In Fastener
11. Rail Cap Assembly
12. Rail Bracket
Assembly
Figure 3--1. AutoFresh Air Exchange
6
8
1
62-10683 3--38
AIR OPENINGS POINT DOWN
TO PREVENT RAIN WATER ENTRY.
Figure 3--2. AutoFresh in Closed Position Figure 3--3. AutoFresh in Open Position
3--39 62-10683
SECTION 4
ENGINE
PARAGRAPH NUMBER
4.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2
ENGINE START--UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Engine Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Variable Glow Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.3 Engine Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.4 Initial Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
RUNNING MODES
4.3.1 Start--Stop Mode
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 CONTINUOUS RUN MODE
4.4
SPEED CONTROL OVERRIDES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
4--3
4--3
4--3
4--3
4--1
4--1
4--1
4--1
4--5
4--6
1
SECTION 4
ENGINE
4.1 INTRODUCTION
This section describes the engine operation and the refrigeration system running modes known as automatic
Start--Stop and Continuous Run.
4.2 ENGINE START--UP
4.2.1 Engine Cranking
When the starting conditions are met the start sequence will begin by fully closing (0% Open) the Compressor
Suction Modulation Valve (CSMV). The CSMV will then open. When it reaches 30% the starting sequence continues by energizing the Run and Clutch relays, along with the solenoid valve (SV2) and both unloaders
(UL1 and UL2.) After 5 seconds the Glow Plug Relay
(GPR) will energize to supply power to the glow plugs and the buzzer will sound for 5 seconds before the starter is energized. On initial power-up, there will be a 5 second delay before the starting sequence begins. If the required glow time is zero (warm engine, short glow time), the microprocessor will energize the starter after a 5 second delay. The engine will crank for a maximum of 10 seconds or until the engine is “running”. The glow relay will also be de-energized at the same time the starter disengages. If the engine does not start, a 15 second rest period will elapse before the next start attempt. The Run Relay, Clutch Relay, both unloaders and SV2 will remain energized and CSMV will remain in pre--start position until the next starting sequence.
Before beginning another starting sequence, the oil pressure is checked to determine if the engine is running or the RPM sensor has failed. For the second and third start attempts the glow time is increased by 5 seconds over the glow time of the first attempt listed below. The microprocessor allows three start attempts (without the engine starting) before the starting is locked out and the
Failed To Start – Auto Mode alarm is activated.
NOTE
If the Engine Coolant Temperature Sensor alarm is Active, the glow time for temperatures less than 32_F (0°C) will be used.
4.2.2 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: Short or Long as follows:
Table 4-1. Glow Time
Engine Coolant Temperature
Glow Time in Seconds
Short
(Default)
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)
5 25
Greater than 78_F (26_C) 0 10
The second start attempt has five 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 62-10683
REPEAT “A”
+ 10 Seconds
GLOW
15 Seconds
STOP
REPEAT “A”
+ 5 Seconds
GLOW
15 Seconds
STOP
MAXIMUM
10 Seconds
Checked at
2 Seconds
CRANK
THIRD
ATTEMPT
SECOND
ATTEMPT
VARIABLE
0 to 55 SECONDS
GLOW
GLOW
FIRST
ATTEMPT “A”
HOMING CSMV
Figure 4--1. Auto Start Sequence
62-10683 4--2
4.2.3 Engine Running
The engine is considered to be running when:
a.Engine RPM are greater than 1000, and b.The engine oil pressure switch contacts are closed within 15 seconds of the engine starting.
OR if the RPM sensor is not reading correctly, and the engine is being started for the second or third attempt, the engine is considered to be running when:
a.For ambient temperatures at or above 32°F
(0°C) the engine oil pressure switch contacts are closed.
b.For ambient temperatures below 32°F (0°C) the alternator charging amps are more than 2 amps.
tivated.
NOTE
If either of these two cases occurs, alarm 130
-- CHECK ENGINE RPM SENSOR will be ac-
NOTE
While the starter is engaged, if the engine speed is less than 50 RPM for more than 3 seconds, the SSR will de--energize to stop the starter.
4.2.4 Initial Engine Operation
If a unit is started when the Engine Coolant Temperature is 79°F (26°C) or below, after the engine starts, the unit will immediately go to low speed 4 cylinder operation until the water temperature reaches 79°F (26°C) or for a minimum of 15 seconds. The CSMV will control suction pressure to 78 PSIG (5.3 Bars) Max. during low speed 4 cylinder operation. (Refer to Chart, Section
5.18). Once the water temperature is greater than 79°F
(26°C), the unit will run at high speed 4 cylinder operation and the CSMV will control to a maximum suction pressure of 42 PSIG (2.9 Bars). (Refer to chart). When the RAT reaches 50°F (10°C), the unit will go to 6 cylinder cool operation and the CSMV will control to a maximum suction pressure of 27 PSIG (1.8 Bars). The unit will continue in high speed 6 cylinder cool until the controlling temperature is 3.2°F (1.8°C) away from setpoint.
The microprocessor will then follow the operating sequence logic on Figure 5--2.
4--3
4.3 RUNNING MODES
Two running modes are possible: automatic Start--Stop and Continuous Run modes. The user can toggle between the two modes by pressing the appropriate key on the keypad. (Refer to Sections 3.6 and 3.7.)
NOTE
The microprocessor may be locked so that the unit will always operate in Start--Stop whenever the set point is within a specific range. Refer to
Range Lock (Section 5.15) and ProductShield
(Section 5.16) for additional information.
4.3.1 Start--Stop Mode
Start--Stop mode is provided to allow fuel--efficient control of refrigerated compartment temperature, while insuring that the refrigerated compartment temperature does not drift too far away from set point. When the refrigerated compartment temperature gets close the set point, the refrigeration system will shut off. This allows the diesel engine to shut down, saving fuel. As the refrigerated compartment temperature drifts away from set point, the refrigeration system and the engine will turn back on.
a. Start--Stop Mode Cycle Off Conditions
Whenever the unit starts in Start--Stop Mode, it will continue to run until all five of the following criteria have been satisfied.
1) The refrigerated compartment temperature is near set point.
After the Minimum Run Time expires, the unit will go into an Off Cycle when the compartment temperature is within ±0.5_F (±0.3_C) of setpoint for set points in the
Perishable range or is less than +0.5_F (+0.3_C) above set point for set points in the Frozen range.
2) The unit has run for the Minimum Run Time.
The Minimum Run Time is selected in the microprocessor Functional Parameter List. (Refer to Section 3.16).
The default setting is 4 minutes. 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 set point.
3) The engine coolant temperature is above 122°F
(50°C).
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). If the engine coolant sensor alarm is active and the ambient temperature is above 32°F (0°C), the engine coolant temperature will be ignored for the OFF cycle. If the engine coolant sensor alarm is active and the ambient temperature is below 32°F (0°C) or the ambient temperature sensor alarm is also active, the unit will run for a minimum of 20 minutes before allowing an OFF cycle.
62-10683
4) The battery voltage is high enough
Provisions are made to sense when the battery voltage is correct. A good battery is defined as having 13.4 VDC at 75_F (23.9°C). This voltage varies with ambient temperature.
5) The battery charging amps are low enough
Provisions are made to sense when the battery charging amps are low enough to indicate that the battery is sufficiently charged. The battery is sufficiently charged when the charging rate is below that selected in the
Configuration List. The selectable range is 1.0 to 10.0
amps in 0.5A increments. The factory setting is 6.5
Amps. (See Section 3.6.2).
NOTE
When conditions 3) thru 5) are met, “OK” will appear in the Unit Data List for battery voltage.
b. Start--Stop Mode Cycle On Conditions
A restart will be initiated when one of the following conditions occurs:
1) Normal restart 1: The Refrigerated Compartment Temperature Has Exceeded Selectable Override Temperature
The microprocessor continually monitors the refrigerated compartment temperature during the Minimum Off
Time. The unit will restart if the refrigerated compartment temperature goes beyond the Override Temperature (above or below set point in the Perishable range or above set point in the Frozen range). The Minimum Off
Time and the Override Temperatures are selected in the microprocessor Functional Parameter List (Refer to
Section 3.17). The default value is 20 minutes for the
Minimum Off Time and 11.0°F (6°C) for the Override
Temperature.
2) Normal restart 2: The Refrigerated Compartment Temperature Has Exceeded Standard Override Temperature
After the Minimum Off Time has expired, the microprocessor continually monitors the refrigerated compartment temperature. If the refrigerated compartment temperature goes more than +3.6°F(+2.0°C) away from set point (above or below set point in the Perishable range or above set point in the Frozen range), the unit will restart. The Minimum Off Time is selected in the microprocessor Functional Parameter List (Refer to Section
3.17). The default setting is 20 minutes.
3) Engine coolant temperature drops below 34_F
(1_C).
If the Engine Coolant Temperature drops below 34°F
(1_C), the unit will restart, and will run until all conditions for shutdown are met.
If Alarm 129 CHECK ENG COOLANT SENSOR 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. If the unit restarts due to this condition, the Minimum Run Time will be at least 20 minutes, regardless of the setting in the Functional Parameter list.
4) Battery voltage falls below voltage selected in the configuration list. (See Section 6.2.1)
The selectable range is between 12.0 to 12.8 VDC. The factory setting is 12.2 VDC.
TIP
While the unit is running, the status of the unit battery can be readily checked by reading the
Battery Voltage in the Data List. If “O.K.” appears after the voltage reading, battery volts is sufficient to allow the unit to cycle off. If “O.K.” does not appear, this condition has not been met, and the unit is not ready to cycle off.
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 load stays within safe temperature ranges, the
Maximum Off Time may be used to force the unit to restart regardless of any change in refrigerated compartment temperature. Maximum Off Time is selected in the microprocessor Functional Parameter List. The default setting is OFF.
NOTE
The unit may remain in low speed for some time after engine start--up when in the Start--Stop
Mode due to the High Speed Delay Functional
Parameter. The High Speed Delay is selected in the microprocessor Functional Parameter
List (Refer to Section 3.17). The default value is
10 minutes.
c. Start--Stop Indicator
To indicate that the unit is in the Start--Stop mode, the
Start--Stop LED indicator on the keypad will be illuminated.
62-10683 4--4
d. 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 will flash on and off once a second.
NOTE
X2 units only -- During a Start--Stop OFF cycle, the micro continues to monitor the ambient air temperature. If the ambient air temperature rises to115°F (46°C), SV4 will energize for 45 seconds to equalize the refrigeration system pressures. This will occur only once during an
Off Cycle, but may be repeated during subsequent Off Cycles.
4.3.2 CONTINUOUS RUN MODE
In the Continuous Run mode, the engine will not shut down except for shut down alarms or if the engine stalls.
Continuous Run mode is normally used for fresh produce and other temperature sensitive product loads. The Start-
Stop /Continuous key is pressed to switch between Continuous Run and Start-Stop operating modes.
NOTE
The microprocessor may be locked so that the unit will always operate in Start--Stop or in Continuous Run whenever the set point is within a specific range. Refer to Section 5.15 -- Range
Lock for additional information.
NOTE
The unit will remain in low speed until the engine coolant temperature reads 79°F (26°C) in Continuous Run Mode. High Speed Delay can be changed from OFF or from 1 to 255 minutes.
Refer to Functional Parameters in Section 3.16.
4--5 62-10683
4.4
SPEED CONTROL OVERRIDES
NOTE
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 Low Speed besides how far the refrigerated compartment temperature is away from set point. 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:
a. High Ambient:
If ambient temperature is 120°F (48.9°C) or above, the unit will run in low speed for a minimum of 2 minutes and until the ambient drops below 110°F (43.3°C). This
applies to Heat and Cool modes only -- not Defrost.
b. Low Suction Pressure/High Discharge Pressure:
If UL1 has been energized (unloaded) and the suction pressure is less than 0 PSIG/Bar for at least 30 seconds or the discharge pressure is greater than 435
PSIG (29.6 Bars) for more than five seconds, the engine will be forced to run in low speed for a minimum of five minutes. After five minutes, the engine can return to high speed if suction pressure is greater than 5 PSIG
(0.34 Bar) for 30 seconds or discharge pressure is less than 410 PSIG (28.0 Bar) for 30 seconds.
c. 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).
The engine will run in low speed (while the engine warms up) until the coolant is above 79_F (26°C).
d. Defrost:
The unit Is generally in High Speed but will run in low speed during Stage 1 (pump--down mode) of High
Ambient Defrost. It will also run at low speed at the end of the defrost cycle when the clutch is re--engaged
e. Door/Remote Switch Configurable for Low
Speed Alarm:
The unit will be forced into low speed if the (optional) door switch, Remote Switch 1, or Remote Switch 2 alarm is active and is configured for the unit to operate in
Low Speed when the door is open
f. Cargo Protect Mode:
If the setpoint is in the frozen range i.e. below
+10.4°F (-12°C), and both RAT and SAT sensor alarms are active, the unit will run in low speed cool.
g. Frozen Setpoint:
If the setpoint is in the frozen range i.e. below
+10.4°F (--12°C), and the refrigerated compartment temperature is below setpoint, the unit will run in low speed
h. High Air Flow:
For Perishable setpoints, the AIR FLOW Functional
Parameter will force the unit to operate in continuous
High Speed operation when AIR FLOW: HIGH is selected. (When AIR FLOW: NORMAL is selected, the unit will cycle normally between high and low speeds.)
High Air is NOT available for setpoints in the frozen range i.e. below +10.4°F (--12°C).
i. Product Shield High Air:
The engine is forced to High Speed if Product Shield
High Air Configuration is set to “ON” and the ambient temperature falls outside the selected range and the temperature difference between the supply air and the return air is greater than the selected value (Refer to
Section 5.16 for more information on Product Shield).
j. Adjustable High Speed Delay on Engine Start-up:
Whenever the engine starts, the unit will remain in low speed according to the selection made in the
Functional Parameter list for High Speed Delay for
Continuous or Start--Stop modes. A different setting is allowed for each mode.
(Refer to Functional
Parameters, Section 3.16. for additional information)
k. Start-Stop Frozen Range:
In Start--Stop Mode with the setpoint in the frozen range i.e. below +10.4°F (--12°C) and minimum run time has expired and the refrigerated compartment temperature is not yet down to setpoint, the engine will be forced to high speed operation.
l. High Speed Delay: When operating in low speed, there is a delay when switching to high speed. The default delay is one minute. Refer to Configuration
Mode, Section 6.2.
Whenever the unit is operating in low speed, there may be a delay before switching to high speed. This delay is selected in the Configuration List. (Refer to
Configuration Mode, Section 6.2. )
62-10683 4--6
SECTION 5
TEMPERATURE CONTROL
PARAGRAPH NUMBER
5.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2
PERISHABLE AND FROZEN SET POINT RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
PULLDOWN / PULL-UP MODE
5.4
HEAT MODE OPERATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5
COOL MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6
UltraFresh 3 TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.1 Heat/Cool/Null Switching Operation
5.6.2 Null Mode Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7
UltraFreeze TEMPERATURE CONTROL
5.7.1 UltraFreeze Offset
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.2 UltraFreeze Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8
FreshProtectt SUPPLY AIR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9
CARGO PROTECT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10 ENGINE SPEED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11 DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.1 Evaporator Temperature Criteria For Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.2 Defrost Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.3 Normal Defrost Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.4 Normal Defrost Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.5 Normal Defrost Termination Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.6 High Ambient Defrost Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.7 High Ambient Defrost Termination Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.8 High Ambient Defrost Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.9 High Ambient Defrost Termination Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.12 UNLOADER CONTROL OPERATION
5.13 SV1 OPERATION :
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.14 SV2 OPERATION : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.15 TEMPERATURE RANGE LOCK 1 & 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.16 ProductShield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.16.1 ProductShield Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.17 UNLOADER CONTROL OVERRIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.18 MAXIMUM SUCTION OPERATING PRESSURE (COOL ONLY) . . . . . . . . . . . . . . . . . . . . .
5.19 MAXIMUM OPERATING PRESSURE (MOP) OVERRIDE
(HEAT AND DEFROST ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.20 SUCTION PRESSURE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
5--11
5--11
5--11
5--12
5--14
5--14
5--18
5--19
5--10
5--10
5--11
5--11
5--8
5--9
5--9
5--9
5--5
5--8
5--8
5--8
5--4
5--4
5--4
5--5
5--2
5--3
5--3
5--4
5--1
5--1
5--2
5--2
5--19
5--20
1
SECTION 5
TEMPERATURE CONTROL
5.1 INTRODUCTION
Temperature control is achieved by controlling engine speed, compressor UL1 and UL2 unloaders, and solenoid valves (SV1, SV2, SV4, and the CSMV).
Temperature control attempts to maintain the compartment temperature at the chosen set point. At times the compartment temperature may not be equal to the set point. This may be due to:
•the unit is still in the process of pulling down or up to set point OR
•the unit is in Start--Stop OFF mode
•the unit has recently terminated defrost
•the compartment door is open
•the product was not at set point when loaded
5.2 PERISHABLE AND FROZEN SET POINT RANGES
There are two ranges defined for set point.
a. Setpoints above +10.4°F (-12°C) are considered Perishable.
b. Setpoints of +10.4°F (-12°C) or below are considered Frozen.
Temperature Control
High Air Flow
Start/Stop Off Cycle
Start/Stop Restart
Cargo Protect Mode (Both RAT and
SAT sensor alarms are active.)
Perishable
When the compartment temperature is near setpoint, the unit will cycle from Heat to Cool to Heat to maintain temperature.
Continuous High Air Functional Parameter is Available
ProductShield High Air is Available
Compartment temperature criteria is satisfied when the temperature is
0.5°F (0.3°C) above or below setpoint.
Unit will restart when compartment temperature is above or below setpoint by the restart value. Restart value during the Minimum Off Time is the Override Temperature selected in the Functional parameter list. Restart value following the Minimum Off Time is 3.6F (2.0C).
Unit will shut down.
Frozen
When the compartment temperature is near setpoint, the unit will operate in Cool with UltraFreeze operating at compartment temperatures more than 3°F (1.7°C) below setpoint.
Continuous High Air Flow is not allowed when the compartment temperature is less than 3.2F (1.8C) above setpoint.
ProductShield High Air is available.
Compartment temperature criteria is satisfied when the temperature is within 0.5°F (0.3°C) above setpoint.
Unit will restart when compartment temperature is above setpoint by the restart value. Restart value during the Minimum Off Time is the
Override Temperature selected in the Functional parameter list. Restart value following the Minimum
Off Time is 3.6F (2.0C).
Unit will operate in low speed six cylinder cool.
5--1 62-10683
5.3 PULLDOWN / PULL-UP MODE
During pulldown mode the unit will run in high speed and high speed capacity (unless there is a high speed override --
Refer to Section 4.4)
5.3.1 Pulldown or Pull-up will be initiated in any of the following conditions:
a. At engine start b. Set point change c. Operational mode change such as: Start-Stop, Continuous Operation d. Defrost termination e. If the system is running in Start-Stop Run Mode, the minimum run time has expired, and other conditions for shutdown are met except that the compartment temperature has not reached set point.
f. Pretrip termination
5.3.2 Pulldown or Pull-up will end in the following conditions: a. For Continuous Run Mode:
•When the RAT and SAT are equally spaced above and below set point AND (
SAT - RAT
2 points below 65°F (18.4_C), AND both supply and return air sensors are good.
) equals set point for set
b. For START-STOP Mode:
When the selected Control Probe Temperature is within ± 0.5°F (0.3°C) of set point.
NOTE
When the system leaves Pulldown (COOL) or Pull--up (HEAT) modes, it will enter UltraFresh 3 temperature
Control Mode (see Section 5.6) when the set point is between +10.4°F and 65°F (--12°C to 18.4°C). For set points at or below +10.4°F (--12°C), the unit will operate in COOL and UltraFreeze (see Section 5.6). For set points above 65°F (18.4°C), the unit will operate in COOL, HEAT and PULSED NULL modes but will not operate in UltraFresh 3.
5.4 HEAT MODE OPERATION
In HEAT Mode, the microprocessor will operate the unit controls as follows:
SV1 SV2 SV4 Engine Speed
Clutch
Output
UL1
CLOSE
Refer to SV2
Operation
OPEN
Refer to
Section 5.10
ENGAGE
Refer to UL1
Operation
UL2
Refer to UL2
Operation
CSMV
100%
Open
HEAT mode is not used for frozen set points.
5.5 COOL MODE OPERATION
In COOL Mode, the microprocessor will operate the unit controls as follows:
SV1 SV2 SV4 Engine Speed
OPEN OPEN CLOSE Refer to Section
Clutch
Output
ENGAGE
UL1
Refer to UL1
Operation
UL2
Refer to UL2
Operation
CSMV
Refer to
CSMV Control
NOTE
The CSMV maintains the maximum suction pressure of the refrigeration system. The selected controlling sensor determines if the unit is running in high speed or low speed and six or four or two cylinders. The controlling sensor may be RAT or SAT depending if the the microprocessor is configured for Return Air Control or
Supply Air Control. Refer to Chart in Section 5.18 for maximum suction pressure limits during each mode of operation in Cool Mode.
62-10683 5--2
5.6 UltraFresh 3 TEMPERATURE CONTROL
UltraFresh 3 is an advanced method of temperature control for set points in both Perishable and Frozen ranges. It produces a reduced capacity state by: throttling down the CSMV and pulsing the SV4 valve (SV4 Pulse Mode), or mixing heating and cooling modes (Pulsed Null Mode).
UltraFresh 3 uses the supply or return air sensor to control compartment temperature, while insuring that the supply air temperature does not get too cold when a perishable set point is chosen.
The sensor that is selected under the Functional Parameters for temperature control is shown below as the selected probe. The Temperature Control Probe is the sensor actually used by the microprocessor to perform the temperature control. In the case of a bad probe, the remaining probe will be used for temperature control. If both probes are bad the unit will run in Cargo Protect Mode.
SELECTED PROBE
Return Air Sensor
TEMPERATURE CONTROL PROBE
Return Air Sensor -- for perishable and frozen set points
Supply Air Sensor for perishable set points
Supply Air Sensor
Return Air Sensor for frozen set points
5.6.1 Heat/Cool/Null Switching Operation
There are three possible modes for UltraFresh 3 control temperatures. These are HEAT, COOL and NULL. (Refer to
Sections 5.4 and 5.5 for descriptions of HEAT and COOL modes.) When not in pulldown, UltraFresh 3 controls the unit based on the following: (Refer to the temperature control operating sequence diagrams).
a. To exit NULL and enter COOL while in Continuous Run, the control temperature must be greater than or equal to
3.6°F (2_C) above set point.
b. To exit NULL and enter COOL while in Start--Stop, the control temperature must be greater than or equal to 1.8°F
(1_C) above set point.
c. To exit COOL and enter NULL while in either Continuous Run or Start--Stop, the control temperature must be less than 1.5°F (0.8_C) above set point.
d. To exit NULL and enter HEAT, the control temperature must be more than or equal to 1.8°F (1_C) below set point.
e. To exit heat and enter NULL the control temperature must be less than 1.5°F (0.8_C) below set point.
5--3 62-10683
5.6.2 Null Mode Operation
Null Band consists of:
a. Pulsed Null Mode Operation
Reduced capacity is produced between the HEAT and COOL Modes by a mode known as Pulsed-Null. This mode is not a constant operating mode, but only operates for a few seconds at a time. During Pulsed-Null, the HEAT and
COOL valves are opened simultaneously to reduce either the heating or cooling capacity. In the Null Mode (Refer to the following charts), the unit will pulse between COOL and NULL, or HEAT and NULL in 10 second increments. The capacity in the NULL Mode is varied by adjusting the pulse rate.
• Cool Mode
SV1 SV2 SV4
Engine
Speed
Clutch
Output
OPEN OPEN CLOSED LOW ENGAGE
UL1
UNLOAD
UL2
UNLOAD
CSMV
Refer to CSMV Control
• Null Mode
SV1 SV2 SV4
Engine
Speed
Clutch
Output
OPEN OPEN OPEN LOW ENGAGE
UL1
UNLOAD
UL2
UNLOAD
CSMV
Refer to CSMV Control
• Heat Mode
SV1 SV2
CLOSED
Refer to SV2
Operation
Section
5.14
SV4
Engine
Speed
Clutch
Output
OPEN LOW ENGAGE
UL1
UNLOAD
UL2
UNLOAD
CSMV
Refer to CSMV Control
Pulsed Null Mode operation will modify the length of each Mode in 10 second cycles. That is, if the unit is in the COOL
NULL Pulse band, the unit may run in COOL for up to nine seconds, then NULL for one second, if the Control
Temperature is away from set point. As the Control Temperature comes closer to set point, the length of COOL time will decrease, and the amount of NULL time will increase. However, the combination of the two will always equal 10 seconds. The same is true for the HEAT NULL Pulse band.
b. CSMV Control:
The CSMV will automatically go to 30% when it enters Ultra Fresh 3 at 1.5°F (-- 0.8°C) above set point. The CSMV will usually control between 30% and 4% depending on the controlling probe and Suction Pressure. However, it can go above 30% for short periods of time. For example, high ambients and low set points may cause the CSMV to open higher than 30%.
5.7 UltraFreeze TEMPERATURE CONTROL
For frozen setpoints, a modified UltraFresh 3 temperature control is used to keep the unit from over cooling and driving the box temperature far below setpoint. UltraFreeze operates similar to UltraFresh 3 except as noted in this section.
UltraFreeze control will be used anytime a frozen setpoint is selected in both continuous and start/stop operation.
When UltraFreeze is active it is normal to hear the refrigerant solenoid valves energize and de--energize every few seconds.
5.7.1 UltraFreeze Offset
In UltraFreeze the unit will control the box temperature between setpoint and up to 3° F (1.6° C) below setpoint while the unit is running.
5.7.2 UltraFreeze Start/Stop
In start/stop operation the micro will control to setpoint by cycling the unit off when the box temperature is within 0.5° F
(0.3° C) of setpoint. Should the unit be required to continue to run after the box temperature is satisfied -- due to either low battery voltage or low engine coolant temperature -- the UltraFreeze logic will control to the 3° F (1.6° C) below setpoint offset until all conditions for an off cycle are met and the unit cycles off.
For frozen set points, a modified UltraFresh 3 temperature control is used to keep the unit from over cooling and driving the compartment temperature far below set point. Except as noted in this section UltraFreeze operates the same as
UltraFresh. UltraFreeze control will be used anytime a frozen set point is selected in either continuous or Start--Stop operation.
62-10683 5--4
5.8 FreshProtect
t
SUPPLY AIR CONTROL
FreshProtect operates between set points of +32.0°F (0° C)and 65.1°F (18.4° C) only.
When the unit is operating in Start-Stop, FreshProtect is only functional after the Return Air Temperature is within
0.5 °F of set point, and criteria for shutdown other than compartment temperature has not yet been reached.
When the unit is operating in Continuous Run, FreshProtect becomes functional once the Return Air Temperature
(RAT) is approximately 10°F (5.6°C) above setpoint.
NOTE
FreshProtect only operates when the unit is set for Return Air Control. (See Table 3-3 for more information on setting controls.) It does not operate when the unit is in Supply Air Control nor when the unit is in
Heat or Defrost cycles.
FreshProtect places a flexible limit on how far below setpoint the SAT can drop while the unit is operating in Cool Mode.
Table 4-2 below shows the functional parameter settings and the corresponding ranges below setpoint that the Supply
Air Temperature can go, when the RAT is 10°F (5.6°C) or less above setpoint. Whenever the RAT is more than 10°F
(5.6°C) above setpoint, it is possible for the SAT to be lower than the shown range since the air temperature within the cargo area is a considerable distance from its desired point and additional cooling capacity is required.
Table 4-2: FreshProtect
For Return Air Temperatures less than 10°F (5.6° C) above set point.
FreshProtect Setting Supply Air Range
(Below Setpoint)
A
B
C
D
E
OFF
2 TO 5°F (1.1 TO 2.8°C)
4 TO 7°F
(
2.2 TO 3.9
°C
6 to 9°F (3.3 TO 5.0° C
8 to 11°F (4.4 TO 6.1 ° C
10 to 13°F (5.6 TO 7.2° C)
NO LIMIT
The process of refrigeration causes the cargo area air to be drawn into the Return Air inlet of the evaporator section.
From there it is directed through the evaporator coil, where it is cooled off, then discharged through the Supply Air blower housing, and back into the cargo area. The warmer the Return Air temperature is in relationship to setpoint, the more cooling capacity is needed to bring the air temperature down to setpoint. As cooling capacity is increased, the
Supply Air temperature drops, as additional heat is removed from the air. If left uncontrolled, the Supply Air temperature can fall as much as 20°F (11.1°C) or more below the Return Air temperature.
When the RAT approaches setpoint, the SAT will also approach setpoint. The SAT may then be closer to setpoint than shown in Table 4-2.
When FreshProtect is set for OFF, the system runs with FreshProtect off, and the SAT will operate as far below setpoint as needed to bring the RAT to setpoint as quickly as possible. All other FreshProtect settings enable
FreshProtect Supply Air Temperature control, and the controller watches the Supply Air Temperature as well as the
Return Air Temperature while the system is operating in the Cool Mode.
5.9 CARGO PROTECT MODE
When both the return air sensor (RAT) alarm and the supply air sensor (SAT) alarm are active, the unit will enter Cargo
Protect Mode for temperature control. When the set point is in the frozen set point range, the unit will run low speed loaded cool. WARNING:NO TEMP CONTROL will be displayed in the MessageCenter. The unit will shutdown when the set point is in the perishable range. (See section 5.2 for definition of perishable & frozen set points).
5--5 62-10683
Note: The following temperature control operating sequence diagrams are after pulldown and do not show overrides.
+3.2_F (+1.8_C )
+2.3_F (+1.3_C )
+1.5_F (+0.8_C )
High Speed
6 Cylinder Cool
Low Speed
6 Cylinder Cool
Low Speed
2 Cylinder Cool
RISING BOX
TEMPERATURE
+3.6_F ( +2.0_C )
+2.7_F (+1.5_C )
Setpoint
UltraFresh 3
Low Speed
2 Cylinder Null
Setpoint
-1.5_F (-0.8_C)
-1.8_F (-1.0_C)
-2.7_F (-1.5_C )
-3.6_F (-2.0_C )
Low Speed
2 Cylinder Heat
Low Speed
6 Cylinder Heat
High Speed
6 Cylinder Heat
-2.3_F (-1.3_C )
-3.2_F (-1.8_C )
FALLING BOX
TEMPERATURE
Note: System can change from Low Speed 2 Cylinder Cool to Low Speed 6 Cylinder Cool when the box temperature rises. However, once the unit enters UltraFresh 3 Mode, it will remain in that
mode until the box temperature rises to 3.6° F (2.0° C) above setpoint at which point it will go to High
Speed 6 Cylinder Cool
Figure 5--1. Continuous Run Temperature Control Operating Sequence -- Perishable Range
RISING BOX
TEMPERATURE
+3.2_F (+1.8_C )
+2.3_F (+1.3_C )
High Speed
6 Cylinder Cool
Low Speed
6 Cylinder Cool
+3.6_F ( +2.0_C )
+2.7_F (+1.5_C )
Setpoint
FALLING BOX
TEMPERATURE
UltraFreeze
2 Cylinder Cool/Null
Setpoint
62-10683
Figure 5--2. Continuous Run Temperature Control Operating Sequence -- Frozen Range
5--6
+3.2_F (+1.8_C )
+2.3_F (+1.3_C )
High Speed
6 Cylinder Cool
Low Speed
6 Cylinder Cool
Low Speed
2 Cylinder Cool *
RISING BOX
TEMPERATURE
+3.6_F ( +2.0_C ) **
+2.7_F (+1.5_C )
+0.5_F (+0.3_C )
Setpoint
Start/Stop
Off Cycle
Setpoint
-0.5_F (-0.3_C)
Low Speed
2 Cylinder Heat
-2.3_F (-1.3_C )
-2.7_F (-1.5_C )
Low Speed
6 Cylinder Heat
-3.2_F (-1.8_C )
-3.6_F (-2.0_C )
High Speed
6 Cylinder Heat
-- 100%
FALLING BOX
TEMPERATURE
* Once the Minimum Run Time has expired, the compressor will operate in 6 cylinders, depending on suction pressure
** During the Minimum Off Time, the unit will restart at Override Temperature selected in the
Functional Parameter List.
Note: System can change from Low Speed 2 Cylinder Cool to Low Speed 6 Cylinder Cool when the box temperature rises. However, once the unit enters UltraFresh 3 Mode, it will remain in that
mode until the box temperature rises to 3.6° F (2.0° C) above setpoint at which point it will go to High
Speed 6 Cylinder Cool
Figure 5--3. Start-Stop -- Temperature Control Operating Sequence -- Perishable Range
RISING BOX
TEMPERATURE
+3.2_F (+1.8_C )
High Speed
6 Cylinder Cool
Low Speed *
6 Cylinder Cool
+3.6_F ( +2.0_C ) **
+0.5_F (+0.3_C )
Setpoint
Start/Stop Off Cycle
Setpoint
FALLING BOX
TEMPERATURE
* Once the Minimum Run Time has expired, the compressor will operate in 6 cylinders, depending on suction pressure
** During the Minimum Off Time, the unit will restart at Override Temperature selected in the
Functional Parameter List.
Figure 5--4. Start-Stop -- Temperature Control Operating Sequence -- Frozen Range
5--7 62-10683
5.10 ENGINE SPEED OPERATION
The engine will operate the compressor at two different speeds (low and high). Speed Control is based on the differences of Controlling Temperature and set point as follows:
Mode
COOL
HEAT
HIGH SPEED
Control Temp is more than 3.6_F (2.0_C) above setpoint
Control Temp is more than 3.6_F (2.0_C) below setpoint
No
LOW SPEED
Control Temp is less than 3_F (1.8_C) above setpoint
Control Temp is less than 3_F (1.8_C) below setpoint
Always NULL
NOTE
For X2 units only -- When the ambient air temperature reaches 120°F (48.9°C), the engine will go to low speed for a minimum of two minutes, and until the ambient air temperature drops below 110°F (43.3°C).
5.11 DEFROST
Defrost is an independent cycle overriding cooling and heating functions in order to de-ice the evaporator as required.
When the unit is in Defrost, the DEFROST LED will be on, the MessageCenter will display DEFROST CYCLE STARTED for the first 5 seconds, then the default message will be displayed for the rest of the Defrost Cycle. The compartment temperature section of the Main Display will show “dF”. The set point will continue to be displayed on the left side.
Compartment temperature will not be displayed during Defrost. The CSMV will always be 100% open during Defrost Mode.
NOTE
The unit will operate in high speed in the defrost mode except during pump down in high ambient defrost.
5.11.1 Evaporator Temperature Criteria For Defrost
Before a defrost cycle can be initiated, DTT (Defrost Termination Temperature sensor) and SAT (Supply Air
Temperature sensor) must be below 40_F (4.4_C) OR SAT must be below 45°F (7.2°C). If the DTT2and SAT alarms are active, then the RAT (Return Air Temperature sensor) must be below 45°F (7.2°C).
5.11.2 Defrost Initiation
When one of the applicable criteria is met, defrost may be initiated by any of four different methods: a. Defrost Interval Timer: The microprocessor contains an internal Defrost Timer (adjustable in the Functional Parameter list) which can be set using the keyboard (Refer to Section 3.16 Functional Change) or the ReeferManage PC
Program. The Defrost Timer may be set for 1.5, 3.0, 6.0, or 12.0 hour intervals. When the unit has run for the selected amount of time, a defrost cycle will be initiated if the evaporator temperature criteria as defined in Section 5.11.1
have been met. .The Defrost Timer is reset to zero whenever a defrost cycle ends(regardless of how it was initiated), and begins counting down until the next defrost cycle. The microprocessor holds in memory the last entered Defrost
Timer interval.
The Defrost Timer only counts time when the engine and compressor are running and evaporator temperature criteria as defined in Section 5.11.1 have been met. When the START/RUN--OFF switch is placed in the OFF position, the defrost timer will be reset to zero. Units running in Start--Stop will not increment the timer during off cycles. For this reason, the defrost timer can not attempt to initiate a defrost cycle during an OFF cycle. However, it is possible that the unit will go into a defrost cycle very shortly after restarting from a Start--Stop OFF Cycle, if the timer expires at that point.
b. Defrost Air Switch: A Defrost Air Switch (DAS) measures the air restriction through the evaporator coil. As ice forms and builds up, the air flow is restricted. Once enough ice builds up, the switch contacts will close, and initiate a defrost cycle f the evaporator temperature criteria as defined in Section 5.11.1 have been met. The Defrost Air Switch requires periodic testing and calibration. (Refer to Section 9.25.2) In the case where the switch is out of adjustment, it will either not put the unit into defrost as soon as needed, or it will attempt to put the unit into defrost prematurely. In the first case, the defrost timer will help correct any icing problem.
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 grill can also cause the Defrost Air Switch contacts to close.
When looking at a unit for a Defrost Air Switch problem, be sure to also inspect the condition and cleanliness of the evaporator coil, and the return air area.
c. Manual Defrost : The Defrost cycle may be started at any time (providing that evaporator temperature criteria as defined in Section 5.11.1 have been met) by pushing the MANUAL DEFROST key (Refer to Section 3.10).
62-10683 5--8
5.11.3 Normal Defrost Operation
SV1 SV2
CLOSE
(energized)
Refer to SV2
Operation
SV4
OPEN
(energized)
SCS
HIGH
Clutch Output
DISENGAGE
(de--energized)
UL1
LOAD
(de--energized)
UL2
LOAD
(de--energized)
CSMV
100%
Open
When the ambient air temperature is greater than 35°F (1.7°C) the compressor discharge pressure will be monitored during the defrost cycle:
NOTE
If the Ambient Air temperature is below 80_F (26.7_C) the Normal Defrost Operation will be used. When the Ambient Air temperature is above 80°F (26.7_C), the High Ambient Defrost Operation will be used .
If the discharge pressure rises to 340 psig (23.1 Bar), UL1 will energize and unload for the remainder of the defrost cycle.
If the discharge pressure rises to 350 psig (23.8 Bar), the SV1 valve will de--energize (open) for 1 second to reduce the discharge pressure. If the discharge pressure remains at 350 psig (23.8 Bar), the SV1 valve may de--energize (open) again ad much as twice a minute.
5.11.4 Normal Defrost Termination
Defrost Termination: Defrost will be terminated once any of the following conditions are met: a. When the defrost termination temperature (DTT) and Supply Air Temperature (SAT) are both above 55_F
(12.8_C) and the sensors are working properly. If both DTT and SAT sensors are bad, then defrost will terminate in
10 minutes. A sensor alarm indicates that the sensor is bad.
b. A54 -- DEFROST NOT COMPLETE ALARM. The microprocessor also has a Defrost Cycle Timer which monitors the total time of the Defrost cycle. This is the amount of time that the system is actually defrosting. This timer starts every time a Defrost Cycle is initiated and it keeps track of the time that the system is actually defrosting. If the
Defrost cycle does not complete within 45 minutes, the following will occur:
• The Defrost cycle will be terminated.
• Defrost Override timer is activated which will initiate another defrost cycle in 1.5 hours regardless of the standard
Defrost Timer setting.
• A54 DEFROST NOT COMPLETE Alarm will be activated
NOTE
If the Defrost Air Switch (DAS) contacts are still closed at defrost termination or if the DAS calls for a defrost cycle within eight minutes of the previous defrost cycle termination in two consecutive defrost cycles, the following will occur:
• The Defrost Air Switch (DAS) is ignored for defrost initiation until the unit has completed another defrost cycle in which the DAS contacts were open at termination. (The manual defrost switch can always start a new Defrost cycle.)
• A55 CHECK DEFROST AIR SWITCH Alarm is activated.
• A Defrost Override timer is activated which will initiate another defrost cycle in 1.5 hours regardless of the standard
Defrost Timer setting.
5.11.5 Normal Defrost Termination Sequence
The following sequence will be used to perform a transition from defrost to normal temperature control: a. The microprocessor will place the engine in Low Speed and Open (de-energize) SV1 and Open (energize) SV2 and
SV4.
b. The microprocessor will return the CSMV to the same % it was prior to the initiation of defrost.
c.The SV4 will close (de-energize) .
d. After a few seconds the Clutch will be engaged (energized). There will be a short delay before the engine can return to High Speed.
e. At this point, the microprocessor will return to normal temperature control. (The data recorder will record a Defrost
Termination Event)
5--9 62-10683
5.11.6 High Ambient Defrost Operation
NOTE
If the Ambient Air temperature is below 80_F (26.7_C) then the Normal Defrost Operation will be used. When the
Ambient Air temperature is above 80°F (26.7_C), the High Ambient Defrost Operation will be used.
If the discharge pressure rises to 340 psig (23.1 Bar), UL1 will energize and unload for the remainder of the defrost cycle.
If the discharge pressure rises to 350 psig, the SV1 valve will de--energize (open) for 1 second to reduce the discharge pressure. If the discharge pressure remains at 350 psig (23.8 Bar), the SV1 valve may de--energize
(open) again ad much as twice a minute.
The High Ambient Defrost Cycle has three separate modes: a. Pump Down Mode -- The Pump Down Mode pumps the low side of the refrigeration system down to a lower suction pressure, and reduces the engine load normally seen at the beginning of a Defrost Cycle.
SV1
OPEN
(de--energized)
SV2
CLOSE
(de--energize)
SV4
CLOSE
(de--energize)
Engine
Speed
LOW
(de--energize)
Clutch
Output
ENGAGE
(energized)
UL1
UNLOAD
(energized)
UL2
UNLOAD
(energized)
CSMV
100% Open
The unit will remain in the Pump Down Mode until the following conditions are met:
• A minimum of 30 seconds, and the suction pressure is less than 10 PSIG (0.68 Bar) or
OR
• A maximum of 5 1/2 minutes, regardless of suction pressure.
b. High Ambient Defrost Mode -- Following the Pump Down Mode, the Defrost Cycle will begin. The unit controls will be opened/closed as follows:
SV1 SV2
CLOSE
(energized)
Refer to SV2 Operation
SV4
OPEN
(energized)
Engine
Speed
HIGH
(de--energized)
Clutch
Output
DISENGAGE
(de--energized)
UL1
UNLOAD
(de--energized
UL2
LOAD
(energized)
CSMV
100% Open c.High Ambient Defrost Termination -- Once the Defrost Termination Temperature Sensor (DTT) and Supply Air Temperature (SAT) reach 55_F (12.8°C), the high ambient defrost cycle will terminate.
5.11.7 High Ambient Defrost Termination Sequence
The following sequence will be used for High Ambient Defrost Termination.
• The unit will remain in High Speed and will reset the CSMV position to the position it was in at the start of defrost.
• The microprocessor will open (de-energize) SV1 and open (energize) SV2 and unload (energize) UL1.
•
When suction pressure has risen 10 PSIG (0.7 Bar) above start point or after 15 seconds, the microprocessor will place the unit in Low Speed, close (de--energize) SV4, and unload (energize) UL2.
• After 5 seconds, the clutch will be engaged.
• After an additional 5 seconds, the microprocessor will return to normal temperature control. (The data recorder will record a Defrost Termination Event)
NOTE
If the Ambient Air temperature is below 80_F (26.7_C) then the Normal Defrost Operation will be used. When the
Ambient Air temperature is above 80°F (26.7_C), the High Ambient Defrost Operation will be used.
62-10683 5--10
5.11.8 High Ambient Defrost Termination
Once the Defrost Termination Temperature Sensor (DTT) and Supply Air Temperature (SAT) reach 55_F (12.8°C), the defrost cycle will terminate.
5.11.9 High Ambient Defrost Termination Sequence
The following sequence will be used for High Ambient Defrost Termination.
a.The unit will remain in High Speed and will reset the CSMV position to the position it was in at the start of defrost.
b.The microprocessor will open (de-energize) SV1 and open (energize) SV2 and unload (energize) UL1.
c.When suction pressure has risen 10 PSIG (0.68 Bar) above start point or after 15 seconds, the microprocessor will place the unit in Low Speed, close (de--energize) SV4, and unload (energize) UL2.
d.After 5 seconds, the clutch will be engaged.
e.After an additional 5 seconds, the microprocessor will return to normal temperature control. (The data recorder will record a Defrost Termination Event)
NOTE
Refer to Section 2.15 for more on the defrost mode.
5.12 UNLOADER CONTROL OPERATION
To “LOAD,” or de-energize, a compressor unloader increases the capacity of the system by increasing the number of cylinders pumping refrigerant in the compressor. To “UNLOAD,” or energize, a compressor unloader decreases the capacity of the system by decreasing the number of cylinders pumping refrigerant. Refer to Section 2.3.4 for more information on compressor unloaders.
Unloaders will use the differences of Controlling Temperature and set point, as follows:
Mode
COOL
(Perishable)
HEAT
COOL
(Frozen)
LOAD (de-energize) UL1 and UL2
Control Temp is more than 3.6_F (2_C) above setpoint
Control Temp is more than 2.7_F (1.5_C) below setpoint
Control Temp is more than 3.6_F (2_C) above setpoint
UNLOAD (energize) UL1 and UL2
Control Temp is less than 2.3_F (1.3_C) above setpoint
Control Temp is less than 2.3_F (1.3_C) below setpoint
Control Temp is less than 1.4_F (0.8_C) above setpoint
When the compressor is fully loaded, it is operating on six cylinders. When the front unloader UL1 is Unloaded (energized), the unit operates on four cylinders. When UL1 and the rear unloader UL2 are both unloaded (energized), the unit operates on two cylinders. UL2 always unloads before UL1.
5.13SV1 OPERATION :
The SV1 valve will be open (de--energized) whenever the system is operating in the Cool Cycle’s SV1 valve will be closed (energized) during Heat and Defrost Cycles. When the system is operating in the Defrost Cycle, and the Discharge Pressure reaches 350 PSIG (23.8 Bars) during Defrost, SV1 opens (de--energizes) for 1 second then closes
(energizes) again to help control Discharge Pressure.
5.14 SV2 OPERATION :
The SV2 valve will be open (energized) whenever the system is operating in the Cool Cycle. The SV2 valve will open and close during the Heat and Defrost Cycles to control Discharge and Suction pressures.
The following SV2 control is used during the Heat and Defrost cycles:
1. If the Discharge Pressure is greater than the SV2 closed value shown in the table below, SV2 is de--energized
(closed).
2. If the Discharge Pressure is less than the SV2 open value, SV2 is energized (open).
SV2 closed and open pressure settings are based on the model number as follows:
Model No.
Ultima XTC and X2 2500
Ultra XTC and X2 2100
SV2 OPEN
190 PSIG
(12.9 Bars)
200 PSIG
(13.6 Bars)
SV2 CLOSE
250 PSIG
(17 Bars)
300 PSIG
(20.4 Bars)
5--11 62-10683
5.15 TEMPERATURE RANGE LOCK 1 & 2 (See Figure 5--5. and Figure 5--6.)
The unit can be locked into Start-Stop or Continuous Run operation for various set points. Two independent ranges are available for selection. Each range can be set to lock the unit into either Start--Stop or Continuous Run based on the current set point
Each Range has its own selectable minimum and maximum temperatures, which define the span of the range. If some set point temperatures are contained in both ranges due to range overlap, the unit operation specified for Range 1 will always have priority over the unit operation specified for Range 2.
Typically, both Range 1 and Range 2 are used to control different set point ranges when the unit is not equipped with the IntelliSet option. For units with IntelliSet, because each IntelliSet is generally programmed for a specific product, only Range Lock 1 is used to hold the unit in either the Start--Stop or Continuous Run Mode, and Range Lock 2 is left
OFF.
For example, if Continuous Run operation is ALWAYS required whenever the set point is between +28°F and +55°F
(--2.2°C and 12.8°C), Range 1 will be set for Continuous Run, with a Range 1 Minimum Temperature of +28°F (--2.2°C) and a Range 1 Maximum Temperature of +55°F (12.8°C). Should Continuous Run operation ALWAYS also be required with set points between --22°F (--30°C) and 0°F (--17.8°C), then Range 2 will be set for Continuous Run, with a
Range 2 Minimum Temperature of --22°F (--30°C) and a Range 2 Maximum Temperature of 0°F (--17.8°C). Any set point outside of Range 1 or Range 2 will allow the user to change unit operation between Start--Stop and Continuous
Run.
62-10683 5--12
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
Figure 5--5. Range Lock 1
In the example shown in Figure 5--5. Range 1 or Range 2 can be changed to lock the unit operation into Start-Stop. It is primarily important to determine which range is to be Range 1 and which is to be Range 2 is when the ranges overlap.
In the example shown in Figure 5--6., the ranges will be set to lock all set points into Start-Stop, except for a small range between +32 and +42°F ( 0 and 5.6°C) during which the unit will always operate in Continuous Run. Range 1
Minimum Temperature will be set for +32°F (0°C), and Maximum Temperature of +42°F (5.6°C). Range 2 will be set for a Minimum Temperature of -22°F (-30°C) and a Maximum Temperature of +89.6°F (32°C).
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
-10
0
10 20
-1.1
30
4.4
10.0
15.6
40 50 60
21.1
26.7
70
80
Figure 5--6. Range Lock 2
5--13 62-10683
5.16 ProductShield
t
NOTE
ProductShield does not operate within Sleep Mode.
ProductShield is a group of configuration settings within the microprocessor that are available in all Advance Microprocessors that have the IntelliSet option installed. The ProductShield Modes work together with the various IntelliSets to allow improved operating efficiency while providing customized product protection for up to 31 different commodities.
Each ProductShield setting allows the user to select an ambient temperature range in which to operate. The Minimum and Maximum range values can be set to OFF, or any value from -20 to +119°F (-28.9 to +48.4°C ).
5.16.1 ProductShield Modes: a. ProductShield: Econo Go To Start--Stop and Go To Continuous Run
ProductShield Econo allows the unit to automatically switch from Start--Stop operation to Continuous run or vice versa based on a change in the ambient air temperature. This allows for maximum product protection while providing for fuel savings -- depending on ambient conditions.
1) When the unit is set for Continuous Run, ProductShield Econo allows the unit to cycle OFF in Start--
Stop when:
•
ProductShield Econo configuration is set to GO TO S/S (Refer to Section 6.2.1) AND
•
The unit has run in Continuous Run for a minimum of either 15 minutes or the Minimum Run Time as selected in the
Functional Parameter list (whichever time is longer) AND
•
The ambient temperature falls within the pre--programmed temperature range AND
•
The unit is not already running in ProductShield Winter mode which forces the unit to operate in Continuous Run only. (Refer to Section c. below) AND
•
All the normal criteria for a Start--Stop Off Cycle (box temperature at set point, engine coolant temperature, battery volts and charging amps) are met.
•
Optionally, if the Econo Delta--T configuration is set for a numerical value and not set to OFF, the operator can pre--program a maximum evaporator coil temperature differential (Delta--T) between the return air (1RAT) and supply air (1SAT) sensors as an additional criteria for switching to Start--Stop. In this case, the unit must bring the Delta--T below this pre--programmed setting before going to Start--Stop.
The product is probably cooled close to set point if the Delta--T is pre--programmed for a relatively low temperature [4 to 6°F (2.2 to 3.3°C)] and that setting has been reached. Reaching the low Delta--T setting is an indication that not much heat is being removed from the product in order to maintain the Return Air Temperature.
Setting the Delta--T for a higher value [8 to 27°F (4.4 to 15°C)]) or leaving the setting OFF enables the unit to cycle into an OFF cycle whether or not the unit is cooling at a higher capacity.
NOTE
In ProductShield Econo: Go to Start--Stop, the Delta-T must be lower than the value selected in order to enter
Start--Stop.
NOTE
If the unit is set for Continuous Run and ProductShield Econo is configured for GO TO CONTINUOUS or OFF, the unit will remain in Continuous Run.
62-10683 5--14
Once the microprocessor detects that the above criteria have been met, the unit will switch from Continuous Run to a
Start--Stop Off Cycle and remain Off for the Minimum Off Time as set in the Functional Parameter list. A restart will be initiated when one of the following four conditions occurs:
a) Normal restart 1: The Refrigerated Compartment Temperature Has Exceeded Selectable Override Temperature
The microprocessor continually monitors the refrigerated compartment temperature during the Minimum Off Time.
The unit will restart if the refrigerated compartment temperature goes beyond the Override Temperature (above or below set point in the perishable range or above set point in the frozen range). The Minimum Off Time and the Override
Temperatures are selected in the microprocessor Functional Parameter List (Refer to Section 3.17). The default value is 20 minutes for the Minimum Off Time and 11.0°F (6°C) for the Override Temperature.
b) Normal restart 2: The Refrigerated Compartment Temperature Has Exceeded Standard Override Temperature
After the Minimum Off Time has expired, the microprocessor continually monitors the refrigerated compartment temperature. If the refrigerated compartment temperature goes more than +3.6°F(+2.0°C) away from set point (above or below set point in the perishable range or above set point in the frozen range), the unit will restart. The Minimum Off
Time is selected in the microprocessor Functional Parameter List (Refer to Section 3.17). The default setting is 20 minutes.
c) Engine coolant temperature drops below 34_F (1_C).
If the Engine Coolant Temperature drops below 34°F (1_C), the unit will restart, and will run until all conditions for shutdown are met.
If Alarm 129 CHECK ENG COOLANT SENSOR 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. If the unit restarts due to this condition, the Minimum
Run Time will be at least 20 minutes, regardless of the setting in the Functional Parameter list.
d) Battery voltage falls below voltage selected in the configuration list. (See Section 6.2.1)
In some ambient conditions, there are times when the unit may be off for very long periods of time. To ensure that the load stays within safe temperature ranges, the Maximum Off Time may be used to force the unit to restart regardless of any change in refrigerated compartment temperature. Maximum Off Time is selected in the microprocessor
Functional Parameter List. The default setting is OFF.
When the unit restarts, it will return to Continuous Run operation for a minimum of 15 minutes or the Minimum Run
Time (as selected in the Functional Parameter list), whichever time is longer. The same ProductShield Econo: Go To
Start--Stop activation conditions must again be met in order for the unit to cycle OFF again. While the unit is running and the set point is between 32 and 65.1°F (0 and 18.4°C), the FreshProtect settings (as selected in the Functional
Parameter list) will be effective.
When ProductShield Econo Maximum Temperature is set for OFF, and ProductShield Econo Minimum Temperature is set for a temperature, the ambient air temperature will be considered to be “inside the range” whenever the ambient air temperature is higher than the Minimum Temperature setting, with no upper limit.
When ProductShield Econo Maximum Temperature is set for a temperature, and ProductShield Econo Minimum
Temperature is set for OFF, the ambient air temperature will be considered to be “inside the range” whenever the ambient air temperature is lower than the Max Temp setting, with no lower limit.
When ProductShield Econo Maximum Temperature is set for OFF, and ProductShield Econo Minimum Temperature is set for OFF, the ambient air temperature will be considered to be “inside the range” at any ambient air temperature.
ProductShield ECONO: GO TO START/STOP EXAMPLES
The following examples apply in situations where all other Start--Stop conditions have been met. (Refer to Section
4.3.1..)
1.
If the Econo Minimum Temperature is set to 30°F (-1.1°C) and the Econo Maximum Temperature is set to
40°F (4.4°C) and the ambient air temperature falls between these temperatures, the unit operation can change to
Econo Start--Stop.
2.
If the Econo Minimum Temperature is set to 30°F (-1.1°C) and the Econo Maximum Temperature is set to
OFF and the ambient air temperature is anywhere above 30°F (-1.1°C), the unit operation can change to Econo
Start--Stop.
3. If the Econo Minimum Temperature is set to OFF and the Econo Maximum Temperature is set to 40°F (4.4°C) and the ambient air temperature falls anywhere below 40°F (1.7°C), the unit operation can change to Econo
Start--Stop.
4. If both the Econo Minimum and Econo Maximum Temperatures are set to OFF, unit operation can change to
Econo Start--Stop at any ambient temperature.
5--15 62-10683
2) When the unit is set for Start--Stop, ProductShield Econo allows the unit to run in Continuous Run when:
•
ProductShield Econo configuration is set to GO TO CONTINUOUS (Refer to Section 6.2.1), AND
•
The unit has run in Start--Stop for a minimum of 15 minutes OR the Minimum Run Time, whichever is longer as set in the Functional Parameter list. (See Table 3-3) AND
•
The ambient temperature falls outside the pre--programmed temperature range.
NOTE
If unit is set for Start--Stop and ProductShield Econo is configured for GO TO START / STOP or OFF, the unit will remain in Start--Stop.
Once the microprocessor 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 Start--Stop when the ambient temperature has fallen within the pre--programmed temperature range by ±3.6°F (±2°C).
NOTE
Delta--T logic is not used or available when unit is configured for GO TO CONTINUOUS.
ProductShield ECONO: GO TO CONTINUOUS EXAMPLES
1. If the Econo Minimum Temperature is set to 0°F (-17.8°C) and the Econo Maximum Temperature is set to
90°F (32.2°C) and the ambient air temperature falls outside these temperatures, the unit operation can change to
Econo Continuous Run.
2. If the Econo Minimum Temperature is set to 0°F (-17.8°C) and the Econo Maximum Temperature is set to OFF and the ambient air temperature falls below 0°F (-17.8°C), the unit operation can change to Econo Continuous Run.
3. If the Econo Minimum Temperature is set to OFF and the Econo Maximum Temperature is set to 90°F
(32.2°C) and the ambient air temperature rises above 90°F (32.2°C), the unit operation can change to Econo
Continuous Run.
4. If both the Econo Minimum and Econo Maximum Temperatures are set to OFF, ProductShield Econo: Go To
Continuous can not operate because no range has been defined and it is therefore impossible for the ambient temperature to be outside of range.
62-10683 5--16
b. ProductShield: High Air
ProductShield High Air mode allows the unit to provide increased airflow by operating the engine in high speed. This generally results in a reduced Delta-T. This can maximize product protection under difficult conditions while allowing the unit to operate more efficiently during less demanding conditions.
When the Air Flow parameter (in the Functional Parameter list) is set for NORMAL, ProductShield High Air allows the unit to run as required -- either High Speed or Low Speed depending on:
•
How far the compartment temperature is away from set point AND
•
Speed Override Conditions -- Refer to Section 4.4
When the ambient temperature falls outside the pre--programmed temperature range, ProductShield High Air mode will be enabled, and the engine will go to high speed to provide high air flow within the refrigerated compartment.
The operator can also optionally pre--program a maximum evaporator coil temperature differential (Delta--T) between the return air (1RAT) and supply air (1SAT) sensors as an additional criteria for switching to ProductShield High Air.
When the Delta--T setting is used, the unit must bring the Delta--T above this pre--programmed setting before going to
High Air Mode. The Delta--T setting is used to prevent ProductShield High Air from operating when the heat load on the refrigeration unit is low.
NOTE
In ProductShield High Air, the Delta-T must be higher than the value selected in order to enter the mode.
ProductShield ECONO: HIGH AIR EXAMPLES
1. If the High Air Minimum Temperature is set to 0°F (-17.8°C) and the High Air Maximum Temperature is set to
90°F (32.2°C) and the ambient air temperature falls outside these temperatures, the unit operation can change to
High Air.
2. If the High Air Minimum Temperature is set to 0°F (-17.8°C) and the High Air Maximum Temperature is set to
OFF and the ambient air temperature falls below 0°F (-17.8°C), the unit operation can change to High Air.
3. If the High Air Minimum Temperature is set to OFF and the High Air Maximum Temperature is set to 90°F
(32.2°C) and the ambient air temperature rises above 90°F (32.2°C), the unit operation can change to High Air.
4. If both the High Air Minimum and High Air Maximum Temperatures are set to OFF, ProductShield Econo: High air can not operate as no range is defined and it is impossible for the ambient temperature to be outside of range.
If the unit shuts down in Auto Start--Stop during High Air, it will not be in 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.
c. ProductShield: Winter
When the unit is set for Start--Stop operation, ProductShield Winter allows it to switch to continuous run when the ambient air temperature falls below a pre--programmed temperature falling between 32 to --20°F (0 to --29°C). This helps protect the unit from the possibility of fuel gelling and other cold weather issues.
NOTE
When the unit is operating in Continuous Run, the unit will not switch into ProductShield Winter.
When the unit is operating in Start--Stop and the microprocessor detects that the ambient temperature has dropped below the pre--programmed temperature, the unit will switch into ProductShield Winter mode which will force the unit to operate in 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 if the ambient temperature has risen more than 3.6°F (2°C) above the pre--programmed ProductShield Winter temperature.
NOTE
All of the ProductShield settings may be viewed in the Data List (Refer to Section 3.14). For units with Intelli-
Sets, the Data List will reflect the ProductShield settings for the IntelliSet that is currently active.
5--17 62-10683
5.17 UNLOADER CONTROL OVERRIDES
The compressor unloaders will operate in either a de--energized (loaded) or energized (unloaded) position, depending on current operating conditions. The list below shows the conditions that will control the operation of the unloaders in addition to the unloader control used by the temperature control described in section 5.12.
There is a delay of 10 seconds between LOADING (de-energizing) compressor cylinders under all operating conditions except engine starting.
The overrides will be allowed in Cargo Protect Mode if the override does not use the return or supply temperature.
Unloader Overrides in priority order. If an override only applies or takes effect for one unloader, continue down the priority list for the other unloader:
a. High Ambient:
If the ambient temperature is above 120°F (48.9°C) when the engine starts UL1 and UL2 will both be unloaded for a minimum of 2 minutes and until the ambient air temperature drops below 110°F (43.3°C)
b. Mop Override, Maximum Operating Pressure Control:
UL1 and UL2 will be energized and de--energized based on Compressor Suction Pressure (CSP). Refer to MOP
Override Section 5.19
If the unit is operating in Defrost or in HEAT, the MOP Override can only UNLOAD the UL1. The UL2 must remain
LOADED.
c. Low Suction Pressure/High Discharge Pressure:
Unloading is used along with low speed to increase the suction pressure or decrease the discharge pressure.
These steps in capacity reduction are taken in the following order: 6--cylinder high speed to 4--cylinder high speed to
4--cylinder low speed to 2--cylinder low speed. Unloading will take place if the following conditions occur: discharge pressure is greater than 435 PSIG (29.6 Bars) for 5 seconds or suction pressure is less than 0 PSIG (0Bar) for 30 seconds.
Therefore, if the engine is running at high speed 6 cylinder operation and one of the conditions listed above occurs, the compressor will be unloaded from 6 to 4 cylinders (UL1 will be energized) and the engine will remain in high speed.
If the condition (discharge pressure greater than 435 PSIG or suction pressure less than 0 PSIG) does not change to at least a drop in discharge pressure to less than 410 PSIG or an increase in suction pressure to above 5 PSIG, the engine will shift to low speed and the compressor will remain running on 4 cylinders). If the condition still does not change, UL2 will energize and the compressor will operate on 2 cylinders, still in low speed operation. Once the engine shifts to low speed, or one or both of the unloaders energize due to these conditions the unit will remain in low speed, and the unloader(s) will remain energized for a minimum of 5 minutes.
d. Defrost: Refer to defrost control (Refer to Section 5.11).
In a Normal Defrost cycle, both unloaders will be loaded (de--energized).
In a High Ambient Defrost Cycle, both unloaders will be unloaded (energized) during the Stage 1 pumpdown mode. The remainder of the Defrost Cycle will have UL1 unloaded (energized) and UL2 loaded (de--energized).
e. Cargo Protect Mode:
If the setpoint is in the frozen range [below +10.4°F (-12°C)] and both RAT and SAT sensor alarms are active, the unit will run fully loaded (UL1 and UL2 de-energized).
f. Start/Stop Override:
If the system is running in Start/Stop--Run Mode, and the minimum run time has expired and the compartment temperature is not at setpoint, and the Return Air Temperature is less than 50°F (10°C), both unloaders will be
LOADED (de-energized) to increase the unit capacity so that set point may be reached more quickly, and allow an Off
Cycle.
g. Continuous Run Low Speed Null Mode: UL1 and UL2 will load and unload periodically as the control system makes adjustments in the system’s capacity to maintain compartment temperature when it is close to setpoint.
62-10683 5--18
5.18 MAXIMUM SUCTION OPERATING PRESSURE (COOL ONLY)
In Cool Mode, the CSMV is used to control Suction Pressure to these MAXIMUM operating limits determined by the compressor speed and number of loaded cylinders, as shown in the following table. Pressures may be lower depending on ambient and control temperatures, etc.
Table 4-3 Suction MOP
Model
Ambient Air Temperatures
below 108.5°F (42.5°C)
Ambient Air Temperatures
above 110.3°F (43.5°C)
6 Cylinders 4 Cylinders 2 Cylinders 6 Cylinders 4 Cylinders 2 Cylinders
Ultima XTC and X2 2500
High Speed
Ultima XTC and X2 2500
Low Speed
Ultra XTC and X2 2100
High Speed
Ultra XTC and X2 2100
Low Speed
25 PSIG
(1.7 Bars)
35 PSIG
(2.4 Bars)
31 PSIG
(2.1 Bars)
35 PSIG
(2.4 Bars)
40 PSIG
(2.7 Bars)
50 PSIG
(1.5 Bars)
50 PSIG
(1.5 Bars)
50 PSIG
(1.5 Bars)
76 PSIG
(5.2 Bars)
76 PSIG
(5.2 Bars)
76 PSIG
(5.2 Bars)
76 PSIG
(5.2 Bars)
19 PSIG
(1.3 Bars)
21 PSIG
(1.4 Bars)
20 PSIG
(1.4 Bars)
20 PSIG
(1.4 Bars)
30 PSIG
(2.0 Bars)
35 PSIG
(2.4 Bars)
40 PSIG
(2.7 Bars)
30 PSIG
(2.0 Bars))
70 PSIG
(4.8 Bars)
60 PSIG
(4.1 Bars)
70 PSIG
(4.8 Bars))
60 PSIG
(4.1 Bars)
5.19 MAXIMUM OPERATING PRESSURE (MOP) OVERRIDE
(HEAT AND DEFROST ONLY)
The microprocessor monitors the suction pressure of the refrigeration system and controls the unloaders to maintain a
Maximum Operating Pressure (MOP). The CSMV is always at 100% open in heat and defrost modes. A Compressor
Suction Pressure (CSP) transducer is used to provide this information to the microprocessor. This MOP is calculated based on suction pressure, ambient air temperature, and mode of operation. From this the microprocessor will be able to determine the system load. The system load will correspond to a maximum horse power, discharge pressure and coolant temperature which the unit can operate within. By overriding temperature control and unloading cylinder banks on the compressor, these conditions can be maintained at the appropriate levels.
When the compressor is fully loaded it is operating on six cylinders. When the front unloader UL1 is UNLOADED
(energized), the unit operates on four cylinders. When UL1 and the rear unloader UL2 are UNLOADED (energized), the unit operates on two cylinders. The front unloader, UL1, always unloads before the rear unloader, UL2.
5--19 62-10683
5.20 SUCTION PRESSURE OPERATION
5.20.1 Directions For Reading the Chart Below
a. 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 (4.3 Bars), both unloaders are unloaded. As the suction pressure drops below 63 PSIG (4.3 Bars), the UL2 unloader is loaded. If the suction pressure drops below 32 PSIG (2.2 Bars), the UL1 unloader is loaded.
When the system is operating in low speed and the suction pressure is greater than 65 PSIG (4.4 Bars), both unloaders are unloaded. As the suction pressure drops below 64 PSIG (4.4 Bars), the UL2 unloader is loaded. If the suction pressure drops below 35 PSIG (2.4 Bars), the UL1 unloader is loaded.
b. 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)
REFRIGERATION SYSTEM SUCTION PRESSURES FOR LOADING AND UNLOADING
PSIG
70
SUCTION
PRESSURE
65
60
55
50
45
40
35
HIGH
SPEED
(UL2)
LOW SPEED (UL2)
LOW SPEED (UL1)
UL1 = FRONT UNLOADER
UL2 = REAR UNLOADER
ABOVE THE LINE = UNLOADED
BELOW THE LINE = LOADED
30
25
20
15
80.00
HIGH
SPEED
(UL1)
90.00
100.00
110.00
120.00
130.00
AMBIENT TEMPERATURE
°F
62-10683 5--20
SECTION 6
TECHNICIAN INTERFACE
PARAGRAPH NUMBER
6.1
PC MODE/DOWNLOAD PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2
MICROPROCESSOR CONFIGURATION AND TECHNICIAN TEST MODES . . . . . . . . .
6.2.1 Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2 Component Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.3 Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3
PC SUPPORT SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.1 ReeferManager And Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4
DOWNLOADING DATA WITH THE PC CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5
INSTALLING NEW SOFTWARE
6.5.1 Software Version Numbers
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.2 Using The Program PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.3 Using ReeferManager to Install Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.4 Troubleshooting Software Loading Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6
RE-SETTING PM (PREVENTATIVE MAINTENANCE) HOURMETERS . . . . . . . . . . . . . . .
6.7
ADVANCE MICROPROCESSOR REPLACEMENT & CONFIGURATION SETUP
6.7.1 Microprocessor Replacement
. . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.2 Microprocessor Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.3 Configurations Via Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.4 Functional Parameters via Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.5 DataRecorder Via ReeferManager PC Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.6 Engine And Switch-on Hourmeters Via ReeferManager PC Program
6.7.7 Configuration/IntelliSet PC Card
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.8 Microprocessor Final Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.9 Replacing Display Bezel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
6--17
6--17
6--18
6--19
6--19
6--20
6--22
6--23
6--1
6--2
6--3
6--12
6--13
6--14
6--14
6--16
6--24
6--25
6--25
6--25
6--26
6--26
6--26
6--27
1
SECTION 6
TECHNICIAN INTERFACE
6.1 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 eight-hour DataRecorder timer.
Connecting a download cable
(P/N 22-01737-00 (6’ Long) or 22-01737-04 (20’ Long) to the download port with the START/RUN-OFF switch 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 ReeferManager 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 DataRecorder may also be configured and downloaded through the download port using the
ReeferManager program.
6--1 62-10683
PC mode can be used for:
•
Changing set point for the next load
• Changing any of the functional parameters for the next load
• Reading Engine hourmeters
•
Reading Maintenance hourmeters
• Resetting Maintenance hourmeters
• Viewing the Active and Inactive alarm lists.
• Entering a Trip Start
• Keeping the microprocessor powered up after turning the START/RUN-OFF switch to the
OFF position
• Demonstrating the operation of the microprocessor without the engine running
• Use any of the PC cards (Download,
Program, Configuration or Option)
To better utilize PC mode, a PC Mode jumper (CTD P/N
22-50180-01) is available. This jumper looks similar to the Configuration jumper (refer to Section 6.2), 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 START/RUN-OFF switch is placed in 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 in the START/RUN position or the unit will start.
6.2
MICROPROCESSOR CONFIGURATION AND
TECHNICIAN TEST MODES
(REMOVE JUMPER MODE)
c. Place the START/RUN-OFF switch in the OFF position.
d. 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.
D
C
E
B
A
Insulated
Jumper
Download Port
Jumper P/N 22-50180-00
WHITE WIRE
WARNING
Do Not Allow Jumper Wire To Touch Any
Ground.
e. Place the START/RUN-OFF switch in the
START/RUN position. The ALARM LED will come on and the set point will appear, but the refrigerated compartment 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 is pressed.
f. 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.
g. Select the mode you wish to access and press the = key. See the following pages for information on these test modes:
• Configuration Mode
•
Component Test Mode
• Service Mode
62-10683 6--2
6.2.1 Configuration Mode
NOTE
To enter Configuration mode, refer to Section 6.2.
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
CONFIGURATION
UNIT MODEL FAMILY
SELECTIONS
ULTRA / ULTIMA
VECTOR
UNIT MODEL NUMBER*
This list contains many selections.
Only those covered by this manual are shown here.
Pick one of these models from the X series model family.
UNIT SERIAL NUMBER
NDL93N*ABO
NDL93P*ABO
NDL93R*ABO
NDL93S*ABO
NDL93S*ABA
NDL93U*ABA
NDL93V*ABO is circular, meaning that once the end is reached, it is repeated from the beginning.
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
Units models are grouped into families. The correct family must be identified for the correct model number to be displayed in the next selection.
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.
TRAILER ID #
SET NEW HOURS
GLOW TIME
(LONG/SHORT)
The unit S/N may be entered. This may be up to 11 characters long. Numbers, letters, and a space are available by scrolling through the available list.
The ID number 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 microprocessor can be installed into replacement micro.
NOTE: Changes to these values may be made for up to 60 minutes based on the real time clock.
This configuration only appears in the list until an hourmeter reaches 25 hours.
LONG = Longer glow times may be used for units in colder ambient conditions.
SHORT= Shorter glow times are used as the factory setting for all engines.
NOTE: Refer to Section 4.2.1 for glow time table.
6--3 62-10683
REFRIGERATION SYS
SHUTDOWN
COMPRESSOR ALARM
SHUTDOWN
(Special activation required)
CURRENT FOR S/S SHUTOFF
ALTERNATOR CHECK SHUT-
DOWN:
CONFIGURATION
OUT OF RANGE SHUTDOWN:
PARAMETERS LOCKOUT:
RPM ALARM SHUTDOWN:
LOW PRESSURE SHUTDOWN:
LP SHUTDOWN DELAY:
HIGH SUCT PRESS SHUTDOWN
VOLTAGE FOR S/S RESTART
ENGINE OIL LEVEL SWITCH:
SELECTIONS
YES/NO
YES/NO
YES/NO
YES/NO
120SECS
(0 - 255 seconds)
YES/NO
YES/NO
YES/NO
DESCRIPTION
YES = When the compartment temperature has been out-of-range for 30 minutes, the alarm light will come on, and the unit will shut down.
NO = When the compartment temperature has been out-of-range for 15 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 ReeferManager.
YES = If Alarm 39 (Check Engine RPM) is active, turn the alarm light on and shut the engine off.
NO = If Alarm 39 (Check Engine RPM) is active, turn the alarm light on and allow the unit to continue to run.
YES = When low refrigerant pressure is sensed in the system (alarm 18 is active), turn the alarm light on and shut the unit down (after the time delay in the following selection).
NO = When low refrigerant pressure is sensed in the system (Alarm 18 is active), turn the alarm light on and the unit will continue to run.
After the Low Pressure signal is received, how long shall the unit continue to run before it is shut down.
YES = If the unit is running and the suction pressure rises to 98 psig (6.67 Bars) or higher for 10 minutes (Alarm 27 is active), the unit will shut down.
NO = High suction pressure will not shut down the unit.
YES = Alarm 28 is Alarm and Shut Down.
NO = Alarm 28 is Alarm only.
YES = The unit will shutdown and not restart when
Alarms 13, 17, 18, 27, 28, 29 or 56 occur three times within two hours.
NO = Normal shutdown rules for above alarms.
Charging amps must be lower than this for startstop off cycle.
6.5A
1A TO 10A
(in .5A increments)
12.2A
12.0 TO 12.8 VDC
(in .5A increments)
YES/NO
YES/NO
This value will be used during Start/Stop-Off cycles.
If battery voltage falls below this value, the unit will restart.
YES = When the alternator is not charging (Alarm
51 is active), turn the alarm light on and shut the unit down.
NO = When the alternator is not charging (Alarm 51 is active), turn the alarm light on and the unit will continue to run.
YES = This unit has a low engine oil level switch installed.
NO = This unit does not have a low engine oil level switch installed.
62-10683 6--4
CONFIGURATION SELECTIONS
ENGINE OIL LEVEL SHUTDOWN YES / NO
ENGINE OIL PRESS SHUTDOWN
HIGH ENGINE TEMP SHUTDOWN
YES / NO
YES / NO
DESCRIPTION
YES = When the A2 -- “LOW ENGINE OIL LEVEL” alarm is activated the alarm light will illuminate and the unit will shutdown.
NO = When the A2 -- “LOW ENGINE OIL LEVEL” alarm is activated the alarm light will illuminate and the unit will continue to run.
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.
Change 09/11
6--4A
62-10689
CONFIGURATION
LOW COOLANT LEVEL
FUEL TANK
SELECTIONS
YES/NO
NO DEVICE
SWITCH
INSTALLED
0 TO 100% SEN-
SOR
DESCRIPTION
YES = A Low Coolant Level sensor is installed in the coolant system.
NO = There is no Low Coolant Level sensor installed in the coolant system.
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.
OFF = No Low Fuel Level Switch or 0 to 100%
Sensor is installed in the tank; OR
FUEL TANK SIZE
OFF
30 GALLONS
50 GALLONS
75 GALLONS
100 GALLONS
120 GALLONS
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.
DISPLAY TOTAL ENGINE HR
DISPLAY TOTAL SWITCH ON HR
DIESEL RESET VALUE
(Refer to Section 2.7 for oil change intervals)
SWITCH ON RESET VALUE
NO/YES
NO/YES
OFF
50 TO 30,000 HRS
OFF
50 TO 30,000 HRS
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 gallon -- 30 min
50 gallon -- 60 min
75 gallon -- 90 min
100 gallon -- 120 min
120 gallon -- 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%.
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 lists.
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 lists.
OFF = The Engine Maintenance hourmeter is turned off.
50 – 30,000 hrs = The value selected here will be the number of hours between engine service intervals.
OFF = The Switch-On Maintenance hourmeter is turned off.
50 – 30,000 hrs = The value selected here will be the number of hours between Switch-On service intervals.
6--5 62-10683
•
CONFIGURATION
PM (1-5)
•PM (1-5) RESET INTERVAL
(This is not displayed unless the PM meter is assigned to a counter in the previous configuration.)
SELECTIONS
OFF
DESCRIPTION
OFF = The PM (1-5) Maintenance hourmeter(s) is turned off.
ENGINE HOURS ENGINE HOURS = PM meter will count engine hours until the next service interval.
SWITCH ON
HOURS
SWITCH ON HOURS = PM meter will count Switch
On Hours until the next service interval.
CLUTCH CYCLES CLUTCH CYCLES = PM meter will count how many times the fan clutch cycled on/off until the next service interval.
START CYCLES START CYCLES = PM meter will count how many times the engine has started until the next service interval.
HIGH SPEED
HOURS
HIGH SPEED HOURS = PM meter will count how many hours the unit operated in high speed until the next service interval.
MAINTENANCE
DAYS
OFF
MAINTENANCE DAYS = PM meter will count how many days until the next service interval.
OFF = The PM (1-5) Maintenance hourmeter(s) is turned off.
ENGINE HOURS ENGINE HOURS = PM Meter will count engine hours until the next service interval.
SWITCH ON
HOURS
SWITCH ON HOURS = PM Meter will count Switch
On Hours until the next service interval.
CLUTCH CYCLES
1,000 TO 90,000
CYCLES in 1,000 cycle increments
START CYCLES
1,000 TO 90,000
CYCLES in 1,000 cycle increments
HIGH SPEED
HOURS
50 – 30000 HRS in 50 hr increments
MAINTENANCE
DAYS
0 to 99,999 DAYS in 10 day increments
CLUTCH CYCLES = PM Meter is connected to the clutch cycle meter. This meter counts every time the fan clutch engages. The reset interval will be
(1,000 to 90,000 cycles).
START CYCLES = PM Meter 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 Meter is connected to the high engine speed hourmeter, which counts only high speed engine hours. The reset interval will be (50 – 30,000 hrs).
MAINTENANCE DAYS = PM (1-5) is connected to the real time clock, which counts only days. The reset interval will be (10 – 99,999 days).
62-10683 6--6
CONFIGURATION
PRODUCTSHIELD SETUP
NOTE: ProductShield is only available when IntelliSet is installed.
Refer to Section 5.16 for more information on the following settings.
SELECTIONS
YES
S
PRODUCTSHIELD ECONO
OFF
GO TO
START--STOP
GO TO
CONTINUOUS
DESCRIPTION
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°
OFF = There is no lower limit for this parameter
.
Select the lower limit of the ambient range desired for this parameter. Refer to Section 5.16 for more information on Econo Min. Temp.
S
S
PRODUCTSHIELD ECONO
MIN TEMP
S
PRODUCTSHIELD ECONO
MAX TEMP
PRODUCTSHIELD ECONO --
DELTA-T
•PRODUCTSHIELD HIGH AIR
•PRODUCTSHIELD HIGH AIR MIN.
TEMP
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
--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
+3.6°F to +27°F
(+2°C to 15°C) (in
0.5° increments
OFF
ON
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 = There is no upper limit for this parameter.
Select the upper limit of the ambient range desired for this parameter. Refer to Section 5.16 for more information on Econo Max. Temp.
OFF = Delta--T is not used for determining the activation/de--activation of ProductShield Econo: Go
To Start/Stop mode
Select the desired Delta--T value for activation of
ProductShield Econo: Go To Start/Stop mode.
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)
OFF = There is no lower limit for this parameter.
Select the lower limit of the ambient range desired for this parameter. Refer to Section 5.16 for more information on High Air Min. Temp.
6--7 62-10683
S
PRODUCTSHIELD HIGH AIR
DELTA-T
CONFIGURATION
•PRODUCTSHIELD HIGH AIR
MAX. TEMP
S
PRODUCTSHIELD WINTER - xx°
RANGE (1-2) LOCK
•RANGE (1-2) MINIMUM TEMP
•RANGE (1-2) MAXIMUM TEMP
MIN SETPOINT
MAX SETPOINT
AUTO FRESH AIR EXCHANGE
SELECTIONS
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
DESCRIPTION
OFF = There is no upper limit for this parameter.
Select the upper limit of the ambient range desired for this parameter. Refer to Section 5.16 for more information on High Air Max. Temp.
+3.6° F to +27°F
(+2°C to 15°C) (in
0.5° increments
OFF
-20°F to +32°F
(-28.9°C to 0°C) (in
0.5° C or °F increments
OFF
START-STOP
CONTINUOUS
OFF = Delta--T is not used for determining the activation/de--activation of High Air Delta--T
Select the desired Delta-T value for activation of
ProductShield High Air
OFF = ProductShield Winter is disabled.
Select the desired ambient temperature below which ProductShield Winter will operate (forced
Continuous Run operation.)
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 set point is within that range.
START-STOP = The unit will always operate in
Start-Stop whenever the set point is between the minimum & maximum temperatures for that range
(see below).
CONTINUOUS = The unit will always operate in
Continuous Run whenever the set point is between the minimum & maximum temperatures for that range (see below).
Select the lowest temperature desired for either
Range 1 and/or Range 2.
-22°F TO +89.6°F
(-30°C to +32°C)
(in 0.1° increments)
⟨-22°F TO +89.6°F
(-30°C to +32°C)
(in 0.1° increments)
-22°F TO +89.6°F
(-30°C to +32°C)
(in 0.1° increments)
-22°F TO +89.6°F
(-30°C to +32°C)
(in 0.1° increments)
NOT
INSTALLED/STAN
DARD
Select the highest temperature desired for either
Range 1 and/or Range 2.
Select the lowest temperature that will ever be used as set point. Set point can not be set lower than this value.
Select the highest temperature that will ever be used as set point. Set point can not be set higher than this value.
Indicates if the Auto Fresh Air Exchange is installed. If AutoFresh Air hardware is not installed, this configuration needs to be set to NOT
INSTALLED to prevent alarms from occurring.
62-10683 6--8
CONFIGURATION
AUTO FRESH AIR DELAY
S/S PARAMETERS
REMOTE TEMP SENSOR (1-3)
(Optional)
NOTE: Sensor(s) on DataRecorder must also be set.
DOOR SWITCH:
(Optional)
NOTE: Door Switch must be set to be recorded on DataRecorder.
DOOR SWITCH UNIT
SHUTDOWN:
(Optional)
SELECTIONS
SETPOINT
0-48 HOURS IN
1 HOUR
INCREMENTS
TOGETHER
SEPARATE
ON/OFF
SWITCH NOT
INSTALLED
OPEN SWITCH
OPEN
DESCRIPTION
SETPOINT -- Once the compartment temperature has reached set point 1.5°F (0.8°C), the Auto-
Fresh Air Exchange system will start to operate based on the parameters selected in the Functional
Parameter list.
0 to 48 Hours -- After this length of time, AutoFresh
Air Exchange will begin if the unit is no longer running in pull down mode (Refer to Section 5.3), even though the compartment temperature has never reached set point.
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 set points.
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 set points.
ON=A remote sensor has been added to the unit and connected into the wire harness at Remote
Temp Sensor (1-3) plug. This enables Remote
Temp Sensor ( 1-3) to be read through the Data
List.
OFF=There is no Remote Sensor (1-3) in this unit.
SWITCH NOT INSTALLED = There is no door switch in this compartment.
DOOR OPEN SWITCH OPEN = A door switch has been installed on one of the refrigerated compartment doors. The switch contacts will be OPEN whenever the door is OPEN.
OPEN SWITCH
CLOSED
ALARM ONLY
ALARM ONLY = When Door switch indicates that the door is open, a warning alarm will be displayed in the MessageCenter.
UNIT SHUTDOWN 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
DOOR OPEN SWITCH CLOSED = A door switch has been installed on one of the refrigerated compartment doors. The switch contacts will be
CLOSED whenever the door is OPEN.
LOW ENGINE SPEED = When Door switch indicates that the door is open, the engine will be forced to low speed.
DATA RECORDER
ONLY
6--9 62-10683
CONFIGURATION
REMOTE SWITCH(1-2)
(Optional)
NOTE: Sensor(s) on DataRecorder must also be set.
REMOTE SWITCH (1-2)
(Optional)
SET TIME
• MONTH
• DAY
• YEAR
• HOURS
• MINUTES
LIGHT BAR
8 HR ADDITIONAL DATA:
DECIMAL
SELECTIONS DESCRIPTION
NOT INSTALLED
NOT INSTALLED = This remote switch is not installed in this unit.
DOOR OPEN
SWITCH OPEN
DOOR OPEN SWITCH OPEN = The Remote switch will be used as a refrigerated compartment door switch. The switch contacts will be OPEN whenever the door is OPEN.
DOOR OPEN
SWITCH CLOSED
SWITCH ON
CONTACTS OPEN
DOOR OPEN SWITCH CLOSED = The Remote switch will be used as a refrigerated compartment door switch. The switch contacts will be CLOSED whenever the door is OPEN.
SWITCH ON CONTACTS OPEN = The Remote switch will be used as a remote control switch. The switch contacts will be OPEN whenever the switch is in the ON position.
SWITCH ON CON-
TACTS CLOSE(D)
ALARM ONLY
ALARM ONLY = When Door switch indicates that the door is open, a warning alarm will be displayed in the MessageCenter.
UNIT SHUTDOWN 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
SWITCH ON CONTACTS CLOSE(D) = The Remote switch will be used as a remote control switch.
The switch contacts will be CLOSED whenever the switch is in the ON position.
DATA RECORDER
ONLY
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
8/2
YES/NO
The following will allow the Real Time Clock in the
DataRecorder 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.
Indicates the type of light bar installed.
YES/NO
YES = When the START/RUN-OFF switch is turned
OFF, the data recorder will continue to record sensor data for an additional eight hours.
YES = When the START/RUN-OFF switch is turned
OFF, the data recorder will continue to record sensor data for an additional eight hours.
NO = When the START/RUN-OFF switch is turned
OFF, the data recorder will stop recording all data.
DISPLAYED
DISPLAYED = Set point will be shown with a decimal and temperatures may be selected to a tenth of a degree.
NOT DISPLAYED NOT DISPLAYED = Set point will not be shown with a decimal. All other temperatures will still be displayed with a decimal.
62-10683 6--10
CONFIGURATION
HIGH SPEED DELAY
SELECTIONS
1 MIN
0 TO 10 MINUTES
IN 0.5 MINUTE IN-
CREMENTS
QUALCOMM
SATELLITE COMM
(Optional)
(This configuration is only visible in the microprocessor configuration list when the DataTrak option is installed in the microprocessor. It is always visible in the configuration list in ReeferManager, although it is non-functional until the DataTrak option is installed.)
OTHER
UNIT OPERATION:*
See Note on Following Page
STANDARD
RAIL
• VEHICLE ID:
This is only available when Unit Operation: “Rail” is selected in above configuration.
•RAIL SHUTDOWN OVERRIDE:
This is only available when Unit Operation: “Rail” is selected in above configuration.
See Note on Following Page
S
RAIL OVERRIDE RESTART:
This is only available when Unit Operation: Rail is selected in above configuration.
ASSET
TRAILER
CAR
NO
YES
1-20
3
DESCRIPTION
Select the length of time unit remains in low speed before transitioning to high speed.
QUALCOMM = The microprocessor is set to send
Qualcomm communication messages.
OTHER = The microprocessor is set to send communication messages to communication telematics companies other than Qualcomm.
STANDARD = The microprocessor is set to control over--the--road trailer refrigeration operation.
RAIL = The microprocessor is set to control Rail refrigeration operation.
If Rail is selected for Unit Operation, this indicates type of vehicle in use. This selection will be used as the label text when displaying Trailer/Asset/Car ID for modification.
NO = When Alarm 30 or Alarm 31 occur, the unit will not automatically restart until the Alarms are cleared.
YES = When Alarm 30 or Alarm 31 occur, the unit will automatically restart after 4 hours.
If Rail is selected for Unit Operation and the Rail
Shutdown Override is in effect this indicates the number of restarts allowed.
ENABLE INTELLISET AT = KEY
CONFIGS COMPLETE = TO EXIT
NO
YES
NO = Pressing the SELECT key will allow the user to access the IntelliSet Menu.
YES = Pressing the = key will allow the user to access the IntelliSet Menu.
Press = to return to the Configuration Main Menu
NOTE
The following changes occur in the unit’s performance when Rail Mode is selected:
• The “Trailer ID” can now be changed in order to more accurately define the vehicle carrying the unit. The choices ae: “ASSET”, “CAR”, or
“TRAILER.”
• Rail Shutdown Override can be selected.
When the Rail Shutdown Override con-
figuration is set to NO the unit will remain off until all alarm(s) are manually reset in cases where: the unit has unsuccessfully attempted to start 3 times OR the unit has shut down on an alarm 3 times.
When the Rail Shutdown Override con-
figuration is set to YES, the unit will restart and attempt to continue to run when: the unit has shut down 3 times OR the unit has failed to start after 3 start attempts AND either Alarm 30 or Alarm 31 is active AND the unit has been off for 4 hours
• Rail Override Restart is the number of times the unit can clear Alarms 30 or 31 after the unit has been off for the 4 hour off time. The factory setting is 3. Setting this number too high may result in a discharged or damaged battery if the unit never actually starts or fails to run long enough to charge the battery prior to shutting down again.
6--11 62-10683
6.2.2 Component Test Mode
To enter Component Test mode refer to Section
6.2.
NOTE
Component Test Mode allows the Technician to energize individual circuits for five minutes at a time while the unit isn’t running. The engine cannot start when the microprocessor is in Component Test Mode.
From the Main Menu, select Component Test Mode and press the =. key. Use the UP or Down arrow keys to scroll through the list when
↑ ↓ TO SCROLL, THEN = TO SELECT appears in the
MessageCenter. Press the = key to select the component desired for testing. For example, if the Front
Unloader (UL1) Light is selected, the UL1 coil will be energized, and the MessageCenter will display
“UL1 OFF IN 5 MINUTES”. The minutes will count down to 0 at which time the UL1 circuit will be de-energized, and the MessageCenter will display the last component tested.
The test may be stopped at any time by placing the
START/RUN-OFF switch in 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 the = key. To select another component to test, press the
UP or DOWN Arrow key to view other components, and press the = key to select the desired component. To go to Service Mode or Configuration Mode, select the Main
Menu and press the = key.
The only keys that operate during Component Test
Mode are the ALARM and SELECT keys. The alarm list is available for viewing any active or inactive alarms.
The SELECT key will only allow access to the Amp
Current Draw for the item in the Data List.
When Component Test mode is selected, the Main
Display will show OFF.
The following components may be tested during the
Component Test mode:
Component/Menu List
Cool Light *
Heat Light *
Defrost Light *
Auto Restart Light *
Out Of Range Light *
MessageCenter
COOL LIGHT OFF IN X MINS
HEAT LIGHT OFF IN X MINS
DEFROST LIGHT OFF IN X MINS
ARL LIGHT OFF IN X MINS
ORL LIGHT OFF IN X MINS
FET LED Board LED
17
8
16
7
15
Fault Light *
Unloader 1 (front)
Unloader 2 (rear)
SV1
SV2
SV4
Clutch Relay
Speed Relay
Run Relay
FAULT LIGHT OFF IN X MINS.
UL1 OFF IN X MINS
UL2 OFF IN X MINS
SV1 OFF IN X MINS
SV2 OFF IN X MINS
SV4 OFF IN X MINS
CLHR OFF IN X MINS
SR OFF IN X MINS
RR OFF IN X MINS
14
23
22
10
21
9
29
27
28
Buzzer
Glow Plug Relay
AutoFresh Air Exchange Relay
Main Menu (To access Component Test mode or Configuration mode)
BUZZER OFF IN X MINS
GPR OFF IN X MINS
AFAR OFF IN X MINS
18
12
30
* These are for the Light Bar only. The FET LED will illuminate, however the corresponding indicator LED on the Display will not illuminate.
NOTE
Electronic speed control modules can not be tested through the microprocessor. Refer to Section 10.4.1 for
Troubleshooting guide for units with Electronic Speed Control Engines.
62-10683 6--12
6.2.3 Service Mode
CAUTION
Service Mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating.
NOTE
The START/RUN--OFF switch MUST be in the
START/RUN position to keep the unit in Service
Mode. If the switch is placed in the OFF position, the unit exits Service Mode and closes the
CSMV to 0% open and de--energizes UL1.
a.
Scroll through the Main Menu then press the = key when SERVICE MODE appears in the
MessageCenter.
b.
“ENTERING SERVICE MODE” will appear in the
MessageCenter and OFF will be displayed in the main display. The CSMV will be set to 100% open and the Front Unloader (UL1) will be energized.
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 NO TAG.
e.
When the refrigeration system is evacuated the system pressure will go into a deep vacuum. While this is occurring, the MessageCenter will change to
“EVAC/CHARGE MODE.” The position of the
CSMV and UL1 does not change in this mode.
f.
To prevent refrigerant migration to the compressor during charging, if all pressure transducers (CSP and CDP) drop below--9.8 psig or –20 inHg (0.68
bar), and then 2 of the 3 pressure transducers rise above 5 psig (0.34 bar), the microprocessor will close the CSMV to 0% open and de-energize UL1.
When the valves are closed,
“CHARGE MODE – HOLD = TO EXIT” is displayed in the MessageCenter. The = key must be pressed and held for six seconds to exit Service mode or the
START/RUN-OFF switch can be be placed in the
OFF position and then back in the START/RUN position.
g.
If the unit shifts to Charge Mode and
“CHARGE MODE – HOLD = TO EXIT” is displayed in the MessageCenter while you are still recovering refrigerant, leak testing or evacuating the refrigeration system, DO NOT CONTINUE. 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.
h.
To exit Service Mode at any time, press and hold the = key for 5 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.
6--13 62-10683
6.3 PC SUPPORT SOFTWARE
6.3.1 ReeferManager And Reports a. ReeferManager enables the user to do the following:
•
Monitor in real--time via the download port (an
RS--232 connection) the current status of the microprocessor inputs, outputs, refrigeration, electrical, engine and temperature sensors and alarms
• Record sensor data to a file for diagnostic purposes
• Download microprocessor and DataRecorder data via serial port communications
•
Display, edit and send unit model number, serial number and trailer ID to the microprocessor
• Display, edit and send functional parameters and configuration settings to the microprocessor and data recorder
• Transfer hour meter values to replacement microprocessors
• Initiate Pretrip and Defrost operations
• Support Download, Configuration and
Program PC Card operations
• Provide a security log on system controlled by a System Administrator
b. The Reports Program enables the user to do the following:
•
Read .DCX download files from the Advance microprocessor
• Create various customized reports that include set point, sensors, and events
• Create various customized graphical reports
• Print numerical, graphical, and event reports
• View and print refrigeration system historical settings and changes
• Filter download data by date range and desired sensors and events
• Search for a sensor or event of interest
•
Synchronize multiple graphical and numerical windows to better understand historical operation
•
PC Setup enables the user to select how to display various parameters for use in the graph and text window.
•
Easily adjust x and y axis and color scheme to accommodate various data
• Export data to a spreadsheet friendly format such as MS Excel.
NOTE
The ReeferManager program does not support
USB port serial connections. In the event that a notebook PC does not have a DB--9 serial port connector, an RS_232 serial port type II
PCMCIA card adaptor may be used to adapt the notebook PC to the Carrier download cable.
For desktop PCs, a PCI bus RS--232 serial card adaptor must be used to accomplish this task.
c. Uninstall earlier versions of ReeferManager And
Reports as follows:
All previous version of both ReeferManager and
Reports must be uninstalled prior to installing newer versions of these programs.
NOTE
These instructions are intended to be generic and not specific to any computer. Because
ReeferManager can be installed on any computer with any operating system (excluding
Vista) there will be some differences within those operating systems from one version to another. The wording may not be exactly the same; however, the procedure below will work for all operating systems mentioned.
• Click the Start button located at the lower left corner of your computer screen.
• Move the mouse pointer up to Settings. A secondary menu will slide out to the right.
Move the mouse pointer over and click on
Control Panel.
•
With the pop--up box, there is an icon or line item named Add / Remove Programs. Double click it.
• In the next pop--up box, scroll down until you find ReeferManager and click it once to highlight it.
•
Click on the Add / Remove button. A “Confirm
File Deletion” or and InstallShield Wizard will appear. If you are certain you have selected the correct program, click Yes, Next or OK buttons and follow the on--screen instructions.
• When ReeferManager has been uninstalled you will receive a confirmation pop--up message. Clear it.
62-10683 6--14
d. Auto Install ReeferManager
NOTE
If this is the first time that ReeferManager has been installed onto a particular computer, Carrier Communications (CCN) must first be installed. If an earlier version of CCN has already been installed onto this computer AND the program communications between the computer and the Advance Microprocessor worked correctly, it is not necessary to uninstall and reinstall CCN. If the communications between the computer and the microprocessor did not work, uninstall and reinstall CCN.
• Close all programs and applications that are currently running.
•
Insert the ReeferManager CD--ROM into the appropriate drive (usually D:\\)
•
The CD--ROM will start running and automatically start the install program.
•
Click the button to install ReeferManager.
Follow the on--screen instructions, using the default settings.
•
Click the Finish button to close the install program.
• Remove the CD from the drive and store for future use.
• Reboot the computer to enable the programs.
6--15 62-10683
6.4 DOWNLOADING DATA WITH THE PC CARD
CAUTION
1. Place the microprocessor in PC Mode (Refer to
Section 6.1), or place the START / RUN--OFF 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 7.1
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 copied from the Download Card onto a computer drive before it can be viewed.
62-10683
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
6--16
6.5 INSTALLING NEW SOFTWARE
NOTE
All units should have the Controller software upgraded to 04.05.00 (04.07.00 for X2 units) or above. It is no longer possible to load any versions of 03 software into that microprocessor. Newer versions can be loaded as they are released.
6.5.1 Software Version Numbers
The first two digits of the software revision number (e.g.
04) indicate the major release. Major releases occur when significant changes are made to the software.
Whenever a major change to software is made and that software is installed into a microprocessor, it is not possible to downgrade the software back to any lower major release version.
The second two digits (e.g. 05) indicate a minor release.
Minor releases occur when new features, new models or other enhancements are added to the software.
Software versions of newer or older minor versions can be installed into a microprocessor as needed.
The third set of digits (e.g. 00) is the actual release number. Production software is generally 00. Test and experimental versions will have a different number. The third digit does not affect the major or minor designation; therefore, the software can still be installed into a microprocessor as needed.
NOTE
Some test or experimental versions may be the
ONLY current version that will operate correctly in a particular unit. Until a new production version is announced, changing the software may result in incorrect unit operation.
6--17 62-10683
6.5.2 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
(CSMV) 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.
CAUTION
1. Place the Microprocessor in PC mode (Refer to
Section 6.1), or place the START/RUN-OFF switch in the START/RUN position.
2. Insert a Program PC card into the PC card slot on the front of the microprocessor. Be certain that the instruction label on Program PC card is facing the “Caution” label on the microprocessor. Do not force card into slot.
Hold the Program PC card at the end opposite the plug end. Do not squeeze the card in the middle while inserting. (See
Section 2.5.4 for PC card care)
3. The MessageCenter will show one of three different messages:
Same SW: “= to Load,
Old SW: “= to Load,
New SW: “= to Load,
↑
To Cancel”
↑
To Cancel”
↑
To Cancel”
4. Verify by the message that you are upgrading/downgrading the software according to your intentions.
5. Press the = key to load the program. The MessageCenter will show
“ENGINE AND MICRO WILL STOP NOW.” If the engine is running, it will shut down. After about
45 seconds the MessageCenter backlight will dim and the message
“INSTALLING PROGRAM SOFTWARE” will be displayed. The Card Status LED adjacent to the
PC card slot will blink together with the Micro Status LED at a rate of 1/2 second on then
1/2 second off 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 Microprocessor 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 START/RUN-OFF
SWITCH OFF DURING THE INITIAL START FOLLOWING A SOFTWARE UPGRADE.
62-10683 6--18
6.5.3 Using ReeferManager to Install Software
CAUTION
It is important that communications between the Microprocessor and the computer not be 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.
NOTE
04.10 software and above can be installed using either the preferred previously described
Program PC card method or by using a minimum of ReeferManager 03.07 and a computer.
Existing Program PC cards may be upgraded to the latest software version by using the Reefer-
Manager program.
The ReeferManager version 03.07 program is designed to be installed and operated on the following Windows operating systems: Windows
95, 98, ME, 2000, and XP. The programs will not operate on Windows Vista.
Prepare the PC that will be used with
ReeferManager as follows:
• The screen saver must be turned off.
•
The battery should be capable of running the
PC for 30 minutes, or the PC should be plugged into an electrical outlet.
• All battery saver features (hard drive time out, monitor time out, etc.) should be set to more than 30 minutes.
•
The download cable must be connected to a
9-pin COM port on the PC. USB to COM Port adaptors will not work.
Follow these steps to use ReeferManager:
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.
6--19 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. Place the START / RUN--OFF switch in 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 Microprocessor Status LED will start blinking at the rate of 0.5 seconds on and 0.5 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 PLACE THE
START/RUN--OFF SWITCH IN THE OFF
POSITION DURING THE INITIAL START FOL-
LOWING A SOFTWARE UPGRADE.
6.5.4 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 Microprocessor 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 Microprocessor 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 Microprocessor Status LED is not on at all, check voltage to QC1 & QC2. Also check for voltage from the START / RUN--OFF switch at 5MPA1. If voltage and grounds check OK, the microprocessor may be dead and require replacement.
62-10683
6.6 RE-SETTING PM (PREVENTATIVE MAINTENANCE) HOURMETERS
TIP
PM hourmeters may be reset for the next maintenance interval from the Functional Parameter list using the keypad.
HEAT COOL DEFROST
-20
ALARM START-STOP CONTINUOUS
+34.5° F
SETPOINT BOX TEMPERATURE
PRESS ↑ ↓ TO VIEW SETTINGS
MANUAL
DEFROST
ALARM LIST START--STOP/
CONTINUOUS
SELECT
1. Press the SELECT key until PRESS ↑↓ TO VIEW SETTINGS.
appears in the MessageCenter.
2. Press the UP ARROW key or the DOWN ARROW key until
RESET PM HOURMETERS is displayed.
3. Press the = key. ↑ ↓ TO SCROLL, THEN = TO SELECT will be displayed in the
MessageCenter.
4. If “NO HOURMETERS TO RESET“ appears there are none to reset.
5. Press the UP or DOWN ARROW key until the PM hourmeter you wish to reset is shown.
6. The MessageCenter will show the hourmeter name with the instructions
“= TO RESET”, followed by the number of hours or cycles that will be used for the next service interval.
7. Press the = key to reset the hourmeter to the new value shown.
8. The name of the hourmeter and “RESET” will be displayed indicating that the reset was successful.
9. Repeat steps 5-7 to Reset additional PM hourmeters
62-10683 6--20
SETTING PM (PREVENTATIVE MAINTENANCE)
HOURMETERS (Continued)
NOTE
The hourmeters must first be configured “ON”
(Refer to Section 6.2.1)
PM (Preventative Maintenance) hourmeters are provided to track unit operation and to notify the user when periodic preventative maintenance is due. Within the Advance Microprocessor, there are seven PM hourmeters available for use:
•
Engine
•
Switch On
•
Five programmable hourmeters
The programmable PM hourmeters (PM1 – PM5) can be configured to count any of the following:
• Engine Hours
• Switch On Hours
•
Clutch Cycles
•
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 Clutch 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.
Maintenance Days are also available for customers who service their equipment by calendar days instead of operating hours or cycles.
Once the PM hourmeters are activated from the
Configuration List, they can only be turned OFF or
RESET for a new interval from the Functional
Parameter List.
The PM Hourmeters may be reset using either a PC and the ReeferManager program 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 reset a PM hourmeter that has not expired and is not found in the Functional Parameter list: a. From the Configuration list, select the
PM hourmeter.
b. Press the = key to change.
c. Select OFF for the interval.
d. Press the = key to enter.
e. Press the = key to change.
f. Select the correct interval.
g. Press the = key to enter.
h. Place the START/RUN-OFF switch in the OFF position then back to START/RUN. Check the Data list.
The correct number of hours should be showing as
“HOURS TO ENGINE MAINT”.
6--21 62-10683
6.7 ADVANCE MICROPROCESSOR REPLACE-
MENT & CONFIGURATION SETUP
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.
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 trailer microprocessor.
As mentioned above, some microprocessor inputs operate at voltage levels other than the conventional 12
VDC. Connection points and the associated approximate voltage levels are listed below for reference only.
Under no circumstances should 12 VDC be applied at these connection points.
Grounded wrist cuffs are available from Carrier (P/N
07-00304-00). These should be worn whenever handling a microprocessor.
Table 6-1. Connection Point Voltage
Connection Point
AAT, CDT, DTT, ENCT,
RAT, SAT
Approximate Voltage
2.5 VDC (Variable)
Although there is less danger of electrical static discharge (ESD) damage in the outdoor environment or in a repair shop -- where the processor is likely to be handled -- proper board handling techniques should always be stressed. Advance Microprocessors should always be handled by the plastic cover and not the exposed printed circuit board. This not only precludes the possibility of ESD damage, but also lowers the possibility of physical damage to the electronic components.
When field diagnosis of a Carrier Transicold Vector 6500 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. All settings -- including unit model number, Trailer ID, unit serial number, and operating hours and cycles -- from the old microprocessor can be installed into the new microprocessor using either the keypad or a computer with the ReeferManager program.
NOTE
A single set of configurations, functional parameters and data recorder settings can be sent serially to the microprocessor using the
ReeferManager program. Multiple sets of settings (IntelliSets) can only be sent to the microprocessor by using a Configuration PC card.
62-10683 6--22
6.7.1 Microprocessor Replacement
a. If possible, power the microprocessor up, either using a PC mode jumper, or by placing the START/RUN-
OFF switch in the START/RUN position. If the microprocessor will not power up, skip ahead to step d.
b. Insert a Download PC card into the PC card slot and download all data from the data recorder. If a Download PC card is not available, data may also be downloaded using a download cable and the
ReeferManager PC Program.
c. Scroll through the DataList and make note of the following from the MessageCenter:
• ID Number
•
Unit Serial Number
• Unit Model Number
•
Engine Protect Hours
• Switch On Protect Hours
•
Engine Sleep Hours
• Switch On Sleep Hours
•
High Speed Hours
• Clutch Hours
•
Start Cycles
• Date And Time d. Remove PC jumper or turn START/RUN-OFF switch 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 door by removing the screws at the bottom. Open control box door and use the retaining rod to hold the door open.
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.
6--23 62-10683
6.7.2 Microprocessor Setup
NOTE
Before starting the unit, the microprocessor must be configured for the correct unit model family and model number. This can be done at the unit keypad, or by using the ReeferManager program. The steps below are used when setting the microprocessor up from the keypad.
Generally, the microprocessor can be setup using a Configuration PC card however certain parameters can not be set using a Configuration PC card. Those parameters can be entered using the keypad or the ReeferManager program. The steps below detail entering the data using the keypad.
a. Ensure that the new microprocessor is in place, all wires connected and the negative battery cable is reconnected.
b. Place the START/RUN-OFF switch in the START/
RUN position. The microprocessor 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 Family appears, and press the = key. Use the
Up or Down Arrow keys to scroll through the list of model numbers 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 key, 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. LAD90887654).
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 key, 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 to 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, and is showing the correct time.
Also, some customers are located in different time zones from where the repair is being made. If you know what time zone they use, enter that time. If you don’t, then enter
the current time where you are located. 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 key 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. 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. Hours are displayed and entered as a 24 hour clock. 0 to 12 is AM. 13 to 24 is
PM.
i. When you are finished, the MessageCenter will diisplay “PRESS = TO SAVE TIME CHANGES”.
NOTE
If you do not press the = key, none of the time changes you just made will be saved.
j. Press the UP ARROW key to go to
“SET NEW HOURS”. Press the = key then the Up Arrow key to enter that menu.
k. The first hourmeter is Engine Protect Hours. Press the = key to select this meter. The cursor will be blinking on the ten-thousands place. Press the UP or
DOWN ARROW key to select the correct value, then press the = key. If the correct number in any of the locations is 0 (zero), just press the = key to enter 0 as the value and move the cursor to the next place. For example, if you are entering 567 hours, you will press the = key twice to leave a 0 for the first two numbers, then use the UP and DOWN ARROW key to scroll through the numbers to enter the correct hours.
When the correct hours for Engine Protect Hours has been entered, press the = key to advance to the next hourmeter. If an invalid number is entered, a warning message will flash in the MessageCenter. For example, you can not enter a higher number of hours for
Engine Protect than the number of Switch On Hours.
62-10683 6--24
NOTE
None of the “Total” hourmeters are listed. When the hours for all the hourmeters are entered, the microprocessor will add the correct hours together and calculate the Total Engine Hours, and Total Switch On Hours. When the end of the list is reached “PRESS = TO SAVE HOURS” will be displayed. Pressing the = key will save the hours, and return you to the configuration list.
If you do not press the = key, none of the time hours or cycles you just entered will be saved.
Hourmeters may be changed for 60 minutes following the initial hour entry. If an error has been made, be certain to correct it within the 60 minute time period. Following that time, the hourmeters will count the appropriate hours because the unit switch is on and the unit is operating, and no further manual changes will be allowed.
NOTE
After the configuration settings are complete use the UP or DOWN ARROW keys until
“CONFIGS COMPLETE, = TO EXIT” is displayed in the MessageCenter. Press the = key to save.
NOTE
If a Configuration card will be used to configure the microprocessor, skip ahead to CONFIGU-
RATION CARD, Section 6.7.7 If the Configurations and Functional Parameters will be set from the keypad, continue with following steps
6.7.3 and 6.7.4
6.7.3 Configurations Via Keypad
Refer to Section 6.2 for a list of available microprocessor configurations. Refer to Section 6.2.1
for instructions on how to access them.
NOTE
Units equipped with IntelliSet MUST have the settings installed using ReeferManager and a
Configuration PC card.
IntelliSet settings CANNOT be installed by using either the keypad, or by using a laptop computer.
6.7.4 Functional Parameters via Keypad
a. Refer to Section 3.16 for the list of available Microprocessor Functional Parameters and for directions on how to access them.
b. Leave the microprocessor powered up as you continue with the next section.
6.7.5 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 3.19 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
6.7.4 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 03.07.00 or higher.
NOTE
ReeferManager 03.07.00 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 DataRecorder/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 pressure, voltage, amperage, &
RPM).
f. When the setup is correct, press the Send button to send the new settings to the microprocessor.
g. From the “Confirm Send Information” Pop Up, check the data you want to send and un-check the data you don’t want to send. Click the OK button.
h. Verify that the settings were sent by waiting for the confirmation pop up message.
NOTE
If the DataRecorder date and time were not set earlier, they can be set from this screen by clicking on DataRecorder Tools>Set Date and Time.
i. Leave the microprocessor powered up as you continue with the next section.
6--25 62-10683
6.7.6 Engine And Switch-on Hourmeters Via
ReeferManager PC Program
a. Start the ReeferManager program. Go to the Serial
Operations Tab.
b. Click on DataRecorder/Microprocessor Setup button.
c. In the upper left menu bar, click on
MicroprocessorTools>Set New Micro Hours.
d. At this screen, enter the hours that were recorded in step b. of Section 6.7.1. Send the new readings to the microprocessor.
NOTE
Hours can only be entered into the microprocessor until either the Total Engine Hours or the
Total Switch On Hours reach 25. However, in the case of incorrect hours being entered, changes can be made for 60 minutes after the initial change has been made -- regardless of the number of hours entered. Once the 60 minutes has expired, and either of the total hourmeters reaches 25 hours, no further changes can be made.
The 60 minute grace period is based on the
Real Time Clock in the DataRecorder. That is why it is important that the Real Time Clock is set to the correct time prior to setting the hour meters.
e. Your computer may now be disconnected and turned off or you can continue setting up the configurations.
6.7.7 Configuration/IntelliSet PC Card
a. Place the START/RUN-OFF switch in the OFF position to power down the microprocessor and to take it out of Configuration mode.
b. Power the microprocessor up by either placing the
START/RUN-OFF switch in the START/RUN position
(Manual Start Operation can be used if the unit is so equipped) or by inserting a PC mode jumper into the download port.
c. Insert the 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 from the card. “LOADING INFO” will be displayed during this time. When finished, the Message-
Center will show “ALL INFO LOADED – REMOVE
CARD”. Remove the Configuration PC card.
d. The MessageCenter will show
“MICRO WILL RESET AND RESTART NOW”, the display will go blank, then come back on after a few seconds.
NOTE
When the microprocessor powers up the display will show
“PRESS = TO VIEW INTELLISETS”. The unit will not start until one of the new IntelliSets has been selected.
e. Press the UP or DOWN ARROW key to scroll through the list of IntelliSets. Pressing the UP ARROW key will bring the first IntelliSet name into the Message
Center.
f. Move to the desired IntelliSet and press the = key.
The desired IntelliSet will automatically become active and the unit will be able to be started.
6.7.8 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 6.7.1 is now accurately displayed in the Data List. Also verify that the correct date and time are 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.
62-10683 6--26
6.7.9 Replacing Display Bezel Assembly
Display Bezel Assembly Removal
a. Place the START/RUN--OFF switch in the OFF position and disconnect the negative battery cable. Attach a grounded wrist strap (CTD P/N 07--00304--00) and ground it to a good unit frame ground.
b. Open the roadside side door containing the
Keypad/Display Assembly. Unplug the display cable from the 10--pin harness.
c. Loosen and remove the (4) hex head 1/4--20 bolts holding the bezel bracket to the door and lay the bezel assembly on a clean work surface.
d. Loosen and remove the (4) 5mm x 20mm lg hex head bolts holding the bezel assembly to the bracket. Carefully separate the bezel assembly from the bracket.
Disconnect the wiring harness from the display board and the START/RUN--OFF switch.
Display Bezel Assembly Installation
(CTD P/N 91--00312--02SV)
CAUTION
Do not over--torque screws. Torque all screws to 11in--lbs (1.2 Nm).
DISPLAY WINDOW
NOTE
Eleven Phillips head screws are used to retain the keypad to the bezel: (8) 3/4” Lg. screws around the perimeter of the keypad and (3) 3/8”
Lg. blunt tip screws in the center of the keypad.
Four 3/8” Lg. Phillips head screws are used to retain the display board to the keypad.
a. Remove the old gasket from the door mounting bracket.
b. Ensure that the surface is completely free of any old gasket material and apply the new gasket (included in the kit) to the bracket.
c. Plug the wire harness into the new display board and reconnect the wires to the START/RUN--OFF switch.
d. Secure the bezel to the control door with the (4) 5mm
X 20mm lg. hex head bolts. Torque bolts to 26 in. lbs.
(2.9 Nm).
e. Fasten bezel and bracket assembly to unit side door using (4) hex head 1/4--20 bolts.
f. Reconnect wire harness (10--pin connector) from the microprocessor.
g. Reconnect negative battery cable and run Pretrip to check unit operation.
DETENT SPRINGS
KEYPAD DOOR
DETENTS
DISPLAY BEZEL
WINDOW GASKET
DISPLAY BOARD
KEYPAD BOARD
WINDOW GASKET
NOTE: GASKET IS
NOTCHED
FOR CLEARANCE AROUND
DETENTS.
MOUNTING BRACKET/CONTROL BOX GASKET
Figure 6 --1. Display Module Assembly
6--27 62-10683
SECTION 7
MessageCenter
PARAGRAPH NUMBER
7.1
MessageCenter MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
7--1
1
SECTION 7
MessageCenter
7.1 MessageCenter MESSAGES
The following table lists all of the messages that do not appear in other lists in this manual and a description of their meaning. Refer to Section 8 for a list of alarm messages. Refer to Section 3.14 for a list of Unit Data messages. Refer to Section 3.16 for a list of Functional Parameter messages. Refer to Section 6.2.1 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
ACTIVE ALARM LIST CLEARED
ALL ALARMS CLEARED
ARL LIGHT OFF IN X MINS
BACK TO CONFIGS
BACK TO FUNC PARAMS
MessageCenter MESSAGES
Description
This message is used when viewing Unit Data. Use the UP and
DOWN arrow keys to move through the data list. Press the = key to lock a data item in the MessageCenter
ALL INFO LOADED -- REMOVE CARD
Press the UP or DOWN arrow key 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 key to scroll through menu selections available in this mode. When you reach the desired selection, press the = key to select it.
An Option PC card has been inserted into the PC card slot. Press the = key to install the option into the microprocessor. The number of installs remaining on the PC card will be shown.
This message will appear in the MessageCenter along with the current IntelliSet indicating that the IntelliSet is active and none of its settings have been modified.
The list of active alarms in the microprocessor alarm lists has been erased. (This does not remove alarms from the data recorder.)
The list of active and inactive alarms in the microprocessor alarm lists have been erased. (This does not remove alarms from the data recorder.)
All data has been loaded into the microprocessor from the PC card.
The card may be safely removed from the microprocessor.
The Auto Restart Light circuit to the Operator’s Light Bar has been energized in Component Test mode. The ARL circuit will continue to be energized for the number of minutes shown.
Pressing the = key with this message showing will return the user to the main microprocessor Configuration list.
Pressing the = key with this message showing will return the user to the main Functional Parameter list.
BAD PC CARD OR CARD SLOT
BUZZER OFF IN X MINS
CALIBRATION UNSUCCESSFUL
CANNOT ENTER TRIP START
CANNOT START DEFROST CYCLE
CANNOT START PRETRIP
CANNOT DOWNLOAD -- BATTERY DEAD
CARD FULL, REMOVE CARD
The microprocessor has detected a problem with either the PC card or the PC card slot.
The Buzzer circuit has been energized in Component Test mode.
The Buzzer circuit will continue to be energized for the number of minutes shown.
Attempt to calibrate discharge transducer failed.
Cannot enter trip start. A problem has been detected within the DataRecorder.
Cannot start defrost cycle. Refer to Defrost Sections 3.10, 5.11,
2.15 and 9.24.
Cannot start pretrip. Refer to Pretrip Section 3.4.
Data cannot be downloaded and software upgrades are prohibited when battery voltage is below 7.0 volts. This message will be displayed until the serial cable is removed.
The PC Download card is full. There is no additional room to download information from the microprocessor. You may safely remove the PC card from the slot.
7--1 62-10683
Message
CARD LOCKED -- REMOVE CARD
MessageCenter MESSAGES
Description
The lock switch on the PC card is in the “Locked” position. To use the PC card, move the switch to the “Unlocked” position.
CARD REMOVED, DATA NOT COPIED The PC card was removed before all data was copied onto the card.
CARD REMOVED, REINSERT CARD
CFG: =TO LOAD,↑ TO CANCEL
CHANGE INTELLISET TO EXIT
CHARGE MODE -- HOLD=TO EXIT
CHECK AT NEXT SERVICE INTERVAL
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 the = key to load configurations or IntelliSets into microprocessor.
The IntelliSleep Intelliset is active. Alternates with
“INTELLI--SLEEP MODE” at 5 second interval whether unit is running or not.
Service mode has the refrigeration system set so that it can be charged with refrigerant through the king valve. Press the = key to manually exit, or wait until the charging is complete.
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.
CHECK COOLANT LEVEL
(Requires Optional Sensor)
CHECK DOOR
CHECK ENGINE OIL LEVEL
(Requires Optional Sensor)
CHECK FUEL LEVEL
(Requires Optional Sensor)
CHECK MICROPROCESSOR
Earlier Units Only
CHK WIRES FROM MICRO TO KEYPAD
Later Units
CLHR OFF IN X MINS
COMPONENT TEST MODE
Door switch indicates that trailer or rail car compartment door is not closed.
The oil level in the diesel engine is low.
The level in the fuel tank is very close to empty.
There is a communication signal lost between the keypad/display and the microprocessor. Check and test the wiring to the keypad/ display
There is a communication signal lost between the keypad/display and the microprocessor. Check and test the wiring to the keypad/ display
The Clutch Relay circuit has been energized in Component Test mode. The Clutch Relay circuit will continue to be energized for the number of minutes shown.
Pressing the = key while this message is being displayed will allow user access to Component Test mode.
The selections following this message are the components available for energizing during Component Test mode.
COMPONENT TEST MODE MENU
SELECTIONS
CONFIG ERROR, REMOVE CARD
CONFIGS COMPLETE,= TO EXIT
CONFIGURATION MODE
CONFIGURATION NOT CHANGED
CONTINUOUS LOCKED
There was an error configuring the microprocessor with the Configuration PC card. Remove the PC card from the slot.
The user has reached the end of the Configurations list. Pressing the UP or DOWN ARROW key will start list over. Press the = key to exit Configuration list.
Press the = key to enter Configuration mode.
New configuration selection was not entered (saved).
The current set point 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 DataRecorder has been copied onto the PC card.
You may safely remove PC card from the slot. XX indicates the number of empty download slots remaining on the card.
62-10683 7--2
Message
COPY ERROR, REMOVE CARD XX
COPYING DATA -- PLEASE WAIT
DATA RECORDER FAILURE
DEFROST CYCLE STARTED
DOOR OPEN
DOOR OPEN -- LOW SPEED
ENTERING SERVICE MODE
EVAC / CHARGE MODE
EXITING PRETRIP MODE
EXITING SERVICE MODE
FUNCTION NOT CHANGED
HOUR METERS NOT CHANGED
INACTIVE ALARMS IN MEMORY
INSTALLED, REMOVE CARD XX
INSTALLING OPTION, PLEASE WAIT
INSTALL STOPPED, REINSERT CARD
KEYPAD LOCKED -- BATTERY TOO LOW
LIST END, = TO CLEAR ALARMS
LOADING INFO
MAIN MENU
MANUAL START MODE SELECTED
MessageCenter MESSAGES
Description
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 indicates the 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.
MAX SETPOINT HAS BEEN REACHED
The microprocessor has stopped recording unit data.
The unit has gone into defrost.
The trailer or rail compartment door is open.
The trailer or rail compartment door is open forcing the unit to run in low speed.
The initial message for Service mode. See Section 6.2.3.
The unit is in Service Mode, and the refrigeration system is ready to be evacuated or changed with refrigerant. See Section 6.2.3.
Pretrip has been aborted either by user or by a pretrip alarm.
Service mode has been turned off and unit is returning to normal operation.
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 microprocessor alarm list which have not yet been cleared.
An Option PC card has been inserted into the PC card slot, and the option has been installed in the microprocessor. The PC card may safely be removed from the slot. XX indicates the 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 microprocessor. 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 been stopped by the PC card not being fully inserted in the slot or by being removed. Remove and reinsert PC card to continue.
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.
The end of the Alarm list has been reached. Pressing the = key will clear the Alarm list.
A Configuration PC card has been inserted into the PC card slot, and information from the Configuration card is being loaded into the microprocessor. DO NOT REMOVE THE CARD WHILE THIS
MESSAGE IS BEING DISPLAYED.
Consists of Configuration mode, Component Test mode and Service modes.
The user has selected manual start mode. The diesel engine must be started using the manual GLOW/CRANK switch. This is available only on units that have a Glow Crank Switch.
Maximum set point allowed by configuration settings has been reached.
7--3 62-10683
MessageCenter MESSAGES
Message
MIN SETPOINT HAS BEEN REACHED
Description
Minimum set point allowed by configuration settings has been reached.
MODIFIED
NEW SW: = TO LOAD, TO ↑ CANCEL
NO ACTION TAKEN, REMOVE CARD
NO ACTIVE ALARMS
NO DATA ON CARD, REMOVE CARD
This message will appear in the MessageCenter along with the current IntelliSet indicating that the IntelliSet is active and one or more of its settings have been modified.
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 microprocessor. Press the = key 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 microprocessor. The PC card may be safely removed from the slot.
There are no active alarms in the microprocessor 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.
NO DATA TO COPY, REMOVE CARD
NO INACTIVE ALARMS
NO INSTALLS LEFT, REMOVE CARD 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.
OLD INTELLISETS -- USE REEFERMAN The IntelliSets that are on the Configuration PC Card were written with too old of a PC Program, like ServiceManager. The software in the microprocessor requires IntelliSets to be written to the Configuration PC Card using ReeferManager. Rewrite the information to the card using ReeferManager, then use it in the microprocessor again.
OLD SW, = CANNOT LOAD -- REMOVE
CARD
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
OLD SW, = TO LOAD, ↑ TO CANCEL
A Program PC Card has been inserted into the PC Card slot, and the major version of the program on the PC Card is an older version than what is already loaded in the microprocessor. Software with older major versions can not be loaded into the microprocessor. Remove the PC Card. (Refer to Section 6.5.1 for software version description.)
A Program PC Card has been inserted into the PC Card slot, and the minor version of the program on the PC Card is an older version than what is already loaded in the microprocessor. Press the = key to load the older program. (Refer to Section 6.5.1 for software version description.)
PC MODE
PM DUE
PM HOUR METER NOT CHANGED
Indicates that the conditions for entering PC Mode are met: the
START/RUN-OFF switch is OFF, the PC mode Jumper is connected and the engine is not running. 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 6.1.
Preventative Maintenance is now due on the unit.
The last change for the PM hourmeter was not received by the microprocessor.
PRESS ↑↓ TO VIEW DATA
PRESS ↑↓ TO VIEW SETTINGS
PRESS ↑↓ TO VIEW PRINT MENU
PRESS = TO MARK TRIP START
PRESS = TO START PRETRIP
PRESS ↑↓ TO VIEW INTELLISET
PRETRIP FAIL & COMPLETED
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.
Press the = key to mark the start of the trip in the data recorder.
Press the = key to begin pretrip tests.
Press the UP or DOWN ARROW key to view IntelliSet list.
Some of the pretrip tests did not pass.
62-10683 7--4
Message
PRETRIP FAIL IN TEST XX
PRETRIP PASS
PRODUCT SHIELD: HIGH AIR ON
PRODUCT SHIELD: WINTER ON
MessageCenter MESSAGES
Description
Some of the pretrip tests did not pass and the pretrip was not completed.
All of the pretrip tests were OK.
The unit is operating in ProductShield High Air which overrides normal unit operation. Refer to Section 5.16.1.b.
The unit is operating in ProductShield Winter which overrides normal unit operation. Refer to Section 5.16.1.c.
PRODUCT SHIELD: ECONO ON
RECOVER / LEAK CHK / EVAC MODE
REMOVE CARD -- BATTERY TOO LOW
REMOTE SWITCH 1 (2) OPEN
REMOTE SWITCH 1 (2) OPEN -- LOW
SPEED
REMOVE JUMPER
SAME SW, = TO LOAD, ↑ TO CANCEL
SERVICE MODE
SETPOINT CHANGED
SETPOINT NOT CHANGED
The unit is operating in ProductShield Econo which overrides normal unit operation. Refer to Section 5.16.1.a.
This message will be displayed when the unit is in Service Mode and the system is ready for recovery and leak testing.
If a PC card is inserted when battery is below 7.0 volts this message will be displayed until card is removed.
Remote switch is open. May be connected to a trailer or rail car compartment door or a remote control switch.
Shows that the remote switch is open and that the unit is running in low speed. Switch may be connected to a trailer or rail car compartment door or a remote control switch.
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 microprocessor. Press the = key to reload the same program or press the UP ARROW key to cancel and remove card.
Indicates that this selection has been made in Configuration and
Test Modes which allows servicing of the refrigeration system.
The new set point has been entered (saved into microprocessor memory). The new set point will be used.
The new set point has NOT been entered (NOT saved into microprocessor memory). The old set point will be used.
SETTING SMV: XXX %
SLEEP MODE, OFF / ON TO WAKE
SLEEP WARNING: DOOR OPEN
The START/RUN-OFF position has been placed in the
START/RUN position and the CSMV is opening.
The unit is cycled off in Sleep Mode. Place the
START/RUN--OFF switch in the OFF position, then back to the
START/RUN position to wake the microprocessor up.
The rail unit is in Sleep Mode and a rail car compartment door is open. The unit will start as needed for Sleep Mode.
SLEEP WARNING: NO TEMP CONTROL The unit is running in Sleep mode.
SLEEP WARNING: REMS1(2) OPEN The rail unit is in Sleep mode and a remote switch is open. Switch may be connected to a door or a remote control switch. The unit will start as needed for Sleep mode.
SMV CLOSING: WAIT xxx SECONDS
START MODE: AUTO or MANUAL
START-STOP LOCKED
Microprocessor is powering up and CSMV is closing. XX indicates the number of seconds remaining until valve is fully closed.
Indicates whether the unit is in Auto Start or Manual Start mode
The set point has been locked into the Start-Stop mode. Continuous Run can not be selected.
START-STOP MODE SELECTED
STATUS OK
TECHNICIAN RESET REQUIRED (A21)
TEST #1 to #16
TIME SELECTION NOT CHANGED
Start--Stop Mode has been selected.
The unit is working correctly.
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 entered in Configuration list.
7--5 62-10683
Message
TRIP START ENTERED
UNIT BATTERY LOW
UNIT SHUTDOWN -- DOOR OPEN
UNIT SHUTDOWN -- SEE ALARM LIST
UNIT SHUTDOWN -- RMS1(2)
UNKNOWN CARD -- REMOVE CARD
WARNING: NO TEMP CONTROL
MessageCenter MESSAGES
Description
The Trip Start marker has been placed in the DataRecorder.
The unit battery has dropped below 7 volts for more than 10 seconds.
WRONG UNIT TYPE, REMOVE CARD
The unit has shut down because the trailer or rail compartment door is open.
An active shutdown alarm has shut the unit down
The unit has shut down because switch is open. May be connected to a door or a remote control switch.
A defective or different type of PC Card has been inserted into the
PC Card slot. The microprocessor can not recognize any data on the card. The card may be safely removed from the microprocessor.
Both RAT and SAT alarms are on and unit is running with a set point in the frozen range in low speed six cylinder cool.
A Configuration PC Card has been inserted into the PC Card slot.
The unit model type on the PC card is not in the same unit family type as the controller. The card may be safely removed from the microprocessor
62-10683 7--6 Change 09/11
SECTION 8
ALARM TROUBLESHOOTING
PARAGRAPH NUMBER
8.1
INTRODUCTION TO ALARM TROUBLESHOOTING GUIDE
8.2
NOTES
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3
DRIVER/OPERATOR ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 SHUTDOWN ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 START UP ENGINE ALARMS
8.6 WARNING / STATUS ALARMS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7 ELECTRICAL ALARMS
8.8 SENSOR ALARMS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9 PRETRIP ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10 MAINTENANCE ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11 MICROPROCESSOR ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
8--19
8--37
8--48
8--56
8--1
8--2
8--3
8--7
8--68
8--103
8--107
1
SECTION 8
ALARM TROUBLESHOOTING
8.1 INTRODUCTION TO ALARM TROUBLE-
SHOOTING GUIDE
The Alarm Troubleshooting Guide should be used whenever an alarm occurs. Alarms will appear in the
MessageCenter 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
Note 1 Section 8.2 ) and make note of all alarms.
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.
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 or rail car is loaded, you may want to perform all the condensing unit checks first, even though some evaporator section checks may be listed before them.
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 inactivate themselves automatically must be cleared manually. (See Note 1 Page 8.2 )
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.
If the message CHECK MICROPROCESSOR 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 for the wiring that connects connector 6 on the microprocessor to the connector at the Keypad/Display assembly.
In later model units this message will read “CHK WIRES
FROM MICRO TO KEYPAD.”
When working on the refrigeration system, an accurately calibrated manifold test set should always be installed. It is also a good idea to connect an additional high pressure gauge to the king valve.
In high or low ambients, it may be necessary to cool or warm the box temperature before performing specific tests providing that the trailer or rail compartment is not loaded with perishable product.
WARNING
Beware of V-belts and belt driven components as the unit may start automatically.
Before servicing unit, make sure the
START/RUN-OFF switch is in the OFF position or the unit is in the Maintenance mode.
Also disconnect the negative battery cable.
WARNING
UNITS EQUIPPED WITH STAR-TRAK TWO
WAY COMMUNICATION CAPABILITIES MAY
HAVE THE ABILITY TO BE STARTED OR
TURNED OFF REMOTELY REGARDLESS OF
THE SETTING OF THE START/RUN-OFF
SWITCH.
The unit is controlled locally and there can be no two-way communication when the
Mode switch on the Remote Monitoring
Control Box is in MAINTENANCE MODE.
Therefore, when performing any work on the unit, place the Mode switch in MAINTE-
NANCE MODE. After the unit is serviced, return the Mode switch to REMOTE ON. (Refer to Section 3.20.3 for more detailed information on two-way communication.)
8--1
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8.2 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 the = key 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 six 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 For units with a Glow/Crank switch, refer to
Note 4, Note 5 and Note 9.
Note 3 To test electrical circuits when unit is without a glow crank switch, locate the 3 “extra” wires inside the control panel that were used to connect to the glow crank switch before April,
2007. Use either a jumper wire to energize the circuits, or connect a temporary GCS into the circuit to continue.
Note 4 To test electrical circuits when the unit is equipped with a glow crank switch, place the unit in Manual Start Operation.
To do this, first turn the unit off. Press and hold the Glow/Crank switch in the Glow position.
Place the Start/Run-Off Switch in Start/Run position. Continue to hold the Glow/Crank switch until the setpoint and box temperature are shown in the display, then release it. The
MessageCenter will show
“Manual Start Mode Selected”, and the Run
Relay will be energized. See Unit non-running amps below for current draw in this state.
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Note 5 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 6.1.
For units with a Glow/Crank switch, an alternative method to power up the microprocessor with no load, hold the
Glow/Crank switch in the glow position, and place the START/RUN-OFF switch in
START/RUN.
Continue to hold the
Glow/Crank switch for two seconds after the self test begins, then release. This is before the setpoint and box temp values are show.
The Message Center will show “Manual Start
Mode Selected,” however no electrical circuits will be energized. Current draw in this state is 0 ± 0.5 Amps.
Note 6 Sensors and sensor circuits may be tested at the 1MP plug.
Remove plug from microprocessor and using the 1MP Plug Map and an ohmmeter, test resistance of circuits.
(See Section 9.28 for chart of resistances for different sensors.)
Note 7 When checking the Defrost Air switch, RPM
Sensor (Standard Engine Only), Engine Oil
Level switch, Door switch, or HPS, unplug
2MP at the microprocessor. Using the 2MP
Plug Map and wiring diagram, check for voltage at the appropriate terminal.
Note 8 When checking the light bar, Solenoid Valves
& Unloader circuits, unplug 3MP at the microprocessor. Using the 3MP Plug Map and wiring diagram, check for voltage at terminal of the circuit you are testing. Should be battery voltage.
Note 9 Some tests can only be conducted while the unit is operating. The unit may be started automatically by placing the
START/RUN-OFF switch in the START/RUN position. Units with a Glow/Crank switch can be started manually by pressing and holding the Glow/Crank switch in the Glow position.
Place the START/RUN-OFF switch in
START/RUN.
Continue to hold the
Glow/Crank switch until the setpoint and box temperature are shown in the display, then release it after glowing the engine for the appropriate time required for the ambient temperature. The MessageCenter will show
“Manual Start Mode Selected.” Hold the
Glow/Crank switch in the Crank position until the engine starts.
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
8.3 DRIVER/OPERATOR ALARMS
1 LOW FUEL LEVEL WARNING (for units with Low Fuel Level 0% to 100% Sensor / fuel level is displayed in Data list)
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: Alarm only
• 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.
a. Check fuel level in the fuel tank
2
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 c. Check for voltage at the harness plug between pins for BLACK (SP24) negative and RED (SPK5) positive wires.
Place START/RUN-OFF switch in START/RUN position.
Voltage should be approximately12VDC.
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.
3
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)
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Alarm
NO.
1
Steps ALARM / CAUSE CORRECTIVE ACTION
LOW FUEL LEVEL WARNING (for units with Low Fuel Level switch/no fuel level display in Data list
• TRIGGER ON: Fuel level is less than 1/8 of a tank for more than 30 seconds.
• UNIT CONTROL: Alarm only
• RESET CONDITION: Auto reset when fuel level is above 1/4 tank for more than 30 seconds.
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
a. . Check fuel level in the fuel tank
2
Check Fuel Level Switch
a. . Inspect fuel level switch & connector pins & terminals b. .Check fuel level switch operation c. .Check for voltage at harness plug between pins A and B
Add fuel as needed to the fuel tank.
No physical damage to switch.
No damaged or corroded pins in plug.
Place unit in Component Test Mode -- Run Relay On, or in
Manual Start Mode (see Note Note 4). DO NOT START
UNIT.
Voltage should be approximately 12VDC at harness plug between pins A and B.
d. .Check continuity of the wire from the harness plug, pin C to the microprocessor plug 2MP04
Place START/RUN-OFF switch in OFF position prior to checking for continuity. Must be less than 10 ohms.
3
Check Circuits With Test (Substitute) Switch
a. Substitute known good sensor and clear alarm. Start unit and run for 30 seconds.
Alarm should not come on. (Install new switch if necessary) b. Check to see if alarm re-occurs.
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8--4
Alarm
NO.
2
Steps ALARM / CAUSE
LOW ENGINE OIL LEVEL
CORRECTIVE ACTION
Note: This is an optional alarm which will not occur unless an oil level sensor is present and configured ON.
•
TRIGGER–ON: Engine oil level is sensed approx. 7 or more qts. (6.62 or more liters) low for longer than
30 seconds.
• UNIT CONTROL: Alarm Only, or may be configured to shut unit down on some models.
• RESET CONDITION: Auto reset if engine oil level is above 4 qt. (3.79 liters) low 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 Engine Oil Level
Add engine oil as needed to fill.
a. Check engine oil dipstick
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
Check Engine Oil Level Switch Harness
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.) b. Check for shorted circuit in harness, and continuity through the harness
No physical damage to harness.
No damaged or corroded pins
Place unit in PC mode, or in Manual Start mode (see Note
Note 4.) DO NOT START UNIT.
Battery voltage reading (12-13 VDC) between wires in plug
4
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.
8--5
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Alarm
NO.
3
Steps ALARM / CAUSE CORRECTIVE ACTION
LOW COOLANT LEVEL
• TRIGGER ON: Engine coolant level is 1 or more quarts (.95 or more liters) low for more than 30 seconds.
• UNIT CONTROL: Alarm only
• RESET CONDITION: Auto reset if engine coolant level is at the full mark for more than 30 seconds. 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
Add coolant as needed to the coolant reservoir and to the fill tube on the radiator b. Check coolant hoses for leaks or breaks
Repair all leaks and breaks as necessary
Add coolant as needed to the coolant reservoir and to the fill tube on the radiator
2
Check Engine Coolant Level Switch
a. Inspect engine coolant level switch & connector pins & terminals b. Check harness wiring to plug.
c. Check engine coolant level switch operation
No physical damage to switch.
No damaged or corroded pins in plug.
Verify wires are in correct plug orifice.
Place unit in Component Test mode, Run Relay On or in
Manual Start mode (see Note Note 4). DO NOT START
UNIT.
Voltage should be 12 volts at harness plug between pins A and B.
d. Check for voltage 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.
3
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)
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8--6
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
8.4 SHUTDOWN ALARMS
11 LOW ENGINE OIL PRESSURE
• TRIGGER–ON: Engine oil pressure is below 12 PSIG (0.82 Bar) for longer than five seconds while the engine is running.
• UNIT CONTROL: Unit Shutdown & Alarm.
• 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 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
Check Engine Oil Pressure Switch
a. Inspect switch & connector pins & terminals b. Check engine oil switch operation.
No physical damage to switch.
No damaged or corroded pins in plug.
Contacts closed when oil pressure is above 15 PSIG (1.02
Bars)
Contacts open when oil pressure is below 12 PSIG (0.82
Bar)
3
Check Engine Oil Switch Harness
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.) b. Check for shorted circuit in harness, and continuity through the harness
No physical damage to harness.
No damaged or corroded pins
START/RUN-OFF switch in START/RUN position, Manual
Start mode (See Note Note 4) or PC mode
Battery voltage reading (12-13 VDC) between wires in plug
4
Check Engine Oil Pressure
a. Connect mechanical oil gauge b. Check engine oil level
Oil pressure must be greater than 15 PSIG (1.02 Bars)
Oil must be in safe range on dipstick
8--7
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
12 HIGH COOLANT TEMPERATURE
• TRIGGER–ON: 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 five minutes.
•
UNIT CONTROL: Unit Shutdown & Alarm.
• 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 Level must be in the Normal range.
b. Check coolant level in radiator 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
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.
3
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.
4
Check Condenser And Water Pump Belts
a. Check upper fan belt tension & condition.
b. Check lower fan belt tension & condition.
c. Check radiator fan belt.
d. Check water pump belt tension & condition.
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping
5
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
Temperature must be within ±20°F (±11.1°C).
(Refer to Section 2.7 for coolant thermostat specifications)
Must not leak, impeller attached tightly to shaft
Must be clear and open.
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8--8
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
13 HIGH DISCHARGE PRESSURE
• TRIGGER–ON: Compressor discharge pressure is over 465 PSIG (31.6 Bars)
• UNIT CONTROL: Immediate Unit Shutdown & Alarm
• 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
If Alarm Occurs During Pretrip Test 11, 12 Or 13
a. Check discharge snubber tee Remove and inspect tee. If snubber restrictor is in place, remove it, reinstall tee, and re-test for alarm.
b. Check SV1 for opening.
During pretrip tests 11, 12 and 13, SV1 may be energized for 1 second to reduce head pressure during tests. If SV1 fails to actually open during the 1 second that it is de-energized, this alarm may occur. Repair SV1 as needed.
2
Check Fan Belts
a. Check upper fan belt tension & condition b. Check lower fan belt tension & condition.
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping
3
Check Wiring
a. Visually Inspect wiring to HPS, SV4, & both Compressor Unloaders
4
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
5
Check System Pressures
a. Install Manifold Test Set and check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Wires must be connected properly & securely to each component
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.
6
Check For Refrigerant Overcharge
a. Check refrigerant level in the receiver tank.
7
Check HPS Switch
a. Inspect switch & connector pins & terminals b. Check switch operation
(Refer to Section 2.11 for pressure settings)
Level must be between upper & lower sight glasses
No physical damage to switch.
No damaged or corroded pins in plug.
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)
Additional steps on the next page.
8--9
62-10683
Alarm
NO.
Steps ALARM / CAUSE
13 HIGH DISCHARGE PRESSURE (Continued)
8
Check HPS Switch Harness
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.) b. Check for shorted circuit in harness, and continuity through the harness
CORRECTIVE ACTION
No physical damage to harness.
No damaged or corroded pins
START/RUN-OFF switch in START/RUN position, Manual
Start mode (See Note Note 4)
Battery voltage reading (12-13 VDC) between wires in plug
9
Perform Pretrip Check
a. Run Pretrip & check for alarms
10
See Refrigeration Trouble Shooting
Section 10.3
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.
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8--10
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: Unit Shutdown & Alarm
• 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 Battery Voltage
a. Test voltage at battery with unit off.
b. Test voltage at battery with unit running.
2
Check Alternator Voltage
Must be between12-16 VDC
Must be between12-16 VDC a. Test voltage at alternator output terminal with unit off
Must be between 12-16 VDC
Must be between 12-16 VDC b. Test voltage at alternator output terminal with unit running.
3
Check Voltage At Microprocessor
a. Check voltage reading at microprocessor input (QC1+ to QC2-) b. Check voltage microprocessor display reading on
Must be between 12--16 VDC.
Must be within 0.5 VDC of reading obtained in 3 Amp
(above)
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
• 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 Alternator Not Charging Alarm
a. Check for alarm 51 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
(Check for battery specifications)
(Check for battery specifications) d. Test specific gravity of battery e. Perform load test on battery (Follow battery manufacturer’s procedure)
3
Check Voltage At Microprocessor
a. Check voltage reading at microprocessor input (MPQC1+ to
MPQC2-).
b. Check voltage microprocessor display reading on
Must be above 11 VDC
Must be within 0.5 VDC of reading obtained in 3a (above)
8--11
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
17 HIGH COMP DISCHARGE TEMP
• TRIGGER–ON:
Ambient temp below 120°F (48.9°C) discharge temp was between 310°F -- 349°F (154.4°C -- 176.7°C) for three minutes, or
Ambient temp above 120°F (48.9°C) Discharge temp was between 340°F -- 349°F (171.1°C -- 176.7°C) for three minutes, or
Discharge temp ever reaches 350°F (176.7°C)
• UNIT CONTROL: Unit Shutdown & Alarm
• 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 (65.4°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
If Alarm Occurs During Pretrip
a. Pump down low side of refrigeration system.
Verify that system will pump down to 0 PSIG and will hold without leak-back.
2
Check Refrigerant Charge
a. Check for undercharged system
3
Check Airflow Through Condenser Coil
Level must be above lower sight glass a. Inspect condenser/radiator fins b. Check airflow (with unit running).
Fins must be straight. 90% or more of the coil surface must be undamaged. No “dead” air spaces.
Condenser/ Radiator coil must be clean.
Even airflow through the entire coil
No “dead” spots
4
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.
5
Check DTT2
a. Visually inspect the mounting and orientation of DTT2 b. Verify the temperature of DTT2.
Must be mounted tightly to the evaporator section, with the long flat surface of DTT2 in contact with the metal surface.
Use a test temperature reading device (infrared, independent thermometer, etc.) to verify that DTT2 temperature is the same as that being displayed in the
Unit Data list. (Refer to Section 3.14.)
6
Perform Pretrip Check
a. Run Pretrip & check for alarms
7
Check compressor reed valves & gaskets
a. Remove compressor heads & inspect condition of all reeds & gaskets
Must be in good condition.
Additional steps on the next page.
Any active alarms must be corrected and cleared before proceeding.
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8--12
Alarm
NO.
Steps ALARM / CAUSE
17 HIGH COMP DISCHARGE TEMP (Continued)
8
Check Expansion Valve (TXV)
a. Visually inspect valve
CORRECTIVE ACTION
b. Check MOP of valve c. Check superheat of valve
9
Check system for non-condensables
a. Check refrigeration system for non-condensable gas(es)
Bulb must be clamped tightly on the suction line and insulated. No physical damage to bulb, capillary tube of valve body.
Refer to Section 2.11
Refer to Section 2.11
No non–condensable gas(es) may be present.
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
18 LOW REFRIGERANT PRESSURE
• TRIGGER–ON:
Suction Pressure is less than -6 inHg (-0.2 Bar) for more than 120* seconds, when the RAT is above -10°F (-23.3°C), or
If the Suction Pressure is less than -16 inHg (-0.41 Bar) for more than 120*seconds at any RAT temperature,
•
UNIT CONTROL: Alarm Only or Unit Shutdown & Alarm (if configured)
•
RESET CONDITION:
Auto Reset after 15 minutes if Suction Pressure is more than -4 inHg (-0.41 Bar), or if RAT falls below -10°F (-23.3°C), or Alarm may be manually reset via keypad or by turning the unit off, then back on again.
* Time may be set from 0 -- 255 seconds in the configuration list. Refer to section 6.2.1.
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 Fan Belts
a. Check upper fan belt tension & condition
2
Check System Pressures
a. Install Manifold Test Set and check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping)
Suction pressure must be above 3 PSIG (0.2 Bar)
Suction & Discharge Pressures must have the same reading on gauges & on micro display.
3
Check Refrigerant Charge
a. Check for undercharged system
4
Manually Defrost Unit
a. Defrost unit automatically.
and terminate
5
Check Evaporator Airflow
a. Check evaporator fan clutch b. Check evaporator section, blower wheel, return air bulkhead, air chute, and cleanliness of evaporator coil
Level must be above lower sight glass
Typical defrost cycle time is 5-20 minutes
Suction pressure should rise gradually during cycle.
Must be engaged
Good Air Flow
Return air not restricted
Air chute in good condition
No damage to blower wheel
Evap. coil clean
6
Perform Pretrip Check
a. Run Pretrip & check for alarms Any active alarms must be corrected and cleared before proceeding.
7
Check Expansion Valve (TXV)
a. Visually inspect valve b. Check MOP of valve c. Check superheat of valve
Bulb must be clamped tightly on the suction line and insulated
Refer to Section 2.11
Refer to Section 2.11
62-10683
8--14
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
19 LOW FUEL SHUTDOWN (for units with Low Fuel Level 0% to 100% Sensor / fuel level is displayed in Data list)
• TRIGGER ON: Fuel level is 10% or less for more than 1 minute.
• UNIT CONTROL: Unit shutdown and Alarm.
• 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
Check For Low Fuel Level Warning Alarm
a. Check for alarm 1 Must be cleared.
b. Check fuel level intake Must be above 1/4 tank.
Fill as needed.
2
Check accuracy of sensor
a. Verify sensor accuracy b. Check wiring to sensor
See Section 9.8.2 for sensor testing.
No physical damage to sensor.
No damaged or corroded pins.
3
Check fuel level sensor 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
START/RUN-OFF switch in START/RUN position.
Battery voltage reading (12-13 VDC) between A and B wires in plug.
19 LOW FUEL SHUTDOWN (for units with Low Fuel Level Switch / no fuel level display in Data list)
• TRIGGER ON: Alarm 1 (LOW FUEL LEVEL) has been on past the allowed run time (See chart below)
• UNIT CONTROL: Unit shutdown and Alarm.
• RESET CONDITION: Auto reset when fuel level is above 1/4 tank for more than 30 seconds or Alarm may be manually reset via keypad or by turning the unit off, then back on again.
30 gal. Fuel tank
50 gal. Fuel tank
30 Minutes
60 Minutes
75 gal. Fuel tank
100 gal. Fuel tank
120 gal. Fuel tank
90 Minutes
120 Minutes
150 Minutes
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 Warning Alarm
a. Check for alarm 1 Must be cleared.
8--15
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
20 MAXIMUM COMPRESSOR ALARMS
• TRIGGER ON: One of the following alarms:
13 -- High Discharge Pressure
18 -- Low Refrigerant Pressure
28 -- Check Refrigerant System
17 -- High Compressor Discharge Temperature
27 -- High Suction Pressure
29 -- Check Heat Cycle
56 -- Check Evaporator Airflow has occurred three times during the last two hours of actual unit operation (off cycle time is not included), AND this alarm (Alarm 20) has been enabled in this microprocessor (“Test 6” or “Compressor Alarm Shutdown” appears in the Installed Options List in Unit Data), AND
Compressor Alarm Shutdown in the configuration list has been set to YES. (Refer to
Section 3.14. for information on Unit Data list)
• UNIT CONTROL: Unit shutdown and Alarm.
• RESET CONDITION: This alarm can only be cleared from the Inactive Alarm list. It can not be cleared from the Active Alarm list, and it will not clear when the START/RUN-Stop switch is turned Off then On again. This is so that drivers and other operators can not reset the alarm. The unit MUST be taken to a repair shop for inspection and repair.
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 trigger on alarms
a. Check the Active Alarm list to see which of the following alarms is also present: A13, A17, A18, A27, A28,
A29, A56
See steps for the active alarm so that the alarm can be cleared.
All Alarm(s) from the above list must be cleared to continue.
Reset Alarm 20 from the Inactive Alarm list.
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
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.
2
Reset Alarm
Reset all alarms from the inactive alarm list.
All alarms must be cleared to start unit.
62-10683
8--16
Change 09/11
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
27 HIGH SUCTION PRESSURE
• TRIGGER ON: Suction pressure has been greater than 98 PSIG (6.7 Bars) for more than 10 minutes
• UNIT CONTROL: Alarm Only or Unit Shutdown & Alarm (if configured)
• RESET CONDITION:
Auto reset when suction pressure is less than 75 PSIG (5.1 Bars) for five minutes if 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. Check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Suction & Discharge Pressures must have the same reading ± 5 PSIG (±0.34 Bar) on gauges & on micro display.
2
Check Compressor Drive Coupling
a. Verify that compressor coupling is intact, and that the compressor crankshaft is turning.
3
Perform Pretrip Check
a. Run Pretrip & check for alarms
Compressor crankshaft must be turning.
Any active alarms must be corrected and cleared before proceeding.
4
Check compressor reed valves & gaskets
a. Remove compressor heads & inspect condition of all reeds & gaskets
Must be in good condition.
5
Check compressor pistons and connecting rods.
a. Check compressor connecting rods.
pistons and Must be in good condition.
6
See Refrigeration Trouble Shooting Section 10.3
8--17
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
28 CHECK REFRIGERATION SYSTEM
• TRIGGER ON: Discharge pressure is not at least 5 PSIG (0.34 Bar) higher than Suction pressure for more than 10 minutes
• UNIT CONTROL: Alarm Only or Unit Shutdown & Alarm (if configured)
• RESET CONDITION: Auto reset when discharge pressure is more than 20 PSIG (1.36 Bars) above the suction pressure for five 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 display.
Suction & Discharge Pressures must have the same reading -- ± 5 PSIG (±0.34 Bar) -- on gauges & on micro display.
2
Check Compressor Drive Coupling
a. Verify that compressor coupling is intact, and that the compressor crankshaft is turning.
Compressor crankshaft must be turning.
3
Perform Pretrip Check
a. Run Pretrip & check for alarms Any active alarms must be corrected and cleared before proceeding.
4
Check compressor reed valves & gaskets
a. Remove compressor heads & inspect condition of all reeds & gaskets
Must be in good condition.
5
Check compressor pistons and connecting rods.
a. Check compressor connecting rods.
pistons and Must be in good condition.
6
See Refrigeration System Troubleshooting, Section 10.3.
29 CHECK HEAT CYCLE
• TRIGGER ON: The unit has been operating in the heat cycle for more than 5 minutes, and the SAT is more than 5.5°F (3°C) colder than the RAT constantly for more than 60 seconds. (Unit is actually cooling the air going through the evaporator).
• UNIT CONTROL: Unit shutdown and alarm.
• RESET CONDITION: Auto reset after 15 minutes or alarm may be manually reset via keypad or by turning the START/RUN-OFF switch OFF and 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 Pretrip Check
a. Run Pretrip & check for alarms Any active alarms must be corrected and cleared before proceeding.
2
See Troubleshooting, Section 10.3. -- Refrigeration System Not Heating
62-10683
8--18
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
8.5 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).
• UNIT CONTROL: Unit Shutdown & Alarm
• RESET CONDITION: Alarm may be manually reset via keypad or by turning the unit off, then back on again.
If Unit Operation mode is set for Rail, this alarm will automatically reset after 4 hours.
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.
8--19
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
31 FAILED TO START -- AUTO MODE
• TRIGGER–ON: Engine has tried to start three times unsuccessfully in the auto start mode.
• UNIT CONTROL: Unit Shutdown & Alarm
• 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 Flash Code On Engine Speed Control Unit (ENSCU)
(Applies to ESC engines only).
a. Check for flash codes on the ENSCU. Refer to Electronic Speed Control Diagnostic tables --
Figure 10--1 thru Figure 10--4. There must be no LED flashing alarm codes occurring to continue.
2
Check Fuel Level In Tank.
a. Check fuel gauge on tank.
Fill tank as needed.
3
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
Alarm conditions must be corrected and the alarm cleared to continue
4
Check Fuel Solenoid (Applies to non--ESC engines only)
a. Check Run Relay LED Must be ON.
b. Check voltage to fuel solenoid Energize Run Relay in Component Test Mode (Refer to section 6.2.2) to energize the fuel solenoid.
Must have 12 VDC between FSC--C (ground) & FSH--A
(hold)
With Manual Crank Switch in crank position (for units with
GCS only)
12 VDC between FSC--C (ground) & FSP--B (pick) c. Inspect solenoid & connector pins & terminals d. Inspect harness & control box connector pins & terminals (See wiring schematic) e. Check resistance of solenoid f. Check operation of solenoid
5
Check Fuel System
a. Check fuel system prime b. Check fuel flow c. Check voltage to glow plugs
For units without GCS, check FSC--B (pick) circuit between fuel solenoid and starter motor.
No damage to solenoid
No damaged or corroded pins
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13
Plunger must move in when energized
No air in fuel system
Unrestricted fuel flow through system
Glow Plug switch ON, Manual Start Mode (units with GCS only)
Units without GCS, energize Glow Plug Relay in
Component Test Mode (Refer to section 6.2.2)
In both cases there must be more than 11 VDC
6
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
Additional steps on the next page.
62-10683
8--20
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
31 FAILED TO START -- AUTO MODE (Continued)
7
Check For Correct Engine Oil
a. Check for correct oil viscosity (weight) for conditions
Refer to Section 2.7
Must be correct for ambient conditions
8
Check Engine Exhaust System
a. Inspect the exhaust system
9
Check Engine
a. Check engine compression
10
Check RPM Sensor
a. Check sensor.
Must be clear and unobstructed
Refer to Section 2.7
Refer to Section 9.8.3.
8--21
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
32 FAILED TO START -- MANUAL
• TRIGGER–ON: The unit was placed in Manual Start mode, and the engine was not manually started within five minutes. or,
The user has tried to start the engine three times unsuccessfully in the Manual Start mode.
•
UNIT CONTROL: Unit Shutdown & Alarm
• RESET CONDITION: Reset by changing to Auto Start mode, 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 If Unit Has A Glow/Crank Switch (GCS).
a. Visually check to see if the unit has a
GCS (Units built after April, 2007 do not have this switch). Refer to Section 3.2
for location of switch.
For units with a GCS, continue with Step 2 below.
For units without a GCS, check the wiring that would connect to the switch if it were present for shorts. It is not possible to place the unit in Manual Start Mode without energizing this circuit.
2
Check For Flash Code On Engine Speed Control Unit (ENSCU)
(Applies to ESC engines only).
a. Check for flash codes on the ENSCU. Refer to Electronic Speed Control Diagnostic tables --
Figure 10--1 thru Figure 10--4. There must be no LED flashing alarm codes occurring to continue.
3
Operator Failed To Crank Engine
Engine starts and runs a. Manually start unit.
4
Check Fuel Level In Tank.
a. Check fuel gauge on tank.
5
Check For Check Glow Plugs Alarm
a. Check for alarm 40
Fill tank as needed.
Alarm conditions must be corrected and the alarm cleared to continue.
6
Check Manual Glow/Crank Switch (GCS) (Only for units with a GCS)
a. Check the glow/crank switch No damaged or corroded pins
No physical damage b. Check voltage to glow/crank switch
- Voltmeter lead on - Battery post
+ Voltmeter lead on switch terminals
(With wires connected to switch)
START/RUN-OFF switch in START/RUN position, Manual
Start mode (See Note Note 4)
Position
Off:
Terminals
1
2 & 3
1 & 3
VDC
11 V (min)
0 V (min)
10 1/2 V (min) Glow
2 0 V (min)
Disconnect wire to Starter Solenoid before checking:
Crank: 1 & 2
3
11 1/2V (min)
0 V (min) c. Check voltage to glow plugs d. Check voltage to starter solenoid
Glow Plug switch ON, Manual Start mode
More than 11 VDC
Crank switch ON, Manual Start Mode
More than 11 VDC
7
Check Glow/Crank Switch Harness -- All Units
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
Additional steps on the next page.
No physical damage to harness.
No damaged or corroded pins
62-10683
8--22
Alarm
NO.
Steps ALARM / CAUSE
32 FAILED TO START -- MANUAL (Continued)
8
Check Fuel Solenoid (Applies to non--ESC engines only)
a. Check Run Relay LED b. Check voltage to fuel solenoid
LED 28 must be ON.
START/RUN-OFF switch in START/RUN position, Manual
Start mode (See Note Note 4)
More than 11 VDC positive and good ground c. Inspect solenoid & connector pins & terminals d. Inspect harness & control box connector pins & terminals (See wiring schematic (See Wiring Schematic
Section 11.)
No damage to solenoid or wires
No damaged or corroded pins
Wires plugged in
No physical damage to harness.
No damaged or corroded pins e. Check resistance of solenoid f. Check operation of solenoid
9
Check Fuel Solenoid Harness
a. Inspect harness & control box connector pins & terminals (See Wiring
Schematic Section 11.)
10
Check Fuel System
a. Check fuel system prime b. Check fuel flow
CORRECTIVE ACTION
Refer to Section 2.13
Plunger must move in when energized
No physical damage to harness.
No damaged or corroded pins
No air in fuel system
Unrestricted fuel flow through system c. Check fuel system check valve from filter to injection pump.
11
Check Engine Air–Intake System
a. Check air filter indicator b. Inspect air intake system
Check valve must hold fuel and not leak back
Flag must not be visible.
Hoses & tubes in good condition.
No kinks or restrictions
12
Check For Correct Engine Oil
a. Check for correct oil viscosity (weight) for conditions
13
Check Engine Exhaust System
a. Inspect the exhaust system
14
Check Engine
a. Check engine compression
Refer to Section 2.7
Must be correct for ambient conditions
Must be clear and unobstructed
Compression must be above 400 PSIG (27.22 Bar)
8--23
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
34 ENGINE FAILED TO STOP
• TRIGGER–ON: Engine is turning more than 500 RPM (or the micro input shows that the engine is turning more than 500 RPM) for 20 seconds after unit was turned off, shut down on an alarm or cycled off in a
Start/Stop Off Cycle, or
Oil Pressure Switch contacts are closed longer than 20 seconds after unit was turned off, shut down on an alarm, or cycled off in a Start/Stop Off Cycle.
•
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 Engine Running
Engine should not be running.
a. Verify that engine is still running.
2
Check RPM Sensor
a. Check actual engine RPM using hand held tachometer.
Adjust engine linkage setting as needed.
b. Compare actual RPM with those shown on display.
Both readings within ± 50 RPM.
3
Check For Bad Engine RPM Sensor Alarm
a. Check for Alarm 130 Alarm conditions must be corrected and the alarm cleared to continue
4
Check Engine Oil Pressure Switch
a. Inspect switch & connector pins & terminals b. Check engine oil switch operation.
No physical damage to switch.
No damaged or corroded pins in plug.
Contacts closed when oil pressure is above 15 PSIG (1.02
Bars)
Contacts open when oil pressure is below 12 PSIG (0.82
Bar)
5
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
Start/Run--Off Switch in Start/Run position, Manual Start
Mode (See Note Note 4) (for units with GCS only)
For units without a GCS, use Component Test Mode to energize the Run Relay (Refer to Section 6.2.2)
Battery voltage reading (12--13 VDC) between wires in plug to Oil Pressure Switch when disconnected from the switch.
6A.
Check Fuel And Speed Actuator (FSA) & Circuit (ESC Engines Only)
a. Check Run Relay LED LED 28 must be OFF.
b. Check for 12 VDC on the Run Relay circuit
Must be 0 VDC c. Check SPK20 for voltage d. Check ENSCU terminals 13 & 15 for voltage
Must be 0 VDC
Must be 0 VDC e. Check FSA plunger b. Check voltage at harness to fuel solenoid (non ESC engines)
Must be free to move
6B.
Check Fuel Solenoid (non--Electronic Speed Controlled (ESC) engines) & Circuit
a. Check Run Relay LED LED 28 must be OFF.
Must be 0 VDC c. Check fuel solenoid plunger Must be free to move
62-10683
8--24
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
35 CHECK STARTER CIRCUIT
• TRIGGER–ON: Engine speed failed to reach 50 RPM during 2 start attempts.
• UNIT CONTROL: Unit Shutdown & Alarm
• 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 Engine Start--Up
a. Does engine actually start, run for a few seconds then shut off?
If NO, continue with step 2 below.
If YES, check wiring to RPM sensor for a broken wire.
2
Check If Unit Has Electronic Speed Control Flash Code (ESC Engines Only)
a. Check for flash codes on the Engine
Speed Control Unit (ENSCU).
Refer to Electronic Speed Control Diagnostic tables --
Figure 10--1 thru Figure 10--4
Must be above 11.5 VDC b. Check for voltage at ENSCU terminal
13 c. Check for ground at ENSCU terminal
19.
3
Check Starter Relay Circuit
a. Check operation of starter solenoid relay b. Check relay socket & terminals
No damage or high resistance.
START/RUN-OFF switch in START/RUN position, Manual
Start mode (See Note Note 4)
Relay contacts closed when crank switch is ON
No signs of discoloration from overheating
No corrosion c. Check voltage to Starter Solenoid
Relay d. Inspect wiring to starter solenoid & starter motor e. Check voltage to starter solenoid f. Check voltage to 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
Must be above 11.5 VDC
Must be above 10 VDC while cranking
4
Check Fuel and Speed Actuator (FSA) & circuit (ESC Engines Only)
a. Check Run Relay LED LED 28 must be ON.
b. Check for 12 VDC on the Run Relay circuit
Must be 0 VDC c. Check SPK20 for voltage d. Check ENSCU terminals 13 & 15 for voltage e. Check FSA plunger
5
Check Starter
a. Inspect starter and wiring.
Must be 12 VDC
Must be 12 VDC
Must be free to move b. Check resistance of solenoid c. Check resistance of starter motor d. Test amperage draw of starter.
Additional steps on the next page.
No damage or corrosion
Wiring and battery cable must be clean and tight.
Refer to Section 2.13
Refer to Section 2.13
Refer to Section 2.13
8--25
62-10683
Alarm
NO.
Steps ALARM / CAUSE
35 CHECK STARTER CIRCUIT (Continued)
6
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.
c. Test specific gravity of battery d. Perform load test on battery (Follow battery manufacturer’s procedure)
7
Check for correct engine oil
a. Check for correct viscosity for conditions
CORRECTIVE ACTION
Must be above 11 VDC
Check
Check
Refer to Section 2.7
Must be correct for ambient conditions
62-10683
8--26
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 five minutes.
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when Coolant temp rises above 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, 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 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 6) b. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
(Refer to Section 2.13 for complete resistance chart)
10k Ohms @ 77°F (25°C)
No physical damage to harness.
No damaged or corroded pins
8--27
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
37 CHECK LOW SPEED RPM
• TRIGGER–ON: Controller is set for low engine speed operation, and RPM being read by the microprocessor are not correct. The correct RPM for low speed are different for different models as shown below:
Less than 1325 or greater than 1625 for Ultima XTC and X2 2500A/R; or
Less than 1200 or greater than 1500 for Ultra XTC and X2 2100A/R for more than 60 seconds (120 seconds when the microprocessor calls for a change from high speed to low speed, or when the unit first starts)
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if controller is set for low engine speed operation and RPM are:
Between 1375 to 1575 for Ultima XTC and X2 2500A/R; or
Between 1250 to 1400 for Ultra XTC and X2 2100A/R for 60 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 Model Number
a. Verify that the model number on the unit data label matches the model number shown in the micro unit data list.
Enter the correct number in the data list. (Refer to Section
3.14.)
2
Check For Proper Voltage To The Engine Speed Control Unit (ENSCU) Pin 22 Based On The
Model. Check For Proper Voltage With Unit Running. (ESC Engine only)
a. Ultima XTC and X2 2500A b. Ultra XTC and X2 2100A
Verify 0 VDC at terminal 16 of the ENSCU.
Verify 12 VDC at terminal 22 of the ENSCU.
Verify 0 VDC at terminal 16 of the ENSCU.
Verify 0 VDC at terminal 22 of the ENSCU.
3
Check Speed Solenoid & Linkage On Non--electronic Speed Controlled (ESC) Engines
(Fuel and Speed Actuator on ESC engines)
a. Check speed solenoid on standard engines (Fuel and speed actuator on
ESC plunger)
Must move in and out freely b. Check engine speed arm and linkage Must move freely
4
Force Low Speed Operation (See Note 9)
a. Using Functional Parameters, set the
Low Speed Start Up Delay to 10 minutes.
Unit will run in low speed. RPM must be within range shown above for each specific model. Adjust speed linkage as needed.
b. Check operation of Speed Relay LED LED 27 must be OFF.
c.Check voltage at engine speed control unit (ENSCU) pin 16.
Must be 0 VDC
5
Check Engine RPM
a. Check actual engine RPM using hand held tachometer
Refer to Section 2.7
Adjust engine linkage setting as needed.
Both readings within ± 50 RPM b. Compare actual RPM with those shown on display.
6
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
Additional steps on the next page.
62-10683
8--28
Alarm
NO.
Steps ALARM / CAUSE
37 CHECK LOW SPEED RPM (Continued)
7
Check Engine Fuel System
a. Check fuel tank level.
b Check fuel lines.
c Check fuel screen.
d Check fuel filters.
8
Check Engine Exhaust System
a. Inspect the exhaust system
CORRECTIVE ACTION
Must have enough fuel to run engine.
Connections are tight and not leaking.
No kinks or sharp bends in the lines.
Fuel screen is located in the inlet fitting to the lift pump.
Screen must be clean.
Fuel filters must be clean and allow full flow of fuel through them.
Must be clear and unobstructed
8--29
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
38 CHECK HIGH SPEED RPM
• TRIGGER–ON: Controller is set for high engine speed operation, and RPM being read by the microprocessor are not correct. The correct RPM for low speed are different for different models as shown below:
Less than 2000, or greater than 2400 for Ultima XTC and X2 2500A/R; or
Less than 1500 or greater than 1900 for Ultra XTC and X2 2100A/R for more than 60 seconds (120 seconds when the microprocessor calls for a change from low speed to high speed)
•
UNIT CONTROL: Alarm Only
•
RESET CONDITION: Auto Reset if controller is set for high engine speed operation and RPM are:
Between 2050 to 2350 for Ultima XTC/X2 2500A/R or;
Between 1550 to 1850 for Ultra XTC/X2 2100A/R for 60 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 Model Number
a. Verify that the model number on the unit data label matches the model number shown in the micro unit data list.
Enter the correct number in the data list. (Refer to Section
3.14.)
2
Check For Proper Voltage To The Engine Speed Control Unit (ENSCU) Pin 22 Based On The
Model. Check For Proper Voltage With Unit Running. (ESC Engine Only)
a. Ultima XTC and X2 2500A Verify 12 VDC at terminal 16 of the ENSCU.
Verify 12 VDC at terminal 22 of the ENSCU.
b. Ultra XTC and X2 2100A Verify 12 VDC at terminal 16 of the ENSCU.
Verify 0 VDC at terminal 22 of the ENSCU.
c. Check circuit from ENSCU terminal 16 to micro connection MPQC3.
Must be 12 VDC
3
Check Speed Solenoid & Linkage On Non--ESC Engines
a. Check speed solenoid plunger on non
ESC engines (Fuel and speed actuator on ESC engines)
Must move in and out freely b. Check engine speed arm & linkage
(non--ESC engines)
Must move freely
4
Check Speed Solenoid Harness (FSA Harness on ESC Engines)
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins or terminals b. Check resistance of speed solenoid
(FSA on ESC units) c. Check amp draw of speed solenoid
Refer to Section 2.13. With the FSA disconnected, check the FSA coil resistance. Spec is 3--4 ohms +/-- 10%.
Refer to Section 2.13.
Use Component Test Mode (Refer to Section 6.2.2) to test.
Refer to Section 2.13 for amp values. View current draw in the Unit Data List. (Section 3.14)
Additional steps on the next page.
62-10683
8--30
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
38 CHECK HIGH SPEED RPM (Continued)
5
Force High Speed operation (See note Note 9)
a. Place unit in continuous run and adjust set point to at least 15 degrees away from box temperature, and a temperature greater than 20°F (5.6°C).
If the unit does not immediately go into
High Speed, set the AIRFLOW
Functional Parameter to HIGH.
Controller will call for High Speed operation.
b. Check operation of Speed Relay LED LED 27 must be ON. (If LED 27 is not on, the microprocessor is not calling for High Speed operation.
Check Speed Overrides in Section 4.4 for more information.) c. Check voltage to speed solenoid (On
ESC engines, check voltage on the engine speed control unit (ENSCU) pin
16)
Must be 12-14 VDC
6
Check Engine RPM
a. Check actual engine RPM using hand held tachometer b. Compare actual RPM with those shown on display
7
Check Engine Air–Intake System
a. Check air filter indicator b. Inspect air intake system
Refer to Section 2.7
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
8
Check Engine Exhaust System
a. Inspect the exhaust system Must be clear and unobstructed
8--31
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
39 CHECK ENGINE RPM
• TRIGGER–ON: Engine RPM have been:
Less than 1200 or greater than 2500 for Ultima XTC and X2 2500A/R; or
Less than 1100 or greater than 2000 for Ultra XTC and X2 2100A/R for more than five minutes
•
UNIT CONTROL: Alarm Only or Unit Shutdown & Alarm (if configured)
• RESET CONDITION: Auto Reset if unit is set for Alarm Only when engine RPM are:
Between 1200 to 2500 for Ultima XTC and X2 2500A/R or:
Between 1100 to 2000 for Ultra XTC and X2 2100A/R for more than five minutes, or
After 15 minutes if the unit is set for RPM Shutdown 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 Model Number
a. Verify that the model number on the unit data label matches the model number shown in the micro unit data list.
Enter the correct number in the data list. (Refer to Section
3.14.)
2
Check For Flash Code On Engine Speed Control Unit (ENSCU)
(Applies to ESC engines only).
a. Check for flash codes on the ENSCU. Refer to Electronic Speed Control Diagnostic tables --
Figure 10--1 thru Figure 10--4
3
On All Units With ESC, Refer To Electronic Speed Control Diagnostic Tables
a. Check speed solenoid plunger on non
ESC engines (Fuel and speed actuator on ESC engines)
Must move in and out freely b. Check engine speed arm & linkage Must move freely
4
Check Fuel System
a. Check for Alarm 1 b. Check fuel flow
Fill tank as needed
Unrestricted fuel flow through system
Fuel not gelled c. Check fuel system prime
5
Check Engine Air–Intake System
a. Check air filter indicator b. Inspect air intake system
No air in fuel system
Flag must not be visible.
Hoses & tubes in good condition.
No kinks or restrictions c. Check voltage to speed solenoid Must be 0 VDC
6
Force Low Speed Operation (See Note 9)
a. Using Functional Parameters, set the
High Speed Delay for at least 10 minutes so the unit starts in low speed.
Unit will run in low speed. RPM must be within range shown above for each specific model. Adjust speed linkage as needed.
b. Check operation of Speed Relay LED LED 27 must be OFF when the microprocessor is calling for Low Speed.
c. Check voltage to speed solenoid (FSA voltage cannot be checked on ESC)
Additional steps on the next page.
Must be 0 VDC
62-10683
8--32
Alarm
NO.
Steps ALARM / CAUSE
39 CHECK ENGINE RPM (Continued)
7
Check Low Speed Engine RPM
a. Check actual engine RPM using hand held tachometer b. Compare actual RPM with those shown on display
CORRECTIVE ACTION
Refer to Section 2.7
Adjust engine linkage setting as needed.
Both readings within ± 50 RPM
8
Force high speed operation (See Note 9)
a. Place unit in continuous run and adjust set point to at least 15 degrees away from box temperature, and a temperature greater than 20° F (5.6°C)
If the unit does not immediately go into
High Speed, set the AIRFLOW
Functional Parameter to HIGH.
Controller will call for High Speed operation.
b. Check operation of Speed Relay LED LED 27 must be ON. (If LED 27 is not on, the microprocessor is not calling for High Speed operation.
Check Speed Overrides in section 4.4 for more information.) c. Check voltage to speed solenoid on standard engines. (FSA voltage cannot be checked on ESC engines.)
Must be 12-14 VDC
9
Check High Speed Engine RPM
a. Check actual engine RPM using hand held tachometer
Refer to Section 2.7
Adjust engine linkage setting as needed.
b. Compare actual RPM with those shown on display
Both readings within ± 50 RPM
8--33
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
40 CHECK GLOW PLUGS
• TRIGGER–ON: Glow Plug amperage is less than 30 Amps, or greater than 43 Amps after 14 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: Alarm Only
• RESET CONDITION: Auto Reset if glow plug amperage is between 30 to 43 amps for at least 14 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 START/RUN-OFF switch in START/RUN position-Manual
Start Operation. (See Note Note 4) Glow Crank switch in
Glow position
OR, use Component Test Mode to energize the Glow Plug
Relay. (Refer to Section 6.2.2) c. Check Non–Running Amps d. Check Glow Plug circuit amperage
LED 30 must be ON
View Current Draw in Data list
Refer to Section 2.13
Current Draw = Non–Running Amps + Glow Plug Amps
In Component Test Mode, only the Glow Plug Amps will be displayed.
Must be 11 VDC or higher e. Check voltage to glow plugs
2
Check Glow Plug Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
3
Check Glow Plugs
a. Check amp draw of each glow plug
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13
62-10683
8--34
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
41 ENGINE STALLED
• TRIGGER–ON: 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 & Alarm
• RESET CONDITION: Auto Restart 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
Check For Alarm 130 -- Check RPM Sensor
a. Check for alarm 130 When Alarms 130 and 41 occur at the same time, generally the engine has run out or is running out of fuel.
This causes the engine RPM to surge and drop. Check fuel tank and add fuel as necessary.
Check fuel lines between the fuel tank and the fuel pump inlet for drawing air in.
2
Check For Flash Code On Engine Speed Control Unit
(ENSCU) (Applies to ESC engines only).
a. Check for flash codes on the ENSCU. Refer to Electronic Speed Control Diagnostic tables --
Figure 10--1 thru Figure 10--4
All flash codes must be cleared before continuing.
3
Was Engine Shut Off Manually?
Correct problem.
a. Check for external cause
4
Check for Bad F2 or F3 Fuse Alarm
a. Check for alarm 71 Alarm conditions must be corrected and the alarm cleared to continue.
5
Check Fuel System
a. Check for Alarm 1 b.Check fuel flow
Fill tank as needed
Unrestricted fuel flow through system
Fuel not gelled c. Check fuel system prime d. Check fuel system check valve from filter to injection pump.
No air in fuel system
Check valve must hold fuel and not leak back
6
Check Fuel Solenoid (non--ESC engines) or Fuel Speed Actuator (ESC engines)
a. Check Run Relay LED LED 28 must be ON.
b. Check voltage to fuel solenoid or
ENSCU module.
c. Inspect solenoid & connector pins & terminals for non--ESC engines
START/RUN-OFF switch in START/RUN position, Manual
Start mode (See Note Note 4)
More than 11 VDC positive and good ground
No damage to solenoid, or wires
No damaged or corroded pins
Wires plugged in
Inspect ENSCU module connector pins
& terminals for ESC engines
ENSCU module, or wires
No damaged or corroded pins
Wires plugged in d. Inspect harness & control box connector pins & terminals (See wiring schematic (See Wiring Schematic
Section 11.)
No physical damage to harness.
No damaged or corroded pins e. Check resistance of solenoid or FSA Refer to Section 2.13
f. Check operation of solenoid or FSA Plunger must move in when energized
Additional steps on the next page.
8--35
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
41 ENGINE STALLED (Continued)
7
Check RPM Sensor (Standard Engines Only)
a. Check Engine RPM in Data list b. Check wiring from RPM Sensor to
Control Box, Connectors and Pins (See
Wiring Schematic)
Must be Steady Accurate Reading
No physical damage to harness
No damaged or corroded pins
Plug connection fits tightly
8
Check Engine Speed Sensor (ENSSN)
(Units With Electronic Speed Control (ESC) engines Only)
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
9
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
10
Check Engine Exhaust System
a. Inspect the exhaust system
11
Check Engine
a. Check Injection pump timing b. Check engine valve adjustment c. Check engine compression
Must be clear and unobstructed
Timing must be correct
Rocker arm clearance must be correct
Compression must be above 27.2 Bars (400 PSIG)
12
Check Refrigeration System
a. Check discharge & suction pressures Must be within normal operating range for conditions
62-10683
8--36
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
8.6 WARNING / STATUS ALARMS
51 ALTERNATOR NOT CHARGING
• TRIGGER–ON: Unit is running (either engine or standby) and the current flow is more than -1.0 Amps
(discharge) between the alternator to the battery for three continuous minutes.
• UNIT CONTROL: Alarm Only or Unit Shutdown & Alarm (if configured)
• RESET CONDITION: Auto Reset (if not shut down) when alternator is charging 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 b. Check direction of wire through current sensor.
START/RUN-OFF switch in START/RUN position, Manual
Start mode, all electrical circuits off. (See Note Note 5)
Must be -2.0 to 1.5 Amps with no load
Must be in correct direction (See arrow on current sensor.) c. Check amp current value with 0 amps going through the current sensor.
Disconnect and remove the wire going through the current sensor, then reconnect it to the fuse holder. Power up micro and check CURRENT DRAW in the Unit Data List.
The value must be between --1.0 and 1.0 Amps. (Refer to
Section 3.14.)
2
Check Alternator Belt
a. Check alternator belt tension & condition
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping
3
Check Alternator Wiring
a. Check output & ground wire (unit OFF) Negative lead on Ground terminal
Positive lead on Output terminal = same as battery voltage.
b. Check exciter wire (if used)
4
Check Aux (D+) Terminal
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
START/RUN-OFF switch in START/RUN position, Manual
Start mode (See Note Note 4)
Must have 11 or more VDC with switch ON
Must have less than 3 VDC with unit OFF
No physical damage to harness.
No damaged or corroded pins b. Check output wire (unit running) Must have 13 or more VDC (when tested against -- battery post) c. Check ground wire (unit running) Must have 13 or move VDC (when tested against + battery post)
5
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
6
Perform Pretrip Check
a. Run Pretrip & check for alarms Any active alarms must be corrected and cleared before proceeding.
8--37
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
53 BOX TEMP OUT-OF-RANGE
• TRIGGER–ON: UNIT CONTROL:
Alarm Only: The box temperature has been in range -- within ±2.7°F (±1.5°C) of setpoint for perishable and frozen -- at least once since the unit was started (Sleep Model and Component Test Modes excluded), and is now further away from setpoint than the limit set in the functional parameters -- 4°, 5.5°, or 7°F (2.°, 3°, or 4°C) for this unit, for more than 15 minutes, or for more than 30 minutes immediately following the end of a defrost cycle. OR
If a unit Shutdown alarm occurs and the box temperature is further away from setpoint than the limit set in the functional parameters -- 4°, 5.5°, or 7°F (2°, 3° or 4°C) -for more than 30 minutes regardless if the box temperature has been in--range.
The box temperature has not been in range, and the unit is operating in Pulldown (Cool) and the DeltaT
(SAT minus RAT) is less than 1°F (0.56°C) OR
The unit is operating in Pullup (Heat) and the SAT is the same temperature or colder than the RAT for more than 30 minutes. (Alarm 122 -- CHECK RETURN AIR SENSOR and Alarm 123 CHECK SUPPLY
AIR SENSOR must not be active).
Shut Down & Alarm:
The box temperature has been in range -- within ±2.7°F (±1.5°C) -- of setpoint for perishable and frozen at least once since the unit was started (Sleep mode, Diagnostic and Component Test modes excluded), and is now further away from setpoint than the limit set in the functional parameters for this unit, for more than 45 minutes
• UNIT CONTROL: Alarm Only or Unit Shutdown & Alarm (if configured)
• 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.
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
Pretrip is started
S
Setpoint is changed
S
A door switch or remote switch is installed and configured as a door switch
NOTE: The 15, 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
1
Check Trailer Or Rail Compartment Doors
a. Inspect all trailer or rail compartment doors
Must be closed, no air leakage
2
Check For Low Refrigerant Pressure Alarm
a. Check for alarm 18 Alarm conditions must be corrected and the alarm cleared to continue
Additional steps on the next page.
62-10683
8--38
Alarm
NO.
Steps ALARM / CAUSE
53 BOX TEMP OUT-OF-RANGE (Continued)
3
Check Refrigerant Level
a. Visually check refrigerant level in receiver tank.
4
Check system pressures
a. Install Manifold Test Set and check system pressures.
CORRECTIVE ACTION
Must be at correct level.
Suction & Discharge Pressures must be in the normal range. Suction & Discharge Pressures must have the same reading on gauges & on micro display.
5
Perform Pretrip Check
a. Run Pretrip & check for alarms Any active alarms must be corrected and cleared before proceeding.
6
Check Delta-T
a. Calculate SAT minus RAT, or check
Delta-T value in Data list.
In cool, SAT must be at least 1°F (0.6°C) than RAT.
In heat, SAT must be at least the same temperature as
RAT or warmer.
8--39
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
54 DEFROST NOT COMPLETE
• TRIGGER–ON: Defrost cycle did not terminate automatically. [DTT2 and SAT did not reach termination temperature of 55°F (12.8°C) within 45 minutes].
• UNIT CONTROL: Alarm Only. While this alarm is active, the Defrost Timer will be temporarily 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 Pretrip Check
a. Run Pretrip & check for alarms Any active alarms must be corrected and cleared before proceeding.
2
Check For Defective Defrost Sensor Location/Correct Installation
a. Has sensor fallen from location?
3
Check Evaporator Fan Clutch
Must be corrected to continue.
a. Check Evap Fan Clutch operation in defrost
Must disengage fan.
4
Check Refrigerant Level
a. Visually check refrigerant level in receiver tank.
Must be at correct level.
5
Check For Low Refrigerant Pressure Alarm
a. Check for alarm 18 Alarm conditions must be corrected and the alarm cleared to continue
6
Verify Temperature Of DTT2
a. Using a service (Test) thermometer check temperature of Evaporator tube sheet at DTT2 and compare with DTT2 temperature in Data list.
b. Check DTT2 and RAT wiring.
Must be within ±2°F (1°C)
Verify that RAT temperature is being displayed as RAT in unit Data list and that DTT2 is being displayed as DTT2.
Correct wiring if required. (Refer to Section 3.14.)
7
Check Accuracy Of DTT2 And SAT Temperature Readings
a. Check DTT2 resistance, and.
Check SAT resistance
(See Note Note 6)
(Refer to Section 2.13 for complete resistance chart)
10K Ohms @ 77°F (25°C)
8
Check DTT2 For Proper Mounting
a. Inspect DTT2 Should be screwed tightly in place.
Flat area of DTT2 must be against metal surface.
9
See Troubleshooting, Section 10.3.6 -- Refrigeration System Not Heating
62-10683
8--40
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 eight minutes of a defrost termination for two consecutive defrost cycles. (The air switch contact must be closed continuously for 15 seconds before the defrost cycle is started.)
•
UNIT CONTROL: Alarm ON. 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 eight 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 defrost air switch setting with
Magnehelic Gauge, and check the resistance of switch contacts
2
Check Switch Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
3
Check Air Switch Hoses
a. Inspect air hoses to switch
Refer to Section 2.11
Contacts closed with pressure applied to high side
Contacts open with no pressure applied
See Note NO TAG
No physical damage to harness.
No damaged or corroded pins
No kinks or other obstructions
No holes
Connected to correct nipple
4
Check Condition Of Evaporator
a. Visually inspect evaporator following defrost.
5
Perform Pretrip
a. Clear Active Alarm list, then run Pretrip
& check for any new alarms.
Coil must be clean and cleared of ice or any other material.
Any active alarms must be corrected and cleared before proceeding.
6
Check Evaporator Pressure Drop
a. Check pressure reading with
Magnehelic Gauge
7
Check Evaporator Fan Clutch
a. Check Evap Fan Clutch operation in defrost
Refer to Section 2.11
Must disengage fan.
8
Check Condition Of Refrigerated Compartment & Load
a. Check condition of refrigerated 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.
8--41
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
56 CHECK EVAPORATOR AIRFLOW
• TRIGGER–ON: In the Cool mode, the Supply Air temperature is 5°F (2.8°C) or more warmer than Return
Air Temperature for five minutes; or
In the Heat mode, the Suction pressure has been higher than 100 PSIG (6.8 Bars) for more than 60 seconds.
NOTE: For this alarm the unit must be running. This alarm will not occur in either the
Defrost or Pretrip cycles.
•
UNIT CONTROL: Unit Shutdown & Alarm
•
RESET CONDITION: Auto Reset in 15 minutes IF Alarm 30 is not also 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 Fan Belts
a. Check upper fan belt tension & condition.
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping b. Check lower fan belt tension & condition.
2
Check Evaporator Air Flow
a. Check evaporator fan clutch b. Check evaporator section, condition of evaporator blower wheels, return air bulkhead, air chute, cleanliness of evap. coil
Must be engaged
Good Air Flow
Return air not restricted
Air chute in good condition
No damage to blower wheel
Evap. coil clean
3
Check System Pressures
a. Install Manifold Test Set and check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
4
Check Refrigerant Charge
a. Check for undercharged system
5
Perform Pretrip Check
Suction & Discharge Pressures must have the same reading on gauges & on micro display.
Level must be above lower sight glass a. Run Pretrip & check for alarms
Any active alarms must be corrected and cleared before proceeding.
6
Check SV4
a. Check SV4 for leakage when closed Must not leak
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8--42
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
57 CHECK REMOTE SWITCH 1
• TRIGGER–ON:Remote Switch 1 is set to trigger alarm (contacts open or contacts closed depending on set up in configuration list for Remote Switch 1) for more than five seconds.
NOTE: SThis alarm is disabled for Shutdown when the ’Unit Operation’ configuration is set for Rail and the unit is operating in Sleep Mode
S
Shut down may be overridden in the Functional Parameter list.
• UNIT CONTROL: Alarm Only, or may be configured to shut unit down.
•
RESET CONDITION:
Alarm Only: Auto Reset after Remote Switch 1 has been set to allow unit to run for more than five seconds.
Unit Shutdown: Auto Reset after three minutes (minimum off time for Remote switch shutdown condition) and
Remote Switch 1 has been set to allow unit to run for more than five seconds.
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 What Remote Switch 1 Is Controlled By
a. Remote Switch 1 may be connected to a refrigerated compartment door, or some other device and used to remotely control the unit.
Find and locate Remote Switch 1
2
Check To See If Refrigerated Compartment Side Or Rear Door Is Open, Or If The Device That
Remote Switch 1 Is Connected To Is Set To Trigger The Alarm
a. Inspect refrigerated compartment doors
Refrigerated compartment door(s) must be closed b. Check device at Remote Switch 1
3
Check Wiring
a. Visually inspect wiring to switch b. Visually inspect condition of switch
4
Check Remote Switch 1
a. Check switch operation
Must have switch in position that allows unit to operate.
Wiring must be connected
Must not be damaged
Contacts must Open & Close as switch is opened and closed.
5
Check Configurations
a. Verify that Configuration is set for the type of switch being used (i.e. when
Door is open, switch contacts are closed; etc.)
Must be correct for type of Remote switch being used.
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Steps ALARM / CAUSE CORRECTIVE ACTION
58 CHECK REMOTE SWITCH 2
• TRIGGER–ON: Remote Switch 2 is set to trigger alarm (contacts open or contacts closed depending on set up in configuration list for Remote Switch 2) for more than five seconds.
NOTE:
S
This alarm is disabled for Shutdown when the ’Unit Operation’ configuration is set for Rail and the unit is operating in Sleep Mode.
S
Shut down may be overridden in the Functional Parameter list.
• UNIT CONTROL: Alarm Only, or may be configured to shut unit down.
•
RESET CONDITION:
Alarm Only: Auto Reset after Remote Switch 2 has been set to allow unit to run for more than five seconds.
Shutdown: Auto Reset after three minutes (minimum off time for Remote switch shutdown condition) and Remote Switch 2 has been set to allow unit to run for more than five seconds.
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 What Remote Switch 2 Is Controlled By
a. Remote Switch 2 may be connected to a refrigerated compartment door, or some other device and used to remotely control the unit.
Find and locate Remote Switch 2
2
Check To See If Refrigerated Compartment Side Or Rear Door Is Open, Or If The Device That
Remote Switch 2 Is Connected To Is Set To Trigger The Alarm
a. Inspect doors refrigerated compartment Refrigerated compartment door(s) must be closed
Must have switch in position that allows unit to operate.
b. Check device at Remote Switch 2
3
Check Wiring
a. Visually inspect wiring to switch b. Visually inspect condition of switch
Wiring must be connected
Must not be damaged
4
Check Remote Switch 2
a. Check switch operation Contacts must Open & Close as switch is opened and closed.
5
Check Configurations
a. Verify that Configuration is set for the type of switch being used (i.e. when
Door is open, switch contacts are closed; etc.)
Must be correct for type of Remote switch being used.
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
59 DATALOGGER NOT RECORDING
• TRIGGER–ON: No data is being recorded by the data recorder.
• UNIT CONTROL: 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) Alarms Clear b. Check for Active Alarm reoccurrence If Inactive, download all data & retain.
If Active, go to next step
2
Microprocessor Defective
a. Download previous data using
Download PC Card, or
ReeferManager 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.)
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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: 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
a. Check Real Time Clock in the Data list, or using ReeferManager.
Must show correct date and time. Change as needed
(Configuration list).
2
Reset Microprocessor
a. Turn main switch off for 30 seconds, then turn on.
b. Check for valid Real Time Clock reading in Data 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
ReeferManager 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.)
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
61 DOOR OPEN
• TRIGGER–ON: Trailer or rail car compartment door has been open for more than five seconds.
NOTE:
S
This alarm is disabled for Shutdown when the ’Unit Operation’ configuration is set for Rail and the unit is operating in Sleep Mode.
S
Shut down may be overridden in the Functional Parameter list.
•
UNIT CONTROL: Alarm Only, or may be configured to shut unit down.
• RESET CONDITION:
Alarm Only: Auto Reset after the door has been closed for more than five seconds.
Shutdown: Auto Reset after three minutes (minimum off time for door open condition) and the door has been closed for more than five seconds.
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 To See If Refrigerated Compartment Side Or Rear Door Is Open
a. Inspect doors refrigerated compartment Refrigerated compartment door(s) must be closed
2
Check Wiring
a. Visually inspect wiring to door switch Wiring must be connected b. Visually inspect condition of switch Must not be damaged
3
Check Door Switch
a. Check switch operation Contacts must Open & Close as door is opened and closed.
4
Check Configurations
a. Verify that Configuration is set for the type of switch being used (i.e. when
Door is open, switch contacts are closed; etc.)
5
Temporary Solution Tip
a. In the event of a defective switch that can not be repaired or replaced, and the switch is forcing the unit into a Shutdown, this alarm may be temporarily overridden by setting the correct Functional Parameter.
Must be correct for type of door switch
In the Functional Parameter list set OVERRIDE DOOR
SHUTDOWN to YES.
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NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
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 (Speed Relay output circuit), or F3 (Run relay output circuit)
• 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 Unit Operation
a. Did unit shut down?
8.7 ELECTRICAL ALARMS
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 2.12
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 2.13
Refer to Section 2.13
72 BAD F4 OR F6 FUSE
• TRIGGER–ON: One or more of the following fuse circuits have been open for more than 2 seconds:
F4 (Clutch Relay output circuit, or F6 (SV & UL valves, Buzzer, & Fuel Heater Relay coil circuit
• UNIT CONTROL: Unit Shutdown & Alarm
• RESET CONDITION: Auto Reset when the fuse is replaced, and the unit is powered up, 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 Fuse
a. Locate blown fuse b. Verify fuse size
Will have open circuit
Refer to Section 2.12
Must be correct rating for circuit (see wiring diagram) c. Inspect fuse & fuse holder b. Check amperage draw on F6 circuit
(See wiring schematic)
Terminals tight; No signs of overheating, melting or discoloration
2
Check Circuit
a. Check amperage draw on clutch circuit Refer to Section 2.13
Refer to Section 2.13
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
78 CHECK SV1 CIRCUIT
• TRIGGER–ON: In either the Heat, Null, or Defrost cycles, the SV1 coil circuit is shorted. (The SV1 output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the SV1 coil itself, or to a positive wire.)
•
UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when unit calls for Heat or Defrost and the SV1 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 SV1 Coil
a. Inspect SV1 coil & connector pins & terminals
No damage to coil
No damaged or corroded pins b. Check resistance of coil c. Check amp draw of coil.
2
Check SV1 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
3
Check SV1 Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
Refer to Section 2.13
Refer to Section 2.13. Use ammeter
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13 for normal current values. View current draw in Data list
79 CHECK SV4 CIRCUIT
•
TRIGGER–ON: In either the Heat or Defrost cycles the SV4 coil circuit is shorted. (The SV4 output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the SV4 coil itself, or to a positive wire.
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when unit calls for Heat or Defrost and the SV4 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 SV4 Coil
a. Inspect SV4 coil & connector pins & terminals b. Check resistance of coil c. Check amp draw of coil.
2
Check SV4 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
No damage to coil
No damaged or corroded pins
Refer to Section 2.13
Refer to Section 2.13. Use ammeter.
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
3
Check SV4 Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) and Alarms 81 thru 90 and Alarms 93 and 97 to test actual current draw of the circuit.
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14)
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
81 CHECK FHR CIRCUIT
• TRIGGER–ON: Fuel Heater Relay circuit is shorted. (The Fuel Heater Relay output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the Fuel
Heater Relay coil itself, or to a positive wire.
•
UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when Fuel Heater Relay 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 Fuel Heater Relay
a. Inspect Fuel Heater Relay & socket No damage to relay
No damaged or corroded pins
Refer to Section 2.13.
b.Check resistance of relay coil
2
Check Fuel Heater Relay Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
3
Check Fuel Heater Relay Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14).
82 CHECK REMOTE OUT-RANGE LIGHT
• TRIGGER–ON: The micro Light Bar configuration is set for an 8--LIGHT BAR, and the Out--of--Range light circuit (to the Light Bar) circuit is shorted. (The Out-Of-Range Light output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the
Out-Of-Range Light itself, or to a positive wire.
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when In–range 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 Out-Of-Range Light
a. Inspect Out-of-Range light & socket No damage to bulb
No damaged or corroded pins b. Check resistance of light bulb Refer to Section 2.13
2
Check Out-Of-Range Light Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
3
Check Out-Of-Range Light Current Draw
a. Use Component Test mode (See
Section 6.2.6.2.2) to test actual current draw of the circuit.
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14)
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
83 CHECK REMOTE DEFROST LIGHT
• TRIGGER–ON: The micro Light Bar configuration is set for an 8--LIGHT BAR, and the Defrost light circuit
(to the Light Bar) circuit is shorted. (The Defrost Light output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the Defrost Light itself, or to a positive wire.
•
UNIT CONTROL: 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 No damage to bulb
No damaged or corroded pins
Refer to Section 2.13
b. Check resistance of light bulb
2 Check Defrost Light Wiring a. Inspect harness & control box connector pins & terminals (See wiring schematic)
3
Check Defrost Light Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14)
84 CHECK REMOTE ALARM LIGHT
• TRIGGER–ON: Remote Alarm light circuit (to the Light Bar) circuit is shorted. (The Alarm Light output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the
Alarm Light itself, or to a positive wire.
• UNIT CONTROL: 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 No damage to bulb
No damaged or corroded pins
Refer to Section 2.13
b. Check resistance of light bulb
2
Check Alarm Light Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
3
Check Alarm Light Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14)
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
85 CHECK UL1 CIRCUIT
• TRIGGER–ON: UL1 (Front) Unloader Coil circuit is shorted. (The UL1 output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the UL1 itself, or to a positive wire.
• UNIT CONTROL: 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 Front Unloader (UL1) Coil
a. Inspect Front Unloader (UL1) coil & terminals
No damage to coil
No damaged or corroded pins b. Check resistance of coil Refer to Section 2.13. Cannot be opened (infinite ohms), shorted (Zero Ohms) or shorted to ground.
c. Check amp draw of coil.
Refer to Section 2.13. Use ammeter.
2
Check Front Unloader (UL1) Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
3
Check Front Unloader (UL1) Coil Wiring
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14) a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
86 CHECK UL2 CIRCUIT
• TRIGGER–ON: UL2 (Rear) Unloader Coil circuit is shorted. (The UL2 output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the UL2 itself, or to a positive wire.
• UNIT CONTROL: 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 Rear Unloader (UL2) Coil
a.Inspect Rear Unloader (UL2) coil & terminals.
No damage to coil
No damaged or corroded pins b. Check resistance of coil Refer to Section 2.13
c. Check amp draw of coil.
Refer to Section 2.13. Use ammeter.
2
Check Rear Unloader (UL2) Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
3
Check Rear Unloader (UL2) Coil Wiring
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14) a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
87 CHECK REMOTE HEAT LIGHT
• TRIGGER–ON: The micro Light Bar configuration is set for an 8--LIGHT BAR, and the Remote Heat light circuit (to the Light Bar) circuit is shorted. (The Heat Light output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the Heat Light itself, or to a positive wire.
•
UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when Heat 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 Heat Light
a. Inspect Heat light & socket No damage to bulb
No damaged or corroded pins
Refer to Section 2.13
b. Check resistance of light bulb
2
Check Heat Light Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
3
Check Heat Light Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14)
88 CHECK REMOTE COOL LIGHT
• TRIGGER–ON: The micro Light Bar configuration is set for an 8--LIGHT BAR, and the Remote Cool light circuit (to the Light Bar) circuit is shorted. (The Cool Light output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the Cool Light itself, or to a positive wire.
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when Cool 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 Cool Light
a. Inspect Cool light & socket No damage to bulb
No damaged or corroded pins
Refer to Section 2.13
b. Check resistance of light bulb
2
Check Cool Light Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic)
3
Check Cool Light Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14)
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Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
89 CHECK REMOTE AUTO LIGHT
• TRIGGER–ON: Remote Auto light circuit (to the Light Bar) circuit is shorted. (The Auto Light output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the Auto
Light itself, or to a positive wire.
•
UNIT CONTROL: 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 No damage to bulb
No damaged or corroded pins
Refer to Section 2.13
b. Check resistance of light bulb
2
Check Auto Light Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
3
Check Auto Light Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14)
90 AUTOFRESH AIR EXCHANGE RELAY
• TRIGGER–ON: AutoFresh Air Exchange circuit (to the relay coil) is shorted. (The AutoFresh Air
Exchange Relay output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the relay itself, or to a positive wire.. Alarm may be manually reset via Keypad or by turning the unit off, then back on again.
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when AFEX 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 Autofresh Air Exchange Relay (AFAR)
a. Inspect AFAR & socket No damage to relay
No damage to socket
Refer to Section 2.13.
b. Check resistance of relay coil
2
Check Afar Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
3
Check Afar Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14)
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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 circuit will not be shorted to ground, but is shorted either within the Buzzer itself, or to a positive wire.
•
UNIT CONTROL: 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
Check Buzzer
a. Inspect Buzzer & wire connections No damage to buzzer
No damaged or corroded pins
Refer to Section 2.13
b. Check resistance of buzzer
2
Check Buzzer Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
3
Check Buzzer Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14)
97 CHECK SV2 CIRCUIT
• TRIGGER–ON: SV2 coil circuit is shorted. (The SV2 output from the Micro is negative, so the circuit will not be shorted to ground, but is shorted either within the SV2 coil itself, or to a positive wire.
•
UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when unit calls for Heat or Defrost and the SV2 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 SV2 Coil
a. Inspect SV2 coil & connector pins & terminals
No damage to coil
No damaged or corroded pins
Refer to Section 2.13
Refer to Section 2.13. Use ammeter.
b. Check resistance of SV2 c. Check amp draw of SV2.
2
Check SV2 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
3
Check SV2 Current Draw
a. Use Component Test mode (Refer to
Section 6.2.2) to test actual current draw of the circuit.
See Notes Note 3, Note 4 & Note 8
No physical damage to harness.
No damaged or corroded pins
Refer to Section 2.13 for normal current values.
View current draw in the Unit Data list. (Refer to Section
3.14)
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8.8 SENSOR ALARMS
121 CHECK AMBIENT AIR SENSOR
• TRIGGER–ON: Ambient Air Sensor circuit has failed open or shorted. If shorted, the data list will display
158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°C)
• UNIT CONTROL: A default 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 Temperature Sensor (AAT)
a. Inspect Ambient Air Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector b. Check Ambient Air Sensor resistance
(See Note Note 6)
(Refer to Section 9.28 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
2
Check Ambient Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals. (See wiring schematic Section 11.) b. Power microprocessor up (See
Note 5 Page 8.2). Disconnect sensor from harness. Check for voltage at harness plug between pins. FROM
VECTOR
No physical damage to harness.
No damaged or corroded pins
Voltage should be 2.5 VDC volts at harness plug between pins.
3
Check Remote Sensor/Switch Connector
a. Locate and inspect 10-way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
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122 CHECK RETURN AIR SENSOR
• TRIGGER–ON: Return Air Sensor circuit has failed open or shorted. If shorted, the data list will display
158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°C)
• UNIT CONTROL: Use Supply Air Sensor reading plus 3.6°F (2°C). If Supply Air Sensor Alarm is on, and setpoint is at or below +10.4°F (-12°C), unit will run in Low Speed Cool only. If setpoint is above +10.4°F
(-12°C), unit will shut down.
• 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 Temperature Sensor (RAT)
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 Note 6)
2
Check Return Air Sensor Wiring
(Refer to Section 9.28 for complete resistance chart)
10,000 Ohms @ 77°F (25°C) a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.) b. Power microprocessor up (See
Note 5 Page 8.2). Disconnect sensor from harness. Check for voltage at harness plug between pins.
No physical damage to harness.
No damaged or corroded pins
Voltage should be 2.5 VDC volts at harness plug between pins.
3
Check Remote Sensor/Switch Connector
a. Locate and inspect 10-way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
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123 CHECK SUPPLY AIR SENSOR
• TRIGGER–ON: Supply Air Sensor circuit has failed open or shorted. If shorted, the data list will display
158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°C)
• UNIT CONTROL: Use Return Air Sensor reading minus 3.6°F (2°C). If Return Air Sensor Alarm is on, and setpoint is at or below +10.4°F (-12°C) unit will run in Low Speed Cool only. If setpoint is above
+10.4°F (-12°C), unit will shut down. If Alarm 132--CHECK DEFROST TERM 2 SENSOR is also active,
Defrost termination will be as described in section 5.11.
•
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 Temperature Sensor (SAT)
a. Inspect Supply Air Sensor & connector No damage to sensor
No damage, moisture, or corrosion in connector b. Check Supply Air Sensor resistance
(See Note Note 6)
(Refer to Section 9.28 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 Section 11.) b. Power microprocessor up (See
Note 5 Page 8.2). Disconnect sensor from harness. Check for voltage at harness plug between pins.
No physical damage to harness.
No damaged or corroded pins
Voltage should be 2.5 VDC volts at harness plug between pins.
3
Check Remote Sensor/Switch Connector
a. Locate and inspect 10-way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
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125 CHECK COMP DISCH SENSOR
• TRIGGER–ON: Compressor Discharge Sensor circuit has failed open or shorted. If shorted, the data list will display 392°F (200°C). If the circuit is open, the data list will show the temperature as -40°F (-40°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 Temperature Sensor (CDT)
a. Inspect Compressor Discharge
Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector b. Check Compressor Discharge Sensor resistance (See Note Note 6) b. Power microprocessor up (See
Note 5 Page 8.2). Disconnect sensor from harness. Check for voltage at harness plug between pins.
(Refer to Section 9.28 for complete resistance chart)
100,000 Ohms @ 77°F (25°C)
2
Check Compressor Discharge Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
Voltage should be 2.5 VDC volts at harness plug between pins.
3
Check Remote Sensor/Switch Connector
a. Locate and inspect 10-way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
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126 CHECK FUEL SENSOR CIRCUIT
• TRIGGER–ON: The Low Fuel Shutdown is configured as a 0% to 100% sensor, and 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
Check For Low Fuel Level
a. Check fuel level in the fuel tank
2
Check Fuel Level Sensor
a. Inspect fuel level sensor& connector pins & terminals
Add fuel as needed to the fuel tank.
No physical damage to sensor.
No damaged or corroded pins in plug.
b. Check fuel level sensor operation c. Check for voltage at harness plug between pins for BLACK (SP24) and
RED (SPK5) wires d. Check continuity of the wire from the harness plug, pin C to the microprocessor plug 1MP26 e. With the Fuel Level Sensor reconnected, check the voltage at the microprocessor plug 1MP26
3
Check Fuel Level Sensor Calibration
Place unit in Manual Start mode (see Note Note 4), OR
Use Component Test Mode to energize the Run Relay.
DO NOT START UNIT. (Refer to Section 6.2.2)
Voltage should be 12 volts at harness plug between pins for BLACK (SP24) and RED (SPK5) wires
START/RUN-OFF switch in OFF position prior to checking for continuity. Must be less than 10 ohms.
Voltage must be between 0.0 -- 5.0 VDC.
a. Check fuel level sensor calibration See Section 9.8.2
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)
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129 CHECK ENG COOLANT SENSOR
• TRIGGER–ON: Engine Coolant Sensor circuit has failed open or shorted. If shorted, the data list will display 266°F (130°C). If the circuit is open, the data list will show the temperature as -58°F (-50°C)
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset when Engine Coolant 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 Engine Coolant Temperature Sensor (ENCT)
a. Inspect Engine Coolant Sensor & connector
No damage to sensor
No damage, moisture, or corrosion in connector b. Check Engine Coolant Sensor resistance (See Note Note 6)
(Refer to Section 9.28 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
2
Check Engine Coolant Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
3
Check Remote Sensor/Switch Connector
a. Locate and inspect 10-way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
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130 CHECK ENGINE RPM SENSOR
• TRIGGER–ON:
With the unit in Auto Start:
The ambient temperature is above 32°F (0°C), and this is the 2nd or 3rd start attempt, and the Engine Oil
Pressure switch is closed (oil pressure good), and engine RPM are sensed at less than 1000 RPM; or
The ambient is below 32°F (0°C) and the DC amp draw is more than 2 amps , and this is the 2nd or 3rd start attempt, and engine RPM are sensed at less than 1000 RPM; or
With the unit in Manual Start:
The ambient temperature is above 32°F (0°C), and this is the 2nd or 3rd start attempt, and the Engine Oil
Pressure switch is closed (oil pressure good) engine RPM are sensed at less than 50 RPM; or
The ambient is below 32°F (0°C) and the DC amp draw is more than 2 amps , and this is the 2nd or 3rd start attempt, and engine RPM are sensed at less than 50 RPM.
NOTE: This alarm can only be triggered on during the engine starting sequence and the 20 seconds immediately following.
• UNIT CONTROL: Alarm Only (Engine will be considered running)
• RESET CONDITION:
With the unit in Auto Start: Auto Reset in Auto Start when engine RPM are greater than 1,000 or,
With the unit in Manual Start:
Auto Reset in Auto Start when engine RPM are greater than 1,000 or, when Oil Pressure switch contacts
OPEN 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 A41 When Alarms 41 and 130 occur at the same time, generally the engine has run out or is running out of fuel. This causes the engine to surge. Check fuel tank and add fuel as necessary.
Check fuel lines between the fuel tank and the fuel pump inlet for drawing air in.
2
Check Engine rpm Sensor (Non--ESC engines only)
a. Inspect Engine RPM Sensor & connector
No damage to sensor.
No damage, moisture, or corrosion in connector.
b. Compare actual engine RPM with those shown on the display using hand held tachometer.
Must be ± 20 RPM
Must be a steady reading.
3
Check Engine Speed Sensor (ENSSN) (ESC engines Only)
a. Inspect circuit from ENSCU terminal 3 to micro connection connector.
2MP18 &
No damage to unit.
No damage, moisture, or corrosion in connector.
b. Compare actual engine RPM with those shown on the display using hand held tachometer.
Must be ± 20 RPM
Must be a steady reading.
c. Check for 12 VDC between ENSSN 12
V terminal & ENSSN ground.
d. Check for 12 VDC at ENSCU terminal
25 to ground
Must be 12 VDC.
Must be 12 VDC.
Additional steps on the next page.
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Steps ALARM / CAUSE
130 CHECK ENGINE RPM SENSOR (Continued)
CORRECTIVE ACTION
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.
4
Check engine RPM sensor wiring (non--ESC engines only)
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
See Note NO TAG
No physical damage to harness.
No damaged or corroded pins b.Check RPM wiring c. Check voltage reading between plug terminals A & B.
Place unit in Manual Start mode (see Note Note 4), OR
Use Component Test Mode to energize the Run Relay.
DO NOT START UNIT. (Refer to Section 6.2.2)
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.
5
Check circuits with test sensor
a. Substitute known good sensor and check Unit Data List reading. (Refer to
Section 3.14)
Must be within ± 20 RPM or reading on tachometer
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132 CHECK DEFROST TERM 2 SENSOR
• TRIGGER–ON: Defrost Termination Temperature Sensor 2 circuit has failed open or shorted. If shorted, the data list will display 158°F (70°C). If the circuit is open, the data list will show the temperature as
-52.6°F (-47°C)
•
UNIT CONTROL: Use RAT or SAT for defrost initiation criteria. (See Defrost mode, Section 5.11)
• RESET CONDITION: Auto Reset when Defrost Termination 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 Defrost Termination Temperature Sensor 2 (DTT2)
a. Inspect Defrost Termination
Temperature Sensor 2 & connector
No damage to sensor
No damage, moisture, or corrosion in connector b. Check Defrost Termination
Temperature Sensor 2 resistance
(See Note Note 6)
(Refer to Section 9.28 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
2
Check Defrost Termination Temperature Sensor 2 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
3
Check Remote Sensor/Switch Connector
a. Locate and inspect 10-way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
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133 CHECK REMOTE TEMP SENSOR 1
• TRIGGER–ON: Remote Temperature Sensor 1 circuit is configured on, and has failed open or shorted. If shorted, the data list will display 158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°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 Temperature Sensor 1 (REMSN1)
a. Verify that Remote Temperature
Sensor 1 has been installed and is correctly wired to the unit.
Remote Temperature Sensor 1 is installed.
Wires are connected to 10-pin connector at cavities E & F.
If sensor is not present change micro configuration to
OFF.
2
Check Remote Temperature Sensor 1
a. Inspect Remote Temperature Sensor 1
& connector
No damage to sensor
No damage, moisture, or corrosion in connector b. Check Remote Temperature Sensor 1 resistance (See Note Note 6)
(Refer to Section 9.28 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
3
Check Remote Temperature Sensor 1 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins b. Check 10-way connector for all remote sensors and switches.
No physical damage, moisture or corrosion to connector.
Cavity plugs are in place for unused circuits.
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134 CHECK REMOTE TEMP SENSOR 2
• TRIGGER–ON: Remote Temperature Sensor 2 circuit is configured on, and has failed open or shorted. If shorted, the data list will display 158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°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 Temperature Sensor 2 (REMSN2)
a. Verify that Remote Temperature
Sensor 2 has been installed and is correctly wired to the unit.
Remote Temperature Sensor 2 is installed.
Wires are connected to 10-pin connector at cavities G&H.
If sensor is not present change micro configuration to
OFF.
2
Check remote temperature sensor 2
a. Inspect Remote Temperature Sensor 2
& connector
No damage to sensor
No damage, moisture, or corrosion in connector b. Check Remote Temperature Sensor 2 resistance (See Note Note 6)
(Refer to Section 9.28 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
3
Check remote temperature sensor 2 wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins b. Check 10-way connector for all remote sensors and switches.
No physical damage, moisture or corrosion to connector.
Cavity plugs are in place for unused circuits.
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135 CHECK REMOTE TEMP SENSOR 3
• TRIGGER–ON: Remote Temperature Sensor 3 circuit is configured on, and has failed open or shorted. If shorted, the data list will display 158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°C)
•
UNIT CONTROL: Alarm only.
• RESET CONDITION: Auto Reset when Remote Temperature Sensor 3 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 Temperature Sensor 3 (REMSN3)
a. Verify that Remote Temperature
Sensor 3 has been installed and is correctly wired to the unit.
Remote Temperature Sensor 3 is installed.
Wires are connected to 10-pin connector at cavities J & K.
If sensor is not present change micro configuration to
OFF.
2
Check remote temperature sensor 3
a. Inspect Remote Temperature Sensor 3
& connector
No damage to sensor
No damage, moisture, or corrosion in connector b. Check Remote Temperature Sensor 3 resistance (See Note Note 6)
(Refer to Section 9.28 for complete resistance chart)
10,000 Ohms @ 77°F (25°C)
3
Check remote temperature sensor 3 wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins b. Check 10-way connector for all remote sensors and switches.
No physical damage, moisture or corrosion to connector.
Cavity plugs are in place for unused circuits.
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8.9 PRETRIP ALARMS
P141 PRETRIP STOPPED BY USER
• TRIGGER–ON: Pretrip cycle was stopped before the Pretrip 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 Pretrip Alarms
a. Scroll the Alarm list for any Active
Pretrip alarms
Alarm conditions must be corrected and the alarm cleared to continue
2
Rerun Pretrip Check (If Desired)
a. Clear Active Alarm List, then run
Pretrip & check for any new alarms.
b. Allow to terminate automatically
Unit running in Pretrip mode. Check for any new alarms.
Pretrip cycle operates normally.
P143 CHECK CLUTCH CIRCUIT
•
TRIGGER–ON: Normal Amps for the Clutch Circuit is 2.0 to 7 Amps. The circuit tests outside this range.
• UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 2” will be displayed in
MessageCenter.
• RESET CONDITION: Auto Reset if Pretrip 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 Or F6 Fuse Alarm
a. Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue.
2
Check Clutch
a. Check resistance of clutch coil b. Check amp draw of clutch coil.
Refer to Section 2.13
Use Component Test mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data list. (Refer to Section
3.14)
3
Check Clutch & Circuit
a. Inspect clutch and wiring b. Inspect clutch relay & socket
No damage or corrosion
Connector fits together tightly, no moisture inside
No signs of discoloration from overheating
No corrosion c. Check operation of Clutch Relay START/RUN-OFF switch in START/RUN-Manual Start
Operation. (See Note Note 4)
LED 29 must be ON
Must be 11.5 VDC or higher d. Check voltage to clutch
4
Check Clutch Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
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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: Pretrip will abort and “PRETRIP FAILED IN TEST 2” will be displayed in
MessageCenter.
• RESET CONDITION: Auto Reset if Pretrip 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 Or F6 Fuse Alarm
a. Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue.
2
Check Front Unloader (UL1)
a. Check amp draw of coil.
Use Component Test mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data list. (Refer to Section
3.14).
Refer to Section 2.13
b. Check resistance of Front Unloader
(UL1) coil.
3
Check Front Unloader (UL1) And Circuit
a. Inspect Front Unloader (UL1) and wiring.
No damage or corrosion
Connector fits together tightly, no moisture inside b. Check operation of UL1 FET (23) START/RUN-OFF switch in Start/Run-Manual Start
Operation. (See Note Note 4) LED must be ON c. Check voltage to Front Unloader (UL1). Must be 11 VDC or higher across the 2 wires
4
Check Front Unloader (UL1) Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
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P145 CHECK SPEED SOL CIRCUIT
• TRIGGER–ON: Normal Amps for the Speed Solenoid Circuit is 3.0 to 9.0 Amps for non--Electronic Speed
Controlled (ESC) engines or
0 to 1.0 Amps for ESC engines. The circuit tests outsidethis range.
•
UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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.
2A
Check Speed Solenoid (Non--ESC engines)
a. Check resistance of speed solenoid Refer to Section 2.13
b. Check amp draw of speed solenoid.
Use Component Test mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data list. (Refer to Section
3.14).
2B
Check Circuit For High Resistance (ESC engines)
a. Check amp draw of engine speed control circuit (ENSCU) pin 16 and
MPQC3 on the micro.
Use Component Test mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data list. (Refer to Section
3.14).
3
Check Speed Solenoid & Circuit
a. Inspect speed solenoid and wiring a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
No damage to solenoid b. Check operation of Speed Relay LED LED 27must be ON c. Check voltage to speed solenoid
4
Check Speed Solenoid Circuit Wiring
Must be 11 VDC or higher across the 2 wires
No physical damage to harness.
No damaged or corroded pins
62-10683
8--70
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P148 CHECK SV1 CIRCUIT
• TRIGGER–ON: Normal Amps for the SV1 Circuit is 0.75 to 2.5 Amps. The circuit tests outside this range.
• UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 2” will be displayed in
MessageCenter.
• RESET CONDITION: Auto Reset if Pretrip 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 Or F6 Fuse Alarm
a. Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue.
2
Check SV1
a. Check resistance of SV1 b. Check amp draw of SV1.
Refer to Section 2.13
Use Component Test mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data list. (Refer to Section
3.14).
3
Check SV1 & Circuit
a. Inspect SV1 and wiring No physical damage to harness.
No damaged or corroded pins
Unit running in Heat Cycle b. Start unit, setpoint more than 10°F
(5.5°C) above box temperature, and set above +11°F (--11.5°C). (See note
Note 9) c. Check operation of SV1 FET (10) d. Check voltage to SV1
4
Check SV1 Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
LED must be ON
Must be 11 VDC or higher across the 2 wires
No physical damage to harness.
No damaged or corroded pins
8--71
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P150 CHECK SV4 CIRCUIT
• TRIGGER–ON: Normal Amps for the SV4 Circuit is 0.75 to 2.0 Amps. The circuit tests outside this range.
• UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 2” will be displayed in
MessageCenter.
• RESET CONDITION: Auto Reset if Pretrip 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 Or F6 Fuse Alarm
a. Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue.
2
Check SV4
a. Check resistance of SV4 b. Check amp draw of SV4.
Refer to Section 2.13
Use Component Test mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data list. (Refer to Section
3.14).
3
Check SV4 & Circuit
a. Inspect SV4 and wiring No physical damage to harness.
No damaged or corroded pins
Unit running in Heat Cycle b. Start unit with setpoint more than 10°F
(5.5°C) above box temperature, and set above +11°F (--11.6°C). (See note
Note 9) c. Check operation of SV–4 FET (9) d. Check voltage to SV–4
4
Check SV4 Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
LED must be ON
Must be 11 VDC or higher across the 2 wires
No physical damage to harness.
No damaged or corroded pins
62-10683
8--72
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: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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. Inspect glow plug relay & socket No signs of discoloration from overheating
No corrosion b. Check operation of Glow Plug Relay START/RUN-OFF switch in START/RUN-Manual Start
Operation. (See Note Note 4) Glow Crank switch in Glow position. LED 30 must be ON c. Check voltage to glow plugs d. Check Glow Plug circuit Amps
Must be 11 VDC or higher
Use Component Test mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data list. (Refer to Section
3.14) e. Check amp draw of each glow plug.
Refer to Section 2.13 for amp values. Use ammeter.
2
Check Glow Plug Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
8--73
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P152 CHECK FUEL SOLENOID CIRC
• TRIGGER–ON: Normal Amps for the Fuel Solenoid Hold Circuit is 0.42 to 3.5 Amps (0.2 to 4.5 Amps for
ESC units)for non--Electronic Speed Controlled (ESC) engines, and 0.2 to 4.5 Amps for ESC engines
(including possible electric fuel pump). The circuit tests outside this range.
•
UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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.
2A
Check Fuel Solenoid (Non--ESC engines only)
a. Check resistance of fuel solenoid b. Check amp draw of fuel solenoid.
Refer to Section 2.13
Use Component Test Mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data list. (Refer to Section
3.14)
2B
Check Fuel And Speed Actuator (FSA) (ESC engines only)
a. Check resistance of FSA Refer to Section 2.13. With FSA unplugged, ohm spec is
3--4 ohms, +/-- 10%.
b. Check amp draw between MPQC4 & terminal 13 and 15 of the ENSCU.
3A
Check Fuel Solenoid & Circuit (Non--ESC engines only)
a. Inspect fuel solenoid and wiring No physical damage to harness.
No damaged or corroded pins
No damage to solenoid b. Check operation of Run Relay Start/Run--Off switch in Start/Run--Manual Start Operation.
(See Note 2) LED 28 must be ON c. Check voltage to fuel solenoid
Use Component Test Mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
Start/Run--Off switch 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)
3B
Check FSA & Circuits (ESC only)
a. Inspect FSA and wiring b. Check operation of Run Relay c. Check voltage to FSA
No physical damage to harness.
No damaged or corroded pins
No damage to solenoid
Start/Run--Off switch in Start/Run--Manual Start Operation.
(See Note 2) LED 28 must be ON
Start/Run--Off switch in Start/Run, Manual Start Mode
(See Note 2) OR component test mode, run relay.12 VDC between engine speed control unit (ENSCU) pins 13 and
19.
12 VDC between ENSCU pins 13 and 19
With Manual Crank Switch in crank position
12 VDC between ENSCU pins 15 and 19
4
Check Fuel Solenoid Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.) b. Check operation of solenoid
No physical damage to harness.
No damaged or corroded pins
Plunger must move in when energized
62-10683
8--74
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P153 CHECK RETURN AIR SENSOR
• TRIGGER–ON: Return Air Sensor is not within the maximum range of --53°F to +158°F (--47°C to +70°C)
• UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 3” will be displayed in
MessageCenter.
• RESET CONDITION: Auto Reset if Pretrip 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 Temperature sensor (RAT)
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.
b. Check Return Air Sensor resistance
(See Note 4 Page 8--2)
10,000 Ohms @ 77°F (25°C) [See section 2.13 for complete table of temperatures and resistance values.]
2
Check Return Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
3
Check Remote Sensor/Switch Connector
a. Locate and inspect 10--way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
8--75
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
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: Pretrip will abort and “PRETRIP FAILED IN TEST 3” will be displayed in
MessageCenter. Defrost termination will be as described in Section 5.11
• RESET CONDITION: Auto Reset if Pretrip 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 Temperature Sensor (SAT)
a. Inspect Supply 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.
b. Check Supply Air Sensor resistance
(See Note 4 Page 8--2)
10,000 Ohms @ 77°F (25°C) [See section 2.13 for complete table of temperatures and resistance values.]
2
Check Supply Air Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
3
Check Remote Sensor/Switch Connector
a. Locate and inspect 10--way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
4
Check Remote Sensor/Switch Connector
a. Locate and inspect 10--way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
62-10683
8--76
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: Pretrip will abort and “PRETRIP FAILED IN TEST 3” will be displayed in
MessageCenter.
• RESET CONDITION: Auto Reset if Pretrip 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 Temperature Sensor (ENCT)
a. Inspect Engine Coolant Sensor & connector
No damage to sensor
No moisture, damage or corrosion in connector
1MP Plug is connected tightly to microprocessor. No wires are pushed back through plug.
b. Check Engine Coolant Sensor resistance (See Note 4 Page 8--2))
10,000 Ohms @ 77°F (25°C) [See section 2.13 for complete table of temperatures and resistance values.]
2
Check Engine Coolant Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
3
Check Remote Sensor/Switch Connector
a. Locate and inspect 10--way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
P156 CHECK BATTERY VOLTS
•
TRIGGER–ON: Battery voltage is less than 11 VDC or greater than 17 VDC
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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 Battery Voltage Too High Alarm
a. Check for alarm 15 Alarm conditions must be corrected and the alarm cleared to continue.
2
Check For Battery Voltage Too Low Alarm
a. Check for alarm A16 Alarm conditions must be corrected and the alarm cleared to continue.
8--77
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P157 CHECK BATTERY CURRENT
• TRIGGER–ON: With all circuits off, current flow of more than +1.5 or --2 Amps is detected in the electrical circuits.
NOTE: If this alarm occurs, Pretrip Test #2 will not be performed. You will need to run Pretrip again.
•
UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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.
a. Note amp draw on display.
(See Note 3)
2
Check Individual Circuits
a. Isolate individual circuits and test amp draw
Must show +1.5 to --2 Amps
Must be in range. (Refer to Section 2.13)
3
Check For Parasitic Loads (Electrical current being used by a non--refrigeration unit component)
a. Check for electrical loads that are drawing current with all circuits OFF.
Check for non--factory installed electrical devices such as lift gates, inside lights, satellite systems, etc). These must have zero amps during Pretrip.
62-10683
8--78
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
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: Pretrip will abort and “PRETRIP FAILED IN TEST 3” will be displayed in
MessageCenter.
• RESET CONDITION: Auto Reset if Pretrip 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 Temperature sensor (AAT)
a. Inspect Ambient Air Sensor & connector
No damage to sensor
No moisture, damage or corrosion in connector
1MP Plug is connected tightly to microprocessor. No wires are pushed back through plug.
b. Check Ambient Air Sensor resistance
(See Note 4 Page 8--2)
10,000 Ohms @ 77°F (25°C) [See section 2.13 for complete table of temperatures and resistance values.]
2
Check ambient air sensor wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
3
Check remote sensor/switch connector
a. Locate and inspect 10--way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
8--79
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P160 CHECK DISCH 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: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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 Temperature Sensor (CDT)
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.
b.Check Compressor Discharge Temp
Sensor resistance
(See Note 4 Page 8--2)
100,000 Ohms @ 77°F (25°C) [See section 2.13 for complete table of temperatures and resistance values.]
2
Check Compressor Discharge Temp Sensor Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
3
Check Remote Sensor/Switch Connector
a. Locate and inspect 10--way connector for optional sensors and switches.
Connector must have cap on,
No corrosion or moisture inside connector.
If there is a problem with the connector and there are no remote sensors or switches in the unit, the connector may be removed and each individual wire separated from the others, terminated and insulated with heat shrink.
62-10683
8--80
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P162 CHECK AUTO FRESH AIR EXCHANGE SOLENOID (AFAS) CIRCUIT
• TRIGGER–ON: Normal Amps for the AFAX Circuit is 0.4 to 2.5 Amps. The circuit tests outside this range.
• UNIT CONTROL: Alarm Only.
• RESET CONDITION: Auto Reset if Pretrip 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 F10 Fuse
a. Check circuit current All conditions must be corrected in circuit
2
Check Auto Fresh Air Exchange Solenoid (AFAS)
a. Check amp draw of AFAS Use Component Test Mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data List.
3
Check AFAS And Circuit
a. Inspect AFAS and wiring b. Check operation of AutoFresh Air
Exchange Relay (AFAR)
No physical damage to harness.
No damaged or corroded pins.
No damage to solenoid
AFAS turned on and LED12 on.
AFAR energized.
c. Check voltage to AFAS 12VDC between AFAS B (ground) and AFAS A (+12VDC) when AFAR is energized.
8--81
62-10683
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: Pretrip will abort and “PRETRIP FAILED IN TEST 3” will be displayed in
MessageCenter.
• RESET CONDITION: Auto Reset if Pretrip 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 or F6 fuse alarm
a. Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue.
2
Check Rear Unloader (UL2)
a. Check resistance of UL2 b. Check amp draw of UL2
Refer to Section 2.13
Use Component Test mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data list. (Refer to Section
3.14
3
Check Rear Unloader (UL2) And Circuit
a. Inspect Rear Unloader (UL2) and wiring.
No damage or corrosion
Connector fits together tightly, no moisture inside b. Check operation of Rear Unloader
(UL2) FET (22).
START/RUN-OFF switch in START/RUN-Manual Start
Operation. (See Note Note 4) LED must be ON c. Check voltage to UL2 Must be 11 VDC or higher across the 2 wires
4
Check Rear Unloader (UL2) Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
62-10683
8--82
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P165 CANNOT PUMP DOWN
• TRIGGER–ON: With SV1, SV2, & SV4 in the closed position, the compressor is not able to pull the low side of the refrigerant system down to 10 PSIG (0.68 Bar).
• UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 11, 12 or 13” will be displayed in
MessageCenter.
• RESET CONDITION: Auto Reset if Pretrip 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
Visually Inspect Unit
a. Is compressor turning with engine?
Compressor must turn with engine.
2
Check System Pressure
a. Check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Suction & Discharge Pressures must have the same reading ± 5 PSIG (±0.34 Bar) on gauges & on micro display.
3
Manually Test Refrigeration System (See Note 9 Page 8--2)
a. See Refrigeration Troubleshooting,
Section 10.3 -- “System Will Not Pump
Down”
Must pass all tests
Correct any problems found before proceeding.
b. Run Quick Check Correct any problems found before proceeding.
8--83
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P174 CHECK LOW SPEED RPM
• TRIGGER–ON in Test #7:
With Speed Relay turned off (speed solenoid de-energized), engine RPM are NOT
Between 1375 and 1600 for Ultima XTC and X2 2500A/R; or
Between 1275 and 1500 for Ultra XTC and X2 2100A/R
•
TRIGGER–ON in Test #9:
15 seconds after the High Speed Test, engine RPM have NOT dropped from the high speed RPM
(in Test #8) by:
Between 450 and 925 for Ultima XTC and X2 2500A/R; or
Between 150 and 525 for Ultra XTC and X2 2100A/R
•
UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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 Speed Solenoid& Linkage On Non--electronic Speed Controlled (ESC) Engines And
The Fuel And Speed Actuator On ESC Engines
a.Check speed solenoid (FSA on ESC) plunger
Must move in and out freely b. Check engine speed arm & linkage Must move freely
2
Force Low Speed Operation (See Note 9 Page 8--2)
a. Set Functional Parameter “LOW
SPEED START” for a high number (30 to 90) then start the unit.
Set Functional Parameter back to original setting after completing repairs.
LED 27 must be OFF b. Check operation of Speed Relay LED LED 27 must be OFF c. Check voltage to speed solenoid (FSA on ESC)
Must be 0 VDC d. On X2 2500 units ONLY, check for voltage on engine speed control unit
(ENSCU) pin 22.
Must be 12 VDC
3
Check For Proper Voltage To The Engine Speed Control Unit (ENSCU) Pin 16 Based On
Requested Speed From The Microprocessor
Must be 0 VDC for all units a. Check voltage at pin 16 with unit running.
4
Check Engine RPM
a. Check actual engine RPM using hand held tachometer b. Compare actual RPM with those shown on display.
Refer to Section 2.7
Adjust engine linkage setting as needed.
Both readings within ± 50 RPM
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 Engine Exhaust System
a. Inspect the exhaust system Must be clear and unobstructed
62-10683
8--84
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P175 CHECK HIGH SPEED RPM
• TRIGGER–ON: With Speed Relay turned on (voltage at the speed solenoid / Engine Speed Control Unit for high speed operation (?)), engine RPM are NOT
Between 2000 and 2300 for Ultima XTC/X2 2500A/R; or
Between 1700 and 2000 for Ultra XTC/X2 2100A/R
•
UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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 Speed Solenoid & Linkage On Non--Electronic Speed Controlled (ESC) Engines, Or
The fuel And Speed Actuator On ESC Engines
a. Check speed solenoid (FSA on ESC) plunger
Must move in and out freely b. Check engine speed arm & linkage Must move freely
2
Force high speed operation (See Note 9 Page 8--2)
a. Set Functional Parameter “LOW
SPEED START” to zero and adjust setpoint at least 10°F (5.6°C) above or below box temperature then start the unit.
Set Functional Parameter back to original setting after completing repairs.
LED 27 must be ON b. Check operation of Speed Relay c. Check voltage to speed solenoid (FSA on ESC)
LED 27 must be ON
Must be 12--14 VDC
Refer to Section 2.13
d. Check resistance of speed solenoid
(FSA on ESC) e. Check amp draw of speed solenoid
(FSA on ESC)
Use Component Test Mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data list. (Refer to Section
3.14
f. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.) a. Check voltage at pin 16 with unit running.
4
Check Engine RPM
No physical damage to harness.
No damaged or corroded pins or terminals g. On X2 2500 units ONLY, check for voltage on engine speed control unit
(ENSCU) pin 22.
Must be 12 VDC
3
Check For Proper Voltage To The Engine Speed Control Unit (ENSCU) Pin 16 Based On
Requested Speed From The Microprocessor
Must be 0 VDC for all units a. Check actual engine RPM using hand held tachometer
Refer to Section 2.7
Adjust engine linkage setting as needed.
b. Compare actual RPM with those shown on display
Additional steps on the next page.
Both readings within ± 50 RPM
8--85
62-10683
Alarm
NO.
Steps ALARM / CAUSE
P175 CHECK HIGH SPEED RPM (Continued)
5
Check engine air-intake system
a. Check air filter indicator b. Inspect air intake system
6
Check engine exhaust system
a. Inspect the exhaust system
CORRECTIVE ACTION
Flag must not be visible.
Hoses & tubes in good condition.
No kinks or restrictions
Must be clear and unobstructed
62-10683
8--86
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) Unloader was loaded (de-energized) or unloaded (energized)
• UNIT CONTROL: If alarm A191 is already on, then Pretrip will be aborted & display will read “PRETRIP
FAILED IN TEST 6”.
• RESET CONDITION: Auto Reset if Pretrip 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
Check for Check UL1 alarm
a. Check for alarm 85 or P144 Alarm conditions must be corrected and the alarm cleared to continue
3
Check system pressures
a. Check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
4
Check for Check SV2 Circuit Alarm
a. Check for alarm 97 or P192
Suction & Discharge Pressures must have the same reading -- ± 5 PSIG (±0.34 Bar) -- on gauges & on micro display.
5
Check Front Unloader (UL1) Operation -- Unit must be running (See Note 9 Page 8--2) (See
Section 9.14 -- Unloader Checkout Procedure)
a. Energize UL1 coil
Alarm conditions must be corrected and the alarm cleared to continue
Pressures must change within 3--4 seconds of coil being energized or de--energized
Suction pressure must raise slightly
Discharge pressure must drop slightly b. De-energize UL1 coil Suction pressure must drop slightly
Discharge pressure must raise slightly
6
Check for Check UL2 Unloader alarm
a. Check for alarm P191 Alarm conditions must be corrected and the alarm cleared to continue
7
Check SV1 for being closed.
a. Check voltage to SV1 coil.
b. Check pressure differential between compressor discharge port and receiver king valve.
Must be 0 VDC
Must be less than 25 PSIG (1.70 Bars).
8
Check the compressor center head snubber tee
a. Check snubber (restrictor) inside the tee assembly for HPS and CDP sensors
Tee must be open and not blocked or overly restricted. If in doubt, remove the snubber restrictor with a hammer and small punch, then restart pretrip.
8--87
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P180 CHECK SUCTION MOD VALVE
• TRIGGER–ON: Suction pressure did not drop as expected during Test 10 in Pretrip, when the CSMV was changing position.
• UNIT CONTROL: Alarm only.
• RESET CONDITION: Auto Reset if Pretrip 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
a. Upgrade software.
Revision level must be 04.06.00 or higher.
2
Check connector to the suction modulation valve
a. Inspect CSMV and wiring.
No damage or corrosion.
Connector fits together tightly. No moisture inside.
3
Check operation of suction modulation valve
a. See CSMV troubleshooting, Section
9.22.2
Must pass all tests.
62-10683
8--88
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P181 CHECK SV4 VALVE
• TRIGGER–ON: Suction pressure did not rise within range & discharge pressure did not drop within range when SV4 was energized (opened)
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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 SV4 Alarm
a. Check for alarms 79, P150 Alarm conditions must be corrected and the alarm cleared to continue
2
Check System Pressures
a. Check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Suction & Discharge Pressures must have the same reading -- ± 5 PSIG (±0.34 Bar) -- on gauges & on micro display.
3
Check SV4 Operation -- Unit Must Be Running In Heat Cycle (See Note 9 Page 8--2)
(See Section 9.21.1, Checking SV4)
a. Set unit to run in high speed cool b. Energize SV4 coil
After 60 seconds note suction and discharge pressures.
Hot gas hissing sound will begin immediately.
Suction pressure must rise slightly
Discharge pressure must drop slightly c. De-energize SV4 coil Hot gas hissing sound will stop immediately.
Suction pressure must drop slightly
Discharge pressure must rise slightly
4
Manually Test Refrigeration System
a. Run Quick Check Must pass all tests
Correct any problems found before proceeding.
8--89
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P182 CHECK SV1 VALVE
• TRIGGER–ON: Discharge pressure did not decrease when SV1 was de--energized (opened) as expected in Heat Pretrip Mode, or discharge pressure did not increase as expected when SV1 was energized
(closed) in Cool Pretrip Mode.
•
UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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 SV1 Alarm
a. Check for alarms 80, P148 Alarm conditions must be corrected and the alarm cleared to continue
2
Check System Pressures
a. Check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Suction & Discharge Pressures must have the same reading -- ± 5 PSIG (±0.34 Bar) -- on gauges & on micro display.
3
Check Sv1 Operation -- Unit Must Be Running In Heat Cycle. (See Note 9 Page 8--2)
(See Section 9.21.2 -- Checking SV1)
a. Set unit to operate in high speed heat After 3 minutes note discharge and suction pressures b. De-energize SV1 coil Compressor discharge pressure will drop
Receiver tank pressure will raise slightly
4
Manually Test Refrigeration System
a. Run Quick Check Must pass all tests
Correct any problems found before proceeding.
62-10683
8--90
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P191 CHECK UL2
• TRIGGER–ON: The pressure differential between discharge and suction pressures did not change as expected when the UL2 (Rear) Unloader was loaded (de-energized) or unloaded (energized)
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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 SV2 Circuit Alarm
a. Check for alarm 97 or P192 Alarm conditions must be corrected and the alarm cleared to continue
2
Check For Check UL2 Unloader Alarm
a. Check for alarm 85 or P144 Alarm conditions must be corrected and the alarm cleared to continue
3
Check System Pressures
a. Check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Suction & Discharge Pressures must have the same reading -- ± 5 PSIG (±0.34 Bar) -- on gauges & on micro display.
4
Check UL2 Operation -- Unit Must Be Running (See Note 9 Page 8--2)
(See Section 9.14 -- Checking Unloaders)
a. Energize UL2 coil Pressures must change within 3--4 seconds of coil being energized or de--energized
Suction pressure must raise slightly
Discharge pressure must drop slightly
Check snubber b. De-energize UL2 coil Suction pressure must drop slightly
Discharge pressure must raise slightly
5
Check The Compressor Center Head Snubber Tee
a. Check snubber (restrictor) inside the tee assembly for HPS and CDP sensors
Tee must be open and not blocked or overly restricted. If in doubt, remove the snubber restrictor with a hammer and small punch, then restart pretrip.
8--91
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P192 CHECK SV2 CIRCUIT
• TRIGGER–ON: Normal Amps for the SV2 Circuit is 0.75 to 2.0 Amps. The circuit tests outside this range.
• UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 2” will be displayed in
MessageCenter.
• RESET CONDITION: Auto Reset if Pretrip 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 Or F6 Fuse Alarm
a. Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue.
2
Check SV2
a. Check resistance of SV2 b. Check amp draw of SV2.
Refer to Section 2.13
Use Component Test mode (Section 6.2.2) to test.
Refer to Section 2.13 for amp values.
View current draw in the Unit Data list. (Refer to Section
3.14
3
Check SV2 & Circuit
a. Inspect SV2 and wiring b. Check operation of SV2 FET (21)
No damage or corrosion
Connector fits together tightly, no moisture inside
START/RUN-OFF switch in START/RUN-Manual Start
Operation. (See Note Note 4) LED must be ON
Must be 11 VDC or higher across the 2 wires c. Check voltage to SV2
4
Check SV2 Circuit Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
62-10683
8--92
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P194 HIGH SUCTION PRESSURE
• TRIGGER–ON: This alarm is generated during Test 4 of Cool Pretrip. Suction pressure is higher than normal. (Maximum suction pressure should be approximate MOP of TXV or a little bit higher during this test.
•
UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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 SV4 Alarm
a. Check for alarm P181 Condition must be corrected and alarm cleared to proceed.
2
Check System Pressures
a. Check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Suction & Discharge Pressures must have the same reading -- ± 5 PSIG ( ±0.34 Bar) -- on gauges & on micro display.
3
Check MOP Of Expansion Valve
a. Test MOP of Expansion valve.
b. Verify that correct TXV is in unit.
Refer to Section 2.11
Must have correct valve.
4
Manually Test Refrigeration System (See Note 9 Page 8--2)
a. Run Quick Check Must pass all tests
Correct any problems found before proceeding.
8--93
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P195 LOW SUCTION PRESSURE
• TRIGGER–ON: This alarm is generated during Test 4 of Cool Pretrip. Suction pressure is lower than normal, using the lesser value of the two following calculations.
Minimum suction pressure should be 15 PSIG (1Bar) less than TXV MOP (see section 2.11 for
MOP values); OR
RAT minus 40°F (22°C) (Calculate suction pressure using a Temperature--Pressure chart See
Table 9-9). For example, if the RAT is +45°F, you would take 45°F minus 40°F which equals 5°F. Look up the saturated suction pressure for 5°F. See Table 9-9.
•
UNIT CONTROL: Alarm Only
•
RESET CONDITION: Auto Reset if Pretrip 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
Check Fan Belts
a. Check upper fan belt tension & condition
4
Check For SV2 Circuit Alarm
a. Check for alarm 97 or P192
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping b. Check lower fan belt tension & condition.
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping
3
Check Evaporator Air Flow (See Note 9 Page 8--2)
a. Check evap fan clutch Must be engaged b. 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
Alarm conditions must be corrected and the alarm cleared to continue
5
Check System Pressures
a. Check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
6
Check Refrigerant Charge
a. Check for undercharged system. (See
Section 9.11.4 -- Checking Refrigerant
Charge)
7
Manually Defrost Unit
a. Defrost unit and terminate automatically.
8
Check system pressures
a. Check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Additional steps on the next page.
Suction & Discharge Pressures must have the same reading -- ± 5 PSIG (±0.34 Bar) -- on gauges & on micro display.
Level must be above lower sight glass
Typical defrost cycle time is 5--20 minutes
Suction pressure should rise gradually during cycle.
Suction & Discharge Pressures must have the same reading -- ± 5 PSIG (±0.34 Bar) -- on gauges & on micro display.
62-10683
8--94
Alarm
NO.
Steps ALARM / CAUSE
P195 LOW SUCTION PRESSURE (Continued)
CORRECTIVE ACTION
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.
9
Manually Test Refrigeration System (See Note 9 Page 8--2)
a. Run Quick Check Must pass all tests.
Correct any problems found before proceeding b. See Refrigeration Troubleshooting,
Section 10.3.9-“Low Suction
Pressure.”
10
Check Expansion Valve (TXV)
a. Visually inspect valve b. Check MOP of valve c. Verify that correct TXV is in unit.
d. Check superheat of valve
Bulb must be clamped tightly on the suction line and insulated
Refer to Section 2.11
Must have correct valve.
Refer to Section 2.11
11
Check For Damage To The Suction Line
a. Visually inspect suction line for any kinks, restrictions, or other damage.
No damage to line
12
Check For Restricted Compressor Suction Screen
a. Visually inspect compressor suction inlet screen for material.
Must be clean and unobstructed.
8--95
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P196 HIGH DISCHARGE PRESSURE
• TRIGGER–ON: This alarm is generated during Test 4 of Cool Pretrip. Discharge pressure is higher than normal. (’Normal” discharge pressure for systems operating in the Cool Mode can be estimated by taking
the temperature of the air entering the condenser coil (Ambient Air Temperature AAT) and adding 30°F
(16.6° C) to it, then looking at a pressure temperature chart--see Table 9-9-- for the corresponding
pressure.)
•
UNIT CONTROL: Alarm Only
•
RESET CONDITION: Auto Reset if Pretrip 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 Fan Belts
a. Check upper fan belt tension & condition
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping b. Check lower fan belt tension & condition.
2
Check Wiring
a. Visually Inspect wiring to SV4 & both
Compressor Unloaders
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping
Wires must be connected properly & securely to each component
3
Check Airflow Through Condenser Coil (See Note 9 Page 8--2)
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
4
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.
5
Check For Refrigerant Overcharge
a. Check refrigerant level in the receiver tank.
6
Check Discharge Check Valve
a. Check that discharge check valve opens fully
Level must be between upper & lower sight glasses
Must open fully with unit running b. Check discharge check valve screen Must be clean of any debris
7
Manually Test Refrigeration System (See Note 9 Page 8--2)
a. Run Quick Check Must pass all tests
Correct any problems found before proceeding.
8
Check System For Non–Condensables
a. Check refrigeration system for non–condensable gas(es)
No non–condensable gas(es) may be present.
b. See Refrigeration Troubleshooting,
Section 10.3.9 -- “High Discharge
Pressure.”
9
Check Compressor
a. Remove all Compressor heads and inspect valve plates, unloaders, reed valves, & gaskets
Must be in good condition.
No broken or missing parts.
62-10683
8--96
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P198 LOW DISCHARGE PRESSURE
• TRIGGER–ON: In the Heat Pretrip mode, the Compressor Discharge Pressure did not rise to normal.
(The minimum ’Normal” discharge pressure for systems operating in the Heat Pretrip Mode can be estimated by taking the temperature of the air entering the condenser coil (Ambient Air Temperature AAT) and looking at a pressure temperature chart--see table Table 9-9--for the corresponding pressure, then adding 80 psig (5.5bars) to it.)
•
UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 4” will be displayed in
MessageCenter.
•
RESET CONDITION: Auto Reset if Pretrip 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 Ambient Sensor Alarm
a. Check for alarm(s) 121 and P158 Alarm conditions must be corrected and the alarm cleared to continue.
b. Check Ambient Sensor calibration
2
Check System Pressures
a. Install Manifold Test Set and check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
Must be within ±10°F (±5.5°C) of actual temperature
Suction pressure must be above 3 PSIG (0.2 Bar)
Suction & Discharge Pressures must have the same reading on gauges & on micro display.
3
Check Refrigerant Charge
a. Check for undercharged system Level must be above lower sight glass
4
Check SV1 Operation. (See Section 9.21.2 -- Checking SV1)
a. Check the operation of the SV1 valve per test procedure
Must perform correctly
Correct any problems found before proceeding
5
Check Compressor For Ability To Pump Up Pressure
a. Check the operation of the high side of the compressor by covering the condenser inlet air.
b. Remove compressor heads & inspect condition of all reeds & gaskets
Discharge pressure must rise a minimum of 50 to 100 psig
(3.4 to 6.9 bars)
Must be in good condition.
8--97
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P200 CHECK UL1 CYLINDERS
• TRIGGER–ON: A problem has been detected inside the front cylinder head of the compressor with a suction reed, discharge reed, head gasket or valve plate gasket.
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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 Refrigerant Charge
a. Check for undercharged system Level must be above lower sight glass
2
Manually Test Refrigeration System (See Note 9 Page 8--2)
a. Run Quick Check Must pass all tests
Correct any problems found before proceeding.
b. Check and compare compressor suction pressure with pressure shown on the microprocessor controller.
Suction Pressure must have the same reading on gauge & on micro display.
3
Check Compressor Front Head Reed Valves & Gaskets
a. Remove compressor front head & inspect condition of all reeds & gaskets
Must be in good condition.
62-10683
8--98
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P201 CHECK UL2 CYLINDERS
• TRIGGER–ON: A problem has been detected inside the rear cylinder head of the compressor with a suction reed, discharge reed, head gasket or valve plate gasket.
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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
Manually Test Refrigeration System (See Note 9 Page 8--2)
a. Run Quick Check Must pass all tests
Correct any problems found before proceeding.
b. Check and compare compressor suction pressure with pressure shown on the microprocessor controller.
Suction Pressure must have the same reading on gauge & on micro display.
2
Check Compressor Rear Head Reed Valves & Gaskets
a. Remove compressor rear head & inspect condition of all reeds & gaskets
Must be in good condition.
P202 HIGH SIDE LEAK
• TRIGGER–ON: With the Low Pressure Side of the refrigeration system forced to low pressure, refrigerant pressure is leaking past one of the components in the High Pressure Side of the refrigeration system into the Low Pressure Side..
• UNIT CONTROL: Alarm Only
•
RESET CONDITION: Auto Reset if Pretrip 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
Manually Test Refrigeration System (See Note 9 Page 8--2)
a. Run Quick Check Must pass all tests
Correct any problems found before proceeding.
b. Check and compare compressor suction pressure with pressure shown on the microprocessor controller.
c. With manifold gauges connected to the compressor discharge and suction valves, and the unit running in Cool, slowly front seat the King Valve until the suction pressure reaches 5 psig (3 bar), then shut the engine off.
Suction Pressure must have the same reading on gauge & on micro display.
Monitor manifold gauges with the unit off. The suction and discharge pressures should not equalize for several minutes.
Correct any problems before proceeding.
8--99
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P203 CHK DISCHARGE CHECK VALVE
• TRIGGER–ON: Refrigerant is leaking backwards through the Discharge Check Valve
• UNIT CONTROL: Alarm Only
• RESET CONDITION: Auto Reset if Pretrip 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 Discharge Check Valve
a. Test Discharge Check Valve for leakage
Must not leak.
2
Manually Test Refrigeration System (See Note 9 Page 8--2)
a. Run Quick Check Must pass all tests
Correct any problems found before proceeding.
b. Check and compare compressor suction pressure with pressure shown on the microprocessor controller.
Suction Pressure must have the same reading on gauge & on micro display.
62-10683
8--100
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P204 LOW SUCTION PRESSURE
• TRIGGER–ON: Suction Pressure is less than --10inHg (--0.34 Bar) for more than 30 continuous seconds, or less than 16inHg (--0.54 Bar) for more than 5 seconds at any time during Pretrip.
• UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST X” will be displayed in
MessageCenter indicating in which test the suction pressure was too low.
• RESET CONDITION: Auto Reset if Pretrip 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 Fan Belts
a. Check upper fan belt tension & condition b. Check lower fan belt tension & condition.
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping
(Refer to Section 9.9 for belt tensions)
No Glazing, no cracking, no slipping
2
Check System Pressures
a. Install Manifold Test Set and check and compare compressor discharge & suction pressures with those shown on the microprocessor controller.
3
Manually Defrost Unit
a. Defrost unit automatically.
and terminate
Suction pressure must be above 3 PSIG (0.2 Bar)
Suction & Discharge Pressures must have the same reading on gauges & on micro display.
Typical defrost cycle time is 5--20 minutes
Suction pressure should rise gradually during cycle.
4
Check Evaporator Air Flow
a. Check evap fan clutch b. Check evaporator section, return air bulkhead, air chute, cleanliness of evap. coil
Must be engaged
Good Air Flow
Return air not restricted
Air chute in good condition
No damage to blower wheel
Evap. coil clean
5
Check Refrigerant Charge -- See Section 9.11.4 -- Checking Refrigerant Charge)
a. Check for undercharged system
6
Check Expansion Valve (TXV)
Level must be above lower sight glass a. Visually inspect valve Bulb must be clamped tightly on the suction line and insulated b. Check MOP of valve c. Check superheat of valve
Refer to Section 2.11
Refer to Section 2.11
8--101
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
P205 CHK DEFROST TERM 2 SENSOR
• TRIGGER–ON: Defrost Termination Temperature Sensor 2 is not within the maximum range of
--53°F to +158°F (--47°C to +70°C)
• UNIT CONTROL: Alarm and defrost cycle will terminate as described in section 5.11.
• RESET CONDITION: Auto Reset if Pretrip 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 2 (DTT2)
a. Inspect Defrost Termination
Temperature Sensor 2 & 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.
b. Check Defrost Termination
Temperature Sensor 2 resistance
(See Note 4 Page 8--2)
10,000 Ohms @ 77°F (25°C) [See section 2.13 for complete table of temperatures and resistance values.]
2
Check Defrost Termination Temperature Sensor 2 Wiring
a. Inspect harness & control box connector pins & terminals (See wiring schematic Section 11.)
No physical damage to harness.
No damaged or corroded pins
62-10683
8--102
Alarm
NO.
Steps ALARM / CAUSE
8.10 MAINTENANCE ALARMS
223 ENGINE MAINTENANCE DUE
• 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
2
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Must be done soon!
Follow instructions on proper maintenance form
3 Reset Engine Maintenance Hour Meter a. Check that the Engine Maintenance
Hour Meter interval is set for your requirements.
b. Reset Engine Maintenance Hour Meter for the next service interval
CORRECTIVE ACTION
Reset Interval in Configuration list as required.
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in Section
9.1.
4
See Note 1 Page 8--2
a. Clear the inactive alarms.
All alarms cleared.
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
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Follow instructions on proper maintenance form
3
Reset General Maintenance Hour Meter
a. Check that the General Maintenance
Hour Meter interval is set for your requirements.
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
9.1.
4
See Note 1 Page 8--2
a. Clear the inactive alarms.
All alarms cleared.
8--103
62-10683
Alarm
NO.
Steps ALARM / CAUSE
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
Check Unit Maintenance Records
a. Schedule unit into service facility for maintenance
2
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Must be done soon!
Follow instructions on proper maintenance form
3
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
CORRECTIVE ACTION
Reset Interval in Configuration list as required.
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in Section
9.1.
4
See Note 1 Page 8--2
a. Clear the inactive alarms.
All alarms cleared
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
Perform Maintenance
a. Perform appropriate engine & unit maintenance
3
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
9.1.
4
See Note 1 Page 8--2
a. Clear the inactive alarms.
All alarms cleared.
62-10683
8--104
Alarm
NO.
Steps ALARM / CAUSE
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
Check Unit Maintenance Records
a. Schedule unit into service facility for maintenance
2
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Must be done soon!
Follow instructions on proper maintenance form
3
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
CORRECTIVE ACTION
Reset Interval in Configuration list as required.
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in Section
9.1.
4
See Note 1 Page 8--2
a. Clear the inactive alarms.
All alarms cleared
229 SERVICE SOON -- PM #4 DUE
• TRIGGER–ON: The Maintenance Hour Meter #4 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
Perform Maintenance
a. Perform appropriate engine & unit maintenance
3
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
9.1.
4
See Note 1 Page 8--2
a. Clear the inactive alarms.
All alarms cleared.
8--105
62-10683
Alarm
NO.
Steps ALARM / CAUSE
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
Check Unit Maintenance Records
a. Schedule unit into service facility for maintenance
2
Perform Maintenance
a. Perform appropriate engine & unit maintenance
Must be done soon!
Follow instructions on proper maintenance form
3
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
CORRECTIVE ACTION
Reset Interval in Configuration list as required.
Hour Meter is reset in the Functional Parameter list.
Follow maintenance interval recommendations in Section
9.1.
4
See Note 1 Page 8--2
a. Clear the inactive alarms.
All alarms cleared.
62-10683
8--106
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
8.11 MICROPROCESSOR ALARMS
232 SETPOINT ERROR
• TRIGGER–ON: There is an error in the Setpoint that is stored in the microprocessor memory, or in the memory sector of the microprocessor that the Setpoint is stored in.
• 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 Set Point
a. Check set point setting
Must be between --22 and +89.6° F (--30°C and +32°C) b. Enter new set point
2
Reset Microprocessor
a. Turn the Start/Run--Off switch off for 30 seconds and then turn back on.
The microprocessor powers up OK and the latest setpoint appears in the display.
b. Valid set point can not be entered.
3
See Note 1 Page 8--2
a. Clear the inactive alarms.
Replace microprocessor
All alarms cleared
233 MODEL # ERROR
• TRIGGER–ON: There is an error in the Model Number that is stored in the microprocessor memory, or in the memory sector of the microprocessor that the Model Number is stored in.
•
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 microprocessor
Number in b. Enter correct Model Number
2
Reset Microprocessor
a. Turn Start/Run--Off switch off for 30 seconds, then turn back on.
Must be a valid Model Number from Configuration List.
From Configuration List, select correct Model Number.
Microprocessor powers up OK b. Check for valid Model number in Data
List.
c. Valid model number can not be entered.
3
See Note 1 Page 8--2
a. Clear the inactive alarms.
Valid number is present.
Alarm is cleared
Replace microprocessor
All alarms cleared
8--107
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
237 FUNCTIONAL PARAMETERS ERROR
• TRIGGER–ON: There is an error in one or more of the Functional Parameters that are stored in the microprocessor memory, , or in the memory sector of the microprocessor that the Functional Parameters are stored in.
•
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 Functional Parameters
a. Check Functional Parameters
2
Reset Microprocessor
a. Turn Start/Run--Off switch off for 30 seconds, then turn back on.
b. Check for valid Functional Parameters in Functional Parameters List.
c. Valid Functional Parameter(s) can not be entered.
3
See Note 1 Page 8--2
a. Clear the inactive alarms.
All must be set for selectable values
Microprocessor powers up OK
Valid number is set for all parameters.
Alarm is cleared
Replace microprocessor
All alarms cleared.
62-10683
8--108
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, or in the memory sector of the microprocessor that the Configurations are stored in.
• UNIT CONTROL: Unit Shutdown & Alarm.
• 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
Check Configurations
a. Check Configurations
2
Check Software Version
a. Check Microprocessor Software version.
All must be set for selectable values
Upgrade to the latest version of software. Newer versions of ReeferManager may contain configurations that were not present in older versions of Microprocessor software.
3
Reconfigure Microprocessor
a. Send settings to Microprocessor.
Using ReeferManager and a Configuration PC Card, write the desired configuration file to the PC Card, then load the file into the Microprocessor. Allow the Microprocessor to reboot itself.
4
Reset microprocessor
a. Turn Start/Run--Off switch off for 30 seconds, then turn back on.
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
5
See Note 1 Page 8--2
a. Clear the inactive alarm.
All alarms cleared.
8--109
62-10683
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 inthe microprocessor memory or in the memory sector of the microprocessor that the calibration value is stored in.
•
UNIT CONTROL: Unit Shutdown & Alarm
• 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 Discharge Pressure Reading Must read valid data.
2
Calibrate Discharge Pressure Sensor
a. Calibrate Discharge Pressure Sensor. Calibration successful.
b. Discharge Pressure Sensor can not be successfully calibrated.
Replace microprocessor
3
See Note 1 Page 8--2
a. Clear the inactive alarms.
All alarms cleared.
243 SUCT/EVAP CALIBRATE ERROR
• TRIGGER–ON: There is an error in the Suction / Evaporator Pressure Sensor Calibration value stored in the microprocessor memory or in the memory sector of the microprocessor that the calibration value is stored in.
• UNIT CONTROL: Unit Shutdown & Alarm
•
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 / Evaporator Pressure
Reading
Must read valid data.
2
Calibrate Suction / Evaporator Pressure Sensor
a. Calibrate Suction/Evaporator Pressure
Sensor.
Calibration successful.
b. Suction/Evaporator Pressure Sensor can not be successfully calibrated.
Replace microprocessor
3
See Note 1 Page 8--2
a. Clear the inactive alarms.
All alarms cleared.
62-10683
8--110
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
246 EEPROM WRITE FAILURE
• TRIGGER-ON: There is an error in the ability to write information to be stored in the memory
• UNIT CONTROL: Unit Shutdown & Alarm
• 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 Microprocessor
a. Check set point setting b. Enter new set point
2
Reset Microprocessor
a. Turn START/RUN-OFF switch off for
30 seconds, then turn back on.
b. Alarm 246 remains active.
3
See Note 1 Page 8--2
a. Clear the inactive alarms.
Must be between -22°F to +89.6°F (-30°C to +32°C)
Microprocessor powers up OK
Replace microprocessor.
All alarms cleared.
248 CONF MODE / HP2 ERROR
• TRIGGER–ON: Microprocessor internal operational program error.
•
UNIT CONTROL: Unit Shutdown & 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 set point setting b. Enter new set point
2
Reset Microprocessor
a. Turn START/RUN-OFF switch off for
30 seconds, then turn back on.
Must be between -22°F to +89.6°F (-30°C to +32°C)
Microprocessor powers up OK b. Alarm 248 remains active.
3
See Note 1 Page 8--2
a. Clear the inactive alarms.
Replace microprocessor.
All alarms cleared.
8--111
62-10683
Alarm
NO.
Steps ALARM / CAUSE CORRECTIVE ACTION
249 MICROPROCESSOR ERROR
• TRIGGER–ON: Microprocessor Input Conversion Error
• UNIT CONTROL: Unit Shutdown & 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
Check Microprocessor & Unit Wiring
a. Check Wiring to Micro and at input devices to the micro.
3 Reset Microprocessor a. Turn START/RUN-OFF switch off for
30 seconds, then turn back on.
Must not be miss wired to allow 12 VDC on any of the sensor input circuits.
Microprocessor powers up OK b. Alarm 249 remains active.
4
See Note 1 Page 8--2
a. Clear the inactive alarms.
Replace microprocessor.
All alarms cleared
62-10683
8--112
SECTION 9
SERVICE
PARAGRAPH NUMBER
9.1
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2
PRETRIP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3
GRILLE INSERT REMOVAL
9.4
SURROUND REMOVAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5
DOOR LATCH MAINTENANCE AND REPLACEMENT
9.6
PRIMING FUEL SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7
SERVICING FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8
ENGINE SERVICE AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.9
SERVICING AND ADJUSTING V-BELTS
9.10 FANSHAFT ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.11 THERMOSTATIC EXPANSION VALVE
9.12 REPLACING THE COMPRESSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.13 CHECKING COMPRESSOR OIL LEVEL
9.14 COMPRESSOR UNLOADER VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.15 REPLACING OR SERVICING CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.16 CHECKING AND REPLACING FILTER-DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.17 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCH (HPS) . . . . . . . . . .
9.18 COMPRESSOR DISCHARGE PRESSURE TRANSDUCER (CDP) . . . . . . . . . . . . . . . . . . .
9.19 COMPRESSOR SUCTION PRESSURE TRANSDUCER (CSP) . . . . . . . . . . . . . . . . . . . . . .
9.21 SERVICING SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.22 COMPRESSOR SUCTION MODULATION VALVE (CSMV)
9.23 LIGHT BAR
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.24 CHECKING DEFROST OR HEATING CYCLE
9.25 DEFROST AIR SWITCH (DAS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.26 EVAPORATOR COIL CLEANING
9.27 CONDENSER COIL CLEANING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.28 MICROPROCESSOR SENSOR CHECKOUT
9.29 UNIDRIVE TORQUE REQUIREMENTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
9--33
9--35
9--37
9--38
9--41
9--43
9--43
9--43
9--44
9--45
9--45
9--47
9--17
9--21
9--24
9--28
9--30
9--31
9--32
9--33
9--10
9--11
9--12
9--12
9--1
9--4
9--8
9--9
1
WARNING
Beware of V-belts and belt driven components as the unit may start automatically.
Before servicing unit, make sure the
START/RUN-OFF switch is in the OFF position or the unit is in Maintenance mode.
Also disconnect the negative battery cable.
SECTION 9
SERVICE
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.
WARNING
UNITS EQUIPPED WITH STAR-TRAK TWO
WAY COMMUNICATION CAPABILITIES MAY
HAVE THE ABILITY TO BE STARTED OR
TURNED OFF REMOTELY REGARDLESS OF
THE SETTING OF THE START/RUN-OFF
SWITCH.
The unit is controlled locally and there can be no two-way communication when the mode switch on the Remote Monitoring control box is in MAINTENANCE MODE.
Therefore, when performing any work on the unit, place the mode switch in MAINTE-
NANCE MODE. After the unit is serviced, return the mode switch to REMOTE ON. (Refer to Section 3.20.3 for more information on two-way communication.)
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.
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.
9.1 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 schedule on the following page.
9--1 62-10683
Table 9-1. Maintenance Schedule
SYSTEM OPERATION a. Daily Maintenance
Pre-Trip Inspection - before starting
Check Engine Hours
Check Engine Oil Level
b. Every Service Interval
1 or Annually
Unit
1. Check unit mounting bolts
2. Check engine and compressor mount bolts
3. Check door latches & hinges
4. Check gauges, switches and electrical connections
5. Check all belt tensions
1
6. Check control box
7. Check gearbox and fan shaft for oil leaks
8. Check fan shaft, idler and gearbox bearings
9. Check clutch air gap and adjust as required
Engine
1. Check oil/filter change interval
1
(refer to section f. of this table)
2. Check for oil leaks
3. Check low oil pressure safety
4. Clean crankcase breather
5. Check engine speeds for units without electronic speed control
Fuel System 1. Clean fuel pump strainer
2. Change fuel filter(s)
1
(refer to section f. of this table)
3. Check fuel heater (optional)
Cooling
System
Exhaust
System
Air Intake
System
1. Clean radiator/condenser fin surface
2. Check antifreeze concentration
1
3. Check water pump
4. Check water temperature sensor functions
1. Check mounting hardware
2. Check muffler and exhaust pipes
1. Change air cleaner element
1
2. Check and replace air filter indicator if needed
Starting
System
Charging
System
1. Check battery condition
2. Clean battery connections and cable ends
3. Check battery hold down clamps
4. Check starter operation
1. Check alternator brushes and replace if necessary
2. Check alternator output
3.4
Check
Check
ACTION/
REFERENCE
SECTION
Check
Check
Check
Check
9.9
Check
Check
Check
Check
9.8.5
Check
2.12
9.8.9
Table 2-1
9.7
9.7
---
9.8.1 and 9.27
9.8.1
Check
2.7
Check
Check
Check
9.8.8
Check/Replace
Check/Replace
Check
Check
Check
2.13
62-10683 9--2
SYSTEM OPERATION
ACTION/
REFERENCE
SECTION b. Every Service Interval
1 or Annually (Continued)
Refrigeration
System
1. Check air switch & calibrate
2. Check & clean evaporator coil and defrost drain hoses
3. Check operating refrigerant pressure
4. Check all sensor calibrations
5. Check manual defrost operation
6. Check Compressor drive coupling
7. Perform Pre--Trip inspection
4.15
9.26
Check
Check
Check
Check
9.2
c.
Every 6000 Hour Maintenance (Normal Operating Conditions) with conventional coolant
Cooling
System
1. Drain and flush cooling system (12,000 hours with Extended Life
Coolant) d. Every 10,000 Hour Maintenance
Section 9.8.1
Perform complete 2000 and 3000 hour Preventive Maintenance and the following:
Fuel System 1. Clean and adjust injector nozzles.
e. Every 12,000 Hour Maintenance with extended life coolant
Cooling
System
1. Drain and flush cooling system (6,000 hours with Conventional
Coolant)
Engine Service Guide
Section 9.8.1
f. Oil And Filter Change Intervals
Oil & Filter Change Interval using
API Class CG engine oil
Standard Oil Filter
ESI Oil Filter
2000 hrs/1yr
3000 hrs/2 yrs
Oil & Filter Change Interval using Mobil Delvac 1 engine oil*
4000 hrs/2 yrs**
* Mobil Delvac1 is the only approved synthetic oil. Maximum oil drain interval is two (2) years.
** New oil filter required at 1 yr interval
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.
9--3 62-10683
9.2 PRETRIP INSPECTION
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.
The following pretrip inspection should be performed before every trip and at regular maintenance intervals.
BEFORE STARTING ENGINE
Drain water from bottom of fuel tank
Drain water from water separator on fuel filter (if applicable)
Check radiator coolant level
Condenser Coil Cleanliness: Check the coil for cleanliness, straighten fins if necessary
Radiator Coil Cleanliness: Check the coil for cleanliness, straighten fins if necessary
Air Cleaner Hoses: insure they’re secure with no leaks
Air Cleaner Indicator: check operation (if applicable)
Engine Oil Level: check and add if necessary
Check condition and tension of belts
Check all fan and idler bearings
Door Latches/Hinges: Check for proper operation
Condenser Fan Blades: Check condition
Check battery fluid level (if applicable)
Battery cables and terminals, are secured and clean
Evaporator Section: check coil(s) for cleanliness and clear of debris
Check air chute (if applicable)
Check bulkhead and return air screen
Defrost Water Drains: No debris & drain properly
Place in Continuous Run, and start unit.
j j j j j j j j j j j j j j j j j j j j j j j j j j j j j j
OK
j j j j
ADJUST/
REPLACE
j j j j
62-10683 9--4
IMMEDIATELY AFTER STARTING
ENGINE
Fuel Leaks: Check fuel lines/filters for leaks
Oil Leaks: Check oil lines/filters for leaks
Coolant System: Check for leaks
Exhaust System: Check for leaks
Condenser Fan: Check for proper airflow.
Evaporator Fan: Check for proper airflow.
Ensure clutch engages properly -- no slip or unusual noises
Check for unusual noises -- alternator, fan shaft, water pump, idler and gearbox bearings
PRETRIP
Initiate Pretrip
List any Pretrip alarms
List Alarms occurring during Pretrip
OK
j j j j j j j j
OK
j j
ADJUST
j j j j j j j j
ADJUST
j j
AFTER OPERATING UNIT FOR 15 MINUTES
OR MORE
OK
Check refrigerant level
Check compressor oil level
Check for proper temperature control
Check engine speeds j j j j
Check auto start--stop operation j
Initiate defrost and allow to terminate automatically j
Allow Defrost to terminate automatically, ending the Pretrip.
j
ADJUST
j j j j j j j
9--5 62-10683
OPERATE IN HIGH SPEED COOL AND RECORD
(from Microprocessor Unit Data List)
SUCTION PRESSURE
DISCHARGE PRESSURE
ENGINE COOLANT TEMP
RETURN AIR TEMP
SUPPLY AIR TEMP
AMBIENT AIR TEMP
DEFROST TERM TEMP #2
COMP DISCH TEMP
CSMV%
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 AND DATE
FINAL
Review Functional Parameters and fill in Table 9-2
Download recorder data (if required)
Enter Trip Start in microprocessor
OK j j j
ADJ
62-10683 9--6
Table 9-2 CHECK AND RECORD THE FOLLOWING
Function
Defrost Timer Set For:
Setting
Set S/S Parameters:
PERISHABLE
Min. Run Time
Min. Off Time
Override Temp
Max. Off Time
FROZEN
Min. Run Time
Min. Off Time
Override Temp
Max. Off Time
Frozen Shutdown Offset
Temp. Control
Display In:
Set PM Hourmeters
Engine
Switch On
PM 1
PM 2
PM 3
PM 4
PM 5
Out of Range Alarm
Air Flow
Unloader Pressure Control
9--7 62-10683
9.3 GRILLE INSERT REMOVAL (See Figure 9--1)
Removal of insert will ease in condenser coil cleaning.
(Refer to Section 9.27).
a. Remove the 3 bolts on each side of the grille insert.
b. Remove the 2 bolts on top of the grille insert.
c. Swing insert down and lift out of locating holes.
d. Reverse above steps to install new grille insert.
GRILLE INSERT MOUNTING BOLTS
SURROUND
GRILLE INSERT
LUBRICATE LATCHES AND PINS
Figure 9--1 Grille Insert Removal And Door Latch Maintenance
62-10683 9--8
9.4 SURROUND REMOVAL
a. Place the Start/Run--Off switch in the OFF position and disconnect the starter.
b. Open both side and front doors.
c. Remove the bolts that secure the surround to the unit.
d. Reverse above steps to install new surround.
SURROUND MOUNTING BOLTS
REMOVE DECAL PLATE TO
ACCESS UNIT MOUNTING STUD.
SURROUND MOUNTING BOLTS
Figure 9--2 Surround Removal
9--9 62-10683
9.5 DOOR LATCH MAINTENANCE AND
REPLACEMENT
Proper maintenance is important for smooth operation of the latch assembly and the latch pins that are mounted on the unit’s frame (See Figure 9--1). In order to keep the movable parts clean and lubricated, CTD recommends the use of a de--greasing cleaner and LPS 2 lubricant. This lubricant should be available at any local automobile and truck parts suppliers.
9.5.1 Front Door Latch Cable Replacement
a. Remove circular clip that secures the cable to the paddle assembly.
b. Slide cable from paddle and rotate other end out of latch assembly.
c. Reverse above steps to install new cable.
UPPER CABLE
9.5.2 Side Door Latch Cable Replacement
a. Remove circular clip that secures the cable to the paddle assembly.
b. Remove the lower cable from the paddle assembly and the lower latch.
NOTE
The lower cable is threaded through the upper cable eyelet and the lower latch assembly.
(See Figure 9--3) c. Remove the upper cable from the upper latch.
d. Reverse above steps to install new cable.
UN--THREAD THE LOWER
CABLE FROM THE UPPER
CABLE AND
LATCH ASSEMBLY
REMOVE CIRCULAR CLIP
PADDLE ASSEMBLY
62-10683
Figure 9--3 Side Door Latch Lower Cable Removal
9--10
9.6 PRIMING FUEL SYSTEM
9.6.1 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 9--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.
Red
Fuel Bleed
Valve
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.
Red
Fuel Bleed
Valve
Manual
Fuel Pump
Plunger
ENGINE WITH ELECTRONIC SPEED CONTROL NON ESC ENGINE
Figure 9--1. Priming Fuel Pump
Manual
Fuel Pump
Plunger
9--11 62-10683
9.7 SERVICING FUEL PUMP
9.7.1 Mechanical Pump (See Figure 9--2)
The fuel filter may become plugged or restricted with foreign particles or wax as a result of using the wrong grade of fuel or untreated fuel in cold weather. This will cause the engine to 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 9.1).
2
4
1
3
1
1. Nut
2. Banjo
3. Filter
4. Copper Rings
Figure 9--2. Mechanical Fuel Pump
a. Turn nut counter-clockwise to loosen and remove nut
(Item 1, Figure 9--2). Use container to catch draining fuel.
b. Remove banjo fitting (Item 2) and let it hang loose.
c. Turn filter (Item 3) counter-clockwise and remove.
Check and clean.
d. Replace copper rings (Item 4).
e. To install reverse above steps.
9.8 ENGINE SERVICE AND COMPONENTS
9.8.1 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 9.9.2)
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 an extended life coolant , which is
Dexcool approved and has 5/150 (5 years/150,000 miles) on the label.
a. Servicing the Cooling System:
1) 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.
2) Drain coolant completely by removing lower radiator hose and radiator cap.
3) 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.
4) Run engine and drain while warm. Rinse system three times after it has cooled down. Refill system with water.
5) Run engine to operating temperature. Drain system again and fill with 50/50 water/anti-freeze mixture.
Unit coolant capacity is 1.67 U.S. gallons. (see Caution Note and Refer to Section 2.7) NEVER POUR
COLD WATER INTO A HOT ENGINE, however hot water can always be added to a cold engine.
62-10683 9--12
9.8.2 Fuel Level Sensor
An optional fuel level sensor 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 sensor has the capability of sending from 0% to
100% of the fuel level to the microprocessor. The fuel tank level will be displayed in the Unit Data list. Some units may have sensors that may be calibrated if necessary.
GROUND
SUPPLY
VOLTAGE
OUTPUT
Figure 9--3. Fuel Level Sensor Wiring
a. Verify that the wiring to sensor is correct and connected properly.
b. Check voltage at the Fuel Level Sensor with the
START/RUN-OFF switch in the START/RUN position. (Unit running, or Unit off and Manual Start mode selected.) 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.
9.8.3 The RPM Sensor (Units beginning with below serial numbers and ALL X2 units. Refer to
Section 9.8.7 for information on units with
Electronic Speed Control).
a. Serial Number Cut--Offs
S
Ultra XTC -- KAV90910396
S
Ultima XTC -- KAV90910334
b. Testing
a. Verify that the wiring to sensor is correct. See wiring schematic in Section 11.
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 five minutes -- before the Failed To Start Manual mode occurs, or Component Test mode will energize the Run Relay for five 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 frayed wire) the MessageCenter will show:
S
Suction Pressure: --14.7 PSIG/Bar
S
Discharge Pressure: 0 PSIG/Bar
S
Engine RPM: 0
9--13 62-10683
9.8.4 Engine Oil And Oil Filter
Cap
Dipstick
To check the engine oil level:
Run the unit to bring the engine up to operating temperature, shut the unit off, and unscrew the cap/dipstick. Wipe the dipstick clean and insert the cap into the oil fill tube without threading it into the oil fill tube.
Remove the dipstick again and check oil level. DO NOT add oil if the level is in the “safe” range.
If needed, add oil as indicated by markings on dipstick until level is in the “safe” range.
QTS 2 1 SAFE
a. To Change Engine Oil and Filter:
1) Warm up the engine and then stop it by placing the
Start/Run--Off switch in the OFF position.
2) Remove drain plug from oil pan and drain engine oil using Oil Drain Tool (CTD P/N 68-15763-00).
3) Lightly oil gasket on new filter before installing. Tighten 3/4 to 1 of a turn after the seal makes contact.
9.8.5 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 2.7)
Warm up engine and check for leaks.
a. Lube Oil And Fuel Flow Diagrams
5
6
3
1
2
4
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.
4) Replace filter and add lube oil. (Refer to Section 2.7.)
Warm up engine and check for leaks.
b. Replace filter and add lube oil. (Refer to Section 2.7.)
Warm up engine and check for leaks.
11
10
9 8
7
1. Fuel Tank
2. Fuel Supply Line
3. Fuel Pump (Optional)
4. Mechanical Lift Pump
5. Fuel Filter
6. Fuel Warmer (Optional)
7. Fuel Bleed Valve
8. Injection Pump
9. Injector Nozzles
10. Fuel Leak-off Line
11. Fuel Return Line
Figure 9--4. Fuel System Diagram
62-10683 9--14
4
3
1. Engine Block
2. Oil Pan
3. Full Flow Oil Filter
4. Engine Oil Connection
5. Oil Pressure Switch
Figure 9--5. Lube Oil Flow Diagram
9.8.6 Speed Control Solenoid And Linkage -- Non
ESC engines only (Units beginning with below serial numbers and ALL X2 units Refer to
Section 9.8.7 for information on units with
Electronic Speed Control).
a. Serial Number Cut--Offs
S
Ultra XTC -- KAV90910396
S
Ultima XTC -- KAV90910334
1
5
4
2
1
2
1. Solenoid
2. Bolt
3. Solenoid Bracket
3
5
4. Linkage (Speed)
5. Clip
Figure 9--6. Speed Control Solenoid b. Servicing the Speed Control Solenoid and
Linkage
NOTE
Check operation of speed solenoid before replacement. If solenoid is sticking, clean and lubricate the solenoid in accordance with Technical
Instruction 98--50234.
1) Solenoid Removal/Replacement a) Disconnect wiring to solenoid. Disconnect linkage arm (Item 4, Figure 9--6) 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.
2) Low Speed Adjustment a) Hold the speed lever against the low speed stop and check the RPM. Adjust the low speed stop screw if necessary.
b) Check engine speed using microprocessor data list.
c) Check for proper operation by running Pretrip (Refer to Section 3.4).
3) High Speed Adjustment a) Loosen but do not remove the 4-speed solenoid mounting nuts.
b) 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.
4) Check for proper unit operation by running Pretrip
(Refer to Section 3.4).
NOTE
LE (Low Emission) DI engines are delivered with a tamper resistant high-speed adjustment screw on the engine. High-speed adjustments are made using the slotted holes in the solenoid mounting bracket and the speed solenoid adjusting bracket with solenoid adjusting bolt and lockout (on the bracket).
Change 09/11 9--15 62-10683
9.8.7 Electronic Speed Control (ESC) (Units beginning with below serial numbers and ALL X2 units)
a. Serial Number Cut--Offs
S
Ultra XTC -- KAV90910396
S
Ultima XTC -- KAV90910334
Refer to Section 11 for schematic wiring diagram. Refer to Section 10 for ESC diagnostic alarms and diagnostic trees.
LED
ENSSN
FSA
Figure 9--7. Electronic Speed Control
Components b. Description
Engines with electronic speed control have no RPM sensor, speed or fuel solenoids. Engine speed is controlled by three components: the engine speed control unit (ENSCU), the fuel and speed actuator (FSA) and the engine speed sensor (ENSSN).
The ENSCU is mounted on the roadside frame behind the upper door. It provides the RPM signal to the microprocessor. The unit has an alarm LED incorporated within it, which is used to diagnose failures within the ESC system.
62-10683 9--16
Figure 9--8. Frame Mounted Engine Speed Control
Unit (ENSCU)
The FSA combines the fuel shutoff solenoid and speed control solenoid into one component. Engine speed is controlled by varying rod position.
The ENSSN provides the RPM signal to the ENSCU for speed control. It is located on the front of the engine in the gear case cover.
9.8.8 Engine Air Filter a. Engine Air Filter Inspection
The dry type air filter should be inspected regularly for leaks. A damaged air filter or hose can seriously affect the performance and life of the engine. The air filter is designed to effectively remove contaminants from the air stream entering the engine. An excessive accumulation of these contaminants in the air filter will impair its operation; therefore, a service schedule should be set up and followed. The air cleaner filter element requires replacement when dirty.
1) Check all connections for mechanical tightness. Be sure filter outlet pipe is not fractured.
2) 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.
3) Air Filter Service Indicator
The air filter indicator is connected to the engine air intake manifold and its function is to indicate when the air filter requires replacement. During operation: when a plugged air cleaner causes the intake manifold pressure to drop to 20” (500 mm) WG, the indicator will move to the red line. The air cleaner should then be replaced and the indicator reset by pressing the reset button.
b. Air Filter Service Procedure
1) Release 2 clips on air cleaner housing and remove bottom cover.
2) Remove filter element, wipe inside of air cleaner housing clean and install new filter element.
3) Wipe inside of bottom cover clean and re-install.
4) Re-secure 2 clips on air cleaner housing and close roadside door.
9.8.9 Engine Crankcase Breather
The engine uses a closed type breather with the breather line attached to the cylinder head cover. (See
Figure 9--9)
The breather assembly should be cleaned once a year or at every 2000 hours maintenance interval (whichever comes first). See Table 9-1
4
3
1
2
1. Screw
2. Breather Cover
3. Breather Valve
4. Breather Tube
Figure 9--9. DI -- Engine Crankcase Breather
9.8.10 Glow Plugs a. Servicing Glow Plugs
The total circuit amp draw for the glow plug circuit is checked during a Pretrip cycle. The glow plugs, when energized, draw a nominal 6 to 9 amps each at 10.5 vdc.
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).
b. Checking for a Defective Glow Plug
1) The entire circuit may be tested using Component
Test mode. (Refer to Section 6.2.2.)
2) To test individual glow plugs, disconnect all glow plugs from each other, and place an ammeter (or clipon ammeter) in series with each glow plug and energize the plugs. Each plug (if good) should show 6 to 9 amps draw (at 12 VDC).
3) A second method is to disconnect the wire connection to the plug and test the resistance from the plug to a ground on the engine block. The reading should be
0.7 to 1.2 ohms if the plug is good.
9.9 SERVICING AND ADJUSTING V-BELTS
WARNING
Beware of V-belts and belt driven components as the unit may start automatically.
Before servicing unit, make sure the
START/RUN-OFF switch is in the OFF position or the unit is in Maintenance mode.
Also disconnect the negative battery cable.
9.9.1 Belt Tension Gauge
Use a belt tension gauge (tester) P/N 07-00253, shown in Figure 9--10 whenever V-belts are adjusted or replaced.
A belt tension gauge provides an accurate and easy method of adjusting belts to their proper tension.
Properly adjusted belts give long lasting and efficient service. Too much tension SHORTENS belt and bearing life, and too little tension causes slippage and excessive belt wear. It is also important to keep belts and sheaves free of any foreign material, which may cause the belts to slip.
The belt tension gauge can be used to adjust all belts.
The readings, which we specify for Carrier Transicold units are applicable only for our belts and application, as the tension is dependent on the size of the belt and distance between sheaves. When using this gauge, it should be placed as close as possible to the midpoint between two sheaves. (See Figure 9--11)
The V-belts must be kept in good condition with the proper tension to provide adequate air movement across the coils.
9--17 62-10683
Table 9-3. Belt Tension (See Figure 9--11)
BELTS
Lbs
Tension
Mkg
Water Pump/Alternator/Crankshaft 45 to 55 6.2 to 7.6
Gearbox to Fan shaft
Engine to Gearbox
70 to 80 9.7 to 11.1
70 to 80 9.7 to 11.1
9.9.2 Water Pump/Alternator/Crankshaft V-Belt
The water pump/alternator/crankshaft V-belt is driven by a sheave on the engine crankshaft. Frayed, cracked or worn belts must be replaced. Adjustment is achieved by altering the position of the front side idler/alternator.
When replacing a V-belt, avoid excessive force when applying tension to the V-belt to prevent damage to the water pump bearings. (Refer to Table 9-3) a. Make sure negative battery terminal is disconnected and remove old belt.
b. Place V-belt on alternator sheave and then install alternator with two bolts loosely in position.
Figure 9--10 Belt Tension Gauge
(Part No. 07-00253)
c. Check the center alignment of the engine drive, alternator and water pump sheaves to ensure proper alignment. Pulley misalignment will create excess belt wear and shorten alternator bearing life. The center line of all three sheaves must be in line.
d. Pivot alternator to place tension on belt using hand force only. Do not use pry bar or excessive force as it
may cause bearing failure. For correct belt tension see Table 9-3. Tighten pivot and adjustment bolts.
e. Reinstall negative battery cable.
Gearbox to Fan Shaft Belt
Engine to Gearbox Belt
Torque to 80 ft-lbs (11.1 Mkg)
Alternator
62-10683
Torque to 15 to 16 ft-lbs
(2.1 to 2.2 Mkg)
Water Pump/Alternator/Crankshaft Belt
Figure 9--11. V-Belt Arrangement None ESC Engine
9--18
Gearbox to Fan Shaft Belt
Engine to Gearbox Belt
Torque to 80 ft-lbs (11.1 Mkg)
Alternator
Torque to 15 to 16 ft-lbs
(2.1 to 2.2 Mkg)
Water Pump/Alternator/Crankshaft Belt
9.9.3 Gearbox To Fan Shaft V--Belt
belt guard.
WARNING
Figure 9--12. V-Belt Arrangement
Electronic Speed Control Engine
Keep hands and arms away from unit when operating without belt guard in place. Never release a unit for service without the belt guard securely tightened in place a. To Replace V-belt:
1) Disconnect negative battery cable and remove V-
2) DO NOT START UNIT UNTIL V-BELT GUARD IS
INSTALLED.
3)Loosen idler pulley.
4) Remove old belt and replace with new belt. (See
Figure 9--11)
5) Using a belt tension gauge (Figure 9--10) on the belt, rotate idler pulley so that the gauge reads the correct tension (Refer to Table 9-3).
6) Tighten idler, carriage bolt, and bolts.
NOTE
The tension of both belts must be checked and adjusted, if necessary, after a brief break-in period. (See step 6)
7) Reconnect negative battery cable, and install belt guard and operate unit in high speed for 5-10 minutes. Remove guard and disconnect battery. Repeat steps 4 and 5.
9--19 62-10683
9.9.4 Engine To Gearbox V-Belt a. To Replace V-belt:
1) Disconnect negative battery cable and remove Vbelt guard, and then loosen idler bolt.
2) Match mark adapter to engine flywheel (See
Figure 9--13A) for ease of assembly.
3) Remove six bolts (5/16-18 x 1 lg), securing adapter drive sheave to engine flywheel, Figure 9--13A.
4) Insert two of the six bolts (5/16-18 x 1 lg) into the threaded holes (jacking holes) provided on engine adapter. Jack adapter from engine flywheel. Remove the two screws from adapter. Insert a pry bar between engine flywheel and adapter, Figure 9--13A and slide the adapter-sheave toward the compressor enough to change the V-belt as shown in
Figure 9--13B. Replace V-belt.
BELT
ADAPTER
MATCH MARK
5) Pry the adapter back toward the engine flywheel or use 5/16-18 x 2-1/2 lg bolts (3) in every other hole of adapter and take up evenly on the bolts until the
5/16-18 x 1 lg bolts engage engine flywheel. Apply thread sealer (Loctite #262) to the bolts used to secure adapter to flywheel. Take up on all bolts evenly and then torque to a value of 28 ft-lb (3.87 Mkg).
6) Place V-belt on the gearbox sheave and adjust belt tension as indicated in Table 9-3. Install V-belt guard. DO NOT START UNIT UNTIL V-BELT
GUARD IS INSTALLED.
7) Reconnect negative battery cable. Start unit and run for 10 minutes to allow for belt stretch.
8) Disconnect battery. Turn unit off, remove belt and recheck belt tension. Install belt guard.
NEW BELT
ATTACHING SCREWS
FLYWHEEL
ADAPTER
Figure A
Figure B
Figure 9--13. Removing V-Belt from Engine Adapter Drive Sheave
FLYWHEEL
62-10683 9--20
9.10 FANSHAFT ASSEMBLY -- SEE FIGURE 9--14
WARNING
Beware of V-belts and belt driven components as the unit may start automatically.
Before servicing unit, make sure the
START/RUN-OFF switch is in the OFF position or the unit is in Maintenance mode.
Also disconnect the negative battery cable.
9.10.1
Clutch Removal
CAUTION
Do not get anti-seize oil/compound onto clutch contact surfaces. Thoroughly clean off oil/compound with contact or brake cleaner if this occurs.
a. Turn the START/RUN-OFF switch to OFF and disconnect the negative battery cable.
b. Loosen the fan belt idler and remove upper drive belt.
c. Remove the top eight bolts (four along top edge and two down each side) that hold fan shroud to condenser frame.
d. Remove the three bolts that thread through the back of the clutch rotor/pulley forward into the condenser fan hub. Carefully remove the condenser fan and hub assembly from unit.
e. Place the three pins of the spanner wrench (CTD P/N
07-00396-01) into the holes on the face of the clutch armature. Place the tool handle between the fan shaft frame support and pod (10 o’clock position) to provide hands free anti-rotation. Loosen and remove the armature retaining bolt and washer.
NOTE
The armature-retaining bolt is a LEFT HAND
THREAD BOLT.
f. Remove the clutch armature. A standard 5/8”-11 X 1” right hand thread bolt can be threaded through the center to jack the armature off the shaft, if needed.
g. Use spanner socket (CTD P/N 07-00303-02) to remove the spanner nut that secures the clutch rotor.
NOTE
The armature-retaining bolt is a LEFT HAND
NYLOCK THREAD BOLT.
h. Slide the clutch rotor/pulley off and remove. If the rotor will not slide off easily, remove the condenser fan hub adapter from the fan. Place the adapter backwards against the fan shaft hub, and thread three
5/16-18 X 2 3/4” long bolts from the back of the rotor forward into the hub adapter. Tighten the bolts evenly to pull the rotor off the fan shaft hub.
i. Unplug the clutch coil connector from the wiring harness, then remove the clutch coil. Be sure to retain
all shims on fan shaft hub, correctly positioned on
Fanshaft pin..
j. Remove the vent hose and 1/8” barb fitting from fan shaft hub. Install a plug to prevent oil from spilling out vent hole while removing fan shaft.
9.10.2 Blower Wheel And Fanshaft Removal
a. Remove bulkhead and air chute (if so equipped). Remove evaporator back panel.
b. Remove the bolts that secure DTT and SAT to the nozzle cover. Care should be taken to prevent cutting wires on evaporator coil.
c. Remove the remaining bolts in the nozzle cover and carefully remove it from the pod.
NOTE
The nozzle cover (CTD P/N 58-04469-00) is sealed with a gasket (CTD P/N 42-00506-00). If the gasket is damaged during removal, it MUST be replaced.
d. Remove the two 1/4”-20 X 1” long bolts from the blower wheel split taper bushing. Insert them into the threaded holes. Tighten bolts evenly to push the blower wheel away from the bushing.
e. Remove the fan shaft seal ring clamp and carefully peel seal from pod (use a putty knife if needed).
NOTE
The fan shaft seal (CTD P/N 42-00372-00) is caulked to the pod. If seal is damaged during removal, it MUST be replaced.
f. Remove the four 3/8” bolts from the fan shaft.
g. Remove fan shaft from unit.
9--21 62-10683
9.10.3 Fanshaft Installation
a. Install two keys into the shaft keyways.
NOTE
If it is necessary to drive the keys into place, be sure to support the shaft while tapping the keys.
b. Position the fan shaft so that the housing is in the normal mounting position, with the shaft horizontal and the vent hole facing directly up. Remove both pipe plugs (1/8” NPT) from fan shaft.
c. Ensure oil in fan shaft is at proper level. If not, fill the fan shaft with oil (07-00373-00) until oil is at the bottom of the level hole (approximately 3 oz/89 ml). Apply pipe thread sealant to the pipe plug on the side of fan shaft housing and tighten. Reinstall pipe plug on hub to prevent oil spillage.
d. Install the fan shaft into the unit with the four fan shaft mounting bolts and torque bolts to 28 to 30 ft-lb (3.9 to
4.1 Mkg), making sure the plug for the vent is pointing up.
NOTE
To aid in fan shaft alignment, install two 3/8”-16 x 1 1/2” studs (bolts with heads cut off) into the fan shaft mounting hub. Once the first two fan shaft mounting bolts are loosely installed, remove the studs and install bolts.
e. Apply pipe thread sealant to barb fitting and install into vent hole. Slide hose vent onto barb fitting.
f. Apply caulk to the fan shaft seal and place on the fan shaft. Place fan shaft seal ring clamp on seal and tighten.
Retaining Bolt
LEFT HAND THREAD
See Clutch Installation, Step 6
25 to 30 ft-lbs. (3.5 to 4.1 Mkg)
Condenser Fan
Hub Adapter
Rotor Shim
Clutch Rotor
3 Bolts
See Clutch Installation
Step 8
18 to 22 ft-lbs. (2.5 to 3.0 Mkg)
Fanshaft Hub
Clutch Armature
10 to 11 ft-lbs. (1.4 to 1.5 Mkg)
Spanner Nut
80 to 85 ft-lbs. (11.1 to 11.5 Mkg)
62-10683
Figure 9--14. Fanshaft Assembly
9--22
Clutch Coil
9.10.4 Blower Wheel Installation
a. Make sure key is properly placed in keyway. Slide blower wheel and bushing onto shaft.
b. Loosely attach blower wheel to bushing and slide assembly forward until blower wheel touches pod. (This will set approximate clearance between blower wheel and pod.) c. Loosely attach the nozzle cover to pod with retaining bolts. Install SAT with at least 1/2” of sensor in the nozzle. Reattach DTT.
d. Slowly and evenly torque blower wheel bushing bolts to 10 to 11 ft-lbs (1.4 to 1.5 Mkg) e. Position nozzle cover so that blower wheel is centered in cover opening. Torque nozzle cover bolts to
20 in-lbs (0.23 Mkg).
f. Rotate blower wheel and check that clearance is approximately 1/4.” Adjust nozzle cover and/or blower wheel if necessary.
g. Reinstall evaporator panel, reattach air chute and bulkhead (if so equipped).
Nozzle Cover Bolts
Blower Wheel
Bushing
Ring Clamp
Fanshaft Seal
Fanshaft
Pod
Nozzle Cover
Nozzle Cover Gasket
Blower Wheel
Spring Clip
Figure 9--15. Blower Wheel And Nozzle Cover Assembly
9--23 62-10683
9.10.5 Clutch Installation
NOTE
The orientation of the clutch coil MUST be on the bottom. Secure the harness to the lower right fan shaft mounting bolt using the cushion clamp provided.
a. Place clutch coil onto fan shaft hub, with coil harness on top. Make sure all original shims are correctly
positioned on fan shaft pin and then slide coil onto hub so fan shaft pin fits into notch in coil.
NOTE
The fan shaft pin is used to position the coil to properly secure the wire harness to the frame.
b. Install rotor spacer and rotor onto the fan shaft.
c. Install the new spanner nut (included in mounting accessory kit (CTD P/N 50-00236-21.) Use CTD spanner socket 07-00303-02 and torque to 80-85 ft-lbs
(11.1 to 11.5 Mkg.)
NOTE
The spanner nut is a LEFT HAND NYLOCK-
THREAD NUT.
d. Slide the armature into place on the fan shaft, making sure the key is in place and the keyway lines up correctly with the shaft key.
e. Install the new armature retaining bolt and washer.
Use spanner wrench (CTD P/N 07-00396-01) at the 2 o’clock position to hold the armature, then torque the retaining bolt to 25-30 ft-lb. (3.5 to 4.1 Mkg)
NOTE
The armature retaining bolt is a LEFT HAND
THREAD BOLT.
f. Measure the clutch air gap with the air gap tool
(CTD P/N 07-00432-00). The gap should be between0.015and0.090inches(0.38and2.3mm).If
it is not, remove entire clutch. If gap is less than
0.015” (0.38 mm), remove enough of the fan shaft hub shims to increase the gap to approximately
0.020” (0.51mm). Shims (CTD P/N 50-00232-30 are 0.010” (0.25mm) each. If the gap is more than
0.090” (2.3 mm), add enough shims to reduce gap toapproximately0.020”(0.51mm).Reinstallclutch
assembly and re--measure to verify air gap.
g. Installcushionclamponcoilharnessapproximately 3” from coil to prevent harness from rubbing on rotor.
h. Reattach the condenser fan and hub assembly to theclutchrotor. Threadthethreebolts frombehind the clutch rotor into the condenser fan hub, and torque the bolts to 18-22 ft-lb. (2.5 to 3.0 Mkg).
i. Reinstall the upper drive belt and adjust idler to attain a belt tension of 70-80 ft-lb. (9.7 to 11.1 Mkg)
62-10683 9--24 j. Remove condenser fan shroud spacer/supports that may have been inserted. Reinstall upper eight bolts that hold shroud to condenser frame.
k. Plug the clutch coil connector back into the wiring harness. Tie-wrap harness as needed to secure.
l. Re-connect negative battery cable.
m. Check unit for proper clutch operation.
WARNING
Do not start unit without installing the evaporator panels as unit damage or body harm may result.
n. Check for proper unit operation by running Pretrip
(Refer to Section 3.4).
9.11 THERMOSTATIC EXPANSION VALVE
CAUTION
Service mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating. Refer to Section
6.2.3.
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.
9.11.1 Replacing Expansion Valve & Screen
a. Pump down the unit by closing the king valve. (Refer to Section NO TAG.) 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 only if the element is being changed and replace by reversing steps a.
through c.
d. Use a wet rag to keep TXV cool whenever brazing.
Heat inlet, outlet and equalizer connections to valve body and remove valve. Clean all tube stubs so new valve fits on easily.
e. Reverse steps a. through d. to install new valve and screen, with cone of screen pointing into liquid line at inlet to the valve.
f. The thermal bulb is located below the center of the suction line (See Figure 9--16). 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. Draw down to 500 microns.
h. Open king valve and then check refrigerant level. See
Section 9.11.4.
i. Check unit operation by running Pretrip (Refer to Section 3.4).
9.11.2 Checking Superheat
NOTE
Do not adjust expansion valve unless absolutely necessary.
Due to the time involved in adjusting the superheat, replace the valve rather than adjusting it.
9.11.3Measuring Superheat
NOTE
The expansion valve and bulb location are shown in Figure 2-7.
a. Remove evaporator panel from rear of unit and then 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 with) TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in
Figure 9--16. 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 9--16. Thermostatic Expansion Valve
Bulb and Thermocouple
NOTE
When conducting this test the suction pressure must be at least 6 PSIG (0.41 Bar) below expansion valve maximum operating pressure
(MOP). For MOP Refer to Section 2.11.
d. Connect an accurate gauge to the 1/4” (0.01mm) port on the suction service valve.
e. Run unit until stabilized. Set controller 10_F (5.5_C) below refrigerated compartment temperature.
f. From the temperature/pressure chart (Refer to
Table 9-9), 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.
9--25 62-10683
15
11
12
14
2
4
3
9
13
4
8
10
5
1 Refrigerant Recovery Unit
2 Refrigerant Cylinder
3 Manifold Gauge Set
4 Valve
5 Evacuation Manifold
6 Vacuum Pump
7 Vacuum Gauge
8 King Valve
9 Receiver
10Condenser
11 Evaporator
12Discharge Service Valve
13Suction Service Valve
14Compressor
15Compressor Suction Modulation Valve
(CSMV)
1
7
4
6
Figure 9--17. Vacuum Pump Connection
62-10683 9--26
CAUTION
Service mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating. Refer to Section
6.2.3.
CAUTION
Do not vapor charge R404A. Only liquid charging through the receiver outlet (king) valve is acceptable.
9.11.4 Checking The Refrigerant Charge
NOTE
High speed operation at some conditions may create high turbulence inside the receiver. If it is difficult to see the refrigerant settling properly in the receiver sight glass, unplug the speed solenoid, forcing low speed operation. There should be less turbulence in the receiver and the liquid refrigerant should settle properly.
Checking Refrigerant Level on Units With S/N Prior to JAR90710713
NOTE
The ambient (air entering the condenser) air temperature should be above 40°F (4.4°C) a. Start unit in cooling mode. Run approximately ten minutes - until the refrigeration system is warmed up and the refrigerated compartment temperature is less than 45°F (7.2C).
b. Check the lower sight glass on the receiver to determine charge. The system is correctly charged when refrigerant level is at centerline of sight glass, then weigh in another 3 lbs. (1.4 kg) of refrigerant.
Checking Refrigerant Level on Units With S/N
Beginning With JAR90710713
NOTE
The ambient (air entering the condenser) air temperature should be above 40°F (4.4°C) a. Start unit in cooling mode. Run approximately ten minutes -- until the refrigeration system is warmed up and the refrigerated compartment temperature is less than 45°F (7.2C).
b. Check the lower sight glass to determine charge. The system is correctly charged when the lower sight
glass is not empty and the upper sight glass is
not full.
c. If the system appears to be overcharged: Remove refrigerant through the king valve to correct refrigerant level.
d. If the refrigerant system appears to be undercharged:
Add refrigerant through the king valve.
9--27
9.11.5 Partial Charge
CAUTION
Do not vapor charge R404A. Only liquid charging through the receiver outlet (king) valve is acceptable.
NOTE
The ambient (air entering the condenser) air temperature should be above 40°F (4.4°C) a. Place drum of refrigerant on scale and note weight.
Backseat discharge and suction service valves and install a manifold gauge set. Purge lines. Connect a second manifold test set discharge gauge to the king valve. Connect the suction pressure hose to manifold dead head port. Connect a charging line between the center tap of the second gauge set and refrigerant drum. Open the LIQUID valve on drum and purge all hoses.
b. Start the unit. Adjust the setpoint so that the unit will run in high speed cool mode.
c. Run the unit for approximately ten minutes -- until the refrigeration system is warmed up and the refrigerated compartment temperature is less than 45°F
(7.2C).
d. Check the appropriate sight glass to determine charge. (See Step g. for determination of charge.) If undercharged proceed with step e.
e. Frontseat the king valve, and monitor the second set of manifold gauges. When the king valve pressure drops below the pressure in the refrigerant drum, open the manifold gauge set discharge valve and allow liquid refrigerant to flow into the system.
f. While monitoring the appropriate sight glass, carefully weigh the refrigerant into the system. Because the unit is in this charging state, it is not possible to accurately determine when the system is full. Therefore, never allow more than 3 lbs. (1.4 kg) of refrigerant into the system at a time.
g. After metering 3 lbs (1.4 kg) of refrigerant into the system, close the valve of the manifold gauge set connected to the king valve. Open the king valve and allow the system to balance out (approximately 4-5 minutes and the refrigerated compartment temperature is less than 45°F (7.2C). Check sight glass(es) to determine charge:
Units With S/N Prior to JAR90710713 -- Once the refrigerant level is at centerline of the lower sight glass, weigh in another 3 lbs. (1.4 kg) of refrigerant.
Units With S/N Beginning With JAR90710713 --
Charge the system until the refrigerant level is at centerline of the lower sight glass. THE LOWER SIGHT
GLASS SHOULD NOT BE EMPTY AND THE UP-
PER SIGHT GLASS SHOULD NOT BE FULL.
h. Start unit and check for noncondensibles and run a unit Pretrip. (Refer to Section 3.4).
62-10683
9.11.6 Adding Full Charge
CAUTION
Do not vapor charge R404A. Only liquid charging through the receiver outlet (king) valve is acceptable.
a. Dehydrate unit to 500 microns and leave in deep vacuum. (Refer to Section Table 9-9) b. Place drum of refrigerant on scale and connect charging line from drum to king valve. Purge charging line at king valve.
c. Note weight of drum and refrigerant.
d. Open liquid valve on drum. Midseat king valve 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 scale indicates that the correct charge has been added, close liquid line valve on drum and backseat the king valve. Remove charging hose.
f. Start unit and check for noncondensibles and run a unit Pretrip. (Refer to Section 3.4).
COMPRESSOR
CDT
HPS
CDP
Figure 9--18. Pressure Switch and Sensor
9.12 REPLACING THE COMPRESSOR
CAUTION
Service mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating. Refer to Section
6.2.3.
NOTE
Service replacement compressors are shipped without oil.
9.12.1 Removal and Replacement of Compressor
NOTE
The service replacement compressor is sold without shutoff valves (but with valve pads).
The valve pads should be installed on the removed compressor prior to return shipping.
Customer should retain the original capacity unloader valves for use on replacement compressor. Check oil level in service replacement compressor. (Refer to Section 9.13)
If compressor is inoperative and unit still has refrigerant pressure, frontseat suction and discharge service valves to trap most of the refrigerant in the unit.
If compressor runs, pump down the unit. (Refer to
Section NO TAG.)
If compressor does not operate, frontseat both suction and discharge service valves, and remove refrigerant charge from compressor (Refer to Section NO TAG.) a. Disconnect negative battery cable.
b. Remove the two rear compressor bracket mounting bolts (compressor shockmount end).
c. Block up engine.
d. Back out suction and discharge service bolt valve flange by two complete revolutions and leave threads engaged.
e. Break seal between service valves and compressor and remove bolts from valve flanges.
f. Remove fuel filter bracket (if necessary) from the compressor bell housing.
g. Disconnect wiring to unloader valve assemblies,
Compressor Discharge Temperature Sensor (CDT),
Compressor Discharge Pressure Transducer (CDP),
Compressor Suction Pressure Transducer (CSP) and the wiring to the high pressure cutout switch
(HPS). Identify wiring and switches if necessary. (See
Figure 9--18)
62-10683 9--28
h. Remove 10 bolts from the engine-compressor bell housing.
i. Disconnect ground strap from frame.
j. Remove Suction Pressure Transducer from suction line.
k. Attach sling or other device to the compressor.
l. Slide compressor enough to clear nylon drive gear
(as shown in Figure 9--19), and remove compressor from unit.
m.Drain oil from defective compressor before shipping.
n. The original unloader valves must be transferred to the replacement compressor. The plug arrangement removed from the replacement is installed in the original compressor as a seal. If piston is stuck, it may be extracted by threading socket head cap screw into top of piston. A small Teflon seat ring at bottom of piston must be removed.
o. Remove the complete High Pressure switch assembly (HPS) (See Figure 9--18) and install on new compressor after checking switch settings. Remove
Compressor Discharge Temperature sensor (CDT),
Compressor Discharge Pressure transducer (CDP), and Compressor Suction Pressure transducer (CSP) and install on new compressor. Install compressor frame to new compressor (if removed with defective compressor).
10
7
2
3
4
6
5
8
9
p. Install compressor in unit by reversing step 4.12.b.
through n. The use of new locknuts is recommended when replacing compressor. Torque bolts to a value of 46 ft/lb (6.4 Mkg). Install new gaskets on service valves and tighten bolts uniformly. Refer to Section
9.29.1 -- drive gear installation.
q. Attach two lines (with hand valves near vacuum pump) to the suction and discharge service valves.
Leak test, then dehydrate and evacuate compressor to 500 microns (29.90” Hg vacuum = 75.9 cm Hg vacuum). Turn off valves on both lines to pump.
r. Fully backseat (open) both suction and discharge service valves.
s. Remove vacuum pump lines and install manifold gauges.
t. Check refrigerant level.
u. Start unit and check for noncondensibles.
v. Check compressor oil level. (Refer to Section 9.13)
Add oil if necessary.
w. Check compressor unloader operation. (Refer to
Section 9.14) x. Check refrigerant cycles by running a unit Pretrip.
(Refer to Section 3.4)
1) Compressor
2) Bolts
3) Compressor Bell Housing
4) Key
5) Compressor Drive Gear
6) Locking Tab
7) Nylon Drive Gear
8) Drive Sheave Bolts
9) V-Belt
10) Engine Adapter Drive Sheave
1
Figure 9--19. Compressor Drive Assembly
9--29 62-10683
9.13 CHECKING COMPRESSOR OIL LEVEL
CAUTION
Service mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating. Refer to Section
6.2.3.
9.13.1 To Check The Oil Level In The Compressor:
a. Operate the unit in high speed, fully loaded cool for at least 15 minutes. Unplug wires to the unloaders if necessary to ensure six cylinder operation.
NOTE
Check the oil sight glass on the compressor to ensure that no foaming of the oil is present after
15 minutes of operation. If the oil is foaming check the refrigerant system for flood-back of liquid refrigerant. Correct this situation before performing step 2.
b. After 15 minutes, initiate a defrost cycle. This will allow any residual oil to be returned to the compressor.
NOTE
Operate the unit in defrost for 3-5 minutes only.
Do not allow the unit to terminate defrost
automatically. The sudden reduction of crankcase pressure at defrost termination could cause a temporary increase in oil circulation and gave a false oil level reading.
c. After 3-5 minutes of defrost operation, turn the unit off and wait 5-15 seconds. Observe the compressor oil level in the sight glass. (See Figure 9--20). Oil level should be between the Minimum and Maximum marks.
- Maximum
- Minimum
Figure 9--20. Oil Level in Sight Glass
9.13.2 Adding Oil With Compressor In System
Two methods for adding oil are the oil pump method and closed system method.
a. Oil Pump Method
One compressor oil pump that may be purchased is a
Robinair, part no. 14388. This oil pump adapts to a one
U.S. gallon (3.785 liters) metal refrigeration oil container and pumps 2-1/2 ounces (0.0725 liters) per stroke when connected to the oil fill (item 3, Figure 9--21). There is no need to remove pump from can after each use.
When the compressor is in operation, the pump check valve prevents the loss of refrigerant, while allowing the technician to develop sufficient pressure to overcome the operating suction pressure to add oil as necessary.
Backseat suction service valve and connect oil charging hose to oil fill (Item 3, Figure 9--21). Purge the oil hose at oil pump. Add oil as necessary (Refer to Section 2.10).
b. Closed System Method
CAUTION
Extreme care must be taken to ensure the hose is immersed in the oil at all times.
Otherwise air and moisture will be drawn into the compressor.
When an oil pump is not available, oil may be drawn into the compressor through the oil fill port or through the suction service valve.
1)Connect the suction connection of the gauge manifold to the compressor suction service valve port, and the common connection of the gauge manifold to a vacuum pump. Remove the discharge hose from the gauge manifold; connect one end to the compressor oil fill port, and immerse the other end in an open container of refrigeration oil. Start the vacuum pump, and pull the compressor into a 10”-15” vacuum. Stop the pump. Watch the oil level in the sight glass. As it reaches the minimum mark, stop the flow of oil from the container. (Refer to Section 2.10).
2)Break any remaining vacuum (raise to 0 Bar/PSIG) with refrigerant remaining in the system (crack open the suction service valve), or from a fresh drum of refrigerant. Replace the oil port plug, and evacuate the compressor crankcase. Open both service valves before starting the unit.
9.13.3 Adding Oil To Service Replacement Compressor
Service replacement compressors may or may not be shipped with oil.
If compressor is without oil:
Add correct oil charge (Refer to Section 2.10) through the suction service valve flange cavity or by removing the oil fill plug (See Figure 9--21)
62-10683 9--30
9.13.4 To Remove Oil From The Compressor:
a. Close suction service valve (frontseat) and pump unit down to 0.07 to 1 to 2 PSIG (0.1 Bar). Frontseat discharge service valve and slowly bleed remaining refrigerant.
b. Slowly remove the oil drain plug from the compressor and drain the proper amount of oil. Replace the plug securely back into the compressor.
c. Open service valves and run unit to check oil level, repeat as required to ensure proper oil level.
10
9
1
2
8
7
6
5
1. High Pressure Switch Connection
2. Suction Service Valve
3. Oil Fill Plug
4. Bottom Plate
5. Oil Drain Plug
6. Oil Level Sight Glass
7. Oil Pump
8. Unloader Solenoid
9. Discharge Thermistor Connection
10. Discharge Service Valve
Figure 9--21. Compressor
4
3
9.14 COMPRESSOR UNLOADER VALVE (See
Figure 9--22)
The compressor unloaders (located on the compressor cylinder heads) are controlled by the Advance
Microprocessor. (Refer to Section 2.3.5)
9.14.1 Unloader Checkout Procedure
a. Connect manifold gauges to the compressor suction and discharge service valves and start unit in cooling with the refrigerated compartment 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.
b. Unplug both unloader coils.
c. Using cable included in the test kit (CTD P/N
07--50006--00), 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).
d. Disconnect UL1 and note pressures. Suction pressure should drop and discharge pressure should rise by same amount as in step c. above.
e. Repeat steps c. & d. for UL2 (rear unloader). At the end of the test, plug both unloaders back in.
NOTE
If either unloader coil energizes and the suction and discharge pressures do not change, the unloader assembly must be checked.
9.14.2 Replacing Unloader Valve Internal Parts
(See Figure 9--22)
a. Pump down the unit. (Refer to Section NO TAG)
Frontseat both service valves to isolate the compressor.
b. Remove coil retaining cap (if equipped), and coil.
c. Remove enclosing tube collar (item 2, Figure 9--22) using installation/removal tool supplied with repair kit
(item 3).
d. Check plunger for restriction due to: (a) Corroded or worn parts; (b) Foreign material lodged in valve; (c)
Bent or dented enclosing tube.
e. Install new parts. Do not over tighten enclosing tube assembly. Torque to a value of 8 ft pounds (1.1 Mkg).
f. Remove supplied installation/removal tool. Install coil, and voltage plate.
g. Evacuate and dehydrate the compressor. (Refer to
Section NO TAG.) h. Start unit and check unloader operation (Refer to
Section 9.14.1.).
i. Check unit operation by running Pretrip (Refer to Section 3.4).
9--31 62-10683
9.14.3 Unloader Coil Replacement
NOTE
The coil may be removed without pumping the unit down.
a. Disconnect leads. Remove retainer, if equipped. Lift off coil. (See Figure 9--22) b. Check unloader coil resistance with an ohm meter.
Correct resistance should be between 7.5 and 10.5
ohms.
c. Verify coil type, voltage and frequency of old and new coil. This information appears on the coil housing.
d. Place new coil over enclosing tube and retainer and connect wiring.
e. Check unit operation by running Pretrip (Refer to Section 3.4).
Note: When installing coil, make sure roll pin is fitted into stem nut, and coil seats properly onto pin to keep it from rotating.
CAUTION
Service mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating. Refer to Section
6.2.3.
9.15 REPLACING OR SERVICING CHECK VALVE
A check valve allows the hot gas to travel in one direction only.
The function of the Hot Gas Bypass check valve is to raise the receiver pressure when the ambient temperature is low so that refrigerant can flow from the receiver to the evaporator when the unit is in heating or defrost.
The function of the Discharge Line check valve is to prevent any liquid refrigerant from migrating into the compressor during the unit off cycle.
3
2
4
5
6
1
Use tool torque stem nut to 2.8 to
20-22 ft-lbs (30
Nm)
1
2
3
4
5
6
7
9
10
Torque 3 Bolts to
12-16 ft-lbs (16 to
22 Nm)
11
12
1. Cap
2. Spring
3. Gasket
4. Stem
5. Seat
6. Body
Figure 9--23. Discharge Check Valve
(Serviceable)
Prior to S/N JAW90756460
8
Figure 9--22. Unloader Valve
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)
07-00457-00
Figure 9--24. Discharge Check Valve
(Non-Serviceable)
Beginning With S/N JAW90756460
62-10683 9--32
Figure 9--25. Hot Gas Check Valve
(Non-Serviceable)
9.15.1To Service Check Valve (See Figure 9--23)
a. Store the refrigerant in an evacuated container.
(Refer to Section NO TAG.a) b. Replace necessary parts.
c. Evacuate and dehydrate unit. (Refer to Section
NO TAG) d. Addrefrigerantcharge.(RefertoSectionNO TAG)
9.15.2To Replace Check Valve (See Figure 9--24 and Figure 9--25)
a. Store the refrigerant in an evacuated container.
(Refer to Section NO TAG) b. Using a pipe cutter, cut the valve stub-outs and unsweat the remaining stub-out from the connecting copper.
NOTE
Inert brazing techniques MUST be followed during replacement of valves.
NOTE
Place magnetic discharge check valve tool
(Carrier Transicold P/N 07-00457-00) on top ofdischargecheckvalve(Figure 9--24)topull the plunger from the body seat.
c. Replace valve.
d. Evacuate and dehydrate unit. (Refer to Section
NO TAG) e. Addrefrigerantcharge.(RefertoSectionNO TAG) f. Check unit operation by running Pretrip (Refer to
Section 3.4.
9.16 CHECKING AND REPLACING FILTER-DRIER
9.16.1 To Check Filter-Drier
The unit must be running in Cool for this test. 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.
9.16.2 To Replace Filter-Drier
a. Pump down the unit per section NO TAG. 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. Close the king valve.
d. Leak test drier connections.
e. Remove the refrigerant pressure from the low side of the system according to Step NO TAG of Section
NO TAG.
f. Evacuate the low side of the system according to
Section NO TAG.
g. Check refrigerant level.
h. Check unit operation by running Pretrip (Refer to Section 3.4).
9.17 CHECKING AND REPLACING HIGH PRES-
SURE CUTOUT SWITCH (HPS)
9.17.1 Checking High Pressure Switch
WARNING
Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is approximately 2350 PSIG (159.9 Bars). Do not use oxygen in or near a refrigerant system as an explosion may occur. (See
Figure 9--26)
9--33 62-10683
1
2
3
4
5
6
1. Cylinder Valve and Gauge
2. Pressure Regulator
3. Nitrogen Cylinder
4. Pressure Gauge
[0 to 400 PSIG (0 to
27.2 Bars)]
5. Bleed-Off Valve
6. 1/4 inch Connection
Figure 9--26. Typical Setup for Testing High
Pressure Switch
a. Remove switch as outlined in Section 9.17.2.
b. Connect ohmmeter or continuity light across switch terminals. Ohmmeter will indicate resistance and continuity light will be lit if switch closes after relieving pressure.
c. Connect switch to a cylinder of dry nitrogen. (See
Figure 9--26) d. Set nitrogen pressure regulator higher than cutout point on switch being tested. Pressure switch open and close points are shown in Section 2.11.
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 a continuity light is used, it will go out. 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. (The light will light or the ohmmeter indicator will move.)
9.17.2 Replacing High Pressure Switch
a. Pump down compressor per Section NO TAG.
Frontseat both suction and discharge service valves to isolate compressor.
b. Slowly equalize compressor pressure through the service valve gauge ports.
c. Recover refrigerant remaining in compressor to 0 psig/bar.
d. Disconnect wiring from defective switch, and remove old switch. The HPS is located on the top cylinder head (See Figure 9--21).
e. Install new HPS after verifying switch settings and reconnect wiring. (Refer to Section 9.17.1) f. Evacuate and dehydrate the compressor. (Refer to
Section NO TAG)
NOTE
Evacuation and dehydration is necessary only in the event that the compressor has reached atmospheric pressure during this procedure.
g. Check unit operation by running Pretrip (Refer to Section 3.4).
62-10683 9--34
9.18 COMPRESSOR DISCHARGE PRESSURE
TRANSDUCER (CDP)
(CTD P/N 12-00352-04 - RED)
HIGH RANGE PRESSURE TRANSDUCER
-- CDP
PRESSURE (PSIG)
Figure 9--27 Discharge Pressure Transducer
Values
9.18.1 Testing Compressor Discharge Pressure
Transducer
a. Verify that the wiring to the transducer is correct. (See wiring diagram, Section 11.) b. Power up the transducer circuit. Place unit into PC
Mode (Refer to Section 6.1).
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 1MP05.
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.
9.18.2 Calibrating Compressor Discharge Pressure
Transducer
The compressor discharge pressure transducer (CDP) has a range of 0 to 500 PSIG (0 to 34.02 Bars). 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, a calibration feature for the CDP built into the microprocessor.
To calibrate the CDP, it must be removed from the compressor and exposed to atmosphere. 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.
NOTE
The Compressor Discharge Pressure on the microprocessor Data list will never read less than 0 Bar/PSIG, 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 6.1), or place unit in Manual
Start mode.
b. Press the Select key until “Press ↑ ↓ to View Data” appears in the MessageCenter.
c. Press the Up Arrow until “Discharge Pressure” is displayed in the MessageCenter.
d. Press and hold the Equal key for six 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.
9--35 62-10683
Bars/PSIG
0/0
0.68/10
1.36/20
2.04/30
2.72/40
3.4/50
4.08/60
4.76/70
Table 9-4. Compressor Discharge Pressure Transducer
Voltage
0.8
0.9
1.0
1.1
0.5
0.6
0.7
0.7
Bars/PSIG
NOTE
The +5.0 VDC (terminal B) is common between the Compressor Discharge Pressure Transducer, the Compressor Suction Pressure
Transducer, and the RPM sensor for non ESC engines or ENSSN for engines with electronic speed control. If this circuit is shorted to ground
(due to one of the mentioned components being defective, or a worn wire) the MessageCenter will show:
S
Suction Pressure: -14.7 PSIG (-1.0 Bar)
S
Discharge Pressure: 0 PSIG/Bar
S
Engine RPM: 0.
5.44/80
6.12/90
6.8/100
8.51/125
10.21/150
11.91/175
13.61/200
15.31/225
9.18.3 Replacing Compressor Discharge Pressure
Transducer
Voltage
1.7
1.9
2.1
2.3
1.1
1.2
1.3
1.5
Bars/PSIG
17.0/250
18.7/275
20.41/300
22.11/325
23.81/350
25.52/375
27.22/400
30.62/450
Voltage
2.5
2.7
2.9
3.1
3.3
3.5
3.7
4.1
a. Pump down compressor per Section NO TAG.
Frontseat both suction and discharge service valves to isolate compressor.
b. Slowly equalize compressor pressure through the service valve gauge ports.
c. Recover refrigerant remaining in compressor to 0 psig/bar.
d. Disconnect wiring from defective transducer, and remove the transducer. The CDP is located on the top cylinder head.
e. Connect wiring and calibrate the transducer per Section 9.18.2.
f. Install new CDP and reconnect wiring.
g. Evacuate and dehydrate the compressor. (Refer to
Section NO TAG)
PSIG/Bars
-10/-0.68
-5/-0.34
0/0
5/0.34
10/0.68
15/1.02
20/1.36
25/1.7
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.
NOTE
Evacuation and dehydration is necessary only in the event that the compressor has reached atmospheric pressure during this procedure.
h. Check unit operation by running Pretrip (Refer to Section 3.4).
Table 9-5. Compressor Suction Pressure Transducer
Voltage
0.7
PSIG/Bars
30/2.04
Voltage
2.1
PSIG/Bars
70/4.76
0.8
1.0
1.2
1.4
35/2.38
40/2.72
45/3.06
50/3.4
2.2
2.4
2.6
2.8
75/5.1
80/5.44
85/5.78
90/6.12
1.5
1.7
1.9
55/3.74
60/4.08
65/4.42
2.9
3.1
3.3
95/6.46
100/6.8
Voltage
3.5
3.6
3.8
4.0
4.1
4.3
4.5
62-10683 9--36
9.19 COMPRESSOR SUCTION PRESSURE
TRANSDUCER (CSP)
(CTD P/N 12-00352-03 - BLUE)
PRESSURE (PSIG)
Figure 9--28 Suction Pressure Transducer Values
9.19.1 Testing Compressor Suction Pressure
Transducer
a. Verify that the wiring to the transducer is correct. (See wiring diagram, Section 11).
b. Power up the transducer circuit. Place unit into PC mode (Refer to Section 6.1), 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 continuity 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.
9.19.2 Calibrating Compressor Suction Pressure
Transducer
The Compressor Suction Pressure Transducer (CSP) has a range of --14.7 to100 psig (--1 to 6.8 bar).
Calibration is not required because the range is so small.
NOTE
The +5.0 VDC (terminal B) is common between the Compressor Discharge Pressure Transducer, the Compressor Suction Pressure
Transducer, and the RPM sensor for non ESC engines or ENSSN for engines with electronic speed control. If this circuit is shorted to ground
(due to one of the mentioned components being defective, or a worn wire) the MessageCenter will show:
S
Suction Pressure: --14.7 PSIG/Bar
S
Discharge Pressure: 0 PSIG/Bar
S
Engine RPM: 0
9.19.3 Replacing Compressor Suction Pressure
Transducer
a. Pump down compressor per Section NO TAG.
Frontseat both suction and discharge service valves to isolate compressor.
b. Slowly equalize compressor pressure through the service valve gauge ports.
c. Recover refrigerant remaining in compressor to 0 psig/bar.
d. Disconnect wiring from defective transducer, and remove old transducer. The CSP is located on the fitting on the crankcase of the compressor.
e. Install new CSP and reconnect wiring.
f. Evacuate and dehydrate the compressor. (Refer to
Section NO TAG)
NOTE
Evacuation and dehydration is necessary only in the event that the compressor has reached atmospheric pressure during this procedure.
g. Check unit operation by running Pretrip (Refer to Section 3.4).
9--37 62-10683
9.20 REPLACING RECEIVER SIGHT GLASS AS-
SEMBLY OR FUSIBLE PLUG
CAUTION
Service mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating. Refer to Section
6.2.3.
a. Remove the refrigerant from the complete system.
(Refer to Section NO TAG.) b. Unscrew the sight glass assembly or fusible plug and discard.
c. Wrap threads of new sight glass or plug with Teflon tape or spread some sealing compound on pipe threads of new sight glass assembly or plug and install. Torque the sight glass to 15 to 25 ft lbs (20 to
34 Nm). Torque the fuse plug to 4 to 8 ft lbs (5 to 11
Nm).
d. Using a trace amount of refrigerant removed from the system in Step a. bring the pressure of the system up to about 10 psig (xxx). Add dry nitrogen to increase the pressure to 100 psig (6.9 bar). Leak check receiver sight glass or fusible plug. (Section NO TAG. ) e. After leak checking unit, release the refrigerant/nitrogen to atmosphere and evacuate and dehydrate as outlined in Section NO TAG.
f. Add refrigerant charge. (Refer to Section NO TAG) g. Check unit operation by running Pretrip. (Refer to
Section 3.4).
9.21 SERVICING SOLENOID VALVES
9.21.1 Solenoid Valve -- SV2/SV4
CAUTION
Do not over tighten or damage the enclosing tube assembly. Torque to 17-ft pounds
(2.4 Mkg). Also make sure all parts are placed on the enclosing tube in proper sequence to avoid premature coil burnout.
a. Replacing the SV2/SV4 Coil
NOTE
The coil may be replaced without removing the refrigerant or pumping the unit down.
1) Unplug from wiring harness, remove coil retainer and coil assembly.
2) Verify coil type, voltage and frequency. This information appears on the coil housing.
3) Place new coil over enclosing tube, retainer and connect wiring.
b. Replacing SV2/SV4 internal parts
CAUTION
Service mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating. Refer to Section
6.2.3.
6
4
2
1
3
7
5
8
1) Coil Assembly
2) Retainer
3) Enclosing Tube Assy
4) Plunger Assy
5) Seal
6) Piston Assy
7. Body
8. Bracket Adapter
Figure 9--29. SV2/SV4 Solenoid Valves
To service the liquid line solenoid valve (SV2) or the hot gas solenoid valve (SV4) first pump the unit down.
(Refer to Section NO TAG.)
Remove and store the refrigerant charge in an evacuated container. (Refer to Section NO TAG.)
1) Remove coil retainer and coil assembly from valve.
Remove enclosing tube assembly and related items.
2) Check for foreign material in valve body.
3) Install new parts.
62-10683 9--38
NOTE
Rebuild kit (P/N 14-00150-51) contains both a black neoprene seal and a white Teflon seal. Use the one that matches seal in existing valve. The valve with the Teflon seal can be identified by two dimples in the housing. (See Figure 9--30)
DIMPLES
Figure 9--30. SV-2/SV-4 MARKING
4) Tighten enclosing tube assembly to a torque value of
17 ft pounds (2.4 Mkg) and leak check the valve. (Refer to Section NO TAG)
5) Install coil assembly and retainer.
6) Start unit and check refrigerant charge (Refer to Section NO TAG.)
7) Check refrigeration cycles.
8) Run Pretrip. (Refer to Section 3.4)
9.21.2 Solenoid Valve -- SV1 a. Solenoid Valve SV1 Checkout Procedure
To obtain proper heating and defrost, the normally open
(N.O.) SV1 solenoid valve must energize and close tightly during the heat and defrost cycles. If the valve does not close tightly due to physical damage, foreign material or wear, refrigerant leakage through the valve can reduce heating capacity.
During normal heat or defrost cycles the following conditions will be observed when the valve is operating properly:
1) Receiver refrigerant level will drop quickly at the initiation of heating or defrost mode.
2) Suction pressure will rise slowly to
90-100 PSIG (6.12 to 6.80 Bar).
3) Discharge pressure will drop quickly, but will begin to rise to a minimum of 250 PSIG (17.0 Bars) within 15 to 20 minutes.
If suction and discharge pressures remain low and the receiver level does not drop, the valve may be inoperative and can be checked by the following method.
1) Verify the solenoid coil has proper voltage and is energized in heating and defrosting.
2) Connect a discharge pressure gauge to the compressor discharge service valve and connect a gauge to the manual shut-off valve (king valve) leaving the receiver tank.
3) With the refrigerated compartment temperature at
35_F (1.7_C) or lower, operate the unit in high speed cool and remove or disconnect the “GND” wire leading to the SV1 coil.
4) With a separate 12 VDC negative ground wire, energize SV1 with the unit in high speed cooling and observe the discharge and receiver pressures. If the valve is closing properly, compressor discharge pressure will begin to rise and the receiver pressure will remain the same or begin to drop slowly. If the valve is not seating properly, both discharge and receiver pressure will rise slowly or remain the same.
5) Operate the unit until discharge pressure reaches
200 PSIG (13.61 Bars) and disconnect jumper wire to
SV1 valve. Discharge and receiver pressure should be within 5 to 15PSIG (0.34 to 1.02 Bars) of each other.
b. Replacing the SV1 Coil
NOTE
The coil may be replaced without removing the refrigerant or pumping the unit down.
1) Remove top locknut, spacer cup and nameplate.
2) Disconnect wiring and remove coil.
3) Replace coil by reversing steps 1 and 2.
9--39 62-10683
c. Replacing SV1 Internal Components (See
Figure 9--31)
CAUTION
Service mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating. Refer to Section
6.2.3.
1) Remove and store the refrigerant charge in an evacuated container. (Refer to Section NO TAG.)
2) Remove the top locknut, spacer cup, nameplate, coil assembly and spacer.
3) Using a 12 point, 1-3/8 inch box wrench, loosen the enclosing tube locknut and bleed off remaining refrigerant.
4) Remove enclosing tube and locknut assembly. The gasket is inside the enclosing tube.
5) Remove seat disc from inside of body and check for obstructions and foreign material.
6) Place the seat disc into the valve body with the smaller diameter end facing up.
7) Place the enclosing tube locknut over the enclosing tube. Install spacer over enclosing tube making sure it is seated properly in the enclosing tube locknut.
Tighten enclosing tube locknut to a torque value of
20 ft-lb (2.78 Mkg). Do not over tighten.
8) Install coil assembly, nameplate and top locknut or screw.
9) Dehydrate and evacuate the system. (Refer to section NO TAG) Charge unit with refrigerant per sections NO TAG.
10) Start unit and check operation.
11)Run Pretrip. (Refer to Section 3.4)
5
6
7
8
9
1
2
3
4
10
SV1
1) Locknut/Screw
2) Spacer Cup
3) Nameplate
4) Coil
5) Spacer
6) Enclosing Tube Lock nut
7. Enclosing Tube
8. Seal
9. Seat Disc
10. Body
Figure 9--31. SV1 Solenoid Valve
62-10683 9--40
9.22 COMPRESSOR SUCTION MODULATION
VALVE (CSMV)
The purpose of the CSMV is to control suction pressure, maintain the compressor within normal operating range 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”. When closing is complete, the MessageCenter will display “SETTING
SMV XXX%”. The XX% will count up to a predetermined percentage depending on ambient temperature and compartment temperature. The unit will then go through its normal start procedure.
CSMV
2-1/8 inch Nut
CAUTION
Do not connect 12 VDC to the CSMV windings in an attempt to rotate the valve or irreparable damage will occur.
9.22.2 CSMV Diagnostics
If the CSMV is suspected to be faulty, the first thing the operator should do is perform a Pretrip test (Refer to
Section 3.4). Some symptoms that could indicate a faulty CSMV 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
Compartment temperature deviates from set point.
If the unit fails Test 10 during pretrip
(P180 “CHECK SUCTION MOD VALVE”) the CSMV could be faulty. The CSMV 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 microprocessor. There are several steps the operator should make in addition to the unit Pretrip to further diagnose the valve.
a. The CSMV 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.
Figure 9--32 Suction modulation valve (CSMV)
9.22.1 Function
The CSMV 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 microprocessor.
Looking at the 4--pin connector on the CSMV coil, the wiring is as follow :
Table 9-6 CSMV Connections
Connector Pin Wire Color Winding/Pole
A
B
BLACK
WHITE
1A
1B
C
D
RED
GREEN
2B
2A
Refer to Section 2.13 for resistance value.
There is no common connection point between the two windings.
The microprocessor opens and closes the CSMV by sending a series of electrical pulses to the coil.
9--41
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 place the Start/Run--Off switch in the the
OFF position. After the engine shuts down, the microprocessor will fully close the CSMV.
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.
62-10683
e. If the CSMV 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.
1) If the suction pressure holds at 0, go to Step f.
2) If the suction pressure rises, go to Step NO TAG f. 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 CSMV is stuck closed (go to Step NO TAG) or there is something obstructing the refrigerant.
NOTE
Opening the valve can also be accomplished by using the microprocessor. Place the Start/Run--
Off switch in the START/RUN position. The microprocessor will go through its self test and the display will show
“SMV CLOSING: WAIT XXX SECONDS”. The
valve is obviously closed at this point, but the microprocessor is programmed to always close the CSMV every time the microprocessor is
powered up. The display will then show “SET-
TING SMV XXX%” . Refer to 9.22 above. If the suction pressure does not go up, the CSMV is stuck closed (go to Step NO TAG) or there is something obstructing the refrigerant.
NOTE
If the valve passes steps a. through f., the valve is operating properly.
g. If the suction pressure rises during Step e., or if the valve is determined to be stuck closed in Step f., turn the unit Off by placing the Start/Run--Off switch in the
OFF position and unplug the 4 pin connector to the
CSMV. 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. Refer to Section 2.13 for standard resistance in normal ambient temperatures.
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
CSMV power head assembly P/N 14--00263--20. Refer to Section 9.22.3.
1A (BLK)
2A (GRN)
1
2
(WHT) 1B
(RED) 2B
Figure 9--33 CSMV Coil
h. Locate the wires on the engine harness side of the
CSMV connector. Locate the wires labeled CSMVA,
CSMVB, CSMVC and CSMVD. These will correlate to the connector pins labeled A, B, C and D. See
Figure 9--33.
i. Place the Start/Run--Off switch in the START/RUN position. DO NOT ALLOW THE UNIT TO START.
When the MessageCenter displays “SMV CLOSING:
WAIT XXX SECONDS”, measure the AC voltage between pins A and B and then between C and D using a voltmeter that is set to read AC volts. The digital voltmeter should read from 10 to 16 VAC for each pair of wires. If this test passes, there is a good signal coming from the microprocessor.
j. If a 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 CSMV connector, or check the microprocessor for proper model number configuration.
k. If all the above tests pass, the CSMV is operating properly and the abnormal unit operation can be contributed to something other than the CSMV.
9.22.3 Replacing The CSMV Power Head
(14--00263--20)
a. Pump the unit down at the king valve (Refer to Section NO TAG).
CAUTION
Service mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating. Refer to Section
6.2.3.
b. Unplug the CSMV connector from the engine harness.
c. Loosen the 2 1/8” nut on the CSMV and remove the power head assembly. (See NO TAG).
d. Install the new CSMV 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.
62-10683 9--42
f. Torque the 2 1/8” nut to 35 to 40 ft--lbs (47.4 to 54.2
Nm) g. Reconnect the CSMV connector to the engine harness.
h. Evacuate the low side of the refrigeration system.
(Refer to Section NO TAG) i. Open the liquid line service valve, run the unit for approximately 10 minutes and initiate a pretrip.
Emergency CSMV Repair Procedures:
In the event that the CSMV 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 per Section NO TAG.
When the unit has reached 0 to 5 psig (0 to 0.34 bar) close the suction service valve and turn the unit OFF.
c. Remove CSMV power head by loosening the 2-1/8 inch diameter nut (see NO TAG), and sliding the power head out.
d. Remove the piston by loosening the Allen screw and removing the piston and screw.
e. Install the power head assembly (without the piston), torque to 35 to 40 foot-lbs (47.4 to 54.2 Nm).
f. Open all valves.
g. Start the unit.
h. 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.
i. Once repair parts become available, repair as required.
9.23 LIGHT BAR
9.23.1 Light Bar Operation and Test
a. The green LEDs illuminate when +12 volts is applied to Pin G and ground is applied to Pin B.
b. The amber LEDs will illuminate when +12 volts is applied to Pin G and ground is applied to Pin B and Pin
H.
c. Use an Ohmmeter to test light bar operation. PIN B should be open to other terminals, and PIN G should have 325 to 550 ohms to PIN H.
9.24 CHECKING DEFROST OR HEATING CYCLE
NOTE
DTT must be 40_F (4.4_C) or lower, before any checks can be made.
9.24.1 Hot Gas Solenoid Valve (SV1 & SV4) Heating and Defrosting
a. Connect a discharge pressure gauge to the manual shut-off valve (king valve) and another gauge to the compressor discharge service valve. Connect a gauge to the compressor suction service valve.
b. Start unit with controller set at least 10_F (5.5_C) below indicated refrigerated compartment temperature to obtain high speed cooling. Press the MANUAL DE-
FROST key to initiate defrost. (DTT must be at or below 40_F (4.4_C). The hot gas solenoid valve (SV4) will energize and the hot gas line will be hot to touch on both sides of the valve. The condenser pressure control solenoid (SV1) closes and suction pressure will rise approximately 10 to 15 PSIG (0.68 to1.02
Bars) after five minutes on unit operation. Refer to
Section 9.21.2 if unit does not heat properly.
c. Unit should remain in defrost until DTT (located on the center tube sheet below the evaporator) reaches
55_F (12.8_C ). At this point the defrost cycle will terminate and the unit will resume automatic operation.
9.25 DEFROST AIR SWITCH (DAS)
9.25.1 Testing The Defrost Air Switch And Circuit
a. To check the Defrost Air switch, run unit in high speed cooling and place a jumper 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 DTT is above 40_F (4.4_C), the
MessageCenter will show
“CANNOT START DEFROST CYCLE.” b. Unit should remain in defrost until DTT reaches 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
Defrost Air switch (DAS) settings using a magnehelic gauge. (Refer to Section 9.25.2)
9--43 62-10683
9.25.2 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 9--34. 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 9--34) c. Install tee in pressure line to high side connection. Tee should be approximately halfway 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 2.11 for switch settings. If switch fails to actuate at correct gauge reading, adjust switch by 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.
9.26 EVAPORATOR COIL 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.
Clean the evaporator coil on a regular basis, not only to remove cardboard dust, but also 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 refrigerated compartment).
b. Remove evaporator bulkhead and back panel, then spray coil with a mild detergent solution such as
Oakite 164 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. Replace evaporator back panel and run unit until defrost mode can be initiated to check for proper draining from drain pan.
62-10683 9--44
9.27 CONDENSER 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.) Use an FDA approved cleaning agent whenever possible. However, 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.
9.28 MICROPROCESSOR SENSOR CHECKOUT
An accurate ohmmeter must be used to check resistance values shown in Table 9-7.
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 9-7.
At least one lead from the sensor must be disconnected from the unit electrical system before any reading is taken. Not doing so will result in a false reading. 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
-40
°C
Ohms
-40 336,500
Table 9-7. Sensor Resistance (ENCT, RAT, SAT, ATT, DTT)
°F
18
°C
-7.8
Ohms
49,060
°F
76
°C
24.4
Ohms
10,250
°F °C
134 56.7
-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
-34 -36.7
270,300
-32 -35.6
251,500
-30 -34.4
234,200
24
26
28
-4.4
-3.3
-2.2
41,100
38,780
36,600
82
84
86
27.8
28.9
30.0
8,862
8,449
8,057
140
142
144
60.0
61.1
62.2
-28 -33.3
218,200
-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
0
2
-4
-2
-12 -24.4
126,100
-10 -23.3
118,100
-8
-6
-22.2
-21.1
110,500
103,600
-20
-18.9
-17.8
-16.7
97,070
91,030
85,400
80,160
4
6
-15.6
75,270
-14.4
70,720
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
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
-1.1
0
1.1
2.2
3.3
4.4
5.5
6.6
7.7
8.9
10
11.1
12.2
13.3
14.4
15.5
16.6
17.7
18.9
20.0
21.1
22.2
23.3
34,560
32,650
30,850
29,170
27,590
26,100
24,700
23,390
22,160
20,990
19,900
18,870
17,900
16,980
16,120
15,310
14,540
13,820
13,130
12,490
11,880
11,310
10,760
88
90
92
94
96
98
120
122
124
126
128
130
132
31.1
32.2
33.3
34.4
35.6
36.7
100 37.8
102 38.9
104 40.0
106 41.1
108 42.2
110 43.3
112 44.4
114 45.5
116 46.7
118 47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
5,327
5,095
4,874
4,665
4,465
4,275
4,095
3,923
7,686
7,334
7,000
6,684
6,384
6,099
5,828
5,571
3,759
3,603
3,454
3,313
3,177
3,049
2,926
146 63.3
148 64.4
150 65.6
155 68.3
160 71.1
165 73.9
170 76.7
175 79.4
180 82.2
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
230 110.0
235 112.8
240 115.6
245 118.3
250 121.1
1,171
1,072
983
902
829
762
702
647
2,208
2,124
2,042
1,855
1,687
1,537
1,402
1,281
598
553
511
473
438
406
378
Ohms
2,809
2,697
2,590
2,488
2,390
2,297
9--45 62-10683
°F °C
Ohms
°F °C
Table 9-8. Sensor Resistance (CDT)
Ohms
°F °C
Ohms
°F °C
Ohms
°F °C
Ohms
-40 -40 3,360,000 18 -7.8 189,690 76 24.4 102,460 134 56.7 28,160 260 126.7 3,290
-38 -38.9 3,121,020 20 -6.7 461,170 78 25.6
97,600 136 57.8 27,040 270 132.2 2,850
-36 -37.8 2,900,710 22 -5.6 434,790 80 26.7
92,990 138 58.9 25,970 280 137.8 2,490
-34 -36.7 2,697,500 24 -4.4 410,080 82 27.8
88,630 140 60.0 24,960 290 143.3 2,170
-32 -35.6 2,509,940 26 -3.3 386,940 84 28.9
84,510 142 61.1 23,980 300 148.9 1,910
-30 -34.4 2,336,720 28 -2.2 365,260 86 30.0
80,600 144 62.2 23,050 310 154.4 1,680
-28 -33.3 2,186,670 3 -1.1 344,930 88 31.1
76,890 146 63.3 22,160 320 160.0 1,480
-26 -32.2 2,028,680 32 0 325,860 90 32.2
73,380 148 64.4 21,310 330 165.5 1,310
-24 -31.1 1,891,780 34 1.1
307,970 92 33.3
70,040 150 65.6 20,500 340 171.1 1,160
-22 -30 1,765,060 36 2.2
291,180 94 34.4
66,880 155 68.3 18,980 350 176.7 1,040
-20 -28.9 1,647,700 38 3.3
275,410 96 35.6
63,880 160 71.1 16,940 360 182.2
920
-18 -27.8 1,538,950 40 4.4
260,590 98 36.7
61,040 165 73.9 15,450 370 187.8
830
-16 -26.7 1,438,120 42 5.5
246,670 100 37.8
58,330 170 76.7 14,070 380 193.3
740
-14 -25.6 1,344,580 44 6.6
233,570 102 38.9
55,770 175 79.4 12,870 390 198.9
670
-12 -24.4 1,257,770 46 7.7
221,260 104 40.0
53,330 180 82.2 11,750 400 204.4
600
-10 -23.3 1,177,150 48 8.9
209,670 106 41.1
51,010 185 85.0 10,750 410 210.0
540
-8 -22.2 1,102,240 50 10 198,760 108 42.2
48,800 190 87.8
9,870 420 215.6
490
-6 -21.1 1,032,600 52 11.1 188,490 110 43.3
46,710 195 90.6
9,050 430 221.1
450
-4 -20 967,830 54 12.2 178,820 112 44.4
44,710 200 93.3
8,320 440 226.7
410
-2 -18.9
907,560 56 13.3 169,700 114 45.5
42,820 205 96.1
7,650 450 232.2
370
0 -17.8
851,450 58 14.4 161,100 116 46.7
41,010 210 98.9
7,050 460 237.8
340
2 -16.7
799,180 60 15.5 152,990 118 47.8
39,290 215 101.7 6,510 470 243.3
310
4 -15.6
750,470 62 16.6 145,340 120 48.9
37,660 220 104.4 6,000 480 248.9
280
6 -14.4
705,060 64 17.7 138,120 122 50.0
36,100 225 107.2 5,540 490 254.4
260
8 -13.3
662,690 66 18.9 131,310 124 51.1
34,610 230 110.0 5,130 500 260.0
240
10 -12.2
623,150 68 20.0 124,870 126 52.2
33,200 235 112.8 4,760
12 -11.1
586,230 70 21.1 118,790 128 53.3
31,850 240 115.6 4,410
14 -10.0
551,740 72 22.2 113,040 130 54.4
30,560 245 118.3 4,090
16 -8.9
519,500 74 23.3 107,600 132 55.6
29,330 250 121.1 3,800
62-10683 9--46
9.29 UNIDRIVE TORQUE REQUIREMENTS
(FIGURE 9--35)
Extensive damage may occur if the proper hardware and procedures are not followed. Periodic inspection of hardware and bolt torque is recommended to insure the integrity of the unidrive.
NOTE
Thread locking sealant, 5/16 flat washer and
5/16 lock washer must be used on bolts between the compressor mounting flange and the engine bell housing. The recommended sealant is Loctite Threadlocker 262.
The following figures show the torque value, size and grade of the hardware to be used when reassembling the unidrive assembly.
9.29.1 Drive Gear
When installing a nylon drive gear always: a. Install with black dot facing steel gear.
b. Use new bolts and locking tabs included in drive gear kit.
c. Use Loctite or a similar thread locking compound on threads of drive gear bolts.
d. DO NOT use Never-Seez or any other lubricating compound on the nylon drive gear or compressor steel gear. The gear must be assembled dry.
e. Torque the (6 bolt) nylon drive gear bolts to 30 ft-lbs.
9--47 62-10683
DIRECT DRIVE
M8 x 1.25 x 20 mm lg
(4 Required) 28 ft-lbs (3.87 Mkg)
5/16-18 x 3/4 lg Grade 8
(4 Required) 25 ft-lbs (3.46 Mkg) or
3/8-16 x 1-3/4 lg Grade 5
(6 Required) 30 ft-lbs (4.15 Mkg)
3/8-24 x 1.00 lg Grade 8
28 ft-lbs (3.87 Mkg)
M12 x 1.25 x 25 mm lg
(3 Required) 65 ft-lbs (8.99 Mkg)
90 ft-lbs (12.45 Mkg)
3/8-16 x 1 lg Grade 5 (10 Required)
28 ft-lbs (3.87 Mkg)
62-10683
Figure 9--35. Unidrive Torque Requirements -- Non ESC Engine
9--48
DIRECT DRIVE
M8 x 1.25 x 20 mm lg
(6 Required) 28 ft-lbs (3.87 Mkg)
3/8-16 x 1-3/4 lg Grade 5
(6 Required) 30 ft-lbs (4.15 Mkg)
3/8-24 x 1.00 lg Grade 8
28 ft-lbs (3.87 Mkg)
M12 x 1.25 x 25 mm lg
(3 Required) 65 ft-lbs (8.99 Mkg)
90 ft-lbs (12.45 Mkg)
3/8-16 x 1 lg Grade 5 (12 Required)
28 ft-lbs (3.87 Mkg)
Figure 9--36. Unidrive Torque Requirements -- Electronic Speed Control Engine
9--49 62-10683
Temperature Pressure
_
C
_
F Bars PSIG
-40 -40 0.31
4.5
-37 -35 0.49
-34 -30 0.68
7.1
9.9
-32 -25 0.89
12.9
-29 -20 1.12
16.3
-28 -18 1.22
17.7
-27 -16 1.32
19.2
-26 -14 1.43
20.7
-24 -12 1.54
22.3
-23 -10 1.65
23.9
-22 -8 1.77
25.6
-21
-20
-6
-4
1.88
2.01
27.3
29.1
-19
-18
-17
-16
-14
-13
-2 2.13
30.9
0 2.26
32.8
2 2.40
34.8
4 2.54
36.8
6 2.68
38.9
8 2.83
41.1
-12 10 2.99
43.3
-11 12 3.14
45.6
-10 14 3.31
48.0
-9 16 3.47
50.4
-8 18 3.65
52.9
-7 20 3.83
55.5
-6 22 4.01
58.1
-4 24 4.20
60.9
-3 26 4.39
63.7
-2 28 4.59
66.5
-1 30 4.79
69.5
Table 9-9. R404A Temperature-Pressure Chart
Temperature Pressure
_
C
_
F Bars PSIG
0 32 5.00
72.5
1 34 5.21
75.6
2 36 5.43
78.8
3 38 5.66
82.1
4 40 5.90
85.5
6 42 6.14
89.0
7 44 6.38
92.5
8 46 6.63
96.2
9 48 6.89
99.9
10 50 7.15 103.7
13 55 7.96 115.4
16 60 8.69 126.1
18 65 9.47 137.4
21 70 10.30 149.4
24 75 11.18 162.1
27 80 12.10 175.5
29 85 13.07 189.6
32 90 14.10 204.5
35 95 15.18 220.2
38 100 16.33 236.8
41 105 17.53 254.2
43 110 18.78 272.4
46 115 20.11 291.6
49 120 21.50 311.8
52 125 22.95 332.9
54 130 24.48 355.0
57 135 26.07 378.1
60 140 27.74 402.3
63 145 29.48 427.6
66 150 31.30 454.0
62-10683 9--50
SECTION 10
UNIT TROUBLESHOOTING
PARAGRAPH NUMBER
10.1 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.2 Engine Starts Then Stops
10.1.3 Starter Motor Malfunction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.4 Malfunction In The Engine Starting Circuit
10.1.5 Miscellaneous Engine Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 ALTERNATOR (12 Volt DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 REFRIGERATION / TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.1 Unit Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.3 System Will Not Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.4 Unit Operates Long Or Continuously In Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.5 Unit Will Not Terminate Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.6 Unit Will Not Heat Or Has Insufficient Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.7 Unit Will Not Terminate Heating
10.3.8 Defrost Cycle Malfunction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.9 Abnormal Pressure
10.3.10 Abnormal Noise
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.11 Control System Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.12 No Evaporator Air Flow Or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.13 Expansion Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.14 Compressor Suction Modulation Valve (CSMV) Malfunction . . . . . . . . . . . . . . . . . . . . .
10.3.15 Solenoid Valve Malfunction (SV1, 2 OR 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 ELECTRONIC SPEED CONTROL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4.1 Advance Microprocessor Troubleshooting Guide
10.5 COMPRESSOR TROUBLESHOOTING GUIDE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
10--4
10--4
10--4
10--4
10--5
10--5
10--5
10--5
10--1
10--1
10--1
10--2
10--2
10--3
10--3
10--4
10--6
10--7
10--7
10--7
10--7
10--8
10--8
10--8
10--13
10--23
1
SECTION 10
UNIT TROUBLESHOOTING
CAUTION
Under no circumstances should anyone attempt to service the Advance Microprocessor. See Section 10.4.1 for microprocessor troubleshooting. Should a problem develop with the Advance Microprocessor, contact your nearest Carrier Transicold dealer for replacement.
NOTE
Run a Pretrip and Check all active alarms before continuing with troubleshooting.
INDICATION / TROUBLE POSSIBLE CAUSES
ACTION /
REFERENCE
SECTION
10.1 DIESEL ENGINE -- See Table 10-1 and Figure 10--1 thru Figure 10--4 for ESC troubleshooting
10.1.1Engine Will Not Start
Battery insufficiently charged
Battery terminal post dirty or defective
Bad electrical connections at starter
Check
Check
Check
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
Starter motor malfunctions
Starter motor solenoid defective
Open starting circuit
Incorrect grade of lubricating oil
Unloaders not unloaded
High refrigeration suction pressure
No fuel in tank
Air in fuel system
Water in fuel system
Plugged fuel filter(s)
Plugged fuel lines to injector(s)
ESC defective
Voltage drop in battery cable(s)
Engine lube oil too heavy
10.1.3
Engine Manual
10.1.4
2.7
9.14
9.22
Check
9.6
Drain Sump
Replace
Check
10.4
Check
2.7.1
10.1.2Engine Starts Then Stops
Engine stops after several rotations
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
Fuel pump (FP) malfunction
Check
Check
Check
Engine
Replace
Engine Manual
Engine Manual
9.8.8
2.12
Engine Manual
9.6
10--1
62-10683
INDICATION / TROUBLE POSSIBLE CAUSES
10.1.3Starter 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 was depressed
Glow/Crank switch defective
Starter motor solenoid defective
Engine is already running
Starter motor does not disengage after engine is starts
Defective starter
10.1.4Malfunction In The Engine Starting Circuit
No power to starter motor solenoid (SS)
Battery defective
Loose electrical connections
ESC defective
No power to Starter Solenoid connector
Battery defective
Loose electrical connections
Oil pressure safety switch (ENOPS) defective
Fuel solenoid does not energize or does not remain energized
Run relay (RR) defective
Engine coolant temp. (ENCT) defective
Fuel solenoid defective
Start/Run-Off switch defective
ACTION /
REFERENCE
SECTION
Check
Check
Replace
Engine Manual
Engine Manual
Engine Manual
Replace
2.7
Clean both, remove burrs, or replace
Replace
Engine Manual
Check
Engine Manual
Check
Tighten
10.4
10.4
Check
Tighten
Replace
Replace
Replace
Engine Manual
Replace
62-10683
10--2
INDICATION/
TROUBLE POSSIBLE CAUSES
10.1.5 Miscellaneous Engine Troubleshooting
Restriction in air cleaner
Air in fuel system
Loss of power
Air vent restricted in fuel tank cap
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/belt
Plugged crankcase breather line
10.2 ALTERNATOR (12 Volt DC)
Alternator fails to charge
Low or unsteady charging rate
Excessive charging rate
(as evidenced by battery requiring too frequent refilling) or amp reading shows constant high amp charge.
Limited charging system operating time
Battery condition
Alternator belt loose/broken
Loose, dirty, corroded terminals, or broken leads
Excessively worn, open or defective brushes
Open blocking diode
Regulator faulty
Open isolation diode
Open rotor (field coil)
Alternator belt loose
Loose, dirty, corroded terminals, or broken leads
Excessively worn, sticky or intermittent brushes
Faulty regulator
Grounded or shorted turns in rotor
Open, grounded or shorted turns in stator
Regulator leads loose, dirty, corroded terminals, or wires broken
Defective regulator
ACTION/
REFERENCE
SECTION
9.8.8
9.6
Clean
Engine Manual
Engine Manuall
Engine Manual
Engine Manuall
Engine Manual
Engine Manual
Replace
Engine Manual
9.8.8
Removel
Engine Manual
9.8.1
8.5.1
replace
Engine Manual
Engine Manual
9.8.9
Check
Check
9.9
Check/Repair
Check
Check
Check
Check
Replace
9.9
Check/Repair
Check
Check
Check
Replace
Clean/Repair
Check
10--3
62-10683
INDICATION/
TROUBLE POSSIBLE CAUSES
10.2 ALTERNATOR (12 Volt DC) -- cont.
Defective or badly worn V-belt
Noisy alternator
Worn bearing(s)
Misaligned belt or pulley
Loose pulley
10.3 REFRIGERATION / TEMPERATURE CONTROL
10.3.1Unit Will Not Cool
Diesel engine Malfunction(s)
Compressor malfunction
Compressor drive defective
Refrigeration system
Compressor defective
Defrost cycle did not terminate
Abnormal pressure
Solenoid valve malfunction
Clutch Failure
Check system for non--condensables
10.3.2Unit Runs But Has Insufficient Cooling
Compressor
Compressor valves defective
Unloader malfunction
Abnormal pressure
Refrigeration system
Engine does not develop full rpm
Unloader malfunction
Expansion valve malfunction
No or restricted evaporator airflow
Clutch Failure
Speed control linkage
Engine malfunction
10.3.3System Will Not Pump Down
Check SV4
Check by-pass check valve
Check SV2
Check king valve
Check compressor
10.3.4Unit Operates Long Or Continuously In Cooling
Hot Load
Refrigerated Compartment
Defective box insulation or air leak
Abnormal pressure
Refrigeration system
Compressor
Temperature sensor malfunction
Check system for non--condensables
Defective
62-10683
10--4
ACTION/
REFERENCE
SECTION
9.9
Replace
9.9
Tighten
9.12
9.14
10.3.9
9.14
10.3.13
10.3.12
9.10.5
9.8.6
10.1
9.21.1
9.15
9.21.1
10.1
9.12
9.12
10.3.8
10.3.9
10.3.15
9.10.5
NO TAG
Pre-cool product
Correct
10.3.9
Check
NO TAG
9.12
INDICATION/
TROUBLE
10.3.5 Unit Will Not Terminate Cooling
Unit fails to stop cooling
POSSIBLE CAUSES
Temperature sensor malfunction
Microprocessor improperly set
ACTION/
REFERENCE
SECTION
Check
Check set point
Check whether microprocessor is set at °C or
°F
10.3.6Unit Will Not Heat Or Has Insufficient Heating
Abnormal pressure
Temperature sensor malfunction
Refrigeration
Compressor
Solenoid valve malfunction
1/4” check valve (bypass) defective
Clutch Failure
Compressor drive defective
Compressor defective
Engine does not develop full rpm
Engine malfunction
FSA malfunction
Diagnostic code on ENSCU
10.3.7 Unit Will Not Terminate Heating
Unit fails to stop heating
Microprocessor temperature improperly set
Microprocessor malfunction
Temperature sensor malfunction
10.3.8Defrost Cycle Malfunction
Will not initiate defrost automatically
Will not initiate defrost manually
Initiates but does not defrost
Frequent defrost
Does not terminate or cycles on defrost
Defrost air switch (DAS) out of calibration
DTT2 is above 40_F (4.4_C)
Defrost air switch (DAS) defective
Loose terminal connections
Air sensing tubes defective or disconnected
Keypad defective
Loose terminal connections
DTT2 is above 40_F (4.4_C)
Unit has been running less than 15 seconds
Low refrigerant charge
Solenoid valve malfunction
Clutch/Gearbox defective
Defrost air switch (DAS) out of adjustment
Wet load
Low refrigerant charge
Defrost air switch (DAS) out of adjustment
Refrigerated Compartment
Hot Load
Defective or insufficient refrigerated compartment insulation or air leak
10.3.9
10.3.11
10.3.15
9.15
9.10.5
9.12
9.12
10.1
10.4
10.4
Reset
10.4.1
Check
9.25.2
Cool Box Down
9.24 & 9.25.2
Tighten
Check
Replace
Tighten
Cool Box Down
Try again
NO TAG
10.3.15
Replace
9.24 & 9.25.2
Normal
NO TAG
9.24 & 9.25.2
Allow time to pull down
Correct
10--5
62-10683
INDICATION/
TROUBLE
10.3.9Abnormal Pressure a. Cooling
POSSIBLE CAUSES
High discharge pressure
Low discharge pressure
High suction pressure
Low suction pressure
Suction and discharge pressures tend to equalize when unit is operating
b. Heating
High discharge pressure
Low discharge pressure
Low suction pressure
Condenser coil dirty
Condenser fan defective
V-belt broken or loose
Discharge check valve restricted
Non--condensables or refrigerant overcharge
Solenoid valve (SV1) malfunction
SV4 leaking
Compressor valves(s) worn or broken
SV4 leaking
Compressor valves(s) worn or broken
Compressor gasket(s) defective
Suction service valve partially closed
King valve partially closed
Filter-drier partially plugged
Low refrigerant charge
Expansion valve malfunction
No evaporator air flow or restricted air flow
Excessive frost on coil
Solenoid valve (SV2) defective
Clutch Failure
Suction modulation valve malfunction
Compressor valves defective
Compressor gasket(s) defective
Solenoid valves (SV1 and SV4) malfunction
Condenser fan defective
V-belts broken or loose
Non-condensables in system
Compressor valve(s) worn or broken
Solenoid valve (SV1) malfunction
Low refrigerant charge
Refrigerant shortage
Solenoid (SV1) open
ACTION/
REFERENCE
SECTION
9.27
9.10
9.9
9.15
NO TAG and
Table 2-1
9.21.2
9.21
9.12
9.21
9.12
9.12
Open
Open
9.16
NO TAG
10.3.13
10.3.12
9.24
9.21
9.10.5
9.22
9.12
9.12
10.3.15
9.10
9.9
NO TAG
9.12
10.3.15
NO TAG
NO TAG
10.3.15
62-10683
10--6
INDICATION/
TROUBLE POSSIBLE CAUSES
10.3.10 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
Defective
Cracked or worn
Clutch/Gearbox
V-belts
10.3.11 Control System Malfunction
Will not control
Sensor defective
Relay(s) defective
Microprocessor malfunction
10.3.12No Evaporator Air Flow Or Restricted Air Flow
Evaporator coil blocked
Frost on coil
Dirty coil
No or partial evaporator air flow
V-belt broken or loose
Clutch/Gearbox defective
Evaporator fan loose or defective
Evaporator fan rotating backwards
Evaporator air flow blocked in refrigerated compartment
10.3.13 Expansion Valve Malfunction
Low refrigerant charge
Low suction pressure with high superheat
Low superheat and liquid slugging in compressor
Fluctuating suction pressure
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
External equalizer line plugged
Ice holding valve open
Foreign material in valve
Pin and seat of expansion valve eroded or held open by foreign material
Improper bulb location or installation
Low superheat setting
Broken capillary
ACTION/
REFERENCE
SECTION
Tighten
9.12
9.12
10.3.13
9.13
Check
9.10
9.10
Replace
9.9
9.28
Check
Check
9.24
9.26
9.9
Replace
9.10
9.9
Check
NO TAG/
NO TAG
Clean
NO TAG
Clean
9.11
Replace
9.11.2
9.11.2
Clean
NO TAG
Clean
Clean
Figure 9--16
9.11.2
Replace
10--7
62-10683
INDICATION/
TROUBLE POSSIBLE CAUSES
10.3.14 Compressor Suction Modulation Valve (CSMV) Malfunction
Coil not seated properly
Coil defective
Loose connector
CSMV not controlling correctly
CSP defective
CDT defective
CDP defective
10.3.15 Solenoid Valve Malfunction (SV1, 2 OR 4)
No power to valve
Improper wiring or loose connections
Coil defective
Solenoid valve does not function properly
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
Solenoid valve closes but refrigerant continues to flow
Foreign material lodged under seat
Defective seat
ACTION/
REFERENCE
SECTION
10.4 ELECTRONIC SPEED CONTROL TROUBLESHOOTING
Table 10-1. ENSCU LED Fault Chart (See following pages for troubleshooting trees)
Fault
1 Engine Over Speed: more than 2,530 RPM
2 No signal from ENSSN for 2 seconds after RPM is greater than 1,000 RPM for 10 seconds, OR for 5 seconds while engine cranking (no voltage at pin 18 of ENSCU).
3 Actuator (FSA) wiring disconnected or open circuit. Coil Resistance Spec: 2.8 ohm +/- 10%.
4 ENSCU supply voltage is greater than 26V.
LED display pattern
One Long–One
Short
Two Long–One
Short
Two Long–Three
Short
Two Long–Seven
Short
Failed component
ENSSN or mechanical engine problem
ENSSN or wiring problem
FSA or wiring problem
ENSCU or alternator problem
Check
Check and Replace
Check and
Tighten
Check and Replace
Check and Replace
Check and Replace
Check
Check
9.21
9.21
9.21
9.21
9.21
9.21
Clean
Replace
62-10683
10--8
NO
NOTE : Ensure the run relay is energized during test . With ENSSN unplugged during testing , unit will stall & go through start sequence again . Unit will not start . This is normal .
Verify there is at least 11 VDC going into the ENSSN 12V terminal ?
YES
NO
Check for high resistance or an open between ENSCU terminal 25 &
ENSSN 12V terminal.
Did you find and correct the condition?
YES
System
OK
NO
Using jumper wire, check for
5 VDC at ENSCU terminal 10.
Do you have 5 VDC at terminal 10?
NO
Check for open or high resistance on circuit between
ENSSN and ENSCU. Did you find and correct the condition?
YES
NO
START HERE
Start unit.
Using strobe light
07-00177-01 or equivalent, check engine RPM.
Is RPM equal to or over 2,530?
YES
Check for high resistance or an open in the ENSSN ground circuit.
Did you find and correct the condition?
NO
YES
System
OK
Check high speed mechanical stop on injection pump assembly for loose screws or tampering.
Are the screws loose?
YES
NO
Set proper high speed RPM per this manual
Did you find and correct the condition?
YES
NO
System
OK
Remove new ENSCU and re-install old
ENSCU back into unit,
ENSCU is not the fault.
Review results of above tests with your supervisor. If necessary, go to the beginning of the table & test again.
Check for proper internal mechanical operation of injection pump assembly and governor assembly. Did you find and correct the condition?
YES
NO
NO
Replace ENSCU. Did you find and correct the condition?
System
OK
Replace ENSSN. Did you find and correct the condition?
YES
Review results of above tests with your super visor. If necessary, go to the beginning of the table & test again.
NO
YES
YES
System
OK
System
OK
Remove new ENSSN and re-install old
ENSSN back into unit,
ENSSN is not the fault.
Review results of above tests with your supervisor. If necessary, go to the beginning of the table
& test again.
Figure 10--1. ESC Diagnostic Tree -- 1 Long, 1 Short LED Code
10--9
62-10683
Using jumper wire, verify there is at least 11
VDC at ENSCU terminal 25?
YES
NO
START HERE
Verify unit starts, go into high speed and stall after running for a few seconds?
Verify there is at least 11
VDC going into the
ENSSN 12 V terminal?
YES
Check for high resistance or an open in the
ENSSNG ground circuit.
Did you find and correct the condition?
NO
Remove new ENSCU and re-install old
ENSCU back into unit, ENSCU is not the fault. Review results of above tests with your supervisor. If necessary, go to the beginning of the table & test again.
Check for high resistance or an open between
ENSCU terminal
25 & ENSSN
12 V terminal.
Did you find and correct the condition?
.
YES
System
OK
YES
NO
Using jumper wire, check for
5 VDC at ENSCU terminal
10. Do you have 5 VDC at terminal 10?
YES
Replace ENSCU.
Did you find and correct the condition?
NO
NO
System
OK
YES
Check for open or high resistance on circuit between ENSSN and ENSCU.
Did you find and correct the condition?
NO
Replace ENSSN. Did you find and correct the condition?
Remove new ENSSN and re-install old
ENSSN back into unit,
ENSSN is not the fault.
Review results of above tests with your supervisor. If necessary, go to the beginning of the table
& test again.
NO
YES
System
OK
YES
System
OK
62-10683
Figure 10--2. ESC Diagnostic Tree -- 2 Long, 1 Short LED Code
10--10
YES
Go to Advance Micro diagnostic table
Figure 10--6
Check for high resistance or an open on the FSA ground circuit terminal 2.
Did you find and correct the condition?
NO
With the FSA disconnected, check the resistance of the
FSA coil. Spec is
2.8 ohms +/- 10%.
Is ohm reading within spec?
NO
Replace the FSA. Did you find and correct the condition?
NO
Remove new FSA and re-install old
FSA back into unit, FSA is not the fault. Review results of above tests with your supervisor. If necessary, go to the beginning of the table & test again.
YES
NO
YES
System
OK
YES
Remove the FSA from the engine & inspect. FSA should move freely without binding and shaft should be straight. Is
FSA functioning properly?
NO
YES
Review results of above tests with your super visor. If necessary, go to the beginning of the table & test again.
START HERE
Does the engine starter engage & turn the engine over?
YES
Verify the proper voltage going into FSA terminal
1. 12 VDC when
Start/Run-Off switch is first turned on for the pull in voltage, 1 VDC for hold in voltage & 0.8 VDC during starter engagement.
Do you have the correct voltage?
NO
YES
Replace ENSCU. Did you find and correct the condition?
NO
NO
Using jumper wire, are the proper voltages present at ENSCU terminal 7?
YES
Check for open or high resistance on circuit between FSA and ENSCU.
Did you find and correct the condition?
NO
YES
.
Remove new ENSCU and re-install old
ENSCU back into unit,
ENSCU is not the fault.
Review results of above tests with your supervisor. If necessary, go to the beginning of the table & test again.
Review results of above tests with your super visor. If necessary, go to the beginning of the table & test again.
System
OK
System
OK
Figure 10--3. ESC Diagnostic Tree -- 2 Long, 3 Short LED Code
10--11
62-10683
Replace ENSCU. Did you find and correct the condition?
NO
NO YES
START HERE
With the Start/Run-Off switch ON and the ENSCU wire 13 removed from the connector (connector plugged in), check voltage at ENSCU terminal 13. Is voltage 26 VDC or higher?
NOTE: With connector unplugged, unit will not start but will crank.
Check voltage while unit is cranking.
YES
NO
Check voltage output at alternator. Is voltage 26
VDC or higher?
YES
Remove new ENSCU and re-install old
ENSCU back into unit, ENSCU is not the fault. Review results of above tests with your supervisor. If necessary, go to the beginning of the table & test again.
System
OK
Starting at terminal
13 at the ENSCU, check circuit for induced voltage creating the 26 VDC signal.
Did you find and correct the condition?
NO
Review results of above tests with your super visor. If necessary, go to the beginning of the table & test again.
YES
System
OK
Replace alternator.
Did you find and correct the condition?
NO
YES
System
OK
Remove new alternator and re-install old alternator back into unit, alternator is not the fault. Review results of above tests with your supervisor. If necessary, go to the beginning of the table & test again.
62-10683
Figure 10--4. ESC Diagnostic Tree -- 2 Long, 7 Short LED Code
10--12
10.4.1Advance Microprocessor Troubleshooting Guide
The purpose of the following procedure is to provide a logical and straightforward guide to be used when troubleshooting operational or other problems occurring with the microprocessor. Often users and technicians have mistakenly worked to correct a problem that has ended up being normal operation. The microprocessor has several different conditions contributing to operating parameters. These conditions are called out in the various diagnostic charts to aid the technician in pinpointing the problem, or in realizing that the unit is performing normally.
When using these tables, it is important to verify the reported symptom or problem and then correctly identify the appropriate table for that particular condition. Using the incorrect table will lead to an incorrect diagnosis. A table of contents is included to easily identify the correct table to use.
When using these Diagnostic Tables, it is very important not to skip any steps. Follow the flow of the tables in the order that they are laid out. These tables are formatted into a logical troubleshooting sequence. Skipping around the tables will most likely lead to errors in diagnosis.
Throughout the tables, the steps will point the technician to areas to look at or check for a problem. Most of the steps will lead the technician to a circuit or other area of the unit to check, test, and possibly repair other than the microprocessor. Some steps will point to a possible problem with the microprocessor. Whenever reaching one of these steps, it is a very good practice to install the new microprocessor, then verify unit operation PRIOR TO writing hours, Trailer ID, Unit Serial Number, etc., into the new microprocessor. Once the technician is satisfied that a new microprocessor is required, the hours, trailer ID, unit serial number, customer configurations, or IntelliSets, etc., should be entered. Should the problem remain even with the new microprocessor in place, once all repairs are made, the original microprocessor is to be reinstalled into the unit, to avoid unnecessary costs to the customer or having the
Warranty Request rejected if there is no problem found with the returned microprocessor.
All steps leading to replacement of the microprocessor have a number associated with them. When filling out the MPR tag that will be attached to the returned part, write the step number on the upper half of the tag in the Failure Description
Field. Include the same information in the Failure Description Field when entering the warranty claim information on line. This will show which diagnostic table was used and the path that was followed to determine the micro was at fault.
10--13
62-10683
START HERE
Is unit equipped with StarTrak?
YES
Disconnect StarTrak from unit and install J1 jumper. This will eliminate StarTrak from the system.
NO
YES
NO
Check the F1 fuse.
Is the fuse blown?
Is Micro Status
LED blinking?
YES
Check Micro Status
LED blink rate.
YES
Replace the fuse.
Did you find and correct the condition?
NO
NO
Return to the top of this chart
Micro Status LED is blinking at 1 second ON & 1 second OFF.
Micro Status LED is blinking at 1/2 second ON & 1/2 second OFF.
YES
YES
YES
YES
YES
System OK
Re-install
StarTrak if
NO
Check voltage between 5MPA1 &
QC2. Voltage should read 11 volts or higher. Is voltage within range?
NO
Check Wiring for high resistance or an open.
Did you find and correct the condition?
disconnected earlier.
Check ground connectors at the battery, starter, engine block and inside the control box.
Did you find and correct the condition?
NO
Check voltage between QC1 & QC2.
Voltage should read
11 volts or higher.
Is voltage within range
NO
Check Wiring for high resistance or an open.
Did you find and correct the condition?
YES
Inspect and repair poor connections at the micro and display. Did you find and correct the condition?
Check the Glow / Crank switch and wiring for shorting. Is the switch or circuit shorted?
YES
NO
YES
YES
NO
Ensure the operator is waiting long enough by turning the
Start/Run-Off switch ON and waiting 2minutes for the display to come on. Did you find and correct the condition?
NO
Is the system operat-ing OK now?
YES
System OK
Re-install
StarTrak if disconnected earlier.
Inspect and repair he 3 wiring harnesses for the micro and display:
YES the cable from the micro to the back of the display, the cable from the back of the display to the display itself and the ribbon cable from the keypad to the board. Did you find and correct the condition?
YES
YES
NO
Load current version
Go To Condition 8 --
Programming Problems with PC Cards if using a PC
Card to upgrade software or
Condition 9 -- Programming
Problems with MicroProgrammer if using a PC to upgrade software.
Did the software load correctly?
Did the loading of the software correct the problem?
NO
NO
of software from http:// www.transcentral.
carrier.com Did the current version of software load correctly?
NO
Replace
Switch and repair wiring as needed. Did you find and correct the problem?
YES
NO
(MPR Code #2)
NO
(MPR Code #1)
Replace micro and operate system in order to verify repair.
Did you find and correct the condition?
Remove new micro and re-install old micro back into the unit. Micro is not the fault.
Review results of above tests with your supervisor. If necessary, go to the beginning of the table & test again.
NO
YES
YES
Review the results of above tests with your supervisor. If necessary, go to the beginning of the table & test again.
System OK
Re-install
StarTrak if disconnected earlier.
Figure 10--5. Micro Diagnostic Tree -- Cond. 1 -- Start/Run-Off Switch On -- Unit Does Not Operate
62-10683
10--14
Wrong Chart.
See Condition 1.
NO
START HERE
The unit starts & runs.
YES
NO
Micro may not be configured properly.
Verify correct model number is selected in the micro via unit data. Did you find and correct the condition?
Unit may be running on old software.
Upgrade software to current version.
Did the software load correctly?
NO
Go To
Condition 8 --
Programming Problems with PC Cards if using a
PC Card to upgrade software
-- or --
Condition 9 --
Programming Problems with MicroProgrammer if using a PC to upgrade software.
Did the software load correctly?
NO
Review the results of above tests with your supervisor. If necessary, go to the beginning of the table
& test again.
Remove new micro & re-install old micro back in the unit. Micro is not the fault. Review results of above tests with your supervisor. If necessary, go to beginning of table & test again.
YES
Did the loading of the software correct the problem?
YES
NO
Check ground connectors at the battery, starter, engine block and inside the control box. Did you find and correct the condition?
NO
Check for active & inactive alarms.
Refer to Section 8 for troubleshooting alarms. Did you find and correct the condition?
NO
Verify function settings, configurations and
IntelliSet settings are installed & correct. Did you find and correct the condition?
NO
Use Pre Trip to check for any alarms.
Use the Component Test Mode (Section
6.2.2) to verify operation. Did you find and correct the condition?
NO
Use this manual to check for correct operation. Did you find and correct the condition?
NO
NO
Download data recorder & review unit operation. Did you find and correct the condition?
NO
Are you sure unit is not operating properly? Operate the system. Did you find and correct the condition?
NO
(MPR Code #5)
Replace micro and operate system in order to verify repair. Did you find and correct the condition?
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
System
OK
YES
Figure 10--6. Micro Diagnostic Tree -- Cond. 2 -- Start/Run-Off Switch On -- Unit Operates But Not Properly
10--15
62-10683
START HERE
Is the unit equipped with
StarTrak?
NO
Turn the Start/Run
-- Off switch to the
OFF position.
Does the engine continue to run?
NO
There a problem with the
StarTrak system.
Repair as necessary.
YES
Disconnect StarTrak from the unit and install
J1 Jumper. This will eliminate StarTrak from the system.
YES
Check for defective
Start/Run-Off switch.
Is Switch defective?
NO
YES
NO
Replace Start/Run
-Off switch. Did you find and correct the condition?
YES
NO
Check wiring to
Start/Run-Off switch for an open or short. Did you find and correct the condition?
NO
Verify the Run Relay de-energizes when the
Start/Run-Off switch is in the OFF position.
YES
System OK
Re-install
StarTrak if disconnected earlier.
Unplug fuel solenoid or fuel and speed actuator. Does the unit stop?
YES
Replace Run
Relay. Did you find and correct the condition?
YES
YES
NO
NO
Is the relay defective?
YES
Check wiring for fuel solenoid of fuel and speed actuator for a short. Did you find and correct the condition?
YES
NO
NO
Check wiring to Run Relay for an open or short. Did you find and correct the condition?
Fuel solenoid or fuel and speed actuator is defective or mechanically seized.
NO
YES
Verify correct fuel solenoid or fuel and speed actuator operation
& replace if needed.
Operate system in order to verify repair. Did you find and correct the condition.
NO
System OK Re-install
StarTrak if disconnected earlier.
YES
YES
Remove connectors from unit one at a time to determine if any other devices are providing power feedback, causing the micro to remain powered.
Did you find and correct the condition?
NO
Did the loading of the software correct the problem?
NO
YES
Review the results of above tests with your supervisor. If necessary, go to the beginning of the table
& test again.
Load current version of software from http://www.
transcentral.carrier.com.
Did the software load correctly?
NO
YES
Remove new fuel solenoid or fuel and speed actuator & reinstall old component.
Old component is not the fault.
Go To
Condition 8 --
Programming Problems with PC Cards if using a
PC Card to upgrade software
-- or --
Condition 9 --
Programming Problems with MicroProgrammer if using a PC to upgrade software.
Did the software load correctly?
Figure 10--7. Micro Diagnostic Tree -- Cond. 3 -- Start/Run-Off Switch Off -- Unit Fails To Stop
62-10683
10--16
YES
START HERE Check the Speed Solenoid or FSA and linkage for correct operation.
Did you find and correct the condition?
NO
Unit may be running old soft ware. Upgrade software from
YES http://www.transcentral.carrier.com.
Did you find and correct the condition?
NO
Check System discharge pressure at compressor.
Is discharge pressure 435PSI or higher?
NO
YES
Check system suction pressure at compressor. Is suction pressure 5PSI or lower?
NO
Check engine coolant temperature. Is coolant temperature 77°F or below?
YES
System OK
YES
System OK
NO both present?
NO
NO
NO
Is unit in defrost?
NO
Does the unit have a door switch or remote switch?
Are alarms A122 and A123
Is the unit in Start/Stop operation?
NO
YES
NO
Is the setpoint 10.5°F or higher?
YES
YES
YES
YES
Is the ambient temp 80°F or higher?
Is the switch configured for low speed?
Has the unit been in defrost for more than
5 1/2 minutes?
NO
YES
NO
Is the door open?
Is setpoint 10°F or lower?
Check funtional parameter settings for high speed delay minutes for continuous run.
YES
NO
Check funtional parameter settings for high speed delay minutes for start/stop
NO
Has the unit been in defrost for less than 30 seconds and suction pressure is less than 10 PSI OR Has the unit been in defrost for up to
5 1/2 minutes and the suction pressure is more than 10 PSI?
YES
YES
NO
Check door switch wiring for an open.
Did you find and correct the condition?
Has the unit been running less that the selected high speed delay minutes?
NO
Check the configurations for high speed delay.
Is the setpoint further away from the selected probe temp for less than the selected minutes?
YES
YES
YES
YES
NO
YES
YES
Is return air temp equal to or colder than setpoint?
NO
NO
Is selected probe temp within
+/- 3.6°F of setpoint?
YES
NO
Is speed relay LED27 illuminated on micro?
YES
YES
Check the F2 circuit for excess amp draw or short to ground. Did you find and correct the condition?
YES
The micro is calling for low speed operation. If you believe this is not correct, review your testing with your supervisor before changing microprocessor.
Is the F2 fuse blown?
NO
Is there voltage at QC3?
NO
NO
YES
NO
NO
Replace relay. Did you find and correct the condition?
YES
YES
Review the test results with your supervisor. If necessary, go to the beginning of the table and test again.
Check for proper operation of the speed relay. Is the relay operating properly?
Micro is calling for high speed. Is there 12V at the speed control solenoid or FSA?
YES
Check for proper operation of the speed control solenoid or FSA. Is the solenoid/actuator operating properly?
YES
NO
NO
NO
YES
Check wiring and connections from QC3 to speed control solenoid or FSA. Did you find and correct the condition?
Repair or replace solenoid or actuator as needed.
YES
Figure 10--8. Micro Diagnostic Tree -- Cond. 4 -- Unit Will Not Run In High Speed
10--17
62-10683
START HERE
Is the unit operating in defrost?
NO
Unit may be running old software. Upgrade software from http: //www.transcentral.carrier.com. Did you find and correct the condition?
NO
Check functional parameter settings for air flow.
Does the setting show high?
NO
Does the unit have IntelliSet options?
NO
YES
Is ProductShield High
Air configured on?
YES
YES
YES
YES
What is the version of software in the micro?
YES
Software Rev 04.02.00
and earlier.
NO
Check to see if the ambient is inside the Min/Max range.
Did you find and correct the condition?
NO
Check setpoint NO
Software Rev 04.03.00
and later.
Check to see if the ambient is outside the Min/Max range.
Did you find and correct the condition?
YES
System OK
Is setpoint +10.4F or lower?
Is setpoint +10.5F or higher?
NO
Is return air temperature equal to or colder than setpoint?
YES NO
Is selected probe tem greater than 3.6F from setpoint?
NO
Is there a voltage of 12V or higher at QC3?
NO
Is there 12V or higher at the
Speed Solenoid or FSA?
YES
Is speed relay LED27 illuminated on the micro? Did you find and correct the condition?
YES
NO
Check wiring for high resist ance or shorted con nections. Did you find and correct the condition?
YES
NO
Check the speed solenoid or FSA and linkage for binding. Did you find and correct the condition?
YES
System OK
YES
NO
Review the test results with your supervisor. If necessary, go to the beginning of the table and test again.
YES
62-10683
Figure 10--9. Micro Diagnostic Tree -- Cond. 5 -- Unit Will Not Run In Low Speed
10--18
YES
“CONNECTION OK”
Are the dates for the data on the download screen?
NO
Data Recorder date & time may be set wrong. Set the correct date
& time. Did you find and correct the condiditon?
YES
YES
System
OK
START HERE
What does the
ReeferManager program display on the bottom of the screen of your PC?
NO
“NOT CONNECTED”
There is no serial connection.
Is the micro status light blinking 1 second on & 1 second off?
YES
NO
Did you have a communication failure during a download?
Go to Condition 1 --
Unit does not operate.
YES
Verify the integrity of the download cable and connections.
Did you find and correct the condition?
NO
NO
When viewing down loaded data, does all the data appear on
Jan 01, 1970?
YES
YES
When viewing the download in Reports, a specific sensor or event does not show up in the data file. The
Reports data filter settings may be set incorrectly or specific sensors and events may not be recorded.
DataRecorder is not configured properly.
Use the Reports Data
Filter pull down menu to set sensors & events to be viewed OR use
Service Manager or
ReeferManager to correctly set up recording parameters. Operate the system in order to verify the repair.
DataRecorder date & time have never been set.
Set date & time. Operate the system in order to verify the repair.
YES
YES
System
OK
YES
NO
Intermittent communication problem. Ensure AC cord is properly connected or PC battery is fully charged. Did you find and correct the condition?
NO
Verify the integrity of the download cable and connections. Did you find and correct the c ondition?
Use PC
Download Card to download data.
NO
Verify PC power saving features are OFF. (I.E. screen saver, monitor time out, hard disc time out, auto power down/sleep mode).
Did you find and correct the condition?
NO
System
OK
YES
Use the configuration jumper to verify that download port wiring is correct and doesn’t have an open, high resistance or a short. See Section XXX. Did you find and correct the condition?
NO
YES
Verify the correct com port is selected in the PC software. See
Help>Contents>PC Setup for additional information. Did you find and correct the condition?
YES
NO
Verify com port availability (I.E. infrared devices turned off, PDA applications turned off, computer has 9 pin serial port. DO NOT connect
USB port. Did you find and correct the condition?
NO
Use PC
Download Card to download data.
Figure 10--10. Micro Diagnostic Tree -- Cond. 6 -- Data Recorder Data Download Problems When Using
ReeferManager and a Download Cable. Data File Analysis Problems Using Reports
10--19
62-10683
START HERE
Make sure the Start/Run-Off switch is ON or the micro is in PC Mode. (See Section 6.1.)
Usint either a PC card or computer with a download cable hooked into the serial port/download plug, load current version of the software into micro. Insert PC card into the PC card slot on the micro.
What does the MessageCenter display say about the PC Card?
“UNKNOWN CARD”
“CARD LOCKED --
REMOVE CARD”
“CARD FULL --
REMOVE CARD”
MessageCenter has addition PC Card error messages.
Doesn’t acknowledge that a PC Card has been inserted..
PC Card may be defective. Try a different card. Did you find and correct condition?
NO
If you have tried 2 or more PC cards on one particular micro, take those same suspect
PC cards and try them on another micro.
If the cards function properly on the second micro, it proves the first micro is not reading the
PC cards properly.
Is the micro at fault?
The card “Write Protect” switch is ON. Unlock PC
Card by sliding “Write
Protect” switch to the
“OFF” position & re-insert the card. Operate the system in order to verify the repair.
YES
(MPR Code #4)
NO
Download card has no more empty memory space. Use
ReeferManager to extract downloaded data & then erase card. Operate the system in order to verify the repair.
System
OK
YES
Replace micro and operate system in order to verify repair. Did you find and correct the condition?
YES
See Section 7.1 for a list of MessageCenter error messages. Find your specific error message and follow the directions in the description column.
Repair as needed.
Operate the system in order to verify the repair.
PC Card is not seated properly. Remove card from slot, wait 10 seconds & re-insert card. Did you find and correct the condition?
YES
PC card slot may be defective. Turn power off and verify status light is not blinking. Check for bent pins in the card slot & straighten as needed. Did you find and correct the condition?
NO
NO
Micro is not the fault.
NO
Micro is not the fault. Remove new micro & re-install old micro.
YES
(MPR Code #4)
Are pins unable to be straightened or pins broken?
Review the test results with your supervisor. If necessary, go to the beginning of the table and test again.
NO
62-10683
Figure 10--11. Microprocessor Diagnostic Tree -- PC Card Problems
10--20
YES
START HERE
Are you trying to load any version of software that is older than 04.00.00?
YES
Does the MessageCenter say
“OLD SOFTWARE: CANNOT LOAD”?
NO
NO
Insert the PC Card into the PC Card slot on the front of the micro. Be certain that the instructions label on the download card is facing the “Caution” label on the micro. Do not force the card into the slot. Handle the card from the edges. Did you find and correct the condition?
NO
YES
Once 04.00 is installed into the micro, it is no longer possible to load any version of 03 or previous software. Newer versions can be loaded as released. If loading 04.00 or 04.02
and the micro has 03.xx or previoius software, incrementally upgrade the software. See
Bulletin SER04-47 for instructions.
Does the MessageCenter acknowledge a program card was nstalled by displaying
“OLD SOFTWARE,” “NEW SOFTWARE” or “SAME SOFTWARE”?
YES
System OK
NO
Verify you are using a Progra PC card and not another PC card. Did you find and correct the condition?
NO
Once the unit shuts down to begin the software installation process, the 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. Did you find and correct the condition?
YES
YES
Can the card be read by the
ReeferManager program?
NO
System OK
YES
NO
Micro display will show
“ENGINE AND MICRO WILL
STOP NOW” and engine will stop. Did you find and correct the condition?
NO
YES
Place card back into the micro and try again. Did this solve the problem?
YES
System OK
NO
Possible defective
PC card. Retry operation with another card.
YES
The display will show “ INSTALLING PROGRAM SOFTWARE.”
Make sure you wait until the display shows “INSTALLL COMPLETE” before removing card. Did you find and correct the condition?
Using the ReeferManager
Program, install Program card into computer and re-install the correct .bex file.
YES
NO
Does MessageCenter display “CARD DATA CORRUPT -- CANNOT LOAD”?
Software has finished loading.
YES
NO
Is the card status LED on solid?
NO
Is the card status LED flashing 1/2 second on and 1/2 second off?
NO
Micro does ot recognize the card. Try another program card, or use MicroProgrammer.
YES
Has the card status
LED been illuminated for more than 5 minutes?
NO
Wait at least 5 minutes.
YES
There is a problem loading the software. Turn unit
Start/Run-Off switch off. Remove the Program card and try again.
Figure 10--12. Micro Diagnostic Tree -- Cond. 8 -- Programming Problems With PC Cards
10--21
62-10683
START HERE
Are you trying to load any version of software that is older than 04.00.00?
NO
YES
Does the MessageCenter say
“OLD SOFTWARE: CANNOT
LOAD”?
NO
YES
Once 04.00 is installed into the micro, it s no longer possible to load any version of 03 or previous software. Newer versions can be loaded as released. If
loading 04.00 or 04.02 and the micro has 03.xx or previoius software, incrementally upgrade the software.
See Bulletin SER04-47 for instructions.
Only MicroProgrammer version 3.14 is to be used to properly install 04.00.00 and later software. Earlier versions of MicroProgrammer should be discarded.
MicroProgrammer only runs on Windows 95/98. It will not run on Windows 2000 or XP. Are you using version 3.14 on a Windows 95/98 machine?
YES
Did you find and correct the condition?
NO
NO
NO
Obtain MicroProgrammer 3.14 and Windows
95/98 for software installation.
Did you find and correct the condition?
YES
When downloading with a cable, make sure cable connections are secure and tight. Turn off all screen savers and power saver options on the laptop. These options can interfere with software download. Did you find and correct the condition?
NO
YES
System OK
YES
Make sure you are not using USB or 9-pin adapters on the computer. Did you find and correct the condition?
NO
Did the MicroProgrammer program launch properly on your computer?
NO
System OK
YES
Try again using a good cable.
NO
Check the integrity of the download cable. Is the cable OK?
When you loaded the problem file, does it say “FILE VALID” on the bottom of the screen?
YES
The PROGRAM MICRO button is not active. Click on the button. Is the software loading?
NO
YES
Did you get a
“Communication Error” message?
NO
NO
Verify you are loading a correct . BEX file for the
Advance micro. Are you loading the correct file?
YES
Problem is with computer. Try loading software with another computer.
YES
Is the Percent
Complete increasing?
YES
NO
YES
NO
YES
Load the correct file and try again.
Close MicroProgrammer and start over again OR use Program PC card.
Did you achieve
100% download?
YES
YES
Problem is with computer. Try loading software with another computer.
YES
NO
Check download port on unit. (Plug in jumper and see if you can put micro into configuration mode.)
Will micro go into configuration mode?
NO
Repair faulty wiring or damaged download port. Did you find and correct the condition?
YES
NO
YES
Make sure you wait at least 5 minutes for software to load. If you waited the 5 minutes, turn the unit off for 30 seconds. Exit out of the MicroProgrammer. Turn unit back on.
YES
Restart MicroProgrammer and try again.
If you are at this table for a second time, program micro using Program PC card.
YES
Figure 10--13. Micro Diagnostic Tree -- Cond. 9 -- Programming Problems With MicroProgrammer
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10--22
10.5 Compressor Troubleshooting Guide
The purpose of the following procedure is to provide a logical and systematic method of determining whether 06D compressor repair or replacement is required.
A. Checkout Procedure For Determining If Compressor Repair Or Replacement Is Required
Certain operating conditions or refrigeration system components may be misdiagnosed and subsequently lead to the determination that the compressor is bad. These conditions or components must be checked prior to replacing a compressor and must be checked after a replacement compressor is installed to prevent replacement compressor damage.
1. Check refrigerant level per Section 9.11.4.
2. Ensure that the compressor crankshaft is turning and that the compressor drive gears are in good condition.
3. Install gauges on the suction and discharge service valves. A separate gauge should be connected to the unit liquid line king valve in order to determine pressures in other steps.
4. Check unloaders as follows: a. With the unit operating in high speed cool, check the status of the front and rear cylinder unloaders. The microprocessor energizes the unloaders independently, based on suction pressure. If one or both unloaders are energized, unplug or disconnect the power source separately for the front and rear unloaders.
b. Using a separate 12V power source energize and de--energize each unloader separately. Note the suction pressure change as each unloader is energized or de--energized. Both unloaders should show a rise in suction pressure rise of 3 to 6 PSIG (0.2 to 0.4 bar) when energized and a drop of 3 to 6 PSIG when de--energized. If little or no change is noticed for either unloader, the cylinder head(s) must be removed for further inspection. See Section B. for inspection procedure.
5. Perform unit pumpdown per Section NO TAG: a. Shut the unit off and observe the suction, discharge, and receiver pressure. Receiver pressure should drop very slowly, and suction and discharge pressure will slowly equalize to within a nominal saturated pressure range. Refer to the refrigerant pressure temperature chart in Table 9-9 for pressures corresponding to approximate ambient temperatures. Remember, the engine compartment temperatures are generally higher than actual ambient air temperatures. A fast reading digital thermometer such as 07--00269 is helpful in determining ambient temperatures.
NOTE
The amount of time required to pump the unit down to 0 PSIG is not by itself an indicator that the compressor is bad. A longer than normal pumpdown time necessitates additional checks to determine the cause.
b. If the suction, discharge, and receiver pressures do not rapidly equalize SV4, discharge and bypass check valves are in good condition. Further compressor evaluation can only be done by following the compressor inspection procedure (Section B.) c. If the suction, discharge, and receiver pressures equalize above saturated pressure, SV4, discharge and bypass check valves must be checked before determining whether further compressor inspection is required
6. To determine the cause of suction, discharge, and receiver pressure equalization, start the unit with the king valve closed and slowly close the suction service valve until suction pressure reaches 0 psig/bar. Turn the unit off and open the hand valves between the suction and discharge gauges.
a. If the pressures equalize to above saturated pressure, the discharge check valve is not holding and must be repaired. Once the discharge check valve is repaired the compressor must be inspected further. (Section B.) a. If the pressures do not equalize, the SV4 or bypass check valve must be repaired. Any repair of these valves also requires further inspection of the compressor. (Section B.)
7. if all refrigeration system components check out, it will be necessary to follow the compressor inspection procedure. (Section B.)
10--23
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B. Compressor Inspection Procedure
NOTE
Only conduct this procedure after running Pretrip.
The system must be OFF during the following procedure.
1. Refrigerant Recovery a. Close (frontseat) the suction and discharge service valves.
b. Reclaim the refrigerant by using an approved refrigerant recovery machine, and reduce the compressor pressure to 0 PSIG. (Refer to Section NO TAG.)
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.
CAUTION
Service mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating. Refer to Section 6.2.3.
When compressor disassembly is required for compressor inspection, disconnect electrical wires in order to isolate power from compressor.
2. Compressor Inspection a. Start with the front cylinder head of the compressor.
b. Remove the cylinder head of the compressor and observe the following cautions.
CAUTION
Leave two cylinder head bolts loose with threads engaged in the crankcase until cylinder head is completely loosened to prevent any residual crankcase pressure.
c. Remove the valve plate.
NOTE
Do not pry the valve plate in order to remove it from the crankcase. If necessary, remove 2 bolts from the discharge valve stop. Remove the valve stop. Using one of the discharge valve stop bolts as a jacking screw, lift the valve plate from the dowel pins, pushing the head off the crankcase.
d. Inspect the parts of the cylinder head and/or the valve plate.
1) Inspect cylinder head gaskets for proper alignment and center web blow--out.
2) Inspect the discharge valves for loose or damaged valve stops, or any debris that may affect the proper operation of the valves.
3) Inspect for broken, cracked, or chipped discharge reeds.
4) If applicable, inspect the discharge check valve to ensure the piston moves and contacts the plate.
5) Inspect for broken, cracked, or chipped suction valves.
6) Inspect the valve plate and the cylinder head for cracks.
7) Inspect valve plate gaskets for damage and wear.
e. Remove oil in the cylinders on top of the pistons to avoid unnecessary clean up. Inspect the top of the piston for damage. Check for debris, burned and carbonized oil sludge, or mechanical failure.
f. Inspect cylinder bores for excessive wear. Excessive wear for cylinder bores is defined as heavy and uneven scratches, gouges, or chipping of the internal wall of the cylinder, with a depth greater than 0.025 inch, which are caused by foreign objects, other than a normal reciprocating movement of the pistons and piston rings.
62-10683
10--24
g. Check compressor rotation.
1) Unplug the fuel solenoid.
2) Rotate the compressor by hand if possible or by using the engine starter to “bump” the compressor.
NOTE
Bumping the compressor means to momentarily energize the starter motor without ignition of the engine.
3) All pistons should move freely and smoothly up and down without any inconsistent resistance or seizure.
h. Repeat Steps 2.b. thru 2.g. for the center head and the rear head.
3. Decision to repair or replace a. The compressor should be REPAIRED if no defects are found, or if the only defects found are in Steps 2.d.1), 4),
5) or 6).
b. The compressor should be REPLACED if it failed the examination of 2.f., 2.g., 2. h., or has broken discharge valves.
4. Replacement of the compressor.
a. Refer to Section 9.12 for compressor replacement procedures.
b. Drain and measure the compressor oil, and put it in a plastic bottle. Follow Carrier Transicold instructions for returning the oil with the compressor.
5. Repair of the compressor.
a. Replace gaskets in addition to all replacement parts.
b. The torque required to reassemble the screws of the valve stop on the valve plate is 12 ft lbs (16. 3 Nm) c. Replace a new valve plate or a cylinder head only when it is defective. The torque required for the bolts of the cylinder head is 35 to 55 ft lbs (40 to 48 Nm) d.The failed compressor may have pumped oil into the system. Do not charge more oil until you install the new compressor and run the unit to determine if oil level is correct.
6. A reminder when shipping for warranty credit a.When shipping the failed compressor for warranty credit, include the completed field failure diagnostic report and the bottled oil sample for the purpose of further analysis.
7. Electrical testing of the compressor.
a.Check current draw of the motor winding with a current meter while the motor is running. Each of the 3 legs should draw an equal amount of current within 10%. The rated load current at 460VAC is 17.5 amps for a high efficiency
41CFM compressor.
b.Check the resistance of each winding while compressor is off and power is isolated and disconnected from any source. The resistance will be approximately 1ohm and should be equal across all legs.
c.Check the resistance to ground from each leg while compressor power is isolated and disconnected from any source. There should be low resistance to ground, open with standard ohmmeter. Because oil and refrigerant fluids are conductors, the use of a megohmeter may show variations in resistance to ground through the case of the compressor using higher test voltages.
10--25
62-10683
Next (center or rear) cylinder heads.
NO
Follow repair procedures.
Repair
START HERE
Gone through the system diagnostics.
No system or other component defect discovered.
The system is OFF.
Recover refrigerant.
Start the compressor inspection with front cylinder head.
Remove the cylinder head.
Inspect the parts of the head and the valve plate.
Inspect pistons.
Inspect the cylinder bores.
Check the compressor rotation.
Done for all heads?
YES
Replace or repair the compressor?
Replace
Follow replacement procedures.
END
62-10683
Figure 10--14 Compressor Diagnostics
10--26
C. Procedure After Compressor Repair Or Replacement
1. Run Pretrip to ensure all refrigeration components function properly.
2. In addition, to ensure the repair of the original compressor or the reliability of the replacement compressor, check the following: a. Verify proper air switch setting using 07--00177 magnehelic gauge or equal.
b. Verify that air switch will initiate defrost by momentarily jumping the air switch contacts.
c. Check all switches and sensors for proper operation.
3. See Section 9.13 for compressor oil level check procedure
4. Perform refrigerant and compressor oil moisture/acid tests per instructions with test kits; change oil or reclaim refrigerant as required. Refer to 98--50037 for system cleanup procedures.
5. If a compressor failure, such as broken valves, had the possibility of releasing large particles into the system, the discharge strainer located in the inlet of the discharge check valve should also be removed and inspected.
10--27
62-10683
SECTION 11
WIRING
PARAGRAPH NUMBER
PLUGS USED WITH SCHEMATIC 62--10499 REV V (STANDARD ENGINE) . . . . . . . . . . . . . . . .
PLUGS USED WITH SCHEMATIC 62--04102 REV -- (ESC ENGINE) . . . . . . . . . . . . . . . . . . . . . .
PLUGS USED WITH SCHEMATIC 62--10300 REV A (ESC ENGINE)
HC PLUG FOR ALL UNITS
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADVANCE MICRO DISPLAY HARNESS CONNECTIONS
VOLTAGE TESTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
11--1
11--2
11--2
10--3
10--4
10--4
1
SECTION 11
WIRING
Plugs used with Schematic 62--10499 Rev V (Standard Engine)
1 MP -- Natural
2 MP -- Black 3 MP -- Grey
1 24 1 24
1 24
12 35 12
Component
REMSN1
REMSN2
CDP
CSP
ENCT
CDT
DTT2
AAT
Terminal
3 (14)
4 (14)
5 (16) (30)
6 (17) (30)
7 (18)
9 (20)
10 (21)
11 (22)
RAT 12 (23)
REMSN1 (SP23) 14 (3)
REMSN2 (SP23) 14 (4)
REMSN3
CDP
CSP
ENCT
CDT
DTT2 (SP11)
AAT
SAT (SP12)
RAT (SP12)
FLS
CDP (SPK4)
CSP (SPK4)
15 (33)
16 (5) (30)
17 (6) (30)
18 (7)
20 (9)
21 (10)
22 (11)
23 (35)
23 (12)
26
30 (5) (16)
30 (6) (17)
Component
REMS1
DAS
ENRPM
CSMV--D
REMS2
ENCLS
DS
ENOPS
ENRPM
CSMV--C
CSMV --A
HC9
ENOLS
HPS
ENRPM
CSMV--B
35
12
Terminal
3
6
7 (18) (31)
8 (19) (20) (32)
Component
SATCOM (C)
SLP (C)
13
15
16
17
18 (7) (31)
19 (8) (20) (32)
20 (8) (19) (32)
25
28
29
31 (7) (18)
32 (8) (19) (20)
ORL
CL
SV2
UL1 (Front)
SLP (E)
SATCOM (B)
SLP (A)
FHR (HC--17)
FL
DL
UL2 (Rear)
SATCOM (A)
SLP (B)
HL
SV4
SV1
35
3
Terminal
5
8
9
11
12
13
15
17
18
19
20
23
27
29
33
34
35
11--1
62-10683
Plugs used with Schematic 62--04102 Rev -- and 62--10300 Rev A (ESC
Engine)
1 MP -- Natural 2 MP -- Black 3 MP -- Grey
1 24 1 24
1 24
12 35 12
Component
REMSN1
REMSN2
CDP
CSP
ENCT
CDT
DTT2
Terminal
3 (14)
4 (14)
5 (16) (30)
6 (17) (30)
7 (18)
9 (20)
10 (21)
AAT 11 (22)
RAT 12 (23)
REMSN1 (SP23) 14 (3)
REMSN2 (SP23) 14 (4)
REMSN3 15 (33)
CDP
CSP
ENCT
CDT
DTT2 (SP11)
16 (5) (30)
17 (6) (30)
18 (7)
20 (9)
21 (10)
AAT
SAT (SP12)
RAT (SP12)
FLS
CDP (SPK4)
CSP (SPK4)
REMSN3
EV1
SAT
22 (11)
23 (35)
23 (12)
26
30 (5) (16)
30 (6) (17)
33 (15)
34
35 (23)
Component
REMS1
DAS
CSMV--D
REMS2
ENCLS
DS
ENOPS
ENSCU
CSMV--C
CSMV --A
HC9
ENOLS
HPS
CSMV--B
35
12
Terminal
3
6
8 (19) (20) (32)
Component
SATCOM (C)
SLP (C)
13
15
16
17
18
19 (8) (20) (32)
20 (8) (19) (32)
ORL
CL
SV2
UL1 (Front)
SLP (E)
SATCOM (B)
25
28
SLP (A)
FHR (HC--17)
29 FL
32 (8) (19) (20) DL
UL2 (Rear)
SATCOM (A)
SLP (B)
HL
SV4
SV1
35
23
27
29
33
34
35
17
18
19
20
3
5
8
9
11
12
13
Terminal
15
62-10683
11--2
HC Plug For All Units
17
16
18
19
7
6
5
1
8
2
4
3
15
14
9
10
11
13
12
Component
+12vdc Input from SPK3 to Fuel Heater Relay Coil
+12vdc Output from (MPQC3) to ENSCU--16
+12vdc Output from transformer to starter motor (SM)
+12vdc Input unswitched Power from Battery (BTY+)
To Main Power In (MPQCI)
+12vdc Output from (MPQC4) to SPK20
+12vdc Output unswitched to – SPK2 SPK3
+12vdc Output from J1 jumper to – SPK5 SPK7
+12vdc Output from Clutch Relay to Clutch (CLH)
+12vdc Output to Starter Solenoid (SS)
+12vcd Output to 2MP25
+12vdc from SROS to J1 jumper
*
+12vdc Output to Glow Plugs (GP)
--12vdc Input Ground from Battery (GRD)
+12vdc Output to Fuel Heater Circuit (FHTS)
--12vdc Output to Fuel Heater Relay Coil (FHR)
Unused Teminals: 10, 12, 13, 18 & 19
NOTE: Terminal 11 used only with units with J--1 Jumper
Terminal
1
2
2C
3
4
5
6
7
8
9
11
*
14
15
16
17
11--3
62-10683
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
62-10683
11--4
A
Advance Microprocessor Troubleshooting
Guide, 10--13
Air Filter Service Procedure , 9--16
Air Switch, 9--44
Alternator Operation , 2--11
Alternator/Regulator, 2--11
Ambient Air Temperature Sensor, 2--14
Auto Fresh Air Exchange (AFAX), 3--38
Automatic Defrost, 3--15
Index
Compressor Unloader, 2--12, 9--31
Condenser Coil, 9--45
Condenser/Subcooler, 2--10
Config. and Tech. Test Modes, 6--2
Configuration Mode, 6--3
Continuous Run Mode, 4--5
Continuous Run Operation, 3--11
Cool Mode Operation, 5--2
B
Belt Tension Gauge, 9--17
Blower Wheel And Fanshaft Removal, 9--21
Blower Wheel Installation, 9--23
CSMV Control, 5--4
CSMV Diagnostics, 9--41
C
Calibrating Compressor Suction Pressure
Transducer, 9--37
Cargo Protect Mode, 5--5
Changing IntelliSets, 3--36
Changing Setpoint, 3--8
Charging Amps, 3--10
Checking for a Defective Glow Plug, 9--17
Checking High Pressure Switch , 9--33
Checking Superheat , 9--25
Clutch Installation, 9--24
Clutch Removal, 9--21
Component Test Mode, 6--12
Compressor, 2--12
Compressor Data, 2--26
Compressor Discharge Pressure Transducer,
2--14, 2--26, 9--35
Compressor Discharge Temperature Transducer, 2--14
Compressor Oil Level, 9--30
Compressor Suction Modulation Valve , 2--14
Compressor Suction Modulation Valve
(CSMV), 9--41
Compressor Suction Pressure Transducer,
2--14, 2--26, 9--37
Compressor Transducers, 2--14
Compressor Troubleshooting Guide, 10--23
D
Data Ohms And Amps, 2--28
Data Recording, 3--33
Defrost, 5--8
Defrost Air Switch, 9--43, 9--44
Defrost Cycle, 9--43
Defrost Initiation, 5--8
Defrost Temperature Sensor, 2--15
Defrost Termination Thermistor , 2--26
Defrost Timer, 2--26
Display, 2--19
Display Bezel Assembly, 6--27
Display Bezel Assembly Installation, 6--27
Door Latch Maintenance, 9--10
Door Switches & Remote Switches, 2--23,
2--24
Download Port, 6--1
Downloading Data With The PC Card, 6--16
Drive Gear, 9--47
Index --1
62--10683
E
Electronic Modules, 2--22
Electronic Speed Control, 9--16
Emergency CSMV repair procedures, 9--43
Engine, 2--10
Engine Air Filter, 9--16
Engine Air Filter Inspection, 9--16
Engine Air System, 2--26
Engine Coolant Level Sensor, 2--10
Engine Coolant Temperature, 3--10
Engine Coolant Temperature Sensor, 2--10
Engine Cooling System, 9--12
Engine Crankcase Breather, 9--17
Engine Cranking, 4--1
Engine Data, 2--25
Engine Oil, 2--25, 9--14
Engine Oil Level Switch, 2--10
Engine Oil Pressure Switch, 2--10
Engine RPM Sensor , 2--10
Engine Screw Thread, 2--26
Engine Sensors, 2--10
Engine Speed Control Unit, 2--10
Engine Speed Operation , 5--8
Engine To Gearbox V-Belt, 9--20
Engine Transducers, 2--10
Evaporator Coil, 2--14, 9--44
Evaporator Sensors, 2--15
Evaporator Transducers, 2--15
Events , 3--33
Expansion Valve, 9--24
Index
Fusible Plug, 2--26
High Ambient Defrost Termination Sequence,
5--10, 5--11
I
G
Gearbox Oil, 2--26
Gearbox To Fan Shaft V--Belt, 9--19
Glow Plugs, 9--17
Grille Insert Removal, 9--8
H
Heat Exchanger, 2--14
Heat Mode Operation , 5--2
Heat/Cool/Null Switching Operation, 5--3
Heating Cycle, 9--43
High Ambient Defrost Operation, 5--10
High Pressure Cutout Switch, 9--33
High Pressure Switch, 2--26, 9--33
F
Failed To Start -- Auto Mode, 4--5
Fanshaft, 9--21
Fanshaft Installation, 9--22
Fanshaft Oil, 2--26
Filter Drier, 2--13
Filter--Drier, 9--33
FreshProtect, 5--5
Fuel and Speed Actuator, 2--10
Fuel Level Sensor, 9--13
Functional Change (Parameters), 3--25
Indicator LEDs, 2--19, 3--33
Installing New Software, 6--17
Integral Voltage Regulator Operation (12
VDC) , 2--11
IntelliSet, 3--35
K
Key Descriptions, 2--20
62--10683
Index --2
L
Language Selection, 3--31
LIGHT BAR, 2--22, 9--43
Light Bar Operation and Test, 9--43
Lube Oil And Flow Diagrams, 9--14
Lube Oil Filter, 9--14
Lube Oil Flow Diagram, 9--15
Lubrication System, 2--25
Index
P
PC Mode, 6--1
PC Support Software, 6--14
Perishable Set Point Ranges, 5--1
Pretrip, 3--4
Pretrip Inspection, 9--4
Priming Fuel System, 9--11
ProductShield, 5--14
Pulldown / Pull--up Mode, 5--2
Pulsed Null Mode Operation, 5--4
M
Maintenance Schedule, 9--1
Manual Defrost, 3--15
Manual Start -- Glow & Crank, 3--2
Max Operating Pressureoverride, 5--19
Measuring Superheat , 9--25
MessageCenter, 2--20
MessageCenter , 7--1
Microprocessor Replacement, 6--22
Microprocessor Sensor Checkout, 9--45
N
Normal Defrost Operation, 5--9
Normal Defrost Termination, 5--9
Normal Defrost Termination Sequence, 5--9
Null Mode Operation, 5--4
O
Oil Filter, 9--14
Index --3
R
Re--Setting PM Hourmeters, 6--20
Receiver, 2--13
Receiver Fuse Plug Setting, 2--26
Receiver Sight Glass, 9--38
ReeferManager, 6--14
Refrigerant Circuit -- Cooling, 2--29
Refrigerant Circuit -- Heating & Defrosting,
2--30
Refrigeration System Data , 2--26
Remote Switches, 2--23
Remove Jumper Mode, 6--2
REPLACING CHECK VALVE , 9--32
Replacing Compressor Discharge Pressure
Transducer, 9--36
Replacing Compressor Suction Pressure
Transducer , 9--37
Replacing Display Bezel Assembly, 6--27
Replacing Expansion Valve & Screen , 9--24
Replacing SV1 Internal Components, 9--40
Replacing SV2/SV4 internal parts , 9--38
Replacing the Compressor, 9--28
Replacing The CSMV Power Head, 9--42
Replacing the SV1 Coil , 9--39
Replacing the SV2/SV4 Coil , 9--38
Replacing Unloader Valve Internal Parts,
9--31
Restart Voltage, 3--10
Return Air Temperature Sensor, 2--15
RPM Sensor, 9--13
Running Modes, 4--3
62--10683
S
Safety Decals, 1--5
Safety Devices, 2--27
Safety Precautions, 1--1
Sensor Checkout, 9--45
Serial Number Cut--Offs, 9--15, 9--16
Service Mode, 6--13
Servicing Check Valve, 9--32
Servicing Fuel Pump, 9--12
Servicing Glow Plugs, 9--17
Servicing Solenoid Valves , 9--38
Servicing the Speed Control Solenoid and
Linkage, 9--15
Sleep Mode On, 3--12, 3--13
Solenoid Valve SV1 Checkout, 9--39
Sortware Version Numbers, 6--17
Speed Control Overrides, 4--6
Speed Control Solenoid And Linkage, 9--15
Start--Run/Off Switch, 2--20
Start--Stop Indicator, 4--4
Start--Stop Mode, 4--3
Start--Stop Mode Cycle Off Conditions, 4--3
Start--Stop Mode Cycle On Conditions, 4--4
Start--Stop Operation, 3--9
Starting Unit -- Auto, 3--1
Stopping Unit, 3--32
Suction MOP (Cool Only), 5--19
Suction Pressure Operation , 5--20
Supply Air Temperature Sensor , 2--15
Surround Removal, 9--9
SV1 , 9--39
SV1 Operation (Defrost Only), 5--11
SV2 Operation (Heating and Defrost), 5--11
SV2/SV4, 9--38
Switch Descriptions, 2--20
Index
T
Temperature Range Lock 1 & 2, 5--12
Testing Compressor Suction Pressure Transducer, 9--37
Testing The Defrost Air Switch, 9--43
Thermal Expansion Valve, 2--14
Thermostatic Expansion Valve, 9--24
Trip Start, 3--16
Troubleshooting, 8--1
Troubleshooting Software Loading, 6--19
Two--Way Remote Communication, 3--37
U
UltraFreeze Offset, 5--4
UltraFreeze Start/Stop, 5--4
UltraFresh 3 Temperature Control , 5--3, 5--4
Unidrive torque Requirements, 9--47
Unit Data, 3--20
Unit Startup -- Engine/Road and Electric
Standby, 3--3
Unloader, 9--31
Unloader Checkout Procedure, 9--31
Unloader Control Operation, 5--11
Unloader Control Overrides, 5--18
Using ReeferManager to Install Software,
6--19
Using The DataShare Program PC Card,
6--18
V
V--Belts, 9--17
Variable Glow Time, 4--1
View Active Alarms, 3--17
View Hourmeters, 3--24
View Inactive Alarms, 3--18
W
Water Pump V--Belt, 9--18
62--10683
Index --4
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
©2009 Carrier Corporation D Printed in U. S. A. 1009
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
- Advance Microprocessor
- Multiple Languages
- IntelliSet
- DataTrakt
- Two-Way Remote Communication
- AutoFresh Air Exchange
- Temperature Control
- Defrost
- Engine Speed Operation
- PreTrip
