advertisement
R
Truck Refrigeration
EVAPORATOR
CONDENSER
TXV
TXV BULB
RECEIVER
OPERATION & SERVICE for
INTEGRA 30S
Truck Refrigeration Units
Beginning With S/N PB 225225
62--10848 Rev B
OPERATION AND
SERVICE MANUAL
INTEGRA 30S
TRUCK REFRIGERATION UNIT
BEGINNING WITH S/N PB 225225
TABLE OF CONTENTS
PARAGRAPH NUMBER
GENERAL SAFETY NOTICES
FIRST AID
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Page
Safety-1
Safety-1
OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety-1
Safety-1
SPECIFIC WARNING AND CAUTION STATEMENTS
DESCRIPTION
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Safety-2
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1-1
1.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
CONDENSING SECTION
1.3.1 Condenser/Subcooler
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.2 Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.3 Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-3
1-3
1-3
1-1
1-1
1-1
1-1
1.3.4 Hot Gas Solenoid Valve (HGS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.5 Condenser Pressure Control Valve (HGS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.6 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.7 Standby Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.8 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.9 High Pressure Switch (HP1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.10 Condenser Pressure Control Switch (HP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4
EVAPORATOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.2 Compressor Pressure Regulating Valve (CPR) (115V Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.3 Defrost Termination Thermostat (DTT)
1.4.4 Quench Valve (BPV)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.5 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.6 Low Pressure Switch (LP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 SYSTEM OPERATING CONTROLS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6
UNIT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
1-4
1-4
1-4
1-3
1-3
1-3
1-4
1-8
1-9
1-9
1-9
1-4
1-4
1-4
1-4
1.6.1 Compressor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2 Refrigeration System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.3 Electrical Data
1.6.4 Torque Values
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.7
SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8
REFRIGERANT Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.1 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.2 Heat And Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10
1-10
1-11
1-12
1-12
1-12 i
62--10848
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
CONTROL SYSTEM
2.1.1 Introduction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.8.3 Microprocessor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.2 Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
START--UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.2 Connect Power
2.2.3 Starting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.3
SETPOINT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4
MANUAL DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5
DEFROST CYCLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6
ALARM DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.1 Accessing Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2 Low Battery Voltage Alarm for Road Only Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.3 Clearing Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7
CHECKING THE EEPROM VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8
STOPPING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9
MICROPROCESSOR CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.1 ROAD ONLY FUNCTIONAL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.2 ROAD/STANDBY FUNCTIONAL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Perishable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Frozen Mode
3.2
DEFROST CYCLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3
MINIMUM OFF TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2
BELT MAINTENANCE AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Standby Motor--Compressor V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
INSTALLING R-134A MANIFOLD GUAGE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Preparing Manifold Gauge/Hose Set For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 Connecting Manifold Gauge/Hose Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.3 Removing the Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4
REMOVING THE REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Refrigerant Removal From A Non--Working Compressor.
4.5
REFRIGERANT LEAK CHECKING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6
EVACUATION AND DEHYDRATION
4.6.1 General
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.3 Procedure For Evacuation And Dehydrating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-2
3-2
4-1
4-1
2-6
2-7
3-1
3-1
3-1
2-4
2-4
2-5
2-5
2-5
2-5
2-6
Page
2-1
2-1
2-1
2-1
2-1
2-2
2-2
2-3
2-3
2-3
2-3
2-3
4-2
4-3
4-3
4-3
4-3
4-2
4-2
4-2
4-2
4-4
4-4
4-4
4-4
62--10848 ii
TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER
SERVICE (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7
CHARGING THE REFRIGERATION SYSTEM
4.7.1 Checking The Refrigerant Charge
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2 Installing A Complete Charge
4.7.3 Adding A Partial Charge
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8
CHECKING FOR NON--CONDENSABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9
REPLACING THE COMPRESSOR
4.9.1 Removing Compressor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.2 Installing Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 CHECKING AND REPLACING FILTER-DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.1 Checking Filter-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.2 Replacing The Filter-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.11 HIGH PRESSURE (HP1) AND CONDENSER PRESSURE (HP2) SWITCHES
4.11.1 Removing Switch
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.11.2 Checking Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12 CHECKING AND REPLACING CONDENSER FAN MOTOR BRUSHES . . . . . . . . . . . . . . . . . . . . .
4.13 HOT GAS (HGS1) AND CONDENSER PRESSURE CONTROL SOLENOID VALVES . . . . . . . . .
4.13.1 Replacing Solenoid Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13.2 Replacing Valve Internal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE (CPR) (115V ONLY) . . . .
4.15 THERMOSTATIC EXPANSION VALVE
4.15.1 Replacing expansion valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.15.2 Measuring Superheat
4.16 DIAGNOSTIC TOOL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.17 MICROPROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.18 EVAPORATOR COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.19 CONDENSER COIL CLEANING
TROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
INTRODUCTION
5.2
REFRIGERATION
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5.2.1 Unit Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Unit Operates Long or Continuously in Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4 Unit Will Not Heat or Heating Insufficient
5.2.5 Defrost Malfunction
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6 Abnormal Pressure
5.2.7 Abnormal Noise
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5.2.8 Cab Command Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.9 No Evaporator Air Flow or Restricted Air Flow
5.2.10 Expansion Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.11 Malfunction Hot Gas Solenoid or Condenser Pressure Regulating Valve
5.2.12 Standby Compressor Malfunction
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC DIAGRAMS
6.1
INTRODUCTION
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4-7
4-7
4-7
4-7
4-8
4-8
4-8
4-6
4-6
4-6
4-6
4-6
4-6
4-6
Page
2-1
4-5
4-5
4-5
4-5
4-5
4-6
4-6
4-9
5-1
5-1
5-2
5-2
4-8
4-9
4-9
4-9
5-4
5-4
5-4
5-4
6-1
6-1
5-2
5-3
5-3
5-3
5-3
5-4
5-4 iii
62--10848
LIST OF ILLUSTRATIONS
FIGURE NUMBER
Figure 1-1 Integra 30S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-2 Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-3 Rear View Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-4 Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-5 Typical Standby Control Box
Figure 1-6 Standby Microprocessor Module
Figure 1-7 Road Microprocessor Module
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-8 Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-9 Refrigeration Circuit Cooling Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-10 Refrigeration Circuit Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-1 Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-2 Green Light Status -- Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-3 Green Light Status -- Road Only
Figure 2-4 Temperature Selection Jumper
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-1 Operating Sequence -- Perishable Mode
Figure 3-2 Operating Sequence -- Frozen Mode
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-1 Belt Tension Gauge
Figure 4-2 Layout of V-belt
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-3 Manifold Gauge Set (R-134a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-4 Vacuum Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-5 Typical Setup For Testing Pressure Switches HP1 And HP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-6 Fan Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-7 Hot Gas or Condenser Pressure Control Solenoid
Figure 4-8 Compressor Pressure Regulating Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-9 Thermostatic Expansion Valve Bulb And Thermocouple
Figure 4-10 Cab Command Diagnostic Tool
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-1 Electrical Schematic Wiring Diagram - Based On Dwg. No. 62-61350 Rev D
Figure 6-2 Electrical Schematic Wiring Diagram - Based On Dwg. No. 62-61350 Rev D
Figure 6-3 Electrical Schematic Wiring Diagram - Based On Dwg. No. 62-61353 Rev A
Figure 6-4 Electrical Schematic Wiring Diagram - Based On Dwg. No. 62-61354 Rev A
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. . . . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . .
Figure 6-5 Electrical Schematic Wiring Diagram - Based On Dwg. No. 62-61354 Rev A
Figure 6-6 Electrical Schematic Wiring Diagram - Based On Dwg. No. 62-61352 Rev A
. . . . . . . . . . . . . .
. . . . . . . . . . . . . .
6-2
6-3
6-5
6-6
4-7
4-7
4-7
4-8
4-8
4-9
6-7
6-9
4-2
4-2
4-3
4-4
2-2
2-7
3-1
3-1
Page
1-2
1-2
1-3
1-3
1-5
1-6
1-7
1-8
1-13
1-14
2-1
2-2
LIST OF TABLES
TABLE NUMBER
Table 1-1 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 1-2 Additional Support Manuals
Table 2-1 Alarms For Road Only Units
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-2 Alarms For Standby Units
Table 4-1 Maintenance Schedules
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-2 Service Category Descriptions
Table 4-3.
Belt Tension (See Figure 4-2)
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-4 R-134a Temperature-Pressure Chart
Table 5-1 Alarm Indications
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Table 5-2 Mechanical Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
1-1
1-1
2-4
2-5
4-1
4-1
4-2
4-10
5-1
5-2
62--10848 iv
SAFETY SUMMARY
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. Stay clear of all moving parts when the unit is in operation and when the ON/OFF switch is in the ON position.
FIRST AID
No injury, no matter how slight, should go unattended. Always obtain first aid or medical attention immediately.
OPERATING PRECAUTIONS
Always wear safety glasses. Wear hearing protection as required.
Keep hands, clothing and tools clear of the evaporator and condenser fans.
No work should be performed on the unit until all circuit breakers are turned off, and battery power supply is disconnected.
Always work in pairs. Never work on the equipment alone.
In case of severe vibration or unusual noise, stop the unit and investigate.
MAINTENANCE PRECAUTIONS
Beware of unannounced starting of the unit. This unit is equipped with Auto--Start in both the road and standby modes.
The unit may start at any time. When performing any check of the system make certain all circuit breakers are turned off, and battery power supply is disconnected.
Be sure power is turned off before working on motors, controllers, solenoid valves and electrical control switches. Tag circuit breaker and vehicle ignition to prevent accidental energizing of circuit.
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.
When performing any arc welding on the unit or container, disconnect all wire harness connectors from the microprocessor. Do not remove wire harness from the modules unless you are grounded to the unit frame with a static safe wrist strap.
In case of electrical fire, open circuit switch and extinguish with CO
2
(never use water).
REFRIGERANTS
The refrigerant contained in 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 you contact your nearest Carrier Transicold authorized repair facility whenever your unit requires refrigeration system service .
Safety--1 62--10848
SPECIFIC WARNING AND CAUTION STATEMENTS
To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation is given with the appropriate consequences:
DANGER -- means an immediate hazard which WILL result in severe personal injury or death.
WARNING -- means to warn against hazards or unsafe conditions which COULD result in severe personal injury or death.
CAUTION -- means to warn against potential hazard or unsafe practice which could result in minor personal injury, product or property damage.
The statements listed below are applicable to the refrigeration unit and appear elsewhere in this manual. These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein.
WARNING
Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. Press OFF key on the cab command and disconnect power plug.
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
Do not attempt to connect or remove power plug before ensuring the unit is OFF (press OFF key on
Cab Command) and external power circuit breaker is open.
WARNING
Beware of V-belt and belt-driven components as the unit may start automatically.
WARNING
Ensure power to the unit is OFF, power plug is disconnected and circuit breaker is open or vehicle engine is OFF and negative battery cable is connected before replacing compressor.
WARNING
Slowly open the plug on the suction and discharge valves of the new compressor to vent the nitrogen holding charge.
WARNING
Do not use a nitrogen cylinder without a pressure regulator. (See Figure 4-5) Cylinder pressure is approximately 2350 psig (160 bars). Do not use oxygen in or near a refrigerant system as an explosion may occur.
62--10848
Safety--2
CAUTION
Under no circumstances should anyone attempt to repair the microprocessor module or Cab Command! Should a problem develop with these components, contact your nearest Carrier Transicold dealer for replacement.
CAUTION
If starting unit for the first time after installation or starting after adding/removing an optional feature or if Owners operating parameters have changed, the Configuration will need to be reset.
CAUTION
Compressor failure will occur if inert gas brazing procedures are not used on units with
R134A and POE oil. For more information see Technical Procedure 98-50553-00 -- Inert Gas
Brazing.
CAUTION
To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before disconnecting.
CAUTION
Do not damage or over tighten the enclosing tube assembly. Place all parts in the enclosing tube in proper sequence in order to avoid premature coil burn-out.
CAUTION
Observe proper polarity when installing battery, negative battery terminal must be grounded.
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 microprocessor.
Use proper board handling techniques. (See Section 4.17).
Safety--3 62--10848
1.1 INTRODUCTION
SECTION 1
DESCRIPTION
1.3 CONDENSING SECTION
WARNING
Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. Press OFF key on the
Cab Command and disconnect power plug.
This manual contains Operating Data, Electrical Data and Service Instructions for the Carrier Transicold
Model 30S truck refrigeration units listed in Table 1-1.
Additional support manuals are listed in Table 1-2.
The model/serial nameplate is located on the cover.
The condensing section (see Figure 1-2) contains the condenser fan & coil, filter--drier, oil separator, hot gas solenoid valve, receiver, and a condenser pressure control valve. On road/standby units the condensing section also houses the standby compressor, control box and rectifier and houses the transformer assembly
(see Figure 1-2 and Figure 1-5 ).
1.3.1 Condenser/Subcooler
The condenser is of the tube and fin type and acts as a heat exchanger in which the compressed refrigerant gas is condensed into a liquid and lowered in temperature. Air movement over the condenser is provided by a fan mounted in the condensing section.
1.2 GENERAL DESCRIPTION
The unit (Figure 1-1) is of the split system type with the condenser mounted outside the truck body, evaporator mounted in the body, and a Cab Command control center mounted in the driver’s compartment. Two types of compressor drive are available:
D
Road operation: the road compressor is located in the engine compartment and is driven by the engine of the vehicle when in operation over--the--road
D
Road/Standby version: a second compressor is mounted in the condensing section and is driven by an electric motor when in standby mode.
A portion of the condenser is occupied by the subcooler.
Refrigerant leaving the receiver is passed through the subcooler where additional heat is removed. Removal of this additional heat helps to ensure that only liquid refrigerant enters the thermal expansion valve.
1.3.2 Filter Drier
The drier is a cylindrical 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.
Table 1-1 Model Chart
Model No.
Description
R134a
LB Kg
Road
Compressor
Standby
Compressor
Condenser Weight
Road
Road and
Standby
Evap. Wt.
8002189
8002191
8002193
8002195
Road Only
Road/Standby
115/1/60Hz
Road/Standby
230/1/60Hz
Road/Standby
230/3/60Hz
4 1.8
TM 16
--
TM 16
88 lb
(40 kg)
165 lb (75 kg
66 lb (30
Kg)
Table 1-2. Additional Support Manuals
Manual Number
62--10835
62--10847
62--10849
Equipment Covered
Supra 30S
Supra 30S
Supra 30S
Type of Manual
Parts List
Easy To Run
Operator’s Manual
1--1
62-10848
1
2
3
CAB COMMAND
Figure 1-1 Integra 30S
4
5
6
7
17
16
15
14
13
1. Nameplate
2. Condenser Coil
3. Transformer (TR)
4. Oil Separator
5. Standby Motor
6. Standby Compressor (See Table 1-1)
7. Control Box
8. Filter Drier
9. Liquid Line Check Valve
12
Figure 1-2 Top View
11
10
9
10. Sight Glass
11. Receiver
12. Discharge Manifold
13. Hot Gas Solenoid Valve (HGS1)
14. Condenser Pressure Control Switch (HP2)
15. Frame
16. High Pressure Switch (HP1)
17. Condenser Pressure Control Valve (HGS2)
8
62-10848 1--2
1
6
2
3
4
5
1. Low Pressure Switch (LP)
2. Expansion Valve (TXV)
3. Quench Valve (BPV)
4. Defrost Termination Thermostat (DTT)
5. Evaporator coil
6. Compressor Pressure Regulating Valve
(CPR)115V only
Figure 1-3 Rear View Evaporator
1.3.3 Oil Separator 1.3.5 Condenser Pressure Control Valve (HGS2)
The oil separator is installed in the discharge line from the road compressor. The hot gas coming from the compressor is forced through a filter which separates the gas from the oil. The oil collects at the bottom after passing through a second filter and then returns to the compressor via a capillary tube.
OIL AND GAS
FROM COMP.
REFRIGERANT
GAS TO
COND.
The condenser pressure control valve (or condenser closing valve) is a normally open valve that is powered when the condenser pressure control switch (HP2) is closed. With the solenoid coil de-energized, the valve is in the cool mode and the compressor discharge gas is delivered to the condenser. In the cool mode, heat is removed from the air inside the truck body and rejected to the surrounding air. With the solenoid coil energized, the valve is in the heat mode and the compressor discharge gas is diverted to the evaporator and rejected to the air inside the truck body.
1.3.6 Compressor
The compressor withdraws 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.
OIL
Figure 1-4 Oil Separator
1.3.4 Hot Gas Solenoid Valve (HGS1)
OIL TO
COMP.
SUCTION
LINE
HGS1 is normally closed and prevents discharge gas from entering the evaporator. The valve opens to allow hot gas refrigerant to be delivered from the compressor to the evaporator during heat or defrost modes.
1.3.7 Standby Motor
The standby motor operates on nominal
115v--1ph--60hz or 208/230v--1ph--60hz or
230v--3ph--60hz power. An overload and short cycle protection is provided along with automatic reset. Units are also equipped with a remote mounted power receptacle.
1.3.8 Receiver
Liquid refrigerant from the condenser is deliver to 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.
1--3
62-10848
1.3.9 High Pressure Switch (HP1)
HP1 is a normally closed switch which monitors the system for high pressure and shuts down the unit when pressure rises above predetermined setting. For HP1 settings see Section 1.6.2.
1.3.10 Condenser Pressure Control Switch (HP2)
HP2 is a normally open switch which closes to signal the microprocessor to activate the condenser fan. HP2 also cycles the condenser pressure control valve (HGS2) and the quench valve (BPV) in addition to the condenser fan in order to maintain head pressure for heating capacity. For HP2 settings see Section 1.6.2.
1.4 EVAPORATOR SECTION
The evaporator assembly consists of an evaporator fan, evaporator coil, thermostatic expansion valve, defrost termination thermostat, a compressor pressure regulating valve (115V only) and a quench valve.
1.4.1 Thermostatic Expansion Valve
The thermostatic 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 preventing liquid from returning to the compressor. For TXV superheat settings see
Section 1.6.2. To adjust the TXV, refer to Section 4.15.2.
1.4.2 Compressor Pressure Regulating Valve
(CPR) (115V Only) (See Figure 1-3)
The CPR valve is installed on the suction line of the standby compressor to regulate the suction pressure entering the compressor. The CPR valve is set to limit the maximum suction pressure. For CPR settings refer to section 1.6.2.
The suction pressure is controlled to avoid overloading the electric motor during high refrigerated compartment temperature operation. To adjust the CPR valve, refer to section 4.17
1.4.3 Defrost Termination Thermostat (DTT)
Normally closed thermal switch on Standby units only.
As evaporator cools to set point, the switch closes and signals microprocessor that defrost may be initiated.
Switch terminates defrost by opening at predetermined set point. For DTT settings refer to section 1.6.2.
1.4.4 Quench Valve (BPV)
The quench valve is a normally closed solenoid valve controlled by the quench thermostat (BPT) mounted on the road compressor discharge line. The valve allows metered liquid refrigerant to enter the suction line in the evaporator in order to provide compressor cooling. For
BPT settings refer to section 1.6.2.
1.4.5 Evaporator
The evaporator is of the 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. Air movement over the evaporator is provided by an electric fan.
1.4.6 Low Pressure Switch (LP)
The low pressure switch is a normally closed switch which signals the microprocessor to shut down the unit when the system is outside the low pressure limit. For
LP settings refer to section 1.6.2.
62-10848 1--4
1
2
3
4
5
6
7
8
9
10
11
14
13
115/1/60
12
115/1/60
12
230/1/60
13
230/1/60
1. Standby clutch fuse (F2) -- 30 Amp
2. Standby Fuse (F3) -- 5 Amp
3. Transformer Fuse (F4) -- 5 Amp
4. Clutch Time Delay Relay (CT) -- Single Phase
Only
5. Clutch Relay (CR)
6. Motor Contactor (MC)
7. Overload Relay (OL) (230V Only)
8. Diode
9. Rectifier Bridge Assembly (BR)
10. Filter Capacitor (C1)
11. Start Relay (STBR)
12. Run Capacitor (CR)
13. Start Capacitor (CS)
14. Heat sink (rectifier bridge)
Figure 1-5 Typical Standby Control Box
1--5
62-10848
1
2
9
3
8
7
6
5
1.
Connector
2.
Road Relay (RR)
3.
12 Volt dc Road Connection
4.
12 Volt dc Standby Connection
5.
Standby Relay (SR)
6.
7.
8.
9.
C_ or F_ Temperature Selector
Microprocessor (PC)
Road Fuse (F1) 30A
Overload Relay (OL) 25A (115V Only)
Figure 1-6 Standby Microprocessor Module
4
62-10848 1--6
1
2
3
1.
C_ or F_ Temperature Selector
2.
Road fuse (25A)
3.
+ Positive Battery Connection
4.
-- Negative Battery Connection
5.
--Microprocessor (PC)
Figure 1-7 Road Microprocessor Module
5
4
1--7
62-10848
1.5 SYSTEM OPERATING CONTROLS AND
COMPONENTS
The unit is furnished with a microprocessor control system. Once the set point is entered at the Cab Command, the unit will operate automatically to maintain the desired temperature within very close limits.
WARNING
Beware of unannounced starting of the, standby motor, evaporator fan or condenser fan. The unit may cycle the standby motor or fans unexpectedly as control requirements dictate.
The control system consists of the Cab Command located in the driver’s section (See Figure 1-8) and the microprocessor module (See Figure 1-6) located in the control box.
The Carrier Transicold Control System incorporates the following features: a. Control return air temperature to tight limits by providing refrigeration control, heat and defrost to ensure conditioned air delivery to the load.
b. Permanently displays the return air temperature and on request the set point temperature.
c. Digital display and selection of data.
CAUTION
Under no circumstances should anyone attempt to repair the microprocessor module or Cab Command! Should a problem develop with these components, contact your nearest Carrier Transicold dealer for replacement.
Figure 1-8 Cab Command
62-10848 1--8
1.6 UNIT SPECIFICATIONS
1.6.1 Compressor Data
Model
Displacement
No. Cylinders
Weight
TM 16
(
9.9 in
162 cm
3
3
)
6
15.5 lbs
(7 kg)
Oil Charge
Approved Oil
5.07in
3
(180 cm
3
)
Mobil Arctic EAL68
1.6.2 Refrigeration System Data a. Defrost Timer
Automatic triggering or at preset intervals :
0 (Disabled), auto, 1h, 2h, 3h, 4h, 5h, 6h
b. Defrost Termination Thermostat (DTT) (Standby
Only)
Opens at: 48_ ¦ 5_F (9_ ¦ 3_C)
Closes at: 37_ ¦ 5_F (3_ ¦ 3_C)
c. High Pressure Switch (HP1)
Opens at : 355 psig ± 10 PSI (24.5 bars)
Closes at : 290 psig ± 10 PSI (20 bars)
d. Condenser Pressure Control Switch (HP2)
Opens at : 130 psig ± 10 PSI (9 bars)
Closes at : 175 psig ± 10 PSI (12 bars)
e. Refrigerant charge
Refer to Table 1-1.
f. Compressor Pressure Regulating Valve (CPR)
115V only
19±1 psig (1.3 Bar)
g. Thermostatic Expansion Valve (TXV)
Superheat setting = 4_C (7.2_F) at refrigerated compartment temperature of - 20_C (0_F).
h. Low Pressure switch (LP)
Opens at : --13.23 in HG ± 6 in HG
(-- 0.45 ± 0.2 bar)
Closes at : +6.5 psig ± 3 psig
(+0.44 ± 0.2 bar)
i. Quench Thermostat (BPT)
Opens at: 248_F (120_C)
Closes at: 220_F (104_C)
1--9
62-10848
1.6.3 Electrical Data a. Fan Motors
Evaporator Fan Motor (EFM)
Bearing Lubrication Factory Lubricated
Horse Power
Operating Amps
Speed
0.1 kw
10.8 amps
2800/3000 rpm
b. Standby Compressor Speed
1740 rpm -- 60 hz
c. Standby Motor Ratings
Operating Amps
Speed
Condenser Fan Motor (CFM)
Bearing Lubrication
Voltage Type of Connection Phase kW HP
115/1/60
208/1/60
230/1/60
230/3/60
∆
∆
∆
∆
1
3
1
1
1.5
2
* MRA = Maximum Rotor Amps
Resistance = 9.2Ω
d. Road Compressor Clutch
LRA = Locked Rotor Amps
Amp Draw = 3.75A
Resistance = 3.2Ω
e. Hot Gas Solenoid Valve (HGS1) Coil
Amp Draw = 1.33 Amp
Resistance = 9.2Ω
f. Condenser Pressure Control Valve (HGS2) Coil
Amp Draw = 1.65 Amp
Resistance = 7.3Ω
g. Quench Valve (BPV) Coil
Amp Draw = 1.16 Amp
Resistance = 10.3Ω
h. Standby Motor Contactor Coil
Amp Draw = 0.19 Amp
Resistance = 60Ω
1.6.4 Torque Values
Assembly
Standby compressor platform
Standby motor platform
Standby motor pulley
Evaporator fan motor
Evaporator fan
Condenser - frame
Mounting Bolts
ft-lb
40
40
32
13
7
7
kg-m
5.5
5.5
4.5
1.8
1.0
1.0
44 to 60 6 to 8
Factory Lubricated
10 amps
3300 rpm
Speed
1745 rpm
1690 rpm
1715 rpm
1700 rpm
Contactor Data
MRA*
18.3
9.2
8.5
5.9
LRA*
132.5
70
60
40
62-10848 1--10
1.7 SAFETY DEVICES
System components are protected from damage caused by unsafe operating conditions by automatically shutting down the unit when such conditions occur. This is accomplished by the following fuses and safety devices.
Unsafe Conditions Safety Device
Automatic restart with fault cleared
Device setting
1
2
Excessive drop in pressure Automatic reset of low pressure switch (LP)
Electronic relay
YES
Cutout : --13.23 in HG
(-- 0.45 bar)
Timer 5 min
Self-protected opening
3
Excessive current draw on all microprocessor outputs (evaporator and condenser fan)
Excessive current draw control circuit
Fuse on electronic board
YES
NO
Self-protected opening
4 Excessive current draw motor compressor
230 = Overload relay
115/1/60 = Circuit Breaker
YES/NO
NO
Depending on Selection
See electrical wiring diagram
Electronic relay
YES
Self-protected opening 5
6
7
Excessive current draw evaporator and condenser fan motors
Excessive compressor discharge pressure
Excessive current draw standby clutch
8
9
Excessive current draw unit in standby operation
Excessive current draw unit in road operation
10 Connection error on primary transformer
Automatic reset of High pressure switch (HP1)
Fuse F3
(a)
Standby fuse F2
Fuse F1
(b)
(a)
Fuse F4 and/or F5
(a)
YES
NO
NO
NO
NO
Cutout : 355 psig (24.5 bar )
Opens at 5 A (12 V)
Opens at 30 A (12 V)
Opens at 30 A (12 V)
Opens at 4 A
11 Excessive temperature on standby motor bearing
12 Clutch malfunction - road (excessive current draw)
13 Clutch malfunction - road (insufficient current draw)
14 Double power supply (road + standby)
15 Low battery voltage
16 Excessive current draw on ignition circuit (Neiman)
Internal Motor Thermostat
(PT0)
Electronic relay
Electronic relay
Microprocessor
Microprocessor
Fuse FI
YES
YES
YES
YES
YES
NO
Self-protected opening
Self-protected opening
Opens 311_ F (155° C)
Detection of min. threshold at 750 mA
Display on Cab Command until one of the 2 power supplies have been disconnected.
Cutout/cut-in at 10 V
Opens at 1 A
(a) On road/standby unit only (b) This fuse is located close to the vehicle battery (12 v).
1--11
62-10848
1.8 REFRIGERANT Circuit
1.8.1 Cooling (See Figure 1-9)
When cooling, the unit operates as a vapor compression refrigeration system. The main components of the system are the reciprocating compressor, air-cooled condenser, thermostatic expansion valve and the direct expansion evaporator.
The compressor raises the pressure and temperature of the refrigerant and forces it through the discharge check valve and condenser pressure control valve into the condenser tubes. The discharge check valves prevent reverse flow through the non operating compressor.
When operating on the road compressor, the flow also passes through the oil separator where oil is removed and returned to the road compressor.
The condenser fan circulates surrounding air over the outside of the condenser tubes. Heat transfer is thus established from the refrigerant gas (inside the tubes) to the condenser air (flowing over the tubes). The condenser tubes have fins designed to improve the transfer of heat. This removal of heat causes the refrigerant to liquefy. Liquid refrigerant flows from the condenser to the receiver.
The receiver stores the additional charge necessary for low ambient operation and for heating and defrost modes.
The refrigerant leaves the receiver and flows through a manual receiver shut-off valve (king valve).
The refrigerant then flows through a check valve. The check valve serves to prevent reverse flow of refrigerant during the heating/defrost cycle.
The refrigerant then flows through the filter-drier, where an absorbent keeps it dry and clean. The refrigerant then flows though a sight glass. The sight glass is fitted with an indicator that changes color to indicate moisture content of the refrigerant. The refrigerant then flows through the subcooler which removes additional heat from the liquid to improve system efficiency.
The liquid than enters the thermostatic expansion valve
(with external pressure equalizer) which regulates the flow rate of refrigerant towards the evaporator in order to obtain maximum use of the evaporator heat transfer surface.
The evaporator tubes have aluminium fins to increase heat transfer; therefore heat is removed from the air circulated through the evaporator. This cold air is circulated throughout the truck to maintain the cargo at the desired temperature.
The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize. The vapor at low temperature and is then drawn out by the compressor. From this point, the cycle starts over.
On 115v units the refrigerant then enters the compressor regulating valve (CPR) which regulates refrigerant pressure entering the compressor. The cycle then starts over.
The quench valve opens as required to maintain a maximum discharge temperature. (Refer to section
1.6.2 for settings.)
1.8.2 Heat And Defrost (See Figure 1-10)
When refrigerant vapor is compressed to a high pressure and temperature in a 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 or defrost cycle.
When the microprocessor activates heating or defrost, the hot gas solenoid valve energizes and the condenser pressure control valve energizes, closing the port to the condenser and opening a port which allows heated refrigerant vapor to flow directly to the evaporator coil .
The main difference between heating and defrosting is that when in heating mode the evaporator fans continue to run thus circulating the air throughout the truck to heat the product. When in defrost, the evaporator fans stop, thus allowing the heated vapor to defrost any ice build-up on the coil.
When the pressure is above the setting of the condenser pressure control switch, the condenser pressure control valve (HGS2) is closed to prevent additional pressure rise in the system. When pressure is below the setting of the condenser pressure control switch, the valve is opened to pressurize the receiver and force additional refrigerant into the system and increase heating capacity.
62-10848 1--12
QUENCH VALVE (BPV)
TXV EQUALIZER LINE
SUBCOOLER
SUCTION
CHARG-
ING
PORT
LP
TXV
FILTER DRIER/SIGHTGLASS
EVAP.
DEFROST
ELEMENT
OIL SEPARATOR
CHECK
VALVE
KING VALVE
RECEIVER
HOT GAS SOLENOID
VALVE (HGS1)
CONDENSER
CPR
115V
ONLY
DISCHARGE
CHECK VALVE
MANIFOLD
ASSEMBLY
HP1
COND.
PRESS.
CONTROL
VALVE
(HGS2)
HP2
DISCHARGE
CHARGING
PORT
QUENCH
THERMOSTAT
(BPT)
STAND BY
COMPRESSOR
ROAD
COMPRESSOR
DISCHARGE
LIQUID
LIQUID INJECTION LINE
HOT GAS LINE
SUCTION LINE
Figure 1-9 Refrigeration Circuit Cooling Cycle
1--13
62-10848
QUENCH VALVE
(BPV)
TXV EQUALIZER LINE
SUBCOOLER
SUCTION
CHARG-
ING
PORT
LP
EVAP.
DEFROST
ELEMENT
OIL SEPARATOR
TXV
FILTER DRIER/SIGHTGLASS
CHECK
VALVE
KING VALVE
RECEIVER
HOT GAS SOLENOID
VALVE (HGS1)
CONDENSER
CPR
115V
ONLY
DISCHARGE
CHECK VALVE
MANIFOLD
ASSEMBLY
HP1
COND.
PRESS.
CONTROL
VALVE
(HGS2)
HP2
DISCHARGE
CHARGING
PORT
QUENCH
THERMOSTAT
(BPT)
STAND BY
COMPRESSOR
ROAD
COMPRESSOR
62-10848
DISCHARGE
LIQUID
LIQUID INJECTION LINE
HOT GAS LINE
SUCTION LINE
Figure 1-10 Refrigeration Circuit Heating Cycle
1--14
SECTION 2
OPERATION
viewed on the display.
2.1 CONTROL SYSTEM
2.1.1 Introduction
CAUTION
Under no circumstances should anyone attempt to service the microprocessor module and Cab Command. Should a problem develop with the control system, contact your nearest Carrier Transicold dealer for replacement components.
The Control System consists of the microprocessor module (Figure 1-6), Cab Command (Figure 2-1) and interconnecting wiring.
a. The Microprocessor Module includes the temperature control software and necessary input/output circuitry to interface with the unit controls.
b. The Cab Command is remotely mounted in the truck.
The Cab Command includes the LCD display and keypad. The keypad and display serve to provide user access and readouts of microprocessor information. The information is accessed by keypad selections and viewed on the display.
1.8.3 Microprocessor Module
The microprocessor controls the following functions: a. Maintains the refrigerated compartment temperature at set point by regulating the cooling, heat, off mode and automatic defrost cycles.
b. Permanently displays the return air temperature and on request the set point temperature.
c. Digital display and selection of data.
For further details on digital message display, see section 2.6.
2.1.2 Cab Command
The Cab Command is mounted in the cab and allows the driver to carry out the control operations:
Figure 2-1 Cab Command a.
Display
The digital display consists of 3 alphanumeric characters. The default value displayed is the refrigerated compartment temperature.
The microprocessor enables selection of the display in degrees Celsius or Fahrenheit. The display also includes settings for defrost operation (dF). The display also includes three LEDs:
Digital Display
Standby operation LED
Road operation LED
Unit operating LED
D
Green : cycling (left-hand side)
D
Red : malfunction (right-hand side)
• start up and shut-down the unit
• automatic start-up in road or standby mode
• adjust the set point
• defrost
The driver can display the refrigerated compartment temperature, and see whether the set point is being maintained by checking the green indicator. The indicator lights up red in the event of a malfunction.
When the battery voltage is too low, a fail-safe system shuts down the unit. Unit restart is automatic and time-delayed if the voltage rises to the normal level.
The command consists of the display and the keypad.
The keypad and display serve to provide user access and readouts of microprocessor information. The information is accessed by keypad selections and
2--1 62-10848
Unit operating LEDs a. Green Light Status for Standby Units
Under normal operation, the green LED will indicate the temperature control status as follows:
Setpoint + 9°F
(5_C)
Green LED flashing 3 Hz
NULL
BAND
Green LED flashing 0.5 Hz
Steady green LED
Setpoint + differential of
1.8°F (1°C),
3.6°F (2°C) or
5.4°F (3_C)
SETPOINT
Steady green LED
Green LED flashing 0.5 Hz
Setpoint -differential of
1.8°F (1°C),
3.6°F (2°C) or
5.4°F (3_C)
Setpoint -- 9°F
(5_C)
Green LED flashing 3 Hz
Figure 2-2 Green Light Status -- Standby a. Green Light Status for Road Only Units
Under normal operation, the green LED will indicate the temperature control status as follows:
b. Red Light Status
After an alarm has been present for 15 minutes, the red unit indicating light flashes at 3 Hz. The light will continue to flash at 0.5 Hz until the temperature returns to set point ± differential. At that point the steady green indicator light will light and the alarm become inactive.
c. Keypad
The keypad consists of six keys that enable the operator to activate various functions, display operating data and modify operating parameters.
Manual defrost control key
Unit start-up key
Unit shut-down key in standby or road mode
On road operation, the unit can also be shut down with the ignition key.
Unit data and function modification keys
The SET key, together with the + and -keys, enables display and modification of unit operating data.
The display scrolls through parameters each time the SET key is pressed.
Decrease key for selected data
Steady green
LED
COOLING
Increase key for selected data
NULL
BAND
Green LED is
OFF
SETPOINT
Green LED flashing 1 Hz
HEATING
Figure 2-3 Green Light Status -- Road Only
62-10848 2--2
2.2 START--UP
2.2.1 Inspection
Before starting the truck engine or connecting standby power check the following a. Check condenser coil for cleanliness b. Check condition of refrigerant hoses c. Check condition and tension of compressor belt(s) d. Check condition of condenser fan blade, motor and brushes e. Check truck battery fluid level f. Check truck battery and terminal connections -- clean and tighten as necessary
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.
g. Check defrost water drains from evaporator h. Check evaporator coil for cleanliness i. Check condition of evaporator fan blades, motor and brushes j. Check oil level in standby compressor sight glass
2.2.2 Connect Power
If the unit is to be operated in the standby mode, connect power as follows:
WARNING
Do not attempt to connect or remove power plug before ensuring the unit is OFF (press
OFF key on Cab Command) and external power circuit breaker is open.
CAUTION
If starting unit for the first time after installation the compressor pressure regulating valve will need to be reset (refer to paragraph 4.14)
CAUTION
If starting unit for the first time after installation or starting after adding/removing an optional feature or if Owners operating parameters have changed the Configuration will need to be reset (refer to paragraph 2.9)
Depending on desired mode of operation, either start the vehicle engine or close the power source circuit breaker.
Press the ON key to start the unit
(For Standby units, start up is time delayed for 10 seconds.
For Road units, start up is time delayed for 40 seconds.)
The digital display of the Cab
Command displays the refrigerated compartment temperature.
Check that temperature set point is correct by pressing the SET key. The set point temperature is highlighted on the digital display.
2.3 SET POINT ADJUSTMENT
It is possible to increase or decrease the set point by whole numbers until the required set point is displayed.
If display stays highlighted, the set point displayed has not been validated.
The new setting for the set point is validated by pressing the SET key.
Displays the set point temperature
Decrease the set point
WARNING
Make sure the power plug is clean and dry before connecting to any power source
a. Check that the external power source corresponds to the characteristics of the unit (see paragraph 1.6.3
step c.). Make sure external power source circuit breaker is open.
b. Make sure unit is OFF by pressing the OFF button on the Cab Command.
c. Plug the power cord into unit receptacle.
2.2.3 Starting
2--3
Increase the set point
Validate set point temperature
Return to display of refrigerated compartment temperature.
2.4 MANUAL DEFROST
Check that refrigerated compartment temperature is
40°F (4.4°C) or lower.
Press manual defrost key to initiate manual defrost.
62-10848
2.5 DEFROST CYCLE ADJUSTMENT
Defrost parameters may be set to eliminate defrost, decrease the time between defrosts, allow full automatic defrost, increase the time between defrosts or set a forced interval between defrosts. To adjust the defrost cycle, do the following:
+
Shut-down unit.
Display parameters.
2.6 ALARM DISPLAY
In the event of a malfunction the unit will shut down and the Cab Command will display an error message or alarm message. The message will remain displayed until the malfunction is corrected. If standby power is connected and the malfunction is such that standby operation can be allowed, the unit will start in the standby mode. A listing of the error messages and alarm codes is provided in Table 2-1.
2.6.1 Accessing Alarm Messages
To access the alarm messages:
OR
Modify parameters.
Press SET for 5 seconds : enables access to alarm messages.
Validate modified settings
Return to display of refrigerated compartment temperature.
OR
In the event of more than one alarm, press the + or -- keys to list them.
NOTE
If no key is pressed within 5 seconds of adjusting settings the system reverts to displaying the refrigerated compartment temperature. Only validated changes are recorded.
Table 2-1 Alarms For Road Only Units
Malfunction
Codes
Description
ALARM
ONLY
A00
Red LED flashes
No malfunction.
Unit in operation.
A01
A02
A04
A06
A07
A09
A10
A11
High or Low pressure switch
High or Low pressure switch
Road clutch malfunction
Condenser fan motor fault
Evaporator fan motor fault
Hot gas solenoid valve malfunction (HGS1)
Quench valve malfunction (BPV)
X
X
X
X
X
X
A15
Condenser pressure control valve (HGS2)
Setpoint adjusted out of the range --20.2 to
86°F (-- 29°C/+ 30°C) or below the programmed low threshold
X
BAT
X
EE
Err
Low battery voltage
Probe malfunction or evaporator temperature out of limits [-- 49° to 174°F (-- 45° to 79°C)]
Programming error on part of operator
X
ALARM AND UNIT SHUT
DOWN
X
X
X
62-10848 2--4
A02
A03
A04
A05
A06
A07
A08
A09
A10
A11
A12
A13
A14
Malfunction
Codes
A00
A01
A15
Red LED flashes
No malfunction.
Unit in operation.
Table 2-2 Alarms For Standby Units
Description
ALARM
ONLY
Low pressure switch
High pressure switch
Electric motor overload protection on start-up
Road clutch malfunction
Standby clutch and contactor
Condenser fan motor fault
Evaporator fan motor fault
Heating option command
Hot gas valve malfunction (HGS1)
Quench valve malfunction (BPV)
Condenser pressure control valve (HGS2)
High temperature alarm
Low temperature alarm
Defrost alarm > 45 minutes
Setpoint adjusted out of the range -- 20.2 to
86°F (-- 29°C/+ 30°C) or below the programmed minimum set point
Low battery voltage
Probe malfunction or evaporator temperature out of limits [-- 49° to 174°F (-- 45° to 79°C)]
Programming error on part of operator
BAT
EE
Err
2.6.2 Low Battery Voltage Alarm for Road Only
Units
There is a 40 second time delay during start--up. After this delay if the battery voltage drops below 10V ±0.2V
for Standby units or 10.5V ±0.5V for Road only units, the microprocessor will react 20 seconds later and the unit will go out of temperature control mode. The microprocessor will check the voltage after another 20 seconds. If battery voltage still has not risen, the unit will remain out of temperature control mode for another 10 minutes, and the battery alarm will be activated and the
Cab Command will display the message “bAt”. Unit will return to temperature control mode if battery voltage has risen after 10 minutes. If the battery voltage has not risen after this 10 minute period the unit will remain out of temperature control mode another 2 minutes and the microprocessor will check the battery voltage every 2 minutes. Unit will return to temperature control mode in its current configuration when battery voltage rises to
10V ±0.2V for Standby units or 10.5V ±0.5V for Road only units.
2.6.3 Clearing Alarm Messages
The alarm list provides information on current alarms and past alarms which may be helpful in trouble shooting unit problems. Once all the alarm information
X
X
X
X
X
X
X
X
X
X
X
X
X
X
ALARM AND UNIT SHUT
DOWN
X -- AFTER 3 SUCCESSIVE
FAULTS
X -- AFTER 5 SUCCESSIVE
FAULTS
X -- AFTER 3 SUCCESSIVE
FAULTS
has been noted and service is complete, the alarm list may be cleared. To clear the alarm messages:
+ +
Press the ON,
the + and the -- keys at the same time.
2.7 CHECKING THE EEPROM VERSION
Start up unit
SEE SECTION 2.6.2
X
Press the SET key to display eeprom version number.
Press SET key to return to refrigerated compartment temperature.
2.8 STOPPING THE UNIT
Press the OFF key or turn the ignition key to off position.
2--5 62-10848
2.9 MICROPROCESSOR CONFIGURATION
CAUTION
If starting unit for the first time after installation or starting after adding/removing an optional feature or if Owners operating parameters have changed, the Configuration will need to be reset.
2.9.1 ROAD ONLY FUNCTIONAL SETTINGS
The procedure for adjusting the functional parameters is as follows:
1. The temperature display is selectable between Fahrenheit and Celsius. Units are configured for Celsius from the factory. To set the display to Fahrenheit, the selection jumper must be removed and discarded.
See Figure 1-6.
NOTE
The board contains another set of pins similar to the Degrees C/Degrees F selection jumper, marked as J1. This jumper is not used for unit operation, but it is used during the microprocessor controller manufacturing process. DO NOT
CONNECT THE J1 PINS TOGETHER.
2. The following steps must be performed with the unit
OFF:
THEN
OR
Shut-down unit.
Hold both keys momentarily in order to display parameters.
Modify parameters. (See a.
and b. below)
Validate modified settings.
NOTE
If no buttons are depressed within 5 seconds of pressing the Defrost and On Keys (Step 2 of the above procedure) or modifying parameters, the
Cab Command reverts to refrigerated compartment temperature display and the configuration procedure is aborted.
a. The defrost duration parameter is displayed. This setting determines the length of time in minutes the unit will remain in defrost once defrost is initiated. The defrost duration can be selected by scrolling through available options (10, 20, 25, 30 or 45 minutes) using the (+) or (--) keys. Selection MUST be validated by pressing the SET key.
b. The defrost interval parameter is displayed next. This setting determines the time between defrosts in hours. The defrost interval can be selected by scrolling through available options (0, 1, 1.5, 2, 2.5, 3, 4, 5,
6 hours) using the (+) or (--) keys. Selection MUST be validated by pressing the SET key.
3. The next steps must be performed with the unit ON:
THEN
OR
THEN
Unit start-up
Press the +, then -- then
DEFROST keys. All keys should be held momentarily after pressing in the correct sequence.
Modify parameters.
(See a., b. and c.
below)
NOTE
If no buttons are depressed within 5 seconds of pressing the ON key or modifying parameters, the Cab Command reverts to refrigerated compartment temperature display and the configuration procedure is aborted.
a. The minimum set point parameter is displayed. The minimum set point can be selected by scrolling through available options [-- 20°F (-- 28.9°C), -- 4°F
(-- 20°C), 32°F (0°C)] using the (+) or (--) keys. Factory setting is -- 20°F. Selection MUST be validated by pressing the SET key.
b. The null mode differential temperature is displayed next. This setting determines the temperature difference between refrigerated compartment temperature and set point that controls compressor cycling.
The differential can be selected by scrolling through available options [1.8°F (1°C), 3.6°F (2°C), or 5.4°F
(3°C)] using the (+) or (--) keys. Factory setting is
3.6°F (2°C). Selection MUST be validated by pressing the SET key.
c. The ON/OFF (Continuous airflow) parameter for the evaporator fan is displayed next. This feature determines whether the evaporator fan is on or off when the unit cycles off upon reaching set point. The factory setting is OFF. Change setting by using the (+) or (--) keys. Selection MUST be validated by pressing the
SET key.
d. The return air temperature will be displayed after the above sequence.
62-10848 2--6
2.9.2 ROAD/STANDBY FUNCTIONAL SETTINGS
The procedure for adjusting the functional parameters is as follows:
1. The temperature display is selectable between Fahrenheit and Celsius. Units are configured for Celsius from the factory. To set the display to Fahrenheit, move the Celsius end of the jumper to the Fahrenheit pin as shown in Figure 2-4.
C F
Figure 2-4 Temperature Selection Jumper
NOTE
The board contains another set of pins similar to the Degrees C/Degrees F selection jumper, marked as J1. This jumper is not used for unit operation, but it is used during the microprocessor controller manufacturing process. DO NOT
CONNECT THE J1 PINS TOGETHER.
2. The following steps must be performed with the unit
OFF:
THEN
OR
Shut-down unit.
Hold both keys momentarily in order to display parameters.
Modify parameters. (See a.
and b. below)
Validate modified settings.
NOTE
If no buttons are depressed within 5 seconds of pressing the Defrost and On Keys (Step 2 of the above procedure) or modifying parameters, the
Cab Command reverts to refrigerated compartment temperature display and the configuration procedure is aborted.
a. The defrost interval parameter is displayed. This setting determines the time between defrosts in hours.
The defrost interval can be selected by scrolling through available options. Settings are for either automatic defrost (AUT) or fixed time intervals between
1 to 6 hours. The setting can be selected by pressing the (+) or (--) keys. Selection MUST be validated by pressing the SET key.
The next steps must be performed with the unit ON:
2--7
THEN
OR
THEN
Unit start-up
Press the +, then -- then
DEFROST keys. All keys should be held momentarily after pressing in the correct sequence.
Modify parameters.
(See a., b., c. and d.
below)
NOTE
Keys must be pressed before the unit starts.
NOTE
If no buttons are depressed within 5 seconds of pressing the ON key or modifying parameters, the Cab Command reverts to refrigerated compartment temperature display and the configuration procedure is aborted.
a. The minimum set point parameter is displayed. The minimum set point can be selected by scrolling through available options [-- 20°F (-- 28.9°C), -- 4°F
(-- 20°C), 32°F (0°C)] using the (+) or (--) keys. Factory setting is -- 20°F. Selection MUST be validated by pressing the SET key.
b. The null mode differential temperature is displayed next. This setting determines the temperature difference between refrigerated compartment temperature and set point that controls compressor cycling.
The differential can be selected by scrolling through available options [1.8°F (1°C), 3.6°F (2°C), or 5.4°F
(3°C)] using the (+) or (--) keys. Factory setting is
3.6°F (2°C). Selection MUST be validated by pressing the SET key.
c. The ON/OFF (Continuous airflow) parameter for the evaporator fan is displayed next. This feature determines whether the evaporator fan is on or off when the unit cycles off upon reaching set point. The factory setting is OFF. Change setting by using the (+) or (--) keys. Selection MUST be validated by pressing the
SET key.
d. The 2ET or 3ET parameter is now displayed. This feature determines heating mode operation based on the presence of a condenser pressure control valve.
Since all 30S units covered by this manual have a condenser pressure control valve installed, 3ET must be selected. This enables cooling, null, and heating modes of operation. Selection MUST be validated by pressing the SET key. Change setting by using the (+) or (--) keys. Selection MUST be validated by pressing the SET key.
WARNING
Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. Press OFF key on the
Cab Command and disconnect power plug.
62-10848
SECTION 3
TEMPERATURE CONTROL
3.1 SEQUENCE OF OPERATION
General operation sequences for cooling, null, and heating are provided in the following paragraphs. The microprocessor automatically selects the mode necessary to maintain refrigerated compartment temperature at set point.
3.1.1 Perishable Mode
The unit operates in the perishable mode with set points above 10°F (--12°C) a. With return air temperature above set point and decreasing, the unit will be cooling with the compressor and evaporator fans operating. (See Section 1.8.1 for a description of the refrigeration circuit during cooling) The condenser fan will operate for the first three minutes after start up then operate under the control of the condenser pressure control switch (HP2). The green unit operating LED will operate in accordance with Figure 2-2 or Figure 2-3.
b. If discharge temperature increases to the set point of the quench thermostat (BPT), the thermostat will close, energizing the quench valve (BPV). This will allow liquid into the suction line in order to cool compressor. Once the discharge temperature decreases to the certainty of the PPT, the thermostat will open,
DE--energizing the PP.
c. Once temperature decreases to the certainty, the unit will enter the null mode. If the continuous air flow parameter is set to ON, the evaporator fans will continue to operate with all other components OFF. If the continuous air flow parameter is OFF, the evaporator fans and all other components will be OFF. A 5 minute delay is required before restart is allowed.
d. If temperature increases during the null mode, the unit will restart in cooling.
e. If temperature continues to decrease the unit will enter the heating mode with the compressor and evaporator fans operating and the hot gas solenoid valve
(HGS1) energized (open). The condenser fan and condenser pressure control valve (HGS2) will operate under the control of the condenser pressure switch (HP2). If the engine coolant or electric heat option is installed, the optional heaters will also be energized. (See Section 1.8.2 for a description of the refrigeration circuit during heat and defrost.)
COOL
UNIT STOPPED
HEAT
Figure 3-1 Operating Sequence -- Perishable
Mode
3.1.2 Frozen Mode
The unit operates in the frozen mode with set points at or below 10°F (--12°C). Operation in the frozen mode is the same as in the perishable mode except no heating takes place.
COOL
UNIT STOPPED
+ 1.8_F (+ 1_C) or + 3.6_F (+ 2_C ) or + 5.4_F (+ 3_C )
SETPOINT
-- 1.8_F (-- 1_C) or -- 3.6_F (-- 2_C) or -- 5.4_F (-- 3_C)
(setting)
+ 1.8_F (+ 1_C ) or + 3.6_F (+ 2_C ) or + 5.4_F (+ 3_C )
SETPOINT
-- 1.8_F (-- 1_C) or -- 3.6_F (-- 2_C) or -- 5.4_F (-- 3_C)
(setting)
Figure 3-2 Operating Sequence -- Frozen Mode
3--1 62-10848
3.2 DEFROST CYCLE
Defrost is an independent cycle overriding cooling and heating functions in order to melt frost and ice from the evaporator when necessary. Defrost may be initiated by the microprocessor or manually by the operator once the defrost termination thermostat has closed. (See
Section 1.6.2 for settings). In defrost mode, the microprocessor displays “dF” on the cab command and set point is no longer displayed.
During defrost, the evaporator fans shut down and operation of the condenser fan is controlled by the microprocessor. The end of the cycle is controlled by the opening of the defrost termination thermostat. (See
Section 1.8.2 for a description of the refrigeration circuit during heat and defrost.)
3.3 MINIMUM OFF TIME
Once the unit has cycled off, it will remain off for the minimum off time of 5 minutes. This prevents the unit from rapid cycling due to changes in air temperature. Air temperature in the refrigerated compartment changes rapidly but it takes time for the product temperature to change.
62-10848 3--2
SECTION 4
SERVICE
WARNING
Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. Press OFF key on the cab command and disconnect power plug.
CAUTION
Compressor failure will occur if inert gas brazing procedures are not used on units with
R134A and POE oil. For more information see 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.
4.1 MAINTENANCE SCHEDULE Table 4-2 Service Category Descriptions
Regular servicing is required in order to optimize the life and reliability of your unit. The recommended scheduled maintenance intervals and categories are provided in
Table 4-1 while descriptions of the service procedures to be carried out under each category are provided in
Table 4-2
Table 4-1 Maintenance Schedules
Kilometers
5
000
30
000
60
000
90
000
120
000
150
000
180
000
210
000
Service A 1. Check the tension of the compressor belt(s).
2 .Check that the vehicle engine idles correctly with unit operating. Check compressor mounting hardware and belt tension. (Paragraph 4.2)
3 .Check the tightness of bolts and screws and that the unit is correctly fastened onto the box.
Miles
Service A
Service B
Service C
Service D
3
000
J
18
000
J
J
Refrigerant : Type R134a.
36
000
J
J
J
54
000
J
J
72
000
J
J
J
J
90
000
J
J
108
000
J
J
J
126
000
J
J
Road compressor oil type: The road compressors are supplied with CARRIER POLYESTER (POE) oil. Oils of
PAG type are strictly incompatible with the operation of this unit, never use an oil other than that approved
by CARRIER.
Service B 1 . Clean evaporator & condenser.
(Paragraphs 4.18 & 4.19)
2. Replace the road and standby compressor belt(s).
3. Check and if required replace the filter-drier. (Paragraph 4.10)
4. Check the operation of cab command.
5. Check the defrost
D
Cut-in
D
Fan shut-down
D
Cut-out
D
Defrost water drain
Service C 1. Check the operation of the evaporator and condenser fans. Change the condenser/evaporator motor brushes.
2. Change the compressor oil. Use polyester oil (POE) approved by CAR-
RIER. Refer to paragraph 1.6.1.
Service D 1. Change the removable relays, fuses and capacitor (if any) in the control box.
4--1 62-10848
4.2 BELT MAINTENANCE AND ADJUSTMENT
WARNING
Beware of V-belt and belt-driven components as the unit may start automatically.
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.
Figure 4-1 Belt Tension Gauge
(Carrier Part Number 07--00203--00)
Belt tension depends on each kit. Refer to Installation
Instructions provided with the kit for belt tension requirements. In each kit installation instruction, we indicate the belt tension (given with belt tension gauge
P/N 07-00203-00.
When installing a new V-belt the tension should be somewhat higher than specified and readjusted after allowing the unit to run for some time.
Standby motor
Compressor
1. Standby Motor-Compressor V-belt
Figure 4-2 Layout of V-belt
Table 4-3. Belt Tension (See Figure 4-2)
BELTS
Standby Motor to Compressor
New Install
Tension
90 ft./lbs
(122 Nm)
Running
Tension
80 to 90 ft./lbs
(108 to 122
Nm)
4.2.1 Standby Motor--Compressor V-Belt
a. Loosen the retaining bolts of the standby motor support plate.
b. Replace the V-belt. Position the motor to correct belt tension. Tighten the motor retaining bolts.
4.3 INSTALLING R-134A MANIFOLD GUAGE SET
A R-134a manifold gauge/hose set with self-sealing hoses is required for service of models covered within this manual. The manifold gauge/hose set is available from Carrier Transicold. (Carrier Transicold P/N
07-00294-00, which includes items 1 through 6,
Figure 4-3). To perform service using the manifold gauge/hose set, do the following:
4.3.1 Preparing Manifold Gauge/Hose Set For Use
a. If the manifold gauge/hose set is new or was exposed to the atmosphere it will need to be evacuated to remove contaminants and air as follows: b. Back seat (turn counterclockwise ) both field service couplers (see Figure 4-3) and midseat both hand valves.
c. Connect the yellow hose to a vacuum pump and an
R-134a cylinder.
d. Evacuate to 10 inHg (254mmHg) and then charge with R-134a to a slightly positive pressure of 1.0 psig
(0.07 Bar).
e. Front seat both manifold gauge set hand valves and disconnect from cylinder. The gauge set is now ready for use.
4.3.2 Connecting Manifold Gauge/Hose Set
To connect the manifold gauge/hose set for reading pressures, do the following: a. Remove access valve cap.
b. Connect the field service coupler (see Figure 4-3) to the access valve.
c. Turn the field service coupling knob clockwise, which will open the system to the gauge set.
d. Read system pressures.
e. Repeat the procedure to connect the other side of the gauge set.
62-10848 4--2
4.3.3 Removing the Manifold Gauge Set
1. While the compressor is still ON, backseat the high side service valve.
2. Midseat both hand valves on the manifold gauge set and allow the pressure in the manifold gauge set to be drawn down to low side pressure. This returns any liquid that may be in the high side hose to the system.
CAUTION
To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before disconnecting.
3. Backseat the low side service valve. Backseat both field service couplers and frontseat both manifold set hand valves. Remove the couplers from the access valves.
4. Install both service valve stem caps and access valve caps (finger-tight only).
Low Pressure
Gauge
1
High Pressure
Gauge
Opened
(Backseated )
Hand Valve
To Low Side
Access Valve
3
BLUE
2
Closed
(Frontseated)
Hand Valve
To High Side
Access Valve
3
RED
6
(Blue Knob)
4
2
3
YELLOW
4
5
(Red Knob)
1. Manifold Gauge Set
2. Hose Fitting (0.5-16 Acme)
3. Refrigeration and/or Evacuation Hose
.
(SAE J2196/R-134a)
4. Hose Fitting w/O-ring (M14 x 1.5)
5. High Side Field Service Coupler
6. Low Side Field Service Coupler
Figure 4-3 Manifold Gauge Set (R-134a)
4.4 REMOVING THE REFRIGERANT CHARGE
NOTE
To avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removing refrigerant.
Connect a refrigerant recovery system (Carrier P/N
MVS--115--F--L--CT (115V) or MVS--240--F--L--CT
(240V) ) to the unit to remove refrigerant charge. Refer to instructions provided by the manufacturer of the refrigerant recovery system.
4.4.1 Refrigerant Removal From A Non--Working
Compressor.
To remove the refrigerant from a compressor that is not operational, do the following: a. Attach a manifold gauge set as shown in Figure 4-3 b. Recover refrigerant with a refrigerant recovery system.
c. Service or replace components as required and leak check the entire system. (See Section 4.5).
4.5 REFRIGERANT LEAK CHECKING
A refrigerant leak check should always be performed after the system has been opened to replace or repair a component. To check for leaks in the refrigeration system, perform the following procedure:
NOTE
Use only R134a 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.
a. If system is without refrigerant, charge system with refrigerant to build up pressure between 30 to 50 psig
(2 to 3.4 Bars). Remove refrigerant cylinder and leak check all connections.
b. Add sufficient nitrogen to raise system pressure to
150 to 200 psig (10.21 to 13.61 bar).
c. Check for leaks. The recommended procedure for finding leaks in a system is with an electronic leak detector. (Carrier P/N 07--00295--00). Testing joints with soap suds is satisfactory for locating large leaks but be necessary when an electronic leak detector will not function correctly.
d. Remove refrigerant using a refrigerant recovery system and repair any leaks. Evacuate and dehydrate the unit. (Refer to section 4.6) Charge unit with refrigerant. (Refer to section 4.7)
4--3 62-10848
4.6 EVACUATION AND DEHYDRATION
4.6.1 General
Moisture can seriously damage refrigerant systems.
The presence of moisture in a refrigeration system can have many undesirable effects. The most common are copper plating, acid sludge formation, “freezing-up” of metering devices by free water, and formation of acids, resulting in metal corrosion.
4.6.2 Preparation
a. Evacuate and dehydrate only after pressure leak test.
(Refer to section 4.5) b. Essential tools to properly evacuate and dehydrate any system include a good vacuum pump (5 cfm =
8m#H volume displacement, P/N 07-00176-01) and a good vacuum indicator such as a thermocouple vacuum gauge (vacuum indicator). (Carrier P/N
0700414--00).
NOTE
Use of a compound gauge is not recommended because of its inherent inaccuracy.
c. Keep the ambient temperature above 60_F (15.6_C) to speed evaporation of moisture. If ambient temperature is lower than 60_F (15.6_C), ice might form before moisture removal is complete. Heat lamps or alternate sources of heat may be used to raise system temperature.
d. Additional time may be saved during a complete system pump down by replacing the filter--drier with a section of copper tubing and the appropriate fittings.
Installation of a new filter--drier may be performed during the charging procedure.
1
4
3
4
2
6
4
5
1
2
3
Refrigerant Recovery Unit
Refrigerant Cylinder
Evacuation Manifold
4 Valve
5 Vacuum Pump
6 Electronic Vacuum Gauge
Figure 4-4 Vacuum Pump Connection
4.6.3 Procedure For Evacuation And Dehydrating System
a. Remove refrigerant using a refrigerant recovery system.
b. The recommended method to evacuate and dehydrate the system is to connect three evacuation hoses (Do not use standard service hoses, as they are not suited for evacuation purposes.) as shown in
Figure 4-4 to the vacuum pump and refrigeration unit.
Also, as shown, connect a evacuation manifold, with evacuation hoses only, to the vacuum pump, electronic vacuum gauge, and refrigerant recovery system.
c.Connect lines to unit and manifold and make sure vacuum gauge valve is closed and vacuum pump valve is open.
62-10848 4--4
d. Start vacuum pump. Slowly open valves halfway and then open vacuum gauge valve.
e. Evacuate unit until the electronic vacuum gauge indicates 2000 microns. Close the electronic vacuum gauge and vacuum pump valves. Shut off the vacuum pump. Wait a few minutes to be sure the vacuum holds.
f. Break the vacuum with clean dry nitrogen. Raise system pressure to approximately 2 psig (0.14 Bar).
g. Purge nitrogen from system.
h. Repeat steps e through g one time.
i. Evacuate unit to 500 microns. Close off vacuum pump valve and stop pump. Wait five minutes to see if vacuum holds. This checks for residual moisture and/ or leaks.
j. With a vacuum still in the unit, the refrigerant charge may be drawn into the system from a refrigerant container on a scale. The correct amount of refrigerant may be added by observing the scale. (Refer to section 4.7)
4.7 CHARGING THE REFRIGERATION SYSTEM
4.7.1 Checking The Refrigerant Charge
a. Start unit in cooling mode and run approximately ten minutes.
b. Partially block off air flow to condenser coil so discharge pressure rises to 174 psig (12 Bars).
c. The unit is correctly charged when there are no bubbles in the sight glass.
4.7.2 Installing A Complete Charge
NOTE
It may be necessary to finish charging the unit using the partial charge method, due to pressure rise in the high side of the system. (Refer to paragraph 4.7.3) a. Dehydrate unit and leave in deep vacuum. (Refer to section 4.6) b. Place refrigerant cylinder on scale and connect charging line from cylinder to receiver outlet (king) valve. Purge charging line at outlet valve.
c. Note weight of refrigerant cylinder.
d. Open liquid valve on refrigerant cylinder. Open king valve half way and allow the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added as indicated by scale. Correct charge will be found in Table 1-1.
NOTE
It is possible that all liquid may not be pulled into the receiver, as outlined in step d. above. In this case, vapor charge remaining refrigerant through the suction service port (See Section
4.7.3).
e. When refrigerant cylinder scale indicates that the correct charge has been added, close liquid line valve on cylinder and backseat the king valve.
f. Replace all valve caps.
g. Start unit and check for non--condensables.
4.7.3 Adding A Partial Charge
cylinder.
valve.
NOTE
When partially charging the refrigeration system with R134a, install a vapor charge.
a. Place refrigerant cylinder on scale and connect charging line between suction port and refrigerant b. Note weight of refrigerant cylinder.
c. Run unit on high speed cool and open cylinder vapor d. If necessary, partially block off air flow to condenser coil so discharge pressure rises to 174 psig (12 Bars).
e. The unit is correctly charged when there are no bubbles in the sight glass.
f. Start unit and check for non--condensables.
4.8 CHECKING FOR NON--CONDENSABLES
To check for non--condensables, proceed as follows: a. Stabilize system to equalize pressure between the suction and discharge side of the system.
b. Check temperature at the condenser and receiver.
c. Check pressure at the receiver outlet (King) valve.
d. Check saturation pressure as it corresponds to the condenser/receiver temperature using the Temperature-Pressure Chart, Table 4-4.
e. If gauge reading is 3 psig (0.2 Bar) or more than the calculated P/T pressure in step d., non--condensables are present.
f. Remove refrigerant using a refrigerant recovery system. (Refer to section 4.4) g. Evacuate and dehydrate the system. (Refer to section 4.6.) h. Charge the unit. (Refer to section 4.7.)
4--5 62-10848
4.9 REPLACING THE COMPRESSOR
4.9.1 Removing Compressor
WARNING
Ensure power to the unit is OFF, power plug is disconnected and circuit breaker is open or vehicle engine is OFF and negative battery cable is connected before replacing compressor.
a.Remove the refrigerant. (See Section 4.4.1).
WARNING
Slowly open the plug on the suction and discharge valves of the new compressor to vent the nitrogen holding charge.
b. Remove bolts from flanges.
c. Release and remove belt.
d. Remove the bolts mounting the compressor. Remove the compressor from chassis.
e. Remove the pulley from the compressor.
4.9.2 Installing Compressor
a.. To install the compressor, reverse the procedure outlined when removing the compressor. Refer to section 1.6.4 for torque values.
NOTE
The service replacement compressor is sold without flanges.
b. Pump down the compressor. (See Section 4.4) c. Charge compressor. (See Section 4.7.2)
NOTE
It is important to check the compressor oil level of the new compressor and fill if necessary. (Refer to section 1.6.1) d. Check refrigerant cycles.
Compressor oil type: The road compressors are supplied with CARRIER POLYESTER (POE) oil.
Ensure compressor is marked with a factory sticker indicating the correct oil has been installed. Oils of PAG type are strictly incompatible with the operation of this unit, never use an oil other than that approved by
CARRIER.
62-10848 4--6
4.10 CHECKING AND REPLACING FILTER-DRIER
4.10.1 Checking Filter-Drier
Check for any obstruction of the filter-drier by feeling the inlet and outlet connections of the liquid line on the filter cartridge. If the temperature of the outlet connection seems lower than the temperature of the inlet connection, replace the filter-drier.
4.10.2 Replacing The Filter-Drier
Remove refrigerant charge (See section 4.4). Remove the drier mounting clip, then replace the filter-drier.
Following drier replacement, evacuate and recharge unit (refer to sections 4.6 & 4.7).
4.11 HIGH PRESSURE (HP1) AND CONDENSER
PRESSURE (HP2) SWITCHES
4.11.1 Removing Switch
a. A SCHRAEDER valve is located under each switch to allow removal and installation without removing the refrigerant charge.
b. Remove switch and test in accordance with paragraph 4.11.2.
c. Replace or reinstall switch.
4.11.2 Checking Pressure Switch
WARNING
Do not use a nitrogen cylinder without a pressure regulator. (See Figure 4-5) Cylinder pressure is approximately 2350 psig
(160 bars). Do not use oxygen in or near a refrigerant system as an explosion may occur.
a. Remove switch as outlined in paragraph 4.11.1.
b. Connect ohmmeter across switch terminals. Ohmmeter will indicate resistance if switch is closed (HP1) or open (HP2) after relieving pressure.
b. Connect switch to a cylinder of dry nitrogen (see
Figure 4-5).
c. Set nitrogen pressure regulator higher than cut-out point on switch being tested. Pressure switch settings points are provided in paragraph 1.6.2.
d. Close valve on cylinder and open bleed-off valve.
e. Open cylinder valve. While observing meter, slowly close bleed-off valve and increase pressure until the switch opens (HP1) or closes (HP2). Slowly open bleed-off valve (to decrease pressure) until switch reverts to normal position.
f. The meter will indicate open. Open pressure on gauge. Slowly open bleed-off valve (to decrease pressure) until switch closes (ohmmeter will move).
g. If switch does not activate within tolerances provided, replace switch. Test new switch before installation.
1
2
3
4
5
6
paper. Wipe out any accumulation of greasy material using a clean rag dampened with solvent. Reassemble the motor. Install new brushes and replace cap.
4.13 HOT GAS (HGS1) AND CONDENSER
PRESSURE CONTROL SOLENOID VALVES
4.13.1 Replacing Solenoid Coil
It is not necessary to remove the refrigerant charge to replace the coil (see Figure 4-7).
a. Remove coil snap cap, voltage plate and coil assembly. Disconnect leads and remove coil junction box if necessary.
b. Verify coil type, voltage and frequency. This information appears on the coil voltage plate and the coil housing.
c. Place new coil over enclosing tube and then install voltage plate and snap cap.
1
2
3
1.
Cylinder valve and gauge
2.
Pressure regulator
3.
Nitrogen cylinder
4.
Pressure gauge (0 to 400 psig = 0 to 28 bars)
5.
Bleed-off valve
6.
1/4 inch connection
Figure 4-5 Typical Setup For Testing Pressure
Switches HP1 And HP2
4.12 CHECKING AND REPLACING CONDENSER
FAN MOTOR BRUSHES
To maintain proper operation of the fan motors, the fan motor commutator and brushes should be checked periodically for cleanliness and wear .
4
5
2
1
1. Brush Cap 2. Brush
Figure 4-6 Fan Motor Brushes
To check brushes proceed as follows : a. With unit off and battery disconnected, remove brush cap (Item 1 ; 2 per motor). See Figure 4-6 b. Remove brushes (Item 2; 2 per motor) and check the length of the brush. If the length is less than 1/4 inch (6 mm) the brushes should be replaced.
c. Blow out the brush holder with low pressure air to remove any carbon dust in the holder. This dust could prevent a good contact between the brushes and commutator.
d. Remove the back cover of the motor and inspect the commutator. If the commutator is heavily grooved, polish it using fine sandpaper. Do not use abrasive
4--7
6
1. Snap cap
2. Voltage plate
3. Coil assembly
4. Enclosing tube
7
5. Plunger assembly
6. Valve body assembly
7.
Direction of flow
Figure 4-7 Hot Gas or Condenser Pressure
Control Solenoid
4.13.2 Replacing Valve Internal Parts
a. Remove the refrigerant charge. (See Section 4.4).
b. Remove coil snap cap, voltage cover and coil assembly. Remove the enclosing tube.
c. Check for foreign material in valve body.
d. Check for damaged plunger and o-ring. If o-ring is to be replaced, always put refrigerant oil on o-rings before installing.
CAUTION
Do not damage or over tighten the enclosing tube assembly. Place all parts in the enclosing tube in proper sequence in order to avoid premature coil burn-out.
e. Tighten enclosing tube.
f. Install coil assembly, voltage cover and snap cap.
62-10848
g. Evacuate, dehydrate and recharge unit. See Sections 4.6 and 4.7.
h. Start unit and check operation.
1 2 3
1. Cap
2. Jam Nut
3. Set Screw
Figure 4-8 Compressor Pressure Regulating Valve
4.14 ADJUSTING THE COMPRESSOR PRESSURE
REGULATING VALVE (CPR) (115V ONLY)
When adjusting the compressor pressure regulating valve (CPR) (see Figure 4-8), the unit must be running in heating or defrost mode. This will ensure a suction pressure above the proper CPR setting. To adjust the
CPR valve, proceed as follows : a. Install a gauge on the suction line .
b. Remove cap from CPR valve.
c. With an 8 mm Allen wrench, loosen the jam nut.
d. Using the 8 mm Allen wrench, adjust the set screw. To raise the suction pressure turn the set screw clockwise; to lower the suction pressure, turn counterclockwise. Refer to paragraph 1.6.2 for CPR valve setting.
e. When the setting has been adjusted, tighten the jam nut securely against the set screw. This will prevent any movement of the set screw due to vibrations in the unit. Replace the cap.
4.15 THERMOSTATIC EXPANSION VALVE
The thermal expansion valve 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.
NOTE
Due to the time involved in adjusting the superheat, replace the valve rather than adjusting it.
4.15.1 Replacing expansion valve
a. Remove refrigerant charge (See section 4.4).
b. Remove insulation from expansion valve bulb and then remove bulb from suction line.
c. Loosen flare nut and disconnect equalizer line from expansion valve.
d. The txv bulb is located below the center of the suction line. This area must be clean to ensure positive bulb contact. Strap bulb to suction line and insulate both.
62-10848 4--8 e. Braze the equalizer tubes to expansion valve.
f. Evacuate, dehydrate and recharge unit. (See Sections 4.6 and 4.7).
g. Check superheat (See Section 1.6.2.g.).
4.15.2 Measuring Superheat
a. Remove insulation from expansion valve bulb and suction line. See Figure 4-9 b. Loosen one TXV bulb clamp and make sure area under clamp (above TXV bulb) is clean.
c. Place thermocouple above (parallel to) the TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in
Figure 4-9 d. Connect an accurate gauge to the
¼” port on the suction service valve.
e. Run unit until stabilized at -- 4_F (-- 20_C) refrigerated compartmenttemperature.
f. From the temperature/pressure chart (Table 4-4), 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. Refer to paragraph 1.6.2 for superheat setting.
i. If required, adjust superheat by turning the adjusting screw located under the cap on the side of the valve.
1
5
2
1. Suction Line
(end view)
2. TXV Bulb Clamp
3. TXV Bulb
4. Thermocouple
5. Nut and Bolt (Clamp)
Figure 4-9 Thermostatic Expansion Valve Bulb
And Thermocouple
3
4
4.16 DIAGNOSTIC TOOL
NOTE
The Cab Command diagnostic tool comes with two jumpers. These are not applicable to the
30S system and should not be used in this application.
PRIMARY
TOOL
REMOTE
TOOL
Figure 4-10 Cab Command Diagnostic Tool
(CTD P/N 07--00440--00)
a. Testing a cab command cable that is already installed on the unit and routed into the truck cab requires the use of both pieces of the diagnostic tool.
b. Unplug the cab command cable from the microprocessor and also from the back of the cab command module.
c. Plug one end of the cable into the primary tool and the other end into the remote tool.
d. Begin the test by turning on the power switch and observing the sequence of green lights. As each circuit is tested, the corresponding light is illuminated. If a fault is found in the cable, the light that corresponds to that particular circuit is not illuminated.
e. To test a cable that is not installed on a unit, simply plug each end of the cable into the primary tool and perform the test as above.
4.17 MICROPROCESSOR
WARNING
Under no circumstances should anyone attempt to repair the microprocessor module or Cab Command! Should a problem develop with these components, contact your nearest Carrier Transicold dealer for replacement.
Although there is less danger of electrical static discharge (ESD) damage in the outdoor environment, where the processor is likely to be handled, proper board handling techniques should be stressed. Boards should always be handled by their edges, in much the same way one would handle a photograph. This not only precludes the possibility of ESD damage, but also lowers the possibility of physical damage to the electronic components. Although the microprocessor boards are fairly rugged when assembled, they are more fragile when separated and should always be handled carefully.
When welding is required on the unit frame, or on the front area of the truck, ALL wiring to the microprocessor
MUST be disconnected. When welding is performed on other areas of the truck and van, the welder ground connection MUST be in close proximity to the area being welded. It is also a good practice to remove both battery cables before welding on either the unit frame or the truck to prevent possible damage to other components such as the alternator and voltage regulator.
4.18 EVAPORATOR COIL CLEANING
The use of recycled cardboard cartons is increasing.
The recycled cardboard cartons create much more fiber dust during transport than ”new” cartons. The fiber dust and particles are drawn into the evaporator where they lodge between the evaporator fins. If the coil is not cleaned on a regular basis, sometimes as often as after each trip, the accumulation can be great enough to restrict air flow, cause coil icing, repetitive defrosts and loss of unit capacity. Due to the ”washing” action of normal defrost the fiber dust and particles may not be visible on the face of the coil but may accumulate deep within.
It is recommended to clean an the evaporator coil on a regular basis, not only to remove cardboard dust, but to remove any grease 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. Spray coil with a mild detergent solution such as any good commercial-grade automatic dish washer detergent and let the solution stand for a few minutes.
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.
b. Run unit until defrost mode be initiated to check for proper draining from drain pan.
4.19 CONDENSER COIL CLEANING
Remove all foreign material from the condenser coil by reversing the normal air flow. (Air is pulled in through the front.) 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.
4--9 62-10848
16
18
20
22
24
26
28
8
10
4
6
-- 6
-- 4
-- 2
-- 0
2
12
14
-- 18
-- 16
-- 14
-- 12
-- 10
-- 8
TEMPERATURE
_
F
_
C
-- 40
-- 35
-- 30
-- 25
-- 20
-- 40
-- 37
-- 34
-- 32
-- 29
-- 28
-- 27
-- 26
-- 24
-- 23
-- 22
-- 9
-- 8
-- 7
-- 6
-- 4
-- 3
-- 2
-- 21
-- 20
-- 19
-- 18
-- 17
-- 16
-- 14
-- 13
-- 12
-- 11
-- 10
Table 4-4. R-134a Temperature-Pressure Chart
15.8
17.1
18.5
19.9
21.4
22.9
24.5
8.6
9.7
10.8
12.0
3.7
4.6
5.6
6.5
7.6
13.2
14.5
2.1
0.6
0.4
1.2
2.0
2.9
BOLD FIGURES = Inches Mercury Vacuum (cm Hg VAC)
LIGHT FIGURES = psig (kg/cm
2 and Bar)
Psig
PRESSURE
Kg/cm
2
Bar
TEMPERATURE
_
F
_
C Psig
14.6
12.3
9.7
6.7
3.5
37.08
31.25
24.64
17.00
8.89
-- .49
-- .42
-- .33
-- .23
-- .12
30
32
34
36
38
-- 1
0
1
2
3
26.1
27.8
29.6
31.3
33.2
5.33
1.52
.03
.08
.14
.20
-- .07
-- .02
.03
.08
.14
.20
40
45
50
55
60
65
4
7
10
13
16
18
35.1
40.1
45.5
51.2
57.4
64.1
1.11
1.20
1.30
1.40
1.50
1.61
1.72
.60
.68
.76
.84
.26
.32
.39
.46
.53
.93
1.02
.26
.32
.39
.45
.52
.59
.67
.74
.83
.91
1.00
1.09
1.18
1.28
1.37
1.48
1.58
1.69
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
52
54
57
60
63
66
68
35
38
41
43
21
24
27
29
32
46
49
184.6
198.7
213.6
229.2
245.6
262.9
281.1
71.1
78.7
86.7
95.3
104.3
114.0
124.2
135.0
146.4
158.4
171.2
12.73
13.70
14.73
15.80
16.93
18.13
19.37
4.90
5.43
5.98
6.57
7.19
7.86
8.56
9.31
10.09
10.92
11.80
2.42
2.76
3.14
3.53
3.96
4.42
Bar
1.80
1.92
2.04
2.16
2.29
12.98
13.97
15.02
16.11
17.27
18.48
19.76
5.00
5.53
6.10
6.70
7.33
8.01
8.73
9.49
10.29
11.14
12.04
PRESSURE
Kg/cm
2
1.84
1.95
2.08
2.20
2.33
2.47
2.82
3.30
3.60
4.04
4.51
62-10848 4--10
SECTION 5
TROUBLESHOOTING
WARNING
Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. Press OFF key on the cab command, turn vehicle engine off or disconnect power plug and open circuit breaker.
CAUTION
Under no circumstances should anyone attempt to service the microprocessor module and cab command. Should a problem develop with the control system, contact your nearest Carrier Transicold dealer for replacement components.
5.1 INTRODUCTION
Under normal circumstances, unit problems will be indicated by an active alarm in the alarm list. Suggested troubleshooting actions for each alarm indication are provided in Table 5-1. Suggested corrective actions for mechanical type problems are listed under subject headings in Table 5-2.
Table 5-1 Alarm Indications
ALARM
A00
A01
A02
A03
Standby
Units
Only
Open
Description
No Malfunction
Low Pressure Switch (LP) or
High Pressure Switch (HP1)
Open (Road)
Low Pressure Switch (LP) or
High Pressure Switch (HP1)
Electric motor overload
CORRECTIVE ACTION
All components functioning normally
Unit undercharged
Liquid line filter--drier restricted
TXV strainer plugged with foreign material/ice.
TXV malfunction
Verify operation of evaporator fans.
Failed switch
Unit overcharged
Verify operation of condenser fan
Noncondensibles in system
Discharge check valve failed closed (standby only
Failed switch
Thermal overload open in motor windings.
Current overload tripped.
Verify line voltage
Reference
Paragraph
----
4.7.1
4.10.1
4.15
4.15
----
4.11.2
4.7.1
----
4.8
Replace
4.11.2
A04
Road Compressor Clutch
(CLHR) Malfunction
Current draw of road clutch coil either high or low Replace
A05
Standby
Units
Only
A06
A07
Standby Contactor (MC) high amp draw
Condenser Fan Motor (CFM) high amp draw
Evaporator Fan Motor (EFM) high amp draw
Contactor coil either high or low (0.2A for 3 phase;
0.5A for 1 phase)
Verify plunger moves freely
Replace contactor
Verify motor rotates freely
Verify condition of brushes
Replace motor
Verify motor rotates freely
Replace motor
----
----
4.12
----
----
----
5--1
62-10848
ALARM
A08
Standby
Units
Only
A09
A10
A11
A12
Standby
Units
Only
A13
Standby
Units
Only
A14
Standby
Units
Only
A15
EE bAt
------
Err
Table 5-1 Alarm Indications -- Continued
Description
Heating option control --
Either the hot water control relay or the electric heat contactor coil amp draw is high
Hot Gas Solenoid Valve
(HGS1) high amp draw
Quench Valve (BPV) high amp draw
Condenser Pressure Control
Valve (HGS2) high amp draw
Out of Range -- High Temperature
Out of Range -- Low Temperature
CORRECTIVE ACTION
Verify coil resistance
Check wiring to controls
Current draw of coil high or low (approx 1.6 amp)
Replace coil
Current draw of coil high or low (approx 1.2 amp)
Replace coil
Current draw of coil high or low (approx 1.6 amp)
Replace coil
Unit out of range for 15 minutes
Verify cooling operation of unit
Hot gas solenoid open
Unit out of range for more than 15 minutes
Verify heating operation of unit
Heating option not active (Set configuration)
Unit terminated defrost after 45 minutes
Defrost Cycle > 45 minutes
Verify HGS1/HGS2 valve operation
Set point adjusted out of the range --20.2 to 86°F
(--29°C/+30°C) or below the programmed low threshold
Return Air Sensor
Low Battery Voltage
Using Road & Standby operation at the same time.
Set point error.
Check set point
Return air sensor defective
Vehicle battery voltage low
Check alternator system
If operating on road, disconnect standby power supply
If operating on standby, shut down vehicle engine.
Programming error. Reset.
Reference
Paragraph
----
----
4.13.1
----
4.13.1
----
4.13.1
Verify Setting
----
4.13.1
Verify Setting
----
2.9
----
4.13
2.3
Replace
Correct
----
----
2.3
Table 5-2 Mechanical Indications
INDICATION/TROUBLE POSSIBLE CAUSES
5.2 REFRIGERATION
5.2.1 Unit Will Not Cool
Compressor malfunction
Refrigeration system
Compressor drive (clutch) defective
Compressor defective
Defrost cycle has not terminated
Abnormal pressure
Hot gas solenoid malfunction (HGS1)
5.2.2 Unit Runs But Has Insufficient Cooling
Compressor Compressor defective
Refrigeration system
Abnormal pressure
Expansion valve malfunction
Non--existent or restricted evaporator airflow
REFERENCE
SECTION
Replace
4.9
5.2.5
5.2.6
4.13
4.9
5.2.6
5.2.10
5.2.9
62-10848
5--2
Table 5-2 Mechanical Indications -- Continued
INDICATION/TROUBLE POSSIBLE CAUSES
5.2.3 Unit Operates Long or Continuously in Cooling
Hot Load
Refrigerated compartment
Refrigeration system
Defective refrigerated compartment insulation or air leak
Abnormal pressure
Temperature microprocessor malfunction
Compressor Defective
5.2.4 Unit Will Not Heat or Heating Insufficient
Refrigeration
Abnormal pressure
Temperature microprocessor malfunction
Hot gas solenoid malfunction (HGS1)
Compressor Compressor drive (clutch) defective
Compressor defective
5.2.5 Defrost Malfunction
Automatic defrost will not initiate
Manual defrost will not initiate
Defrost thermostat (DTT) open or defective
Hot gas solenoid valve malfunction
Defrost disabled through cab command
Microprocessor defective
Defrost thermostat (DTT) open or defective
Defrost cycle initiates but does not defrost
Frequent defrost
Hot gas solenoid malfunction (HGS1)
Condenser Pressure Control valve malfunction (HGS2)
Wet load
Defrost settings set to low.
Defrost thermostats (DTT) shorted closed Does not terminate or cycles on defrost
5.2.6 Abnormal Pressure
5.2.6.1 Cooling
High discharge pressure
Low discharge pressure
High suction pressure
Low suction pressure
Suction and discharge pressures tend to equalize when unit is operating
5.2.6.2 Heating
Condenser coil dirty
Noncondensibles in system
Refrigerant overcharge
Condenser fan/motor defective
Compressor defective
Hot gas solenoid malfunction
Low refrigerant charge
Compressor defective
Hot gas solenoid malfunction
Compressor pressure regulator misadjusted (CPR)
Filter–drier partially plugged
Low refrigerant charge
Expansion valve malfunction
No evaporator air flow or restricted air flow
Excessive frost on coil
Compressor defective
Hot gas solenoid malfunction
High discharge pressure
Low discharge pressure
Low suction pressure
Overcharged system
Condenser fan or HP2 pressure switch defective
Noncondensibles in system
Condenser motor/fan defective
Compressor defective
Hot gas solenoid valve malfunction
Low refrigerant charge
Compressor pressure regulating valve misadjusted (CPR)
Condenser Pressure Regulating valve fault (HGS2)
REFERENCE
SECTION
Insufficient pull down time
Correct
5.2.6
5.2.8
4.9
5.2.6
5.2.8
4.13
Check
4.9
4.19
4.8
4.7.1
4.12
4.9
4.13
4.7.1
4.9
4.13
4.14
4.10
4.7.1
5.2.10
5.2.9
Check
4.9
4.13
Replace
4.13
2.5
Replace
Replace
4.13
4.13
----
2.5
Replace
4.7.1
4.11
4.8
4.12
4.9
4.13
4.7.1
4.14
4.13
5--3
62-10848
Table 5-2 Mechanical Indications -- Continued
INDICATION/TROUBLE POSSIBLE CAUSES
5.2.7 Abnormal Noise
Compressor
Condenser or evaporator fan
5.2.8 Cab Command Malfunction
Loose mounting bolts
Worn bearings
Worn or broken valves
Liquid slugging
Insufficient oil
Loose shroud
Bearings defective
Fan loose on shaft
Bent shaft
Cab Command non–operational
Fuse open
Microprocessor malfunction
Microprocessor/Cab command cable
5.2.9 No Evaporator Air Flow or Restricted Air Flow
Evaporator coil blocked
Heavy frost on coil
Coil dirty
No or partial evaporator air flow
Evaporator fan loose or defective
Evaporator fan rotating backwards
Evaporator air flow blocked in refrigerated compartment
Fan motor(s) malfunction
5.2.10 Expansion Valve
Low suction pressure with high superheat
Low refrigerant charge
External equalizer line plugged
Broken capillary
Superheat setting too high
Low superheat and liquids lugging in compressor
Superheat setting too low
External equalizer line plugged
Pin and seat of expansion valve eroded or held open by foreign material
Fluctuating suction pressure
Improper bulb location or installation
Insulation missing from sensing bulb
Low superheat setting
High superheat Expansion valve setting
5.2.11 Malfunction Hot Gas Solenoid or Condenser Pressure Regulating Valve
Valve does not function properly
No power to valve
Improper wiring or loose connections
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 tube
Valve shifts but refrigerant continues to flow
Foreign material lodged under seat
Defective seat
5.2.12 Standby Compressor Malfunction
Standby compressor fails to start
Motor contactor defective
Motor Overload open
Improper power supply
5–minute timer active
Standby motor starts, then stops Motor Overload open
REFERENCE
SECTION
Tighten
4.9
4.9
5.2.10
Check
Check
Check
Check
4.13
Replace
Check
Correct
Check
Check
Replace
Replace
Check
Check
4.18
Check
Check
Check
Replace
4.7.1
Repair
Repair
4.15.2
4.15.2
Repair
4.15
4.15
Replace
4.15.2
4.15.2
Check
Check
4.13
62-10848
5--4
SECTION 6
ELECTRICAL SCHEMATIC WIRING DIAGRAM
6.1 INTRODUCTION
This section contains Electrical Schematic Wiring Diagram covering the Models listed in Table 1-1. The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein.
WARNING
Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. Press OFF key on the cab command and disconnect power plug.
WARNING
Under no circumstances should ether or any other starting aids be used to start engine.
WARNING
Under no circumstances should anyone attempt to repair the microprocessor module or Cab
Command! Should a problem develop with these components, contact your nearest Carrier
Transicold dealer for replacement.
CAUTION
Observe proper polarity when installing battery, negative battery terminal must be grounded.
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 microprocessor.
Use proper board handling techniques. (See Section 4.17).
6--1 62--10848
62--10848
6--2
6--3
62--10848
6--4
62--10848
6--5
62--10848
6--6
62--10848
6--7
62--10848
6--8
62--10848
6--9
62--10848
A
Abnormal Noise, 5-4
Abnormal Pressure, 5-3
Accessing Alarm Messages, 2-4
Alarm Display, 2-4
Alarm Indications, 5-1
B
Belt Adjustment, 4-2
Belt Tension, 4-2
C
Cab Command, 2-1
Cab Command Malfunction, 5-4
Checking The Eeprom Version, 2-5
Checking the Refrigerant Charge, 4-5
Clearing Alarm Messages, 2-5
Compressor, 1-3
Compressor Pressure Regulating Valve, 4-8
Compressor Pressure Regulating Valve, 1-4
Condenser Coil Cleaning, 4-9
Condenser Fan Motor, 1-10
Condenser Fan Motor Brushes, 4-7
Condenser Pressure Control Solenoid , 4-7
Condenser Pressure Control Valve, 1-10
Condenser Pressure Control Valve , 1-3
Condenser Pressure Switch, 4-6
Condenser Pressure Switch, 1-4
Condenser Pressure Switch (HP2), 1-9
Condenser/Subcooler, 1-1
Connect Power, 2-3
Control System, 2-1
Cooling, 1-12
D
Defrost Cycle, 2-3, 3-2
Defrost Malfunction, 5-3
Defrost Termination Thermostat, 1-9
Defrost Timer, 1-9
INDEX
Description, 1-1
Diagnostic Tool, 4-9
E
Electrical Data, 1-10
Evacuation and Dehydrating System, 4-4
Evacuation And Dehydration, 4-4
Evaporator, 1-4
Evaporator Coil Cleaning, 4-9
Evaporator Fan Motor, 1-10
Expansion Valve, 5-4
F
Filter Drier, 1-1
FILTER--DRIER, 4-6
Frozen Mode, 3-1
H
Heat And Defrost, 1-12
High Pressure Safety Switch, 1-4
High Pressure Switch , 4-6
Hot Gas Solenoid, 4-7
Hot Gas Valve, 1-10
Hot Gas Valve 1, 1-3
I
Inspection, 2-2
Installing a Complete Charge, 4-5
Insufficient Cooling, 5-2
L
Low Battery Alarm, 2-5
Low Pressure Switch, 1-4
M
Maintenance Schedule, 4-1
Manual Defrost, 2-3
Microprocessor, 4-9
Minimum Off Time, 3-2
Index--1 62--10848
N
No Evaporator Air Flow or Restricted Air Flow, 5-4
O
Oil Separator, 1-3
OPERATION, 2-1
P
Partial Charge, 4-5
Perishable Mode, 3-1
INDEX
Service, 4-1
Set--point, 2-3
Standby Compressor Malfunction, 5-4
Standby Compressor Speed, 1-10
Standby Motor , 1-3
Standby Motor Contactor, 1-10
Standby Motor Ratings, 1-10
Standby Motor--Compressor V--Belt, 4-2
Start--up, 2-2
Starting, 2-3
Stopping, 2-5
Q
Quench Valve, 1-4, 1-10
Quench Valve (BPV), 1-9
R
Receiver, 1-3
Refrigerant Leak Checking, 4-3
Refrigerant Removal From Compressor, 4-3
Refrigeration System, 1-9
Replacing The Compressor, 4-6
Road Compressor Clutch, 1-10
T
Temperature Control, 3-1
Thermal Expansion Valve, 1-4
Thermostatic Expansion Valve, 4-8
Thermostatic Expansion Valve, 1-9
Torque Values, 1-10
Troubleshooting, 5-1
U
Unit Operates Long or Continuously in Cooling, 5-3
Unit Will Not Cool, 5-2
Unit Will Not Heat or Heating Insufficient, 5-3
S
Safety Devices, 1-11
Sequence Of Operation, 3-1
W
Wiring Diagram, 6-2, 6-3, 6-5, 6-6, 6-7, 6-9
62--10848
Index--2
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. 0909
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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