advertisement
R
Truck Refrigeration
EVAPORATOR
CONDENSER TXV
TXV BULB
RECEIVER
OPERATION & SERVICE for
Supra 644, 744 & 844
Truck Refrigeration Units
Beginning with S/N HFY90593608
62--10808 Rev B Change 09/06
OPERATION AND
SERVICE MANUAL
FOR
Supra 644, 744 & 844
TRUCK REFRIGERATION UNITS
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
SAFETY SUMMARY
DESCRIPTION
Safety-1
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1-1
1.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
CONDENSING SECTION
1.3.1 Engine
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1.3.2 Clutch Assembly
1.3.3 Standby Motor
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1.3.4 Alternator/Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.5 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.6 Compressor Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.7 Condenser/Subcooler
1.3.8 Accumulator
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1.3.9 Compressor Pressure Regulating Valve (CPR)
1.3.10 Hot Gas Solenoid Valve
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1.3.11 Hot Gas Bypass Solenoid Valve
1.3.12 Filter Drier
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1.3.13 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
1-5
1-6
1-6
1-6
1-4
1-4
1-5
1-5
1-1
1-1
1-1
1-1
1-4
1-4
1-4
1.4
EVAPORATOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1 Thermal Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.2 Heat Exchanger
1.4.3 Evaporator
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1.4.4 Electric and Water Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5
SYSTEM OPERATING CONTROLS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.1 SWITCHES AND CONTROLS
1.6
Unit Specifications
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1.6.1 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2 Compressor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7
REFRIGERATION SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8
ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9
TORQUE VALUES
1.10 SAFETY DEVICES
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1.11 REFRIGERANT CIRCUIT
1.11.1 Cooling
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1.11.2 Heat and Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10
1-10
1-11
1-11
1-12
1-12
1-12
1-6
1-6
1-7
1-9
1-6
1-6
1-6
1-6
1-9
1-9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
MICROPROCESSOR CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1 Introduction
2.1.2 Digital Display
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2.1.3 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
MICROPROCESSOR CONFIGURATION.
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2-1
2-1
2-1
2-2
2-2
2-3 i i
TABLE OF CONTENTS -- continued
PARAGRAPH NUMBER
2.3
OPERATOR MICROPROCESSOR SETTINGS
2.3.1 Setpoint
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Page
2-3
2-3
2.3.2 Functional Parameters
2.4
UNIT DATA
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2.5
ALARM DISPLAY
2.6
PRE-TRIP
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2.7
MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1 Startup and Pull Down -- Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.2 Startup and Pull Down -- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.3 Null Mode Overrides
2.7.4 Dual Probe Operation
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2-9
2-9
2.7.5
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.6 DEFROST CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9
2-10
2.8
PRE--TRIP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.1 Pre-trip Inspection -- Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.2 Pre-trip Inspection -- Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.3 Pre-trip Inspection -- After Starting
2.9
MANUAL START
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2-10
2-10
2-10
2-10
2-11
2-3
2-5
2-6
2-8
2-9
2-9
2-9
2.10 AUTOMATIC START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11 STARTING -- STANDBY MOTOR DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11
2-11
2.12 STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.13 CONTROL CIRCUIT OPERATION -- ENGINE DRIVE
2.14 CONTROL CIRCUIT OPERATION -- STANDBY
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2.15 AUTO START SEQUENCE
SERVICE
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2-11
2-11
2-12
2-13
3-1
3.1
3.1
3.2
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICING ENGINE RELATED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-2
3-3
3.2.1 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 Changing Lube Oil and Lube Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3 Replacing the Speed and Run Control Solenoids
3.2.4 Engine Air Cleaner
3.2.5 Servicing Fuel Pump
3.2.6 Servicing Glow Plugs
3.2.7 Alternator
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3-3
3-3
3-3
3-4
3-5
3-5
3-5
3.3
SERVICING AND ADJUSTING V-BELTS
3.3.1 Belt Tension Gauge
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3.3.2 Alternator V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 Water Pump Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.4 Standby Motor--Compressor V-Belt
3.3.5 Engine--Compressor V-Belts
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3-5
3-5
3-6
3-6
3-6
3-6
62--10808 ii
TABLE OF CONTENTS -- continued
PARAGRAPH NUMBER
3.4
PUMPING THE UNIT DOWN OR REMOVING THE REFRIGERANT
CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
3-7
3.5
REFRIGERANT LEAK CHECKING
3.6
EVACUATION AND DEHYDRATION
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3.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7
3-7
3-7
3-7
3.6.3 Procedure for Evacuation and Dehydrating System
3.7
CHARGING THE REFRIGERATION SYSTEM
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3.7.1 Installing a Complete Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7.2 Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8
REPLACING THE COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8
3-8
3-8
3-9
3-9
3.9
CHECKING 05K COMPRESSOR OILLEVEL
3.10 COMPRESSOR UNLOADER VALVE
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3-9
3-10
3.11 CHECKING AND REPLACING FILTER-DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.12 CHECKING AND REPLACING HIGH PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . .
3-11
3-11
3.12.1 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.12.2 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11
3-11
3-12 3.13 CHECKING CALIBRATION OF THE DEFROST AIR SWITCH . . . . . . . . . . . . . . . . . . . . . . . .
3.14 CHECKING AND REPLACING EVAPORATOR
FAN MOTOR BRUSHES & COMMUTATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.15 EVAPORATOR COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.16 CONDENSER COIL CLEANING
3.17 HOT GAS (Three-Way) VALVE
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3-12
3-12
3-13
3-13
3-13 3.17.1 Replacing Solenoid Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.18 ADJUSTING THE COMPRESSOR PRESSURE REGULATING
VALVE (CPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.19 THERMOSTATIC EXPANSION VALVE
3.20 MICROPROCESSOR CONTROLLER
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3.21 MICROPROCESSOR REPLACEMENT and CONFIGURATION . . . . . . . . . . . . . . . . . . . . . .
3-13
3-13
3-14
3-15
3.22 CONTROLLER SENSOR CHECKOUT
3.23 SUCTION PRESSURE TRANSDUCER
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TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17
3-17
4-1
4-1
4.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3 Starter Motor Malfunction (CONTINUED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-1
4-2
4.1.4 Malfunction In the Engine Starting Circuit
4.2
ALTERNATOR (AUTOMOTIVE TYPE)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
REFRIGERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Unit Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
4-2
4-3
4-3
TABLE OF CONTENTS -- continued
PARAGRAPH NUMBER
4.3.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.3 Unit Operates Long or Continuously in Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.4 Unit Will Not Heat or Has Insufficient Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.5 Defrost Cycle Malfunction
4.3.6 Abnormal Pressure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
4-3
4-3
4-3
4-4
4-4
4.3.6.1 Cooling
4.3.6.2 Heating
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.7 Abnormal Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.8 Control System Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.9 No Evaporator Air Flow or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4
4-5
4-5
4-5
4-5
4.3.10 Expansion Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.11 Hot Gas (Three-Way) Valve Malfunction
4.4
Standby Motor Malfunction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SCHEMATIC WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
4-6
4-6
5-1
5-1
LIST OF ILLUSTRATIONS
FIGURE NUMBER
Figure 1-1. Condensing Section -- Top View/Cab Command
Figure 1-2. Unit Curbside View
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-3. Unit Roadside View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-4. Cylinder Head -- Unloaded
Figure 1-5. Cylinder Head -- Loaded
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
1-2
1-3
1-3
1-4
1-5
Figure 1-6. Hot Gas Valve -- Cooling Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-7. Hot Gas Valve -- Heat and Defrost Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-8. Water and Electric Heat Components
Figure 1-9. Electrical Box
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-10. Control Relay Board
Figure 1-11. Refrigeration Circuit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8
1-13
1-5
1-6
1-7
1-8
Figure 2-1. Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-2. Auto Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-13
Figure 3-1. Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3
Figure 3-2. Speed and Run Control Solenoids
Figure 3-3. Fuel System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3-4
Figure 3-4. Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-5. 70 Amp Alternator (P/N 30--60050--04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-6. V-Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
3-5
3-6
Figure 3-7 Belt Tension Gauge (Part No. 07-00203)
Figure 3-8. Vacuum Pump Connection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-9. Compressor -- Model 05K
Figure 3-10. Unloader Solenoid Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
3-8
3-10
3-11
62--10808 iv
LIST OF ILLUSTRATIONS -- continued
FIGURE NUMBER
Figure 3-11. Typical Setup for Testing High Pressure Switch
Figure 3-12. Defrost Air Switch Test Setup
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
3-11
3-12
Figure 3-13. Fan Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-14 Hot Gas (HGS2) or Condenser Pressure Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-15. Compressor Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12
3-13
3-13
Figure 3-16. Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-17. Thermostatic Expansion Valve Bulb and Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-1. Electrical Schematic Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14
3-14
5-2
LIST OF TABLES
TABLE NUMBER
Table 1-1. Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 1-2. Additional Support Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
1-1
1-1
Table 1-3. Safety Devices -- Microprocessor Controller
Table 2-1. Function Parameters
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-11
2-3
Table 2-2. Unit Data Codes
Table 2-3. Alarm Display
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5
2-7
Table 2-4. Manual Glow Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3-1. Belt Tension (See Figure 3-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11
3-5
Table 3-2. Connection Point Voltage
Table 3-3. Configuration Settings
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3-4. Sensor Resistance -- Micro Units (ATS,CDT, RAS, SAS & WTS)
Table 3-6. R-404A Temperature--Pressure Chart
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14
3-16
3-17
3-18
SAFETY SUMMARY
GENERAL SAFETY NOTICES
The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. The general safety notices are presented in the following three sections labeled:
First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions appearing elsewhere in the manual follows the general safety notices.
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 unit main power switch is in the START/RUN position.
FIRST AID
An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.
OPERATING PRECAUTIONS
Always wear safety glasses. 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 and the Emergency Switch 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 the Emergency Switch is in the
OFF position.
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).
AUTO-START
Your refrigeration unit is equipped with Auto-Start in both Start/Stop and Continuous Run modes. The unit may start at any time. A buzzer will sound for 5 seconds before the unit is started. When performing any check of the refrigeration unit (e.g., checking the belts, checking the oil), make certain that the Start-Run / Off switch is in the OFF (0) position.
ENGINE COOLANT
The engine is equipped with a pressurized cooling system. Under normal operating conditions, the coolant in the engine and radiator is under high pressure and is very hot. Contact with hot coolant can cause severe burns. Do not remove the cap from a hot radiator; if the cap must be removed, do so very slowly in order to release the pressure without spray.
REFRIGERANTS
The refrigerant contained in 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--10808
BATTERY
This unit is equipped with a lead-acid type battery. The battery normally vents small amounts of flammable hydrogen gas. Do not smoke when checking the battery. A battery explosion can cause serious physical harm and/or blindness.
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 specifically applicable to this refrigeration unit and appear elsewhere in this manual.
These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein.
WARNING
Beware of unannounced starting of the engine, standby motor, evaporator fan or condenser fan. The unit may cycle the engine, standby motor or fans unexpectedly as control requirements dictate
WARNING
Under no circumstances should ether or any other starting aids be used to start engine.
WARNING
Beware of V-belts and belt driven components as the unit may start automatically. Before servicing unit, make sure the Run-Stop switch is in the STOP position. Also disconnect the negative battery cable.
WARNING
Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is approximately 2350 psi (160 bar). Do not use oxygen in or near a refrigerant system as an explosion may occur.
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
Make sure the power plug is clean and dry before connecting to any power source.
WARNING
Testing of the generator presents hazards which can result in personal injury or death. Only persons qualified to carry out electrical and mechanical servicing should undertake this work
WARNING
When flashing the generator, the jumpers should be connected to 12VDC for no longer than one second.
WARNING
Ensure power to the unit is OFF and power plug is disconnected or vehicle engine is OFF and negative battery cable is disconnected before replacing the compressor.
CAUTION
Under no circumstances should anyone attempt to repair the Logic or Display Boards. Should a problem develop with these components, contact your nearest Carrier Transicold dealer for replacement.
CAUTION
Unit with R404A and POE oil, the use of inert gas brazing procedures is mandatory; otherwise compressor failure will occur. For more information see Technical Procedure 98-50553-00 Inert Gas Brazing
62--10808
Safety-2
CAUTION
Use only ethylene glycol anti-freeze (with inhibitors) in system as glycol by itself will damage the cooling system.
Always add pre-mixed 50/50 anti-freeze and water to radiator/engine. Never exceed more than a 50% concentration of anti-freeze. Use a low silicate anti-freeze.
CAUTION
Extreme care must be taken to ensure the manifold common connection remains immersed in oil at all times. Otherwise air and moisture will be drawn into the compressor.
CAUTION
Observe proper polarity, reverse polarity will destroy the diodes. As a precaution, disconnect positive terminal when charging.
CAUTION
Do not damage or over tighten the enclosing tube assembly. Also make sure all parts are placed in the enclosing tube in proper sequence to avoid premature coil burn-out.
CAUTION
Under no circumstances should a technician electrically probe the microprocessor 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 microprocessor.
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.
CAUTION
Under no circumstances should anyone attempt to service the microprocessor . Should a problem develop with the microprocessor, contact your nearest Carrier Transicold dealer for replacement.
CAUTION
Refrigerant R404A must be charged as a liquid. Refrigerant R404A is a blend. Charging as a vapor will change the properties of the refrigerant.
Safety-3 62--10808
SECTION 1
DESCRIPTION
1.1 INTRODUCTION
WARNING
Beware of unannounced starting of the engine, standby motor, evaporator fan or condenser fan. The unit may cycle the engine, standby motor or fans unexpectedly as control requirements dictate
This manual contains operating data, electrical data and service instructions for the Carrier Transicold Supra model truck refrigeration units listed in Table 1-1.
Additional Supra support manuals are listed in
Table1--2.
The model/serial number plate is located inside of the unit on the frame as shown in Figure 1-2.
1.2 GENERAL DESCRIPTION
The Supra models are self contained one piece refrigeration/heating units designed for truck applications.
The units consist of a condenser section, located outside the truck body, and an evaporator section which extends inside the body. Two types of drives may be included:
Road Operation
Both the TDB and TDS model units are equipped with an engine. In the Road Operation mode, the compressor and alternator are driven by the engine. TDB units do not have standby motors, a standby motor shell is installed
(without the motor winding) to allow the same belt arrangement for both units.
Table 1-1. Model Chart
Standby Operation
TDS units are equipped with an internal combustion diesel engine and an electric standby motor. In Standby
Operation, the compressor and alternator are driven by the electric standby motor.
1.3 CONDENSING SECTION
The condensing section (see Figure 1-1, Figure 1-2 &
Figure 1-3) contains the drive equipment, alternator and the high side refrigeration system equipment. The engine radiator and refrigerant condenser are incorporated into a single condenser/radiator assembly.
The drive equipment includes the engine, engine mounted clutch, air cleaner, muffler, coolant overflow bottle, drive belts and standby motor.
The condensing section mounted refrigeration system equipment includes the compressor, accumulator quench valve, defrost air switch, filter drier, receiver, hot gas (three way) valve and compressor pressure regulating valve.
1.3.1 Engine
The engine (Figure 1-1,item 3) is a 3 cylinder TriVortex diesel manufactured by Kubota. Engine operation is controlled by a Run Solenoid and a Speed Solenoid.
The engine is cooled by a radiator which is integral with the refrigerant condenser. The cooling system is fitted with a Coolant Overflow Reservoir. Engine air cleaners are dry type.
MODEL
Supra 644, TDB-16
Supra 644, TDS-16
Supra 744, TDB-19
Supra 744, TDS-19
Supra 844, TDB--24
Supra 844, TDS--24
REFRIGERANT
R--404A
LB
11
11
KG
5.0
5.0
12
12
15
15
5.4
5.4
6.8
6.8
ENGINE COMPRESSOR
05K 012 y
05K 024
4Cylinder
STANDBY
MOTOR
60 hz
--
7.6 hp
--
7.6 hp
--
7.6 hp
Manual Number
62--10483
62--10690
62--02638
62--03717
Table 1-2. Additional Support Manuals
Equipment Covered
Supra 644,744
Supra 844
Engine
Engine
Type of Manual
Parts List
Parts List
Operation and Service
Parts List
1-1
62--10808
1 2 3 4 5 6 7 8 9 10
11
12
16 15 14 13
ALARM/FAULT
FUNCTION
SETPOINT
BOX TEMPERATURE
ENTER
AUTO START/STOP
PRETRIP
O
I
ROAD
CITY
SPEED
MAN
DEFROST
BUZZER OFF
STANDBY
CAB COMMAND
1. Muffler
2. Thermal Expansion Valve (Location)
3. Engine (Refer toTable 1-1)
4. Heat Exchanger (Location)
5. Compressor
6. Alternator
7. Electric Standby Motor
8. Defrost Air Switch
9. Compressor Pressure Regulating Valve (CPR)
10. Accumulator
11. Filter-Drier
12. Hot Gas Bypass Solenoid (HGS2)
13. Receiver
14. Hot Gas Valve (Three-Way) (HGS1)
15. Condenser
16. Radiator Overflow Reservoir
Figure 1-1. Condensing Section -- Top View/Cab Command
62--10808
1-2
1
1. Fuel Filter
2 3 4
2. Serial/Model Number Plate
3. Speed & Run Solenoid
5
4. Air Cleaner
5. Oil Filter
Figure 1-2. Unit Curbside View
1. Receiver Sight Glasses
2. Electrical Box (See Figure 1-9)
3. Evaporator
Figure 1-3. Unit Roadside View
1-3
1
2
3
62--10808
1.3.2 Clutch Assembly
The clutch assembly is mounted on the engine crankshaft. All units have centrifugal type clutches.
1.3.3 Standby Motor
The standby motor operates on nominal
460v--3ph--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.
1.3.4 Alternator/Regulator
The alternator supples power for operation of the system controls, evaporator fan motors and for charging of the unit battery, if equipped. The alternator is three phase, full-wave rectifier type with integral all-electronic, transistorized regulator.
1.3.5 Compressor
The compressor assembly includes the refrigerant compressor, suction and discharge service valves, high pressure switch and the suction pressure transducer.
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.
1.3.6 Compressor Unloader
The Model 844 unit’s compressor is fitted with one electric unloader valve. The capacity controlled cylinders are easily identified by the solenoid which extends from the side of the cylinder head. When the solenoid is energized the cylinders unload. The unloaded cylinders operate with little or no pressure differential, consuming very little power. A description of unloader operation is provided in the following steps.
a. Unloaded Operation
Pressure from the discharge manifold (Figure 1-4, item
15) passes through the strainer (9) and bleed orifice (8) to the back of the piston bypass valve (7). Unless bled away, this pressure would tend to close the piston (6) against the piston spring (5) pressure.
With the solenoid valve (1) energized the solenoid valve stem (2) will open the gas bypass port (3).
Refrigerant pressure will be bled to the suction manifold
(10) through the opened gas bypass port . A reduction in pressure on the piston bypass valve will take place because the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice
(8).
When the pressure behind the piston has been reduced sufficiently, the valve spring will force the piston bypass valve back, opening the gas bypass from the discharge manifold to the suction manifold.
Discharge pressure in the discharge manifold will close the discharge piston check valve assembly (14) isolating the compressor discharge manifold from the individual cylinder bank manifold.
The unloaded cylinder bank will continue to operate fully
unloaded
until the solenoid valve control device is de-
energized
and the gas bypass port is closed.
2 3
4
5
6
7
11
1
8
9
14
15
10
12
13
1. Solenoid Valve
2. Valve Stem
3. Gas Bypass Port
4. Spring Guide
5. Spring
6. Piston
7. Piston Bypass Valve
8. Bleed Orifice
9. Strainer
10.Suction Manifold
11. Cylinder Discharge
Valve
12. Valve Plate
13. Cylinder Suction
Valve
14. Discharge Piston
Check Valve
Assembly
15. Discharge Manifold
Figure 1-4. Cylinder Head -- Unloaded b. Loaded Operation
Discharge pressure bleeds from the discharge manifold
(Figure 1-5, item 15) through the strainer (9) and (8) bleed orifice to the solenoid valve stem (2) chamber and the back of the piston bypass valve (7).
With the solenoid valve (1) de-energized the solenoid valve stem will close the gas bypass port (3).
Refrigerant pressure will overcome the bypass valve spring (5) tension and force the piston (6) forward clos-
ing
the gas bypass from the discharge manifold to the suction manifold (10).
Cylinder discharge pressure will force open the discharge piston check valve assembly (14). Refrigerant gas will pass into the compressor discharge manifold.
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1-4
The loaded cylinder bank will continue to operate fully loaded until the solenoid valve control device is energized and the gas bypass port is opened.
1
2
9
14
15
8
3
4
6
7
10
11
12
13
1.3.10 Hot Gas Solenoid Valve
The Hot Gas Valve (HGS1) directs flow of refrigerant through the system. 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.
In the heat mode, heat is removed from the air surrounding the truck body and rejected to the air inside the truck body. A description of valve operation is provided in the following sub--paragraphs.
a. Cooling Operation (See Figure 1-6.)
With the solenoid coil de-energized the valve is in the cool operating mode and the refrigerant gas is diverted to the condenser. The volume directly above the piston assembly is open to suction pressure through the external pilot connection and the volume underneath the piston assembly is open to discharge pressure through the compressor discharge connection. This difference in pressure across the piston assembly results in the piston assembly being shifted upward, shutting the heat and defrost port, opening the condenser port, and allowing refrigerant to flow to the condenser.
To compressor suction
1. Solenoid Valve
2. Valve Stem
3. Gas Bypass Port
4. Spring Guide
5. Spring
6. Piston
7. Piston Bypass Valve
8. Bleed Orifice
9. Strainer
10.Suction Manifold
11. Cylinder Discharge
Valve
12. Valve Plate
13. Cylinder Suction
Valve
14. Discharge Piston
Check Valve
Assembly
15. Discharge Manifold
Figure 1-5. Cylinder Head -- Loaded
1.3.7 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 on the standby motor/motor shell shaft.
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.
1.3.8 Accumulator
The accumulator is a refrigerant holding tank located in the suction line between the evaporator and compressor. The purpose of the accumulator is to prevent entry of any liquid refrigerant into the compressor.
Refrigerant vapor leaves the accumulator outlet pipe at a point well above any liquid level thus preventing the entrance of liquid. The outlet pipe is equipped with an orifice that controls oil return to the compressor and prevents accumulation of oil within the tank.
1.3.9 Compressor Pressure Regulating Valve
(CPR)
This adjustable regulating valve regulates the suction pressure entering the compressor. The suction pressure is controlled to avoid overloading the electric motor or engine during high box temperature operation.
Solenoid de-energized
To evaporator
From compressor
To condenser
Figure 1-6. Hot Gas Valve -- Cooling Flow b. Heat and Defrost Operation (See Figure 1-7.)
When the hot gas solenoid coil is energized, discharge gas flows to the evaporator for heating or defrost. When energized, the solenoid plunger is lifted, allowing discharge gas to fill the volume above the piston assembly.
Discharge gas is also allowed to fill the volume below the piston assembly through the compressor discharge connection. The pressure on both sides of the piston assembly is now equal and the piston spring exerts a force on top of the piston assembly and shifts it downward. The condenser port is now closed and the evaporator port is open. In both the energized and de-energized positions, the bypass of discharge gas to the suction port is prevented.
1-5
62--10808
Solenoid energized
To evaporator
From compressor
Figure 1-7. Hot Gas Valve -- Heat and Defrost
Flow
1.3.11 Hot Gas Bypass Solenoid Valve
The hot gas bypass solenoid valve (HGS2) opens during heating and allows the compressor to draw vapor from the top of the receiver resulting in increased heating capacity.
1.3.12 Filter Drier
The drier is cylinder shell containing a drying agent and screen. It is installed in the liquid line and functions to keep the system clean and remove moisture from the refrigerant. A sight glass may also be installed downstream of the drier. The sight glass is fitted with a paper element that changes color to indicate moisture content.
1.3.13 Receiver
Liquid refrigerant from the condenser drains into the receiver. The receiver serves as a liquid reservoir when there are surges due to load changes in the system; as a storage space when pumping down the system and as a liquid seal against the entrance of refrigerant gas into the liquid line.
The receiver is provided with two bull’s--eye sight glasses, for the observation of liquid level, and a pressure relief valve.
1.4 EVAPORATOR SECTION
The evaporator section contains the evaporator coil, expansion valve, heat exchanger, defrost termination thermostat(s) and electrical evaporator fan motors.
1.4.1 Thermal Expansion Valve
The thermal expansion valve is an automatic device which controls the flow of liquid to the evaporator according to changes in superheat to the refrigerant leaving the evaporator. The thermal expansion valve maintains a relatively constant degree of superheat in the gas leaving the evaporator regardless of suction pressure.
Thus, the valve has a dual function; automatic expansion control and prevention of liquid return to the compressor.
1.4.2 Heat Exchanger
The heat exchanger is of the tube in tube type connected in the main suction line and liquid line. Within the heat exchanger, the cold suction gas is used to cool the warm liquid refrigerant. This results in greater system capacity and efficiency.
1.4.3 Evaporator
The unit evaporator is a tube and fin type. The operation of the compressor maintains a reduced pressure with the 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 condenser is provided by two or three electric fans.
1.4.4 Electric and Water Heat
The unit can be equipped with Electric Heat, Water
Heat, and Electric/Water heat. See Figure 1-8. When the controller calls for heat, the heater contactor will close or valve will open and engage the heat system .
1.5 SYSTEM OPERATING CONTROLS AND
COMPONENTS
The unit is furnished with a microprocessor control system. Once the set point is entered at the controller, the unit will operate automatically to maintain the desired temperature within very close limits. The control system automatically selects high and low speed cooling or high and low speed heating as necessary to maintain the desired temperature.
Units also have a auto start/stop feature. Auto start/stop operation provides automatic cycling of the diesel engine or standby motor, which in turn offers an energy efficient alternative to continuous operation.
62--10808
1-6
3
Water Heat Coil
2
Electric
Heat
Elements
ELECTRIC HEAT CONTROL BOX
4
1
HOT WATER HEAT COMPONENTS
1. Water Valve
2. Water Tube (HWH)
3. Hose (HWH)
4. Harness (HWH)
UNIT CONTROL BOX
Figure 1-8. Water and Electric Heat Components
1.5.1 SWITCHES AND CONTROLS
Manual control switches are located on the side of the electrical box. Components required for monitoring and controlling the diesel engine and refrigeration system are located on the engine, compressor or system piping.
1. RUN-STOP switch (RS)
This switch controls supply of power to the microprocessor and cab command. The switch is placed in the ON position to allow manual or automatic unit operation.
With the switch in the OFF position the unit will be shut down and neither manual or automatic starting is allowed.
2. Manual Glow/Crank Switch (MGC)
This switch is a three position switch. This switch is held in the GLOW position to energize the glow plugs and pre-heat the combustion chamber. The switch is moved to the CRANK position to manually engage the engine starter. When the switch is released, it returns to the middle position to de--energize both components.
3. Oil Pressure Safety Switch (OP)
This switch will automatically stop the engine upon loss of oil pressure. The switch is located on the side of the engine.
4. Water Temperature Sensor (WTS)
The microprocessor will stop the unit when this sensor signals a high water temperature condition. The sensor is located near the thermostat housing in the cylinder head.
5. High Pressure Cutout Switch (HP1)
This switch will automatically stop the engine when compressor discharge pressure exceeds the set point.
The switch is located on the compressor cylinder head.
6. Compressor Discharge Temperature Sensor (CDT)
The microprocessor will stop the unit when this sensor signals a high discharge temperature condition. The sensor is located on the compressor body.
7. Compressor Suction Pressure Transducer (SPT)
The Compressor Suction Pressure Transducer signal is used by the microprocessor in the compressor protection logic to protect the compressor under excessive suction pressure conditions and under excessively low suction pressure conditions. The sensor is located on the compressor body.
8. Ambient Temperature Sensor (ATS)
The Ambient Temperature Sensor signal is used by the microprocessor in the compressor protection logic to determine expected conditions.
1-7
62--10808
3
4
5
7
2
1
1. Run-Stop Switch (RS)
2. Manual Glow/Crank Switch (MGC)
3. Relay/Fuse Board (See NO TAG &
Figure 1-10)
4. Standby Motor Contactor (MC)
5. Motor Overload Relay (MOL)
6. Microprocessor Module
7. Fuse (F1, 80 amp)
Note: See Figure 2-1 for Cab Command
Figure 1-9. Electrical Box
6
62--10808
Figure 1-10. Control Relay Board
1-8
1.6 Unit Specifications
1.6.1 Engine Data
Engine Model
Used on
Displacement
No. Cylinders
Horsepower
Weight
Oil Capacity
Operating
High
Low
Injection Setting
Water Safety
Switch
Oil Pressure
Switch
Glow Plug
Fuel Heater Thermostat
CT3-44TV (D744)
SUPRA 644/744/844
719 cc (43.9 in
3
)
3
10.3 kw (13.4 hp) @2200rpm
63 kg (139 lbs)
3.7 liters (3.9 U.S. quarts)
Use 50/50 to 60/40 ethylene glycol/water mix, standard or extended life antifreeze
8.1 liters (8.5 U.S. quarts)
644; 2025 to 2100 rpm
744; 2200 to 2250 rpm
844: 2300 to 2350 rpm
1800 to 1850 rpm
140 to 150 kg/cm
2
(1991 to 2133 psi)
Closes at: 230
_ ¦
5
_
F (110
¦
3
_
C)
Closes at: 15
¦
3 psig (1.05
¦
1.4 ohms at 11 volts.
0.2 kg/cm
Closes on temperature falls at 45+ 6.5
_
F
Opens on temperature rise at: 75+ 6.5
_
F
2
)
Lubrication System
Lube Oil Viscosity: (API Classification CD)
Outdoor Temperature
Fahrenheit
Below 32
_
Centigrade
Below 0
_
C 10W or 10W30
32
_ to 77
_
F
Over 77
_
F
0
_ to 25
_
C 20W
Over +25
_
C 30W or 15W40
1.6.2 Compressor Data
Model (Unit)
Displacement
No. Cylinders
No. Unloaders
Weight
Oil Charge
05K 012 (644/744)
200 cc (12.2 in
3
)
2
0
38 kg (84 lbs)
1.9 L (4.0 pints
Refrigerant
APPROVED COMPRESSOR OIL
05G
Mobile Arctic EAL 68
Castrol Icematic SW-68C
05K 024 (844)
400 cc (24.4 in
3
4
1
49 kg (108 lbs)
2.6 L (5.5 pts))
)
1-9
62--10808
1.7 REFRIGERATION SYSTEM DATA a. Defrost Timer
1-1/2, 3, 6, or 12 hours
b. Defrost Thermostat
Opens at: 47
_ ¦
5
_
F (8
_ ¦
3
_
C)
Closes at: 37
_ ¦
5
_
F (3
_ ¦
3
_
C)
c. Defrost Air Switch Setting
844; Initiates at: 0.70
¦
.07 inch (17.8
¦
1.8 mm wg)
644/744; Initiates at: 1.00
¦
.07 inch
SUPRA 99 (25.4
¦
1.8 mm wg) *Identified by an “A” at the end of the model number.
644/744; Initiates at: 0.75
¦
.07 inch (19.0
¦
1.8 mm wg)
d. High Pressure Cutout Switches
HP1 -- R-404A
Cutout at: 465
¦
10 psig (32.7
¦
0.7 kg/cm
@
) Cut-in at: 350
¦
10 psig (24.6
¦
0.7 kg/cm
@
)
HP2 -- R-404A
Cutout at: 367
¦
12 psig (25
¦
0.8 kg/cm
@
) Cut-in at: 440
¦
10 psig (29.9
¦
0.7 kg/cm
@
)
e. Refrigerant Charge
Refer to Table 1-1
f. Compressor Pressure Regulating Valve (CPR)
SUPRA 644
SUPRA 744
SUPRA 844
CPR Setting psig
28
±
1
32
±
1
29
±
1
g. Thermostatic Expansion Valve Superheat
CPR Setting kg/cm
@
1.97
±
0.07
2.25
±
0.07
2.04
±
0.07
Setting at 0
_
F (--17.8
_
C) box temperature: 8--10
_
F (--13.3 to --12.2
_
C)
h. Compressor Discharge Temperature Sensor
Unit shut down at:
310
_
F (154
_
C) for 3 minutes or 350
_
F (177
_
C)
1.8
ELECTRICAL DATA a. Evaporator Fan Motors
Bearing Lubrication: Factory lubricated, additional grease not required
Horsepower
Operating
Current
Speed Voltage
1/5 hp (.15 kw) 7 to 10 amps
2250 rpm
12 vdc
b. Standby Motors
Bearing Lubrication: Factory lubricated additional grease not required
Rotation Speed: 1760 rpm@ 60hz/1500 rpm@ 50hz
Voltage
3ph, 60 hz
SUPRA 644/744
Power
HP
230
460
∆
Y
SUPRA 844
230
460
∆
Y
23
13
19.6
9.8
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1-10
c. Alternator: 70 amps
d. Standby Motor Overload
MODEL
644/744
844
SETTING
230V, 3 ph, 60 hz 460V, 3 ph, 60 hz
20 AMPS
20 AMPS
14 AMPS
12.5 AMPS
1.9 TORQUE VALUES
Assembly
Power Tray to Frame
Standby Motor to Power Tray
Engine to Power Tray
Compressor to Power Tray
Standby Motor Pulley
Engine Pulley
Compressor Pulley
ft--lb
40
40
50
40
32
22
22
kg--m
5.5
5.5
7.0
5.5
4.5
3.0
3.0
Evaporator Fan Motor
Evaporator Fan Grille
Condenser Coil to Chassis
Tensioner to Power Tray
Engine Support
Run & Speed Solenoids
Condenser Fan Blade
Engine Clutch
13
7
7
22
40
7
18
40
1.10 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 safety devices listed in Table 1-3.
Table 1-3. Safety Devices -- Microprocessor Controller
Unsafe Conditions
1.
Low engine lubricating oil pressure
2.
High engine cooling water temperature
Fuse (F1)
Safety Device
Oil pressure safety switch (OP) automatic reset
Water temperature sensor
(microprocessor)
Device Setting
Opens below 15
¦
3 psig (1
¦
0.2 kg/cm
@
)
Opens above 230
¦
5
_
F
(110
¦
3
_
C)
Opens at 80 amps
3.
Excessive current draw by glow plug circuit , control circuit or starter solenoid (SS)
4.
Excessive current draw by microprocessor
5.
Excessive current draw by control circuit
6.
Excessive current draw by speed control solenoid
Fuse (F2)
Fuse (F3)
Fuse (F4)
Opens at 5 amps
Opens at 25 amps
Opens at 15 amps
Fuse (F5) Opens at 7 1/2 amps 7.
Excessive current draw by auto restart or out-of-range lights
7.
Excessive current draw by Compressor clutch or front unloader
8.
Excessive current draw by evaporator fan motors
9.
Excessive current draw by fuel pump
10.
Excessive compressor discharge pressure
11.
Excessive compressor discharge temperature
Fuse (F6)
Fuse (F7, F8, F9, F10)
Fuse (F11)
High pressure cutout switch (HP) automatic reset
Compressor discharge temperature sensor (CDT)
Opens at 5 amps
Opens at 20 amps
Opens at 5 amps
Refer to Section 1.7.d.
Shuts unit down above
310
_
F (154
_
C) for 3 minutes or 350
_
F (177
_
C)
1.8
1.0
1.0
3.0
5.5
1.0
2.5
5.5
1-11
62--10808
1.11 REFRIGERANT CIRCUIT
1.11.1 Cooling (See Figure 1-11)
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, direct expansion evaporator, and hot gas valve.
In the cooling mode, the hot gas valve is de--energized.
With the hot gas valve de--energized, flow through the valve is from the side discharge connection to the bottom condenser connection.
The compressor raises the pressure and temperature of the refrigerant and forces it into the condenser tubes.
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 and through a check valve 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 shutoff valve (king valve) to the subcooler. The subcooler occupies a portion of the main condensing coil surface and gives off further heat to the passing air.
The refrigerant then flows through a filter-drier where an absorbent keeps the refrigerant clean and dry. A sight glass with moisture indicator may also be fitted downstream of the drier.
The refrigerant then flows to the “Liquid/suction” heat exchanger. Here the liquid is further reduced in temperature by giving off some of its heat to the suction gas.
The liquid then flows to an externally equalized thermostatic expansion valve (TXV) which reduces the pressure of the liquid and meters the flow of liquid refrigerant to the evaporator to obtain maximum use of the evaporator heat transfer surface.
The evaporator tubes have aluminum 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.
This low temperature, low pressure vapor passes through the “suction line/liquid line” heat exchanger where it absorbs more heat from the high pressure/high temperature liquid and then returns to the accumulator.
The compressor draws this vapor out of the accumulator through a pick-up tube which is equipped with a metering orifice. This orifice prevents the accumulation of oil in the accumulator tank. The metering orifice is calibrated to control the rate of oil flowing back to the compressor.
The vapor refrigerant then enters the compressor pressure regulating valve (CPR) which regulates refrigerant pressure entering the compressor, where the cycle starts over.
1.11.2 HEAT AND DEFROST (See Figure 1-11)
When refrigerant vapor is compressed to a high pressure and temperature in a reciprocating compressor, the mechanical energy necessary to operate the compressor is transferred to the gas as it is being compressed. This energy is referred to as the “heat of compression” and is used as the source of heat during the heating cycle.
When the controller calls for heating or defrost, the hot gas valve solenoid energizes, closing the port to the condenser and opening a port which allows heated refrigerant vapor to flow through the drainpan heater tube to the evaporator coil.
The hot gas bypass solenoid valve also opens during heating to provide additional refrigerant to the compressor from the receiver. This increases the amount of refrigerant in circulation, increasing heating capacity.
The main difference between heating and defrosting is that, when in heating all the evaporator fans continue to run, blowing the air over the heated coils to heat the product. When defrosting, the evaporator fans stop, allowing the heated vapor to defrost any ice build up there maybe.
The bypass line draws refrigerant from the receiver and injects it through a metered valve into the discharge line past the compressor pressure regulator valve. This will raise the discharge pressure and raise discharge temperature.
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1-12
EVAPORATOR
FILTER DRIER
TXV
BULB
DRAIN PAN HEATER
TXV
CHECK
VALVE
HOT GAS
BYPASS
SOLENOID
VALVE
(HGS2)
RECEIVER VALVE
RECEIVER
INLET
CHECK
VALVE
HEAT
EXCHANGER
HOT GAS
VALVE (HGS1)
SUBCOOLER
COMPRESSOR
PRESSURE
REGULATOR
VALVE
DISCHARGE
SERVICE
VALVE
HP
SPT
CONDENSER
METERING
ORIFICE
ACCUMULATOR
TXV
BULB
SUCTION
SERVICE
VALVE
Discharge
Liquid
Suction
COMPRESSOR
COOLING CYCLE
EVAPORATOR
TXV
DRAIN PAN HEATER
CHECK
VALVE
FILTER DRIER
HOT GAS
BYPASS
SOLENOID
VALVE
RECEIVER VALVE
RECEIVER
INLET
CHECK
VALVE
HEAT
EXCHANGER
HOT GAS
VALVE
SUBCOOLER
COMPRESSOR
PRESSURE
REGULATOR
VALVE
HP
DISCHARGE
SERVICE
VALVE
SPT
METERING
ORIFICE
ACCUMULATOR
SUCTION
SERVICE
VALVE
COMPRESSOR
HEAT AND DEFROST CYCLE
Figure 1-11. Refrigeration Circuit
1-13
CONDENSER
Discharge
Liquid
Suction
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2.1 MICROPROCESSOR CONTROLLER
2.1.1 Introduction
CAUTION
Under no circumstances should anyone attempt to repair the Logic or Display Boards.
Should a problem develop with these components, contact your nearest Carrier Transicold dealer for replacement.
The Microprocessor System consists of the microprocessor module (Item 3, Figure 1-9), relay/fuse board
(Item 6, Figure 1-9), 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 Relay Module contains replaceable relays, diodes and fuses.
c. The Cab Command is remote mounted in the truck.
The Cab Command includes the LCD display and
12 13 14 15 16 17 18
SECTION 2
OPERATION
keypad. The key pad and display serve to provide user access and readouts of microprocessor information. The information is accessed by key pad selections and viewed on the display.
The Carrier Transicold Microprocessor System incorporates the following features: a. Control supply or return air temperature to tight limits by providing refrigeration control, heat and defrost to ensure conditioned air delivery to the load.
b. Default independent readouts of set point (at the left of the display) and actual supply or return air temperature (at the right).
c. Digital readout of unit data points such as pressures, temperatures and other microprocessor inputs.
d. Digital readout of selectable operating parameters
(Function Codes) and the ability to change those settings.
e. Digital display of Alarm Indications.
f. A self-test check on program memory and data memory at start--up.
19 20
FUNCTION
SETPOINT BOX TEMPERATURE
ENTER
ALARM/FAULT
i
UNIT DATA
2
AUTO START/STOP
3
1
PRETRIP
4
O
I
11 10
1.
Unit Data Key
2.
Auto Start/Stop --
Continuous Run Key
3.
Pretrip Key
4.
Stand-by Key
5.
Buzzer Off Key
6.
Enter Key
ROAD
9
CITY
SPEED
MAN
DEFROST
8 7
7. Manual Defrost Key
8. City Speed Key
9. Road Key
10. Function Key
11. ON--OFF Key
12. Cool Mode
13. Heat Mode
6
Figure 2-1. Cab Command
BUZZER
OFF
STANDBY
5
14. Defrost Mode
15 Road Mode
16. Auto Start/Stop Mode
17. Stand-by Mode
18. City Speed Mode
19. Out-of-range
20. Fault Light
2-1
62--10808
g. A Pre-Trip checkout of refrigeration unit operation.
h. An optional RS232 communication port to communicate unit operating data to a mobile satellite transmitter. This information will then be relayed back to the office via a modem to a computer.
There are presently three (3) protocols supported.
The protocol for the QualComm transmitter, the protocol for the HUGHES transmitter, and the Carrier
Communication Protocol. The microprocessor will transmit a HUGHES protocol packet every hour.
Transmission with the Carrier or QualComm protocol is by request.
2.1.2 Digital Display
The Digital Display (see Figure 2-1) has 9 positions. The default display is setpoint on the left and actual supply or return air temperature on the right. The readout may be set to read in Degrees F or Degrees C.
The display also has symbol type indicators for the following modes: Cool, Heat, Defrost, Road (diesel) Operation,
Auto Start/Stop mode, Stand-By mode, City Speed mode and Out-Of-Range operation. The indicator is illuminated to indicate the mode or condition is active.
On each power-up, the microprocessor will perform a self test. Errors, if any, will be indicated on the display as an EER.# where “#” is a number corresponding to the number of the failed test.
ERROR
ERR.1
ERR.2
ERR.3
ERR.4 or
Display
CAUSE
Processor failure
Check chip installation or Replace microprocessor.
Display board to logic board communication failure.
This can be caused by a defective ribbon cable or ribbon cable not plugged in properly.
2.1.3 Keypad
The keypad (Figure 2-1) has 12 keys which allow the operator to initiate various functions, display operating data and change operating parameters.
Arrow Keys
displayed data. If the unit is in the default display these keys are pressed to change the setpoint selection.
The up and down ARROW keys are used to modify (increment or decrement) the
Enter Key
The ENTER key is used to accept a change in function codes or a change in setpoint.
Manual Defrost Key
The MANUAL DEFROST KEY is used to initiate a defrost cycle. If the predetermined conditions for defrost are not met, the unit will not enter defrost and the display will return to the default screen.
Pretrip Check Key
The PRETRIP key is used to initiate a pretrip test cycle. If the predetermined conditions for pretrip are not met, the unit will not enter pretrip and the display will return to the default screen.
Auto Start/Stop -- Auto Start/Continuous Run Key
The AUTO START/STOP key is used to change the operating mode from “Auto
Start/Continuous Run” to “Auto Start/
Stop.” Each push of the key will alternate the operating modes. The microprocessor retains the last entered setpoint in memory even if the unit is shut down or a power failure occures. The Auto Start/Stop indicator on the display will illuminate when Auto Stop/Start is enabled. If the indicator is not illuminated, the unit is in the Auto
Start/Continuous Run Mode.
To start the unit in manual start mode, the auto start/stop
--auto start/continuous selection must be in continuous run mode and the Auto/Manual Start Operation function parameter set to “MAN OP” (FN10 OFF)
NOTE
When configuration CNF11 is “ON” and setpoint is 32 to 42
_
F (0 to 5.5
_
C) the unit is locked into continuous run. The AUTO START/STOP key is disabled.
Function Change Key
The FUNCTION CHANGE key is used to display the function codes. Each time this key is pressed the display will advance to the next code. This key, in conjunction with the ARROW and ENTER keys, will allow the user to change the
Function Parameters.
Unit Data Key
i
The UNIT DATA key is used to display the unit operating data. This key, in conjunction with the ARROW keys, will allow the user to display the unit’s operating data values (i.e, coolant temperature, battery voltage, etc.).
City Speed Key
The CITY SPEED key enables the city speed mode of operation. In the city speed mode, the unit will operate in low speed.
Each push of the key toggles the operating mode. The microprocessor retains the last entered setpoint in memory even if the unit is shut down or a power failure occures. The city speed indicator on the display will illuminate when the city speed mode is enabled.
Buzzer Off Key
The BUZZER OFF key will disable the cab command buzzer. When not disabled by use of this key, the buzzer is activated whenever the alarm/fault indicator is illuminated. The buzzer off indicator on the display will illuminate when the buzzer is disabled.
62--10808 2-2
Road Key
The ROAD key selects the diesel engine operating mode. The microprocessor retains the last entered setpoint in memory even if the unit is shut down or a power failure occures.
Stand-by Key
The STAND-BY key selects the electric motor operating mode. The microprocessor retains the last entered setpoint in memory even if the unit is shut down or a power failure occures. “NO POWER” will be displayed, if unit is switched to standby and power is not available.
2.2 MICROPROCESSOR CONFIGURATION
The microprocessor is configured in accordance with the equipment supplied on an individual unit and the requirements of the original purchase order. The configurations do not require change unless the unit has an equipment change or a change is required by the owner.
Although the configurations may not be modified using the key pad, operational differences will be noted throughout the following descriptions and operating procedures.
2.3 OPERATOR MICROPROCESSOR SETTINGS
The microprocessor settings that may be changed at the keypad include the Set Point and Function Parameters. Changes to the Functional Parameters allow the operator to taylor certain unit operations as desired.
2.3.1 Setpoint
NOTE
If configuration CNF3 is “ON” maximum setpoint is increased to 90
_
F.
Setpoints of --22
_
F to +86
_
F (--30
_
C to +30
_
C) may be entered via the keypad.
With the default screen showing on the display, the up or down ARROW key may be pressed to bring the set point to the desired reading. The display will flash to indicate that the reading being displayed is a non-entered value.
Depress the ENTER key to activate the new setting.
If the ENTER key is not pressed within five seconds after the last key stroke, the display will revert to the previous active setting. The microprocessor retains the last entered setpoint in memory even if the unit is shut down or a power failure occurs.
2.3.2 Functional Parameters
NOTE
If configuration CNF11 is “ON” functional parameters are locked out and the ability to change functional parameters from keypad is disabled.
The Function Parameters control selected operating features of the unit. These parameters can be displayed by pressing the FUNCTION CHANGE key. When multiple choices are available, the display will show the function description on the left side with the corresponding function choice on the right side. The list can be scrolled through by pressing the FUNCTION CHANGE key or by using the ARROW keys. With each FUNCTION
CHANGE key push, the list is advanced one. If the
FUNCTION CHANGE key is pressed and held for one second, the list will scroll at a rate of one item every 0.5
seconds. Once the end of the list is reached the list will scroll back to the first entry.
With a function parameter displayed, the data choice can be changed by pressing ENTER then pressing either the up or down ARROW keys. The displayed choice will then flash to indicate that the choice has not been entered. Depress the ENTER key to activate the new choice. The display will stop flashing to indicate that the choice has been entered.
If the new choice is not entered in 5 seconds, the display will revert back to the last entered choice. All function parameters are retained in memory. Descriptions of the function parameters and operator choices are provided in the following paragraphs. A function parameter listing is also provided in Table 2-1.
Table 2-1. Function Parameters
CODE ENGLISH DATA
FN0 DEFR Defrost Interval
FN1 ON CITY SPD Low Speed
FN1 OFF HIGH SPD High Speed
FN2 OFF T Minimum Off-time
FN3
FN4 a
ON T
REM
PROBE
On-time
Controlling Probe --
Return Air
FN4 b
SUP
PROBE
Controlling Probe --
Supply Air
FN5
FN6 ON
Degrees
F or C
TIME
STRT
TEMP
STRT
Temperature Unit
_
C or
_
F
Maximum Off-time 30 Min.
FN6 OFF
Temperature Based
Restarting
FN7
FN8
MOP STD Future Expansion
2SET Compartment 2 Setpoint
FN9 3SET Compartment 3 Setpoint
FN10 ON AUTO OP Auto Start Operation
FN10
OFF
MAN OP Manual Start Operation
FN11 T RANGE Out-of-Range Tolerance
Code vs English = Code or English display format
Manual Glow Override = Normal or Add 30sec
Alarm RST = Alarm Reset Required
Alarm CLR = No Alarm Active
2-3
62--10808
Code Vs English Messages
The function descriptions, unit status and alarms can be displayed in English or codes through this function selection. The choices are displayed as “ENGLISH” or
“CODES”. Refer to Table 2-1 for a listing of the display readings when the English or Code choice is activated.
Manual Glow Override
The auto start glow time can be manually overridden through this function. The choices are displayed as
“NORM GLOW” or “ADD GLOW”. If the “ADD GLOW” selection is entered, the control will add 30 seconds of glow to the default glow times. This feature must be selected before the 3 start attempts have been completed. At higher ambients, this override will only affect the second or third start attempt. The add glow time is deselected when the engine starts or fails to start.
Alarm Reset
Alarms can be reset through this function. The messages are displayed as “ALARM RST” or “ALARM
CLR”. If the “ALARM RST” is displayed then there is at least one alarm present. Pressing the ENTER key will clear all the alarms. If “ALARM CLR” is displayed then there are no alarms present.
Defrost Interval
The English display for Defrost Interval is “DEFR” the code display is “FN0”. The choices are displayed with one decimal place and then the capital letter H for hours
(i.e., DEFR 12.0H). The defrost choices are 1.5, 3, 6 or
12 hours.
Speed Control
The Speed Control parameter overrides the normal microprocessor speed control solenoid operation. Parameter English displays are “CITY SPD” or “HIGH SPD”.
The code displays are “FN1 ON” or “FN1 OFF”. With
“CITY SPD” or “FN1 ON” displayed the unit is locked into low speed. With “HIGH SPD” or “FN1 OFF” displayed, speed is under normal microprocessor control.
Minimum Off-Time
The auto start mode Minimum Off-Time parameter English display is “OFF T” the code display is “FN2”. The choice for the off-time is displayed with two digits and then the capital letter M for minutes (i.e. OFF T 20M or
FN2 20M). The off-time choices are 10, 20, 30, 45 or 90 minutes.
Minimum On-Time
The auto start mode Minimum On-Time parameter English display is “ON T”. The code display is “FN3”. The choice for the on-time is displayed with two digits and then the capital letter M for minutes (i.e. ON T4 M).The
on-time choices are 1 or 4 minutes.
Controlling Probe
The Controlling Probe parameter English displays are
“REM PROBE” or “SUP PROBE”. The code displays are “FN4 A” or “FN4 B”. With “REM PROBE” or “FN4 A” displayed, the microprocessor is set for operation with a single probe sensing return air temperature. With “SUP
PROBE” or “FN4 B” displayed, the microprocessor is set for dual probe (supply air or return air) control.
Standard Units Select
The Standard Unit Select parameter allows selection of
English or metric data display. The English display is DE-
GREES F or C. The code display is FN5. The choices are
_
C and
_
F. This parameter will also convert pressure readings to psig or bars.
Maximum Off Time
The auto start mode Maximum Off Time English display is “TIME START” or “TEMP START” the code display is
“FN6 ON” or “FN6 OFF”. With “TIME START” or “FN6
ON” displayed the engine will be started 30 minutes after shutdown. With “TEMP START” or “FN6 OFF” displayed the engine will be under normal microprocessor temperature control.
Diesel Backup Feature:
If the unit is in standby mode and AC power is lost for 5 minutes or more, the diesel engine will start and run until
AC power is restored and applied for 5 minutes. The
ROAD icon will blink once every second while the PLUG icon will stay on constantly to indicate that this feature is active.
When the 5 minute shutdown timer expires and AC power is present, the unit will shut down the diesel engine and restart the standby motor. If AC power is NOT present, the diesel engine will operate.
If the unit is set to “TEMP START” the standby diesel back up feature will be turned off and the unit will operate in normal standby mode.
MOP STD -- Future Expansion
This function is not used at this time. The English display is
“MOP STD”. The code display is FN7.
Compartment 2 Setpoint
The English display for Compartment 2 Setpoint is
“2SET” the code is “FN8”. With “2SET” or “FN8” displayed the setpoint for the second compartment may be entered. The setpoint procedure is the same as the main compartment, refer to paragraph 2.3.1.
Compartment 3 Setpoint
The English display for Compartment 3 Setpoint is
“3SET” the code is “FN9”. With “3SET” or “FN9” displayed the setpoint for the 3rd compartment may be entered. The setpoint procedure is the same as the main compartment, refer to paragraph 2.3.1.
Auto/Manual Start Operation
The English displays for Auto/Manual Start Operation are “AUTO OP” and “MAN OP”. The code displays are
“FN10 ON” and “FN10 OFF”. With “AUTO OP” or “FN10
ON” displayed the unit will be in the Auto Start/Stop
Operation mode. With “MAN OP” or “FN10 OFF” displayed the unit will be in the Manual Start mode.
To start the unit in manual start mode, the Auto Start/
Stop -- Auto Start/Continuous Run selection must be in
“continuous run” mode.
62--10808 2-4
Out-of-Range Tolerance
NOTE
If configuration CNF9 is “ON” the unit will shut down if an out of tolerance condition exists for over 45 minutes. If configuration CNF9 is “OFF” and an out of tolerance condition exists, the unit will continue to operate.
The English display for Out-Of-Range Temperature Tolerance is “T RANGE”. The code display is FN11. The choices are A, B or C. A = 3.6
_
F(2
_
C), B = 5.4
_
F(3
_
C) and C = 7.2
_
F (4
_
C).
When the out-of-range temperature is configured ON, the microprocessor indicates out-of-range when the temperature has been within the tolerance band at least once, and then goes outside the tolerance band for 45 minutes. Also, the unit will shut down.
When the out-of-range temperature is configured OFF, the microprocessor indicates out-of-range when the temperature has been within the tolerance band at least once, and then goes outside the tolerance band for 15 minutes. Also, the unit will continue to operate.
For set points at or below +10
_
F (--12.2
_
C) frozen range the unit is only considered out-of-range for temperatures above set point.
2.4 UNIT DATA
The UNIT DATA key can be used to display the microprocessor input data values. The display will show the description of the input on the left side with the actual data on the right side. The unit data list can be scrolled through by pressing the UNIT DATA key. With each successive key push, the list is advanced one. If the
UNIT DATA, or an ARROW key is held for one second, the list will scroll at a rate of one item every 0.5 seconds.
Once the end of the list is reached, the list will scroll back to the first entry. The display will revert back to the default display if no keys are pressed for 5 seconds.
If the ENTER key is pressed, the display time will be increased to 30 seconds. A description of the unit data readings is provided in the following paragraphs. A Unit
Data listing is provided in Table 2-2.
Suction Pressure
The English display for Suction Pressure is “SUCT”, the code display is “CD1”. The English units are designated by a “P” (psig) following the reading while the metric are designated by a “B” (bars). English readings below 0 are in inches of mercury. The display range is --0.7 to 29.4
Bar (--20 hg to 420 psig).
Engine Hours
The English display for Engine Hours is “ENG”, the code display is “CD2”. The data is displayed with units designator H (i.e, ENG 5040H or CD2 5040H). The display range is 0 to 99999.
Engine Temperature
The English display for Engine Temperature is “WT”, the code display is “CD3”. The English units are designated by an “F” following the reading (i.e, WT 185.0F or CD3
185.0F) while the metric are designated by a “C” (i.e,
WT 85.0C or CD3 85.0C). The display range is 10
_
F to
266
_
F (--12
_
C to 130
_
C).
Return Air Temperature
The English display for Return Air Temperature is
“RAS”, the code display is “CD4”. The English units are designated by an “F” following the reading (i.e, RAS
35.0F or CD4 35.0F) while the metric are designated by a “C” (i.e, RAS 1.7C or CD4 1.7C). The display range is
10
_
F to 266
_
F (--12
_
C to 130
_
C).
TABLE 2-2. UNIT DATA CODES
CODE ENGLISH
CD
1 SUCT
DATA
Suction Pressure
ENG Engine Hours CD 2
CD
3
CD 4
*
CD
5
*
CD
6
WT
RAS
SAS
REM
ATS
Engine Temperature
Return Air Temperature
Supply Air Temperature
Remote Air Temperature
Ambient Temperature CD 7
CD
8
CD 9
CD
10
CD
11
EVP
CDT
BATT
SBY
Future Expansion
Discharge Temperature
Battery Voltage
Standby Hours
MOD V Future Expansion CD 12
CD
13
CD 14
CD
15
REV
SERL
SERU
Software Revision
Serial Number Low
Serial Number Upper
CD
16 2RA
Compartment 2
Air Temperature
CD
17 3RA
Compartment 3
Air Temperature
CD 18
CD
19
MHR1 Maintenance Hour Meter 1
MHR2 Maintenance Hour Meter 2
CD
20 SON Switch On Hour Meter
* Codes 5 & 6 are variable. SAS is displayed when the SUP Probe Function is selected. REM is displayed when the REM Probe Function is selected.
Supply Air Temperature
The English display for Supply Air Temperature is
“SAS”, the code display is “CD5”. The English units are designated by an “F” following the reading (i.e, SAS
35.0F or CD5 35.0F) while the metric are designated by a “C” (i.e, SAS 1.7C or CD5 1.7C). The display range is
--36
_
F to 158
_
F (--38
_
C to 70
_
C). The data will be displayed only if the SUP PROBE is selected in the controlling probe functional parameter.
Remote Air Temperature
The English display for Remote Air Temperature is
“REM”, the code display is “CD6”. The English units are designated by an “F” following the reading (i.e, REM
35.0F or CD6 35.0F) while the metric are designated by a “C” (i.e, REM 1.7C or CD6 1.7C). The display range is
--36
_
F to 158
_
F (--38
_
C to 70
_
C). The data will be displayed only if the REM PROBE is selected in the controlling probe functional parameter.
2-5
62--10808
Ambient Temperature
The English display for Ambient Air Temperature is
“ATS”, the code display is “CD7”. The English units are designated by an “F” following the reading (i.e, ATS
85.0F or CD7 85.0F) while the metric are designated by a “C” (i.e, ATS 29.4C or CD7 29.4C). The display range is--36
_
F to 158
_
F (--38
_
C to 70
_
C).
EVP -- Future Expansion
This unit data is not used at this time. The English display is “EVP”. The code display is CD8.
Compressor Discharge Temperature
The English display for Compressor Discharge Temperature is “CDT”, the code display is “CD9”. The English units are designated by an “F” following the reading (i.e,
CDT 185.0F or CD9 185.0F) while the metric are designated by a “C” (i.e, CDT 85.0C or CD9 85.0C). The display range is --40
_
F to 392
_
F (--40
_
C to 200
_
C).
Battery Voltage
The English display for Battery Voltage is “BATT”, the code display is “CD10”. The reading is displayed the capital letter V for volts (i.e, BATT 12.2V or CD10
12.2V). The voltage reading is displayed with a “+” plus sign if the battery status is good.
Standby Hours
The English display for Standby Motor Hours is “SBY”, the code display is “CD11”. The data is displayed with units designator H (i.e, SBY 5040H OR CD11 5040H).
The display range is 0 to 99999.
MOD V -- Future Expansion
This unit data is not used at this time. The English display is “MOD V”. The code display is CD12.
Software Revision
The English display for the Eprom Software Revision is
“REV”. The code display is “CD13”. The actual Eprom software revision number is displayed on the right. If the
ENTER key is depressed for three seconds while the
Eprom Software Revision is displayed, the display will revert to the Board Mounted Software display. The English display will change to “REV U2” on the left and the actual board mounted software revision number will be displayed on the right.
Serial Number Low
The English display for the Low Serial Number of the
Eprom is “SERL” The code display is “CD14”. The lower
3 digits of the Eprom serial number will be displayed on the left. (i.e, SERL 504 or CD14 504).
Serial Number Upper
The English display for the Upper Serial Number of the
Eprom is “SERU” The code display is “CD15”. The upper 3 digits of the Eprom serial number will be displayed on the left. (i.e, SERH 001 or CD14 001).
Compartment 2 Air Temperature
The English display for the Second Compartment Air
Temperature is “2RA”, the code display is “CD16”. The
English units are designated by an “F” following the reading (i.e, 2RA 35.0F or CD16 35.0F) while the metric are designated by a “C” (i.e, 2RA 1.7C or CD16 1.7C).
The display range is --36
_
F to 158
_
F (--38
_
C to 70
_
C).
Compartment 3 Air Temperature
The English display for the Third Compartment Air Temperature is “3RA”, the code display is “CD17”. The English units are designated by an “F” following the reading
(i.e, 3RA 35.0F or CD17 35.0F) while the metric are designated by a “C” (i.e, 3RA 1.7C or CD17 1.7C). The display range is --36
_
F to 158
_
F (--38
_
C to 70
_
C).
Maintenance Hour Meter 1
The English display for the Maintenance Hour Meter 1 is
“MHR 1”, the code display is “CD18”. The data is displayed with units designator H (i.e, MHR 1 5040H OR
CD18 5040H). The display range is 0 to 99999. The maintenance hour meter is compared to one of the hour meters (diesel, standby, or switch on) determined by its mode. If the hour meter is greater than the maintenance hour meter an alarm will be generated.
Maintenance Hour Meter 2
The English display for the Maintenance Hour Meter 2 is
“MHR 2”, the code display is “CD19”. The data is displayed with units designator H (i.e, MHR 2 5040H OR
CD19 5040H). The display range is 0 to 99999. The maintenance hour meter is compared to one of the hour meters (diesel, standby, or switch on) determined by its mode. If the hour meter is greater than the maintenance hour meter an alarm will be generated.
Switch On Hour Meter
The Switch On Hour Meter displays the total operating hours (engine & standby) on the unit. The English display for the Switch On Hour Meter is “SON”, the code display is “CD20. The data is displayed with units designator H (i.e, SON 5040H OR CD20 5040H). The display range is 0 to 99999.
2.5 ALARM DISPLAY
When an alarm is generated, the display will alternate between the default display (setpoint/air temperature) and the active alarm(s). Each item will be displayed for 3 to 10 seconds and the display will continue to scroll through the items until the alarms are cleared. Refer to paragraph 2.3.2--Alarm Reset for the procedure on resetting alarms.
The fault light (FL) will be illuminated when selected alarms are generated. An alarm listing with indication of which alarms are accompanied by the fault light is provided in Table 2-2. A description of the alarms is provided in the following paragraphs.
62--10808 2-6
Table 2-3. Alarm Display
ALARM DISPLAY
✔
= FAULT LIGHT ON
CODE
ENGLISH DESCRIPTION
AL0
ENG OIL
✔
Low Oil Pressure
AL1 ENG HOT
✔
High Coolant Temperature
AL2 HI PRESS
AL3 STARTFAIL
AL4 LOW BATT
AL5 HI BATT
AL6 DEFR FAIL
AL7 ALT AUX
AL8 STARTER
AL9 RA
SENSOR
AL10 SA
SENSOR
AL11 WT
SENSOR
AL12 HIGH CDT
AL13
CD
SENSOR
AL15 FUSE BAD
AL16 SYSTEM CK
AL17 DISPLAY
AL18 SERVICE 1
AL19 SERVICE 2
AL20 RAS OUT
AL23 NO POWER
✔ High Discharge Pressure
✔ Auto Start Failure
✔ Low Battery Voltage
✔ High Battery Voltage
Defrost Override
✔ No Alternator Auxiliary Output
✔
Starter Motor Fault
✔
Return Air Sensor Fault
✔
✔
✔
Supply Air Sensor Fault
Coolant Temperature Sensor
High Discharge Temperature
Discharge Temperature Sensor Fault
Fuse Open
Check Refrigeration System
Display
Maintenance Hour Meter 1
Maintenance Hour Meter 2
✔
Main Compartment Out--of--
Range
No AC Power When Unit Is In
Standby
Low Oil Pressure Alarm
The English display for the Low Oil Pressure alarm is
“ENG OIL”. The code display is “AL0”. This alarm is generated if the microprocessor senses low oil pressure any time after a short delay allowed at startup. When this alarm is generated, the fault light will illuminate and the engine will shut down.
High Coolant Temperature Alarm
The English display for the High Coolant Temperature alarm is “ENG HOT”. The code display is “AL1”. This alarm is generated if the microprocessor senses coolant temperature above 230
_
F (110
_
C). When this alarm is generated, the fault light will illuminate and the engine will shut down.
High Pressure Alarm
The English display for the High Pressure alarm is “HI
PRESS”. The code display is “AL2”. This alarm is generated if the high pressure switch opens. When this alarm is generated, the fault light will illuminate and the engine will shut down.
Start Failure Alarm
The English display for the Start Failure alarm is
“STARTFAIL”. The code display is “AL3”. This alarm is generated if the start sequence has completed and the engine has failed to start. When this alarm is generated, the fault light will illuminate.
If function parameter MAN OP (FN10 OFF) is selected the start failure alarm will be generated if the engine is not started in 5 minutes.
Low Battery Voltage Alarm
The English display for the Low Battery Voltage alarm is
“LOW BATT”. The code display is “AL4”. This alarm is generated if the battery voltage falls below 10 vdc.
When this alarm is generated, the fault light will illuminate.
High Battery Voltage Alarm
The English display for the High Battery Voltage alarm is
“HIBATT”. The code display is “AL5”. This alarm is generated if the battery voltage rises to 17 vdc. When this alarm is generated, the fault light will illuminate and the engine will shut down.
Defrost Override Alarm
The English display for the Defrost Override alarm is
“DEFR FAIL”. The code display is “AL6”. This alarm is generated if the defrost has been terminated by the 45 minute timer. The fault light will not be illuminated by this alarm.
Alternator Auxiliary Alarm
The English display for the Alternator Auxiliary alarm is
“ALT AUX”. The code display is “AL7”. This alarm is generated if the alternator auxiliary signal is not present with the engine running. When this alarm is generated, the fault light will illuminate.
Starter Motor Alarm
The English display for the Starter Motor alarm is
“STARTER”. The code display is “AL8”.This alarm is generated if the starter motor input signal is not present with starter solenoid energized. When this alarm is generated, the fault light will illuminate.
Return Air Sensor Alarm
The English display for the Return Air Sensor alarm is
“RA SENSOR”. The code display is “AL9”. This alarm is generated if the return air sensor is open or shorted.
If the microprocessor is set to allow operation on a second sensor, it will switch control to that sensor. If the unit is not fitted with a second sensor or if the microprocessor is not set to allow control on the second sensor, one of two actions will be taken.
1. If the unit is operating in the perishable range, the unit will shut down.
2. If the unit is operating in the frozen range, the unit will switch to low speed cool.
When this alarm is generated, the fault light will illuminate.
2-7
62--10808
Supply Air Sensor Alarm
The English display for the Supply Air Sensor alarm is
“SA SENSOR”. The code display is “AL10”. This alarm is generated if the supply air sensor is open or shorted.
This alarm will be disabled if the REM PROBE (FN4 A) is selected in the controlling probe functional parameter.
The fault light will not be illuminated by this alarm.
Coolant Temperature Sensor Alarm
The English display for the Coolant Temperature Sensor alarm is “WT SENSOR”. The code display is “AL11”.
This alarm is generated if the coolant temperature sensor is open or shorted. The fault light will not be illuminated by this alarm.
Compressor Discharge Temperature Alarm
The English display for the Compressor Discharge Temperature alarm is “HIGH CDT”. The code display is
“AL12”. This alarm is generated if the microprocessor senses discharge temperature above 310
_
F (155
_
C) for 3 minutes. When this alarm is generated, the fault light will illuminate.
If the discharge temperature exceeds 350
_
F (177
_
C), the fault light will illuminate and the engine will be shut down immediately.
Compressor Discharge Temperature Sensor Alarm
The English display for the Compressor Discharge Temperature Sensor alarm is “CD SENSOR ”. The code display is “AL13”. This alarm is generated if the sensor is open or shorted. The fault light will not be illuminated by this alarm.
Standby Motor Overload Alarm
The English display for the Standby Motor Overload alarm is “SBY MOTOR ”. The code display is “AL14”.
This alarm is generated if the MOL is open and the diesel/electric relay is energized (indicating standby mode).
Fuse Alarm
The English display for the Fuse alarm is “FUSE BAD ”.
The code display is “AL15”. This alarm is generated when the FUSE input is sensed low. When this alarm is generated, the fault light will illuminate.
System Check Alarm
The English display for the System Check alarm is
“SYSTEM CK”. The code display is “AL16”. This alarm is generated when refrigerant system pressure is low.
The fault light will be illuminated by this alarm.
Display Alarm
The English display for the Display alarm is “DISPLAY”.
The code display is “AL17”. This alarm is generated when no communications exist between the main board and the display. The fault light will not be illuminated by this alarm.
Maintenance Hour Meter 1 Alarm
The English display for the Maintenance Hour Meter 1 alarm is “SERVICE 1”. The code display is “AL18”. This alarm is generated when the designated hour meter is greater than maintenance hour meter 1. The fault light will not be illuminated by this alarm.
Maintenance Hour Meter 2 Alarm
The English display for the Maintenance Hour Meter 2 alarm is “SERVICE 2”. The code display is “AL19”. This alarm is generated when the designated hour meter is greater than maintenance hour meter 2. The fault light will not be illuminated by this alarm.
Out-Of-Range Alarm
The English display for the Out Of Range alarm is “OUT
RANGE”. The code display is “AL20”. This alarm is generated when the main compartment temperature is outside the designated range from set point. When this alarm is generated, the fault light will illuminate.
Remote Compartment 2 Out-of-range Alarm
The English display for the Remote Compartment 2 alarm is “2RAS OUT”. The code display is “AL21”. This alarm is generated when the second compartment temperature is outside the designated range from set point.
When this alarm is generated, the fault light will illuminate.
Remote Compartment 3 Out-of-range Alarm
The English display for the Remote Compartment 3 alarm is “3RAS OUT”. The code display is “AL22”. This alarm is generated when the second compartment temperature is outside the designated range from set point.
When this alarm is generated, the fault light will illuminate.
No Power for Standby Alarm
The display for the No Power alarm is “NO POWER”.
This alarm is generated when the unit is placed in the
Standby mode and there is no power to the power supply detector
2.6 PRE-TRIP
Pre--Trip is a test sequence that the operator may innate to check unit operation. During Pre--Trip the microprocessor operates the unit in various modes allowing evaluation of unit operation. If a failure occurs during
Pre--Trip, the microprocessor will generate an alarm.
The following steps detail the sequence: a. The unit is operated to bring box temperature below
40
_
F (4.4
_
C).
b. The operator presses the PRETRIP key. If the defrost thermostat (DTT) is closed, the microprocessor will display “PPPP” and the test is started. If DTT is open, the test will end.
c. After 30 seconds in high speed cool, unit cycles to low speed loaded cool.
d. After 30 seconds, unit cycles to low speed unloaded cool.
e. After 30 seconds, unit cycles to low speed unloaded heat.
f.
After 30 seconds, unit cycles to low speed loaded heat.
g. After 30 seconds, unit cycles to high speed heat and displays coolant temperature.
h. After 30 seconds, unit cycles to high speed cool and displays the defrost interval selection for 30 seconds, then unit cycles to defrost if DTT is closed.
i.
After standard defrost cycle, Pre-trip is terminated and unit returns to normal operation.
62--10808 2-8
2.7 MODES OF OPERATION
The operational software responds to various inputs.
These inputs come from the temperature and pressure sensors, the temperature set point, the settings of the configuration variables and the function code assignments. The action taken by the operational software will change if any one of the inputs changes. Overall interaction of the inputs is described as a “mode” of operation.
The modes of operation include cooling, heat and defrost. Refer to paragraph 1.11 for a description of the refrigerant circuit.
If the unit is operating in Auto Start/Stop, a fourth mode is added. This is the null mode. In the null mode, the unit shuts down until further cooling or heating is required.
The cooling mode is further divided into the perishable
(chill) range operation and frozen range operation. At setpoints above 10 ° F (--12 ° C) the unit will operate in the perishable range. In perishable range, all modes of operation are available to the microprocessor. At a setpoint of 10 ° F (--12 ° C) or below, the unit will operate in the frozen range. In frozen range, heat is locked out and only the cool and defrost modes are available to the microprocessor. Heat lockout can be overriden by setting CNF4 to “ON”. See Table 3-3.
2.7.1 Startup and Pull Down -- Engine Operation
At startup the unit starts in high speed cool. After 45 seconds the microprocessor checks to see if City Speed is activated. If city speed is activated, high speed is locked out. The unit will be brought to low speed and the following operations will all take place in low speed.
Also, the unit is locked in cooling during the oil pressure delay. If heating is required, the unit will switch to heating after the oil pressure delay time has expired.
If City Speed is not activated, the unit will remain in high speed heat or cool for the selected minimum run time
(Function Code FN3).
As box temperature is reduced, the microprocessor will switch to low speed at 2.2
° F (1.2
° C) above set point.
The microprocessor will switch from cool to heat at setpoint. If box temperature rises when in low speed pulldown, the microprocessor will switch back to high speed at 2.7
° F (1.5
° C) above set point.
After completing the pulldown, switching points are no longer at a fixed temperature point. The microprocessor will monitor the rate of temperature reduction or increase and switch operation as required to limit overshoot. This greatly increases the accuracy of the microprocessor.
The microprocessor will continue monitor changes in temperature and switch the unit between high speed cool, low speed cool, low speed heat and high speed heat as required to maintain desired temperature. If
Auto Start Stop is activated, the microprocessor will add a null mode at or near setpoint and shut down the unit when conditions allow.
The microprocessor will monitor temperature while in the null mode and restart the unit following the same procedures used to prevent overshoot when switching to other modes. The length of time the unit will remain in the null mode is also dependent on Function Code settings. Function Code FN2 will control the minimum off time after shut down, Code FN3 will control the minimum on time before the null mode can be entered again,
Code FN6 will control the maximum off time or allow temperature based restarting. Refer to paragraph 2.3.2
for Functional Parameter descriptions.
2.7.2 Startup and Pull Down -- Standby Operation
Operation in standby follows the same sequence as operation on the engine except the standby motor operates at a single speed. The microprocessor will monitor changes in temperature and switch the unit between the cool mode, null mode and heat mode. The microprocessor will add the null mode at or near setpoint and de--energize the motor when conditions allow.
2.7.3 Null Mode Overrides
When in the null mode two conditions will override normal microprocessor off time and/or temperature control.
If the unit is in the Engine Drive or Standby mode and battery voltage falls below 11 volts, the engine or motor will be restarted to allow the alternator to recharge the battery. If the unit is in the Engine Drive mode and the engine coolant temperature drops below 34 ° F (1 ° C) the engine will be restarted.
2.7.4 Dual Probe Operation
The microprocessor is fitted with a connection for a second thermistor. This thermistor is installed in the supply air stream and activated using Function Code
FN4. With Function Code FN4 set to “FN4 ON” or “REM
PROBE” the microprocessor is set for dual probe control.
With the microprocessor set for dual probe control, the microprocessor will select the supply air probe for control when in Perishable Range operation and the return air probe when in Frozen Range operation. Operating on the supply air probe in the Perishable Range minimizes top freezing while operating on the return air probe in the Frozen Range keeps the product at or slightly below setpoint.
In the event of a probe failure on a single probe unit, the unit will be shut down if operating in the Perishable
Range or switched to low speed cooling if operating in the Frozen Range. When operating in the Frozen Range and on standby, the unit continues to operate in cooling.
An alarm will be generated to advise the operator of the probe failure.
With dual probe control, the microprocessor will switch over to the other probe in the event of an “active” probe failure. This allows continued “normal” operation. The appropriate alarm will be generated to advise the operator of the probe failure.
2.7.5 Fuel Heater
Energizing the heater relay provides a circuit to the fuel heater thermostat (FHT). A thermostat (FHT), internal to the fuel filter bowl, closes to energizes the fuel heater
(FH) at temperatures below the cut in setting.
2-9
62--10808
2.7.6 DEFROST CYCLE
Defrost is an independent cycle overriding cooling and heating functions to de-ice the evaporator as required.
The microprocessor displays “DF” on the right of the display during defrost mode . The left display will continue to display the setpoint. Defrost may be terminated in any of three ways; timer initiation, air switch initiation and manual initiation.
Defrost may only be initiated if the defrost termination thermostat (DTT) is closed. The DTT closes, on a temperature fall, at 37
°
F (3
°
C) to signal the microprocessor that the coil temperature is low enough to allow the build up of frost. Defrost is terminated when the DTT opens again, on a temperature rise, at 47 ° F (8 ° C) signaling the microprocessor that the coil has been warmed to the point that the frost buildup should have been removed.
During defrost the unit enters the heat mode and the evaporator fans are de--energized. This will prevent the circulation of warm air to the load. If the unit is shut down for any reason during a defrost cycle (run relay is de--energized) the microprocessor defrost cycle is terminated and the unit will restart normally.
a. Defrost Timer Initiation
Timed defrost is controlled by the setting of Functional
Parameter FN0 and may be set for 1.5, 3, 6 or 12 hours.
The microprocessor will place the unit into the defrost mode each time the timer expires.The defrost timer runs only when the defrost termination thermostat is closed also, it does not accumulate time when the unit is in the null mode. The defrost timer is reset to zero whenever a defrost cycle is initiated.
b. Defrost Air Switch Initiation
The defrost air switch is of the diaphragm type and it measures the change in air pressure across the evaporator coil. When the pressure differential is increased to set point, due to the formation of ice on the coil surface, the switch closes to signal the microprocessor to place the unit in the defrost mode.
c. Manual Defrost Initiation
Defrost may be initiated manually by pressing the
MANUAL DEFROST key.
e. Fail safe Defrost Termination
Should the defrost cycle not complete within 45 minutes or if the external defrost signal does not clear at defrost termination, the microprocessor places the unit in the defrost override mode and the defrost cycle is terminated. The internal timer is reset for 1.5 hours, the Functional Parameter setting and defrost air switch signal is ignored for defrost initiation. The manual defrost switch will override this mode and start a new 45 minute cycle.
When defrost override is active, the appropriate alarm will be indicated.
2.8 PRE--TRIP INSPECTION
2.8.1 Pre-trip Inspection -- Before Starting
Before Starting Engine check the following points:
1.Drain water and sediment from fuel tank sump. Then fill tank with diesel fuel.
2.Drain water from fuel filter separator (if applicable).
3.Check radiator coolant level. Antifreeze should be adjusted for climate conditions, minimum 50/50 mixture, maximum 60/40 mixture.
62--10808 2-10
4.Check condenser/radiator coil for cleanliness.
5.Check air cleaner and hoses.
6.Check defrost air switch and hoses.
7.Check engine oil level.
8.Check condition and tension of all belts.
9.Check all fan and idler bearings.
10.Check door latches and hinges.
11. Check condition of condenser fan blades.
12.Check battery fluid level (if applicable)
13.Check battery cables and terminals
14.Check evaporator coil for cleanliness.
15.Check evaporator fan
16.Check air chute (if applicable)
17.Check bulkhead and return air screens (if applicable)
18.Check defrost water drains
19.Check glow plugs
2.8.2 Pre-trip Inspection -- Starting
Start the unit in manual start -- continuous run. Refer to paragraph 2.9
2.8.3 Pre-trip Inspection -- After Starting
After starting engine check the following points:
1. Check electric fuel pump.
2. Check fuel lines and filters for leaks.
3. Check oil lines and filters for leaks.
4. Check coolant hoses for leaks.
5. Check exhaust system for leaks.
6. Check condenser and evaporator fans for proper air flow.
7. Initiate Pre--Trip and monitor all operating modes.
Check unloader operation (844).
After operating unit 15 minutes or more:
8. Check water temperature. Should be 160 to 175
_
F
(72 to 80
_
C)
9. Check refrigerant level. (Refer to section 3.7)
10.Check compressor oil level. (Refer to section 3.7.2)
11. Put unit into manual defrost and monitor. Allow unit to terminate defrost automatically.
12 Change over to desired operating mode, enter set point and change functional parameters as required to match the requirements of the load.
2.9 MANUAL START
a. To start the unit manually, place the RUN/STOP switch in the RUN position and the ON-OFF Switch
(Cab Command) to ON position.
b. If the AUTO START/STOP indicator on the cab command is illuminated, press the AUTO START/STOP key to place the unit in continuous run mode (indicator not illuminated).
c. Press the FUNCTION Key until AUTO OP or MAN
OP appears on the display. If MAN OP appears, proceed to step d. If AUTO OP appears:
1. Press the Enter Key.
2. Press the Up Or Down Arrow Key to bring MAN
OP on the display.
3. Press the Enter Key. To place the unit in the
MANUAL START mode.
WARNING
Under no circumstances should ether or any other starting aids be used to start engine.
d. Use the MANUAL GLOW/CRANK Switch to start the unit. Refer to Table 2-4 for required glow times.
Table 2-4. Manual Glow Time
Less than 32
33
51
_
_
F to 50
F to 77
_
_
_
F (0
F (1
Greater than 78
_
F (11
_
_
_
C)
C to 10
F (26
_
_
C to 25
C)
C)
_
C)
Glow Time in d
55
40
25
10 e. Enter Set Point and change Functional Parameters to match the requirements of the load. Refer to paragraph 2.3.
2.10 AUTOMATIC START
a. Place the RUN-STOP Switch in the RUN position.
b. Place the On-Off Switch (Cab Command) in the ON position and press the ROAD Key. The microprocessor will perform a self-test. Then setpoint and box temperature will be displayed.
c. The microprocessor will energize glow cycle and start the engine.
d. Observe the AUTO START/STOP indicator. If it is illuminated, the unit is in the Auto Start/Stop mode . If
Auto Start/Continuous Run operation (unit will operate continuously after starting) is desired, press the
Auto Start/Stop key to change the operation to Auto
Start/Continuous Run.
e. Enter Set Point and change Functional Parameters to match the requirements of the load. Refer to paragraph 2.3.
2-11
2.11 STARTING -- STANDBY MOTOR DRIVE
a. Ensure the ON-OFF (Cab Command) and RUN/
STOP switches are in the OFF position and power supply breaker is open. Plug in the power plug. Close power supply breaker.
b. Place the ON-OFF (Cab Command) and RUN/
STOP switches in the ON position and press the
STANDBY Key. The microprocessor will perform a self-test (all display messages will appear in display window). Then setpoint and box temperature will be displayed.
“NO POWER” will be displayed if unit is switched to
STANDBY and power is not available.
c. Enter Set Point and change Functional Parameters to match the requirements of the load. Refer to paragraph 2.3.
2.12 STOPPING INSTRUCTIONS
To stop the unit, from any operating mode, place the
ON-OFF (Cab Command) or RUN STOP switch in the
OFF position.
2.13 CONTROL CIRCUIT OPERATION -- ENGINE
DRIVE
Refer to Figure 5-1 for a schematic diagram of the unit controls. To facilitate location of the components referred to in the written text, the schematic has map coordinates added to the margins. These locations have also been added to the legend. In order to provide complete information, the following description is written as if all options are installed. Indications of specific unit applicability and optional equipment are provided on the schematic diagram. The microprocessor controls operation of the various relays and components by completing or by breaking the circuit to ground.
To start the unit the RUN/STOP switch( RSS) is placed in the RUN position and the cab command ON--OFF switch is placed in the ON position. Operation of the control circuit is the same for microprocessor or manual start except in manual start the operator uses the
MANUAL GLOW/CRANK switch (MGC) to energize the glow plugs and crank the engine.
With the switches positioned, the ROAD key is pressed to begin the start process. Power flows from RSS through fuse F2 to the Run Control Relay (RCR). RCR is grounded by the microprocessor through the Door
Switch Relay (DSR) and cab command to energize
RCR. The RCR contacts close to provide power to the control relays. Power to the Run Relay (RR) is dependent on the High Pressure Switch (HPS) being closed. If the high pressure switch is open, power will not be applied to microprocessor terminal M1 and operation will not be allowed.
Energizing RR closes a set of contacts to supply power to the alternator (ALT) Run Solenoid (RS), Fuel Pump
(FP) and Fuel Heater Relay (FHR). RS energizes to open the engine fuel rack, FP energizes to pump fuel to the injection pump and FHR energizes to close a set of contacts supplying power to the fuel heater thermostat.
The fuel heater thermostat closes to energize the fuel heater at temperatures below the option setting. The engine is thus prepared for start up.
The microprocessor will now run the Auto Start Sequence (refer to paragraph 2--15) to start the engine.
62--10808
The Glow Plug Relay (GPR) is energized to close a set of contacts (SSC) and provide power to the Glow Plugs
(GP) as required to preheat the engine cylinders. The
Starter Solenoid Relay (SSR) will then be energized to close a set of contacts and energize the Starter Solenoid (SS). Energizing SS closes a set of contacts to energize the Starter Motor (SM) and crank the engine.
During cranking a signal is also supplied to microprocessor terminal L2. Once the engine starts and and the alternator begins to produce power, the microprocessor senses the power at terminal L3 and the start sequence is terminated. The microprocessor ignores the Oil Pressure Switch (OP) signal for 15 seconds to allow the engine time to develop sufficient pressure to close OP.
Once the engine has started, the microprocessor will complete the Defrost Transistor (DT) circuit to energize the Electric Fan Motor Relays (EFMR 1 through 3) which close contacts to energize the Electric (Evaporator) Fan Motors (EFM1 through 3).
The microprocessor continues to monitor inputs to determine required modes of operation. The inputs include the Suction Pressure Transducer (SPT), Water temperature Sensor, Supply Air Sensor (SAS), and the Compressor Discharge Transducer (CDT).
As required, the microprocessor will take the following actions:
When in the low speed mode, the microprocessor also energizes the Unloader Front Relay (UFR). Energizing
UFR closes a set of contacts to energize the compressor Unloader (UF) deactivating two cylinders.
On call for heat, the Heater Relay (HR1) is energized to close a set of contacts and energize the hot gas bypasssolenoid valve (HGS2) and the hot gas valve (HGS1) placing the unit in the heat mode. If the unit is equipped with hot water heat, the contactor will open the hot water heat solenoid valve. Units equipped with electric heat will energize the heater elements.
On call for defrost, the microprocessor energizes the hot gas bypass valve (HGS2) and the hot gas valve (HGS1) in the same manner as in heat. Also, DT is de--energized, stopping the evaporator fan motors.
2.14 CONTROL CIRCUIT OPERATION -- STANDBY
Refer to Figure 5-1 for a schematic diagram of the unit controls. To facilitate location of the components referred to in the written text, the schematic has map coordinates added to the margins. These locations have also been added to the legend. In order to provide complete information, the following description is written as if all options are installed. Indications of specific unit applicability and optional equipment are provided on the schematic diagram. The microprocessor controls operation of the various relays and components by completing or by breaking the circuit to ground.
To start the unit the RUN/STOP switch( RSS) is placed in the RUN position and the cab command ON--OFF switch is placed in the ON position.
With the switches positioned, the STANDBY key is pressed to begin the start process. When the STANDBY key is pressed, the microprocessor provides a ground path to energize the Diesel Electric Relay (DER). Energizing DER opens a set to contacts to break the circuit to the engine drive controls and closes a set of contacts to allow power to the electric drive controls.
Power flows from RSS through fuse F2 to the Run Control Relay (RCR). RCR is grounded by the microprocessor through the Door Switch Relay (DSR) and cab command to energize RCR. The RCR contacts close to provide power to the control relays. Power to the Run
Relay (RR) is dependent on the High Pressure Switch
(HP1) being closed. If the high pressure switch is open, power will not be applied to microprocessor terminal M1 and operation will not be allowed.
Energizing RR closes a set of contacts to supply power through the motor Overload (OL) to the Motor Contactor
(MC1). Energizing MC1 closes it’s contacts to start the
Standby Motor (SBM).
On Supra 844 units, power is also supplied from the
DER contacts to energize the Standby Unloader Front
Relay (SUFR). Energizing SUFR opens a set of normally closed contacts in the power line to the unloader preventing unloaded operation.
Once the motor starts the alternator begins to produce power. The microprocessor senses the power at terminal L3 and it will complete the Defrost Transistor (DT) circuit to energize the Electric Fan Motor Relays (EFMR
1 through 3). The relays close contacts to energize the
Electric (Evaporator) Fan Motors (EFM1 through 3).
The microprocessor continues to monitor inputs to determine required modes of operation. The inputs include the Suction Pressure Transducer (SPT), Return Air
Sensor(RAS), Supply Air Sensor (SAS), and the Compressor Discharge Transducer (CDT) .
As required, the microprocessor will take the following actions:
On call for heat, the Heat Relay (HR) is energized to close a set of contacts and energize the hot gas bypass solenoid valve (HGS2) and the hot gas valve (HGS1) placing the unit in the heat mode. In the heat mode the microprocessor also energizes the Evaporator Heat
Relay (EHR). Energizing EHR closes a set of contacts to energize the Evaporator heat Contactor (EHC) which closes it’s contacts to energize the Evaporator Heaters.
On call for defrost, the microprocessor energizes the hot gas bypass solenoid valve (HGS2) and the hot gas valve (HGS1) in the same manner as in heat. Also, DT is de--energized, stopping the evaporator fan motors.
If AC power is lost for 5 minutes or more, configuration
10 is active and TIME START is enabled, the diesel engine will start and run until AC power is restored and applied for 5 minutes. When the 5 minute shutdown timer expires and AC power is present, the unit will shut down the diesel engine and restart the standby motor. If
AC power is NOT present, the diesel engine will operate as required.
62--10808 2-12
2.15 AUTO START SEQUENCE
Refer to Figure 5-1 for a schematic diagram of the unit controls. To facilitate location of the components referred to in the written text, the schematic has map coordinates added to the margins. These locations have also been added to the legend.
The Auto Start Sequence will begin once conditions for engine starting have been established, and the Run
Relay (RR) has been energized to provide power to the
Run Solenoid (RS), Fuel Pump (FP) and Fuel Heater
(FH). Refer to paragraph 2.13 for control circuit operation. The sequence consists of three start attempts each including a predetermined period with the glow plugs energized and operation of the starter motor (see
Figure 2-2).
Five seconds after the run relay is energized, the microprocessor will start the sequence by energizing the glow plug relay (GPR) to supply power to the glow plugs.
If the Manual Glow Override Function Parameter is set to “NORMAL”, the glow time for the first start attempt will vary in duration based on engine coolant temperature as follows:
Engine Coolant Temperature Glow Time
Temperature Seconds
Less than 32
_
F (0
_
C)
33
_
F to 50
_
F (1
_
C to 10
_
C)
55
40
51
_
F to 77
_
F (11
_
C to 25
_
C)
Greater than 78
_
F (26
_
C)
25
10
REPEAT FIRST
+ 5 Seconds
GLOW
15 Seconds
STOP
REPEAT FIRST
+ 5 Seconds
GLOW
15 Seconds
STOP
MAXIMUM
10 Seconds
Checked at
2 Seconds*
CRANK
VARIABLE
0 to 85 SECONDS
GLOW
GLOW
THIRD
ATTEMPT
SECOND
ATTEMPT
FIRST
ATTEMPT
* Starter engagement time is increased to 20 seconds when the water temperature sensor is at 32 ° F (0 ° C) or below
Figure 2-2. Auto Start Sequence
The second and third start attempts have a glow time that is 5 seconds greater than the table amount.
If the Manual Glow Override Function Parameter is set to “ADD 30 SECONDS” the additional time will be added to the first attempt. Actual time added to the second and third attempts will vary with ambient temperature.
After the glow time has expired, the starter solenoid
(SS) is energized to crank the engine. The engine will crank for 10 seconds or until engine operation is sensed by the microprocessor at alternator signal input at terminal L3.
If the engine has not started, a 15 second null cycle will elapse before subsequent start attempts. The run relay will remain energized during the null cycle.
Before the next starting sequence, the oil pressure and alternator auxiliary input is checked to insure that the engine is not running. For the second and third start attempts the glow time is increased by 5 seconds over the glow time of the first attempt. The control allows three consecutive start attempts before starting is locked out and the start failure alarm is activated.
If battery voltage drops below 10 volts at any point during the Auto Start Sequence, the sequence will be stopped and the start failure alarm is activated.
2-13
62--10808
SECTION 3
SERVICE
WARNING
Beware of V-belts and belt driven components as the unit may start automatically. Before servicing unit, make sure the Run-Stop switch is in the STOP position. Also disconnect the negative battery cable.
CAUTION
Unit with R404A and POE oil, the use of inert gas brazing procedures is mandatory; otherwise compressor failure will occur. 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.
3.1 MAINTENANCE SCHEDULE a. Daily Maintenance
Pre-Trip Inspection -- before starting
Pre-Trip Inspection -- after starting
Check Engine Hours
b. Every 750 Hour Maintenance (Normal Operating Conditions)
Unit
1. Check unit mounting bolts
2. Check engine and compressor mount bolts
3. Check door latches & hinges
4. Check muffler and exhaust pipes
5. Check gauges, switches and electrical connections
6. Check all belt tensions
7. Check control panel door gasket
8. Check idler bearings
Engine
1. Check oil/filter change interval (refer to section f.of this table)
2. Check for oil leaks
3. Check low oil pressure safety
4. Check high and low rpm
Fuel System 1. Drain fuel tank sump
2. Clean fuel pump strainer
3. Change fuel filter(s)
4. Check fuel heater (optional)
5. Check for fuel leaks
6. Check fuel lines for chafing
7. Ensure both fuel lines are 1” from bottom of tank
Cooling
System
1. Check antifreeze
2. Clean radiator/condenser fin surface
3. Check hoses and connections
4. Check water pump
5. Check water temperature sensor functions
2.1.a
2.1.b
Check
SECTION
Check
Check
Check
Check
Check
3.3
Check
Check
3.2.2
Check
Check
1.1
------
3.2.5
3.2.5
------
Check
Check/Replace
Check
3.2.1
3.2.1
Check/Replace
Check
Check
3-1 62--10808
3.1 MAINTENANCE SCHEDULE (continued)
Exhaust System
1. Check mounting hardware
2. Check muffler and exhaust pipes
Air Intake
System
1. Check air intake tubing and clamps
2. Check air cleaner -- clean or replace as required
Starting System 1. Check battery
2. Clean battery connections and cable ends
3. Check battery hold down clamps
4. Check starter operation
5. Check glow plug operation
Charging
System
1. Check alternator mounting bolts
2. Check alternator brushes
3. Check alternator output
Refrigeration
System
1. Check air switch & calibrate =1.0” +/-- .07_ W.C. (644/744)
.7”+/--.07_ W.C. (844)
2. Check & clean evaporator
3. Check compressor oil level
4. Check refrigerant level
5. Check operating refrigerant pressure
6. Check all sensor calibrations
7. Check defrost drains
8. Check auto start/stop operation (if applicable)
9. Check quench valve operation
10. Check manual defrost operation
11. Check CPR setting: 644 = 24+/-- 1 PSIG
744 = 32+/-- 1 PSIG
844 = 29+/-- 1 PSIG
c. Every 1500 Hour Maintenance (Normal Operating Conditions)
Perform complete 750 hour Preventive Maintenance and the following:
Fuel System
1. Clean and adjust injector nozzles
2. Check oil/filter change interval (refer to section f.of this table)
d. Every 2000 Hour Maintenance
Charging System
1. Replace alternator brushes
2. Check oil/filter change interval (refer to section f.of this table)
e. Every 3000 Hour or 2 years Maintenance (Normal Operating Conditions)
Perform complete 1500 hour Preventive Maintenance and the following:
Engine
1. Check compression reading
2. Adjust engine valves
3. Check oil/filter change interval (refer to section f.of this table)
Fuel System
1. Check injector nozzles (replace if necessary)
Cooling System 1. Drain and flush engine coolant system
Check
Check
4.2.4
4.2.4
Check/Replace
Check/Replace
Check
Check
4.26
4.2.7
4.2.7
4.2.7
4.15
4.17
4.9
4.7.3
1.7
Check
Check
2.1.2/2.15
Check
2.7.6
Engine Service Guide
4.2.7
Engine Service Guide
Engine Service Guide
Engine Service Guide
f. Oil Change Intervals
Oil Type
Without
Bypass Oil Filter
With
Bypass Oil Filter
Petroleum
Synthetic**
750 Hours
1500 Hours
1000 Hours
2000 Hours
* Maximum oil drain interval is one year (12 months).
** Mobil Delvac1 is the only approved synthetic oil. Maximum oil drain interval is two (2) years. Oil filter change required once a year (every 12 months).
62--10808
3-2
Change 09/06
3.2 SERVICING ENGINE RELATED
COMPONENTS
3.2.1 Cooling System
The condenser and radiator can be cleaned at the same time. The radiator must be cleaned internally as well as externally to maintain adequate cooling. See
Figure 3-1.
The condenser and radiator are incorporated into a single assembly. The condenser fans draw the air through the condenser and radiator coil. To provide maximum air flow the condenser fan belt should be checked periodically and adjusted if necessary to prevent slippage.
CAUTION
Use only ethylene glycol anti-freeze (with inhibitors) in system as glycol by itself will damage the cooling system.
Always add pre-mixed 50/50 anti-freeze and water to radiator/engine. Never exceed more than a 50% concentration of antifreeze. Use a low silicate anti-freeze.
a. Remove all foreign material from the radiator/condenser coil by reversing the normal air flow. (Air is pulled in through the front and discharges over the standby motor.) 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.
b. Drain coolant by removing lower radiator hose and radiator cap.
c. Install hose and fill system with clean, untreated water to which three to five percent of an akalined based radiator cleaner should be added (six ounces -- dry
151 grams to one gallon = 3.78 liters) of water.
Water
Temperature
Sensor
(microprocessor)
Thermostat
Coolant outlet
(hot side)
Pressure cap d. Run engine 6 to 12 hours and drain system while warm. Rinse system three times after it has cooled down. Refill system with water.
e. Run engine to operating temperature. Drain system again and fill with treated water/anti-freeze. (see Caution and refer to section 1.2) NEVER POUR COLD
WATER INTO A HOT ENGINE, however hot water can always be added to a cold engine.
3.2.2 Changing Lube Oil and Lube Oil Filters
After warming up the engine, stop engine, remove drain plug from oil reservoir and drain engine lube oil.
Replace filter(s), lightly oil gasket on filter before installing and add lube oil. (Refer to section 1.2) Warm up engine and check for leaks.
3.2.3 Replacing the Speed and Run Control
Solenoids a. Run Solenoid (see Figure 3-2).
1. Remove spring (item 2) from the engine run lever.
2. Disconnect wiring to solenoid. Remove clip (item 5) from linkage rod (item 4). Remove mounting hardware and solenoid.
3. Attach linkage to new solenoid and install the clip to the linkage rod. Install the replacement solenoid and mounting hardware loosely. Connect the ground wire and spring.
4. Energize the solenoid with a jumper wire connected to a battery. Slide the solenoid far enough back on the bracket to set the engine run lever (item 3) against the stop. Tighten solenoid mounting hardware.
5. De-energize the solenoid. If the engine does not shut off, repeat step 4 and adjust the solenoid forward slightly. When operating correctly, tighten solenoid mounting hardware and reconnect the positive wire.
Coolant pump
Overflow Tank
Coolant inlet
(cold side)
Figure 3-1. Coolant System
3-3 62--10808
1
10
5
4
3
2
7
9
10
5
8
6
1. Run Solenoid
2. Spring (Run Control)
3. Engine Run Lever
4. Linkage Rod (Run)
5. Clip
6. Speed Solenoid
7. Spring
(Speed Control)
8. Linkage Rod
(Speed )
9. Engine Speed Lever
10. Boot
Figure 3-2. Speed and Run Control Solenoids b. Speed Control Solenoid (see Figure 3-2).
1. Remove spring (item 7) from the engine speed lever
(item 9).
2. Disconnect wiring to solenoid. Disconnect linkage rod (item 8) from solenoid. Remove mounting hardware and solenoid.
3. Attach linkage to new solenoid and install the clip
(item 5) to the linkage rod. Install the replacement solenoid and mounting hardware loosely. Connect the ground wire and spring.
4. Energize the solenoid with a jumper wire connected to a battery. Slide the solenoid far enough back on the bracket to set the engine speed lever against the stop. Tighten solenoid mounting hardware.
5. Check engine speed. Speed may be verified using a strobe, Carrier Transicold P/N 07-00206.
6. Disconnect the jumper wire and start the engine. The engine is in low speed. Refer to section 1.6 for engine speed. Reconnect the jumper wire to energize the solenoid. The engine should increase to high speed. If engine speed is not correct (engine lever against stop), stop engine and move the solenoid forward slightly. Repeat procedure if adjustments need to be made.
7. When operating correctly, tighten solenoid mounting hardware and reconnect the positive wire.
8. If adjustment is not achieved by doing step 6, stop engine and remove linkage from solenoid. Remove boot (item 10) from solenoid and pull solenoid shaft out (far enough to loosen jam nut on solenoid shaft).
Energize solenoid for maximum force (pull) and then turn shaft clockwise to shorten.
9. De-energize solenoid, tighten shaft jam nut and replace boot. Connect linkage and repeat steps 5 and
6.
3.2.4 Engine Air Cleaner a. Inspection
The air cleaner, hose and connections should be inspected for leaks. A damaged air cleaner or hose can seriously affect the performance and life of the engine. If housing has been dented or damaged, check all connections immediately.
Stop engine, remove air filter. Install new air filter.
When inspecting air cleaner housing and hoses, check the connections for mechanical tightness and look for fractures in the inlet and outlet hoses. When leakage occurs and adjustment does not correct the problem, replace necessary parts or gaskets. Swelled or distorted gaskets must always be replaced.
Return tube
Injection pump
Bleed port
62--10808
Fuel pump
Fuel filter
Figure 3-3. Fuel System
3-4
Injectors
Supply line
Return line
3.2.5 Servicing Fuel Pump a. To Check or Replace Filter (Refer to Figure 3-3 for fuel system overview)
1. Remove 3 screws from cover (item 1, Figure 3-4).
2. Remove cover, gasket and filter.
3. Wash filter in cleaning solvent and blow out with air pressure. Clean cover.
4. To Install reverse above steps.
4
3
2
1
1. Cover
2.Gasket
3. Filter
Figure 3-4. Electric Fuel Pump
3.2.6 Servicing Glow Plugs
When servicing, the glow plug is to be fitted carefully into the cylinder head to prevent damage to glow plug.
Torque value for the glow plug is 0.8 to 1.5 mkg (6 to 11 ft-lb).
Checking for a Defective Glow Plug
a. One method is to place an ammeter (or clip-on ammeter) in series with each glow plug and energize the plugs. Each plug (if good) should show amperage draw.
2
3
1
b. A second method is to disconnect the wire connection to the plug and test the resistance from the plug to a ground on the engine block.
3.2.7 Alternator
CAUTION
Observe proper polarity, reverse polarity will destroy the diodes. As a precaution, disconnect positive terminal when charging.
The alternator and regulator are housed in a single assembly. A diagram for alternator troubleshooting or replacement is provided below. See Figure 3-5.
3.3 SERVICING AND ADJUSTING V-BELTS
WARNING
Beware of V-belts and belt driven components as the unit may start automatically.
3.3.1 Belt Tension Gauge
It is recommended that a belt tension gauge (Carrier
P/N 07-00203, see Figure 3-7) is used whenever Vbelts are adjusted or replaced. The belt tension gauge provides an accurate and easy method of adjusting belts to their proper tension. Properly adjusted belts give long lasting and efficient service. Too much tension shortens belt and bearing life, and too little tension causes slippage and excessive belt wear. It is also important to keep belts and sheaves free of any foreign material which may cause the belts to slip.
The belt tension gauge can be used to adjust all belts.
The readings which we specify for Carrier Transicold units are applicable only for our belts and application, as the tension is dependent on the size of the belt and distance between sheaves. When using this gauge, it should be placed as close as possible to the midpoint between two sheaves. (See Figure 3-6)
L
B--
4
1.
Positive Output
Terminal
2.
Regulator
3.
12vdc Test Lamp
Terminal
4.
Ground Terminal
B+
Figure 3-5. 70 Amp Alternator (P/N 30--60050--04)
3-5 62--10808
Engine
1
2
3
Standby
Motor
Supra 844
Engine
1
2
3
Standby
Motor
Supra 644 to 744
1 Engine to Compressor V-belt
2 Alternator V-belt
3 Standby Motor to Compressor V-belt
Figure 3-6. V-Belt Arrangement
The V-belts must be kept in good condition with the proper tension to provide adequate air movement across the coils.
When installing any new belts , preset the tension to the setting specified in the ”New Install Tension column”.
After initial run in, check the tension; it should settle out to the setting specified in the ”Running Tension” column.
If the run tension is below the ”Running Tension” range, re--tighten the belt to a value within this range. Refer to
Table 3-1.
Table 3-1. Belt Tension (See Figure 3-7)
BELTS
Water pump
Engine to
Compressor
Alternator
Standby Motor to
Compressor
New Install
Tension
(ft./lbs)
Running
Tension
(ft./lbs)
30 to 40
110 to 120
80 to 90
110 to 120
110 to120
80 to 90
80 to 90
Figure 3-7 Belt Tension Gauge
(Part No. 07-00203)
3.3.2 Alternator V-Belt
a. Make sure negative battery terminal is disconnected.
b. Place V-belt on alternator sheave and driving pulley.
c. Pivot alternator to place tension on belt using hand force only. Do not use pry bar or excessive force as it
may cause bearing failure.
For correct belt tension see Table 3-1. Tighten pivot and adjustment bolts.
3.3.3 Water Pump Belt Tensioner
Water pump belt is driven by the diesel engine crankshaft pulley. The automatic belt tensioner ensures the correct tension.
To change the water pump belt, proceed as follows: a. To compress the tensioner spring, place a threaded bolt or rod into hole and turn clockwise. This will draw the spring up and slacken V-belt for easy removal.
b. After replacing V-belt, remove the bolt to release the spring to return the idler to it’s correct tension.
3.3.4 Standby Motor--Compressor V-Belt
a. Remove alternator V-belt. (Refer to Section 3.3.2) b. Loosen the V-belt idler securing bolt (22mm).
c. Replace V-belt and alternator V-belt. Position the idler to correct belt tension. Tighten the idler retaining bolt.
3.3.5 Engine--Compressor V-Belts
a. To allow for easy removal, installation and adjustment of the V-belts, it is recommended that the muffler be disconnected from the muffler bracket and moved.
b. Remove alternator V-belt. (Refer to Section 3.3.2) c. Remove the standby motor--compressor V-belt.
(Refer to Section 3.3.4) d. Loosen belt idler bolt (24 mm). Move idler to remove
V-belts.
e. Replace V-belts. Position the idler to the correct belt tension. Tighten the idler retaining bolt.
62--10808
3-6
3.4 PUMPING THE UNIT DOWN OR
REMOVING THE REFRIGERANT CHARGE
NOTE
To avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removing refrigerant.
a. Pumping the Unit Down
To service the filter-drier, expansion valve, CPR valve or evaporator coil, pump most of refrigerant into condenser coil and receiver as follows:
1. Backseat suction and discharge service valve (turn counterclockwise) to close off gauge connection and attach manifold gauges to valves.
2. Open valves two turns (clockwise). Purge gauge line.
3. Close the receiver outlet (king) valve by turning clockwise. Start unit and run in high speed cooling.
Place Run-stop switch in the STOP position when unit reaches 0.1 kg/cm
@
(1 psig).
4. Frontseat (close) suction service valve and the refrigerant will be trapped between the compressor suction service valve and the manual shutoff (King) valve.
5. Before opening up any part of the system, a slight positive pressure should be indicated on the pressure gauge.
6. When opening up the refrigerant system, certain parts may frost. Allow the part to warm to ambient temperature before dismantling. This avoids internal condensation which puts moisture in the system.
7. When service has been completed. Open (backseat) King valve and midseat suction service valve.
8. Leak check connections with a leak detector. (Refer to section 3.5)
9. Start the unit in cooling and check for noncondensibles.
10.Check the refrigerant charge. (Refer to section
3.7.2)
NOTE
Store the refrigerant charge in an evacuated container if the system must be opened between the compressor discharge valve and receiver.
NOTE
Whenever the system is opened, it must be evacuated and dehydrated. (Refer to section 3.6)
b. Removing the Refrigerant Charge
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 instruction provided by the manufacture of the refrigerant recovery system.
3.5 REFRIGERANT LEAK CHECKING
If system was opened and repairs completed, leak check the unit.
a. The recommended procedure for finding leaks in a system is with an electronic leak detector (Carrier p/n
07--00295--00). Testing joints with soapsuds is satisfactory only for locating large leaks.
b. If system is without refrigerant, charge system with refrigerant to build up pressure between 2.1 to 3.5 kg/ cm
@
(30 to 50 psig). Remove refrigerant cylinder and leak check all connections.
NOTE
Use only the correct refrigerant 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.
c. Remove refrigerant using a refrigerant recovery system and repair any leaks. Evacuate and dehydrate the unit. (Refer to section 3.6) Charge unit with refrigerant. (Refer to section 3.7)
3.6 EVACUATION AND DEHYDRATION
3.6.1 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.
3.6.2 Preparation
a. Evacuate and dehydrate only after pressure leak test.
(Refer to section 3.5) 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.
3-7 62--10808
4
3
7
1
11
10
6
4
4
8
9
5
2
1. Refrigerant Recovery Unit
2. Refrigerant Cylinder
3. Evacuation Manifold
4. Valve
5. Vacuum Pump
6. Electronic Vacuum Gauge
7. Evaporator Coil
8. Receiver Outlet (King) Valve
9. Condenser Coil
10. Suction Service Valve
11. Discharge Service Valve
Figure 3-8. Vacuum Pump Connection
3.6.3 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 3-8 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. With the unit service valves closed (back seated) and the vacuum pump and electronic vacuum gauge valves open, start the pump and draw a deep vacuum. Shut off the pump and check to see if the vacuum holds. This operation is to test the evacuation setup for leaks, repair if necessary.
d. Midseat the refrigerant system service valves.
e. Then open the vacuum pump and electronic vacuum gauge valves, if they are not already open. Start the vacuum pump. Evacuate unit until the electronic vacuum gauge indicates 2000 microns. Close the electronic vacuum gauge and vacuum pump valves. Shut off the vacuum pump. Wait a few minutes to be sure the vacuum holds.
f. Break the vacuum with clean dry refrigerant. Use refrigerant that the unit calls for. Raise system pressure to approximately 2 psig.
g. Remove refrigerant using a refrigerant recovery 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 weight scales. The correct amount of refrigerant may be added by observing the scales. (Refer to section 3.7)
3.7 CHARGING THE REFRIGERATION SYSTEM
CAUTION
Refrigerant R404A must be charged as a liquid. Refrigerant R404A is a blend. Charging as a vapor will change the properties of the refrigerant.
3.7.1 Installing a Complete Charge
a. Dehydrate unit and leave in deep vacuum. (Refer to section 3.6) 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 scales. Correct charge will be found in section 1.3.
NOTE
It is possible that all liquid may not be pulled into the receiver, as outlined in step d. In this case, vapor charge remaining refrigerant through the suction service valve.
e. When refrigerant cylinder weight (scale) indicates that the correct charge has been added, close liquid line valve on cylinder and backseat the king valve.
62--10808
3-8
3.7.2 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 210 psig (14.8 kg/cm
@
).
c. The unit is correctly charged when the lower receiver sight glass is full and no refrigerant is in the upper receiver sight glass.
3.8 REPLACING THE COMPRESSOR a. Removing
If compressor is inoperative and unit still has refrigerant pressure, frontseat suction and discharge service valves to trap most of the refrigerant in the unit.
If compressor runs, pump down the unit. (Refer to section 3.4.a)
1. Slowly release compressor pressure to a recovery system.
2. Remove bolts from suction and discharge service valve flanges.
3. Disconnect wiring to compressor discharge temperature sensor (CDT), suction pressure transducer and the wiring to the high pressure switch (HP).
4. Release idler pulleys and remove belts.
5. Remove the four bolts holding the compressor to the power tray. Remove the compressor from chassis.
6. Remove the pulley from the compressor.
7. Drain oil from defective compressor before shipping.
b. Installing
1. To install the compressor, reverse the procedure outlined when removing the compressor. Refer to section 1.9 for torque values.
NOTE
The service replacement compressor is sold without shutoff valves (but with valve pads).
Customer should retain the original capacity control valves for use on replacement compressor. Check oil level in service replacement compressor. (Refer to sections 1.3, and 3.9)
2. Attach two lines (with hand valves near vacuum pump) to the suction and discharge service valves.
Dehydrate and evacuate compressor to 500 microns
(29.90” Hg vacuum = 75.9 cm Hg vacuum). Turn off valves on both lines to pump.
3. Fully backseat (open) both suction and discharge service valves.
4. Remove vacuum pump lines and install manifold gauges.
5. Check refrigerant level (Refer to section 3.7.2)
NOTE
It is important to check the compressor oil level of the new compressor and fill if necessary.
6. Check compressor oil level. (Refer to section 3.9)
Add oil if necessary.
7. Check refrigerant cycles.
3.9 CHECKING 05K COMPRESSOR OIL
LEVEL a. To Check Oil Level in 05K Compressor:
1. Operate the unit in high speed cooling for at least 20 minutes.
2. Check the oil sight glass on the compressor to ensure that no foaming of the oil is present after 20 minutes of operation. If the oil is foaming excessively after 20 minutes of operation, check the refrigerant system for flood-back of liquid refrigerant. Correct this situation before performing step 3.
3. Check the level of the oil in the front sight glass with the compressor operating. The correct level should be between bottom and 1/4 of the sight glass. If the level is above 1/4, oil must be removed from the compressor. To remove oil from the compressor, follow step d. If the level is below sight glass, add oil to the compressor following step b.
b. Adding Oil with Compressor in System
Two methods for adding oil are the oil pump method and closed system method.
1. Oil Pump Method
One compressor oil pump that may be purchased is a
Robinair, part no. 14388. This oil pump adapts to a one
U.S. gallon (3.785 liters) metal refrigeration oil container and pumps 2-1/2 ounces (0.0725 liters) per stroke when connected to the suction service valve port. Also there is no need to remove pump from can after each use.
When the compressor is in operation, the pump check valve prevents the loss of refrigerant, while allowing servicemen to develop sufficient pressure to overcome the operating suction pressure to add oil as necessary.
Backseat suction service valve and connect oil charging hose to port. Crack the service valve and purge the oil hose at oil pump. Add oil as necessary.
2. Closed System Method
In an emergency where an oil pump is not available, oil may be drawn into the compressor through the suction service valve.
CAUTION
Extreme care must be taken to ensure the manifold common connection remains immersed in oil at all times. Otherwise air and moisture will be drawn into the compressor.
Connect the suction connection of the gauge manifold to the compressor suction service valve port, and immerse the common connection of the gauge manifold in an open container of refrigeration oil. Crack the suction service valve and gauge valve to vent a small amount of refrigerant through the common connection and the oil to purge the lines of air. Close the gauge manifold valve.
With the unit running, frontseat the suction service valve and pull a vacuum in the compressor crankcase.
SLOWLY crack the suction gauge manifold valve and oil will flow through the suction service valve into the compressor. Add oil as necessary.
3-9 62--10808
c. Adding Oil to Service Replacement Compressor
Service replacement compressors may or may not be shipped with oil.
If compressor is without oil:
Add correct oil charge (Refer to section 1.3) by removing the oil fill plug (See Figure 3-9)
d. To remove oil from the compressor:
1. Close suction service valve (frontseat) and pump unit down to 2 to 4 psig (0.1 to 0.3 kg/cm
@
). Frontseat discharge service valve and slowly bleed remaining refrigerant.
2. Remove the oil drain plug from compressor and drain the proper amount of oil from the compressor.
Replace the plug securely back into the compressor.
3. Open service valves and run unit to check oil level, repeat as required to ensure proper oil level.
1
2
6
2
1
5
5
3
4
3
4 CYLINDER
1. Suction Service Valve
2. Discharge Service Valve
3. Oil Level Sight Glass
4. Oil Drain Plug
5. Oil Fill Plug
6. Unloader Assembly
2 CYLINDER
Figure 3-9. Compressor -- Model 05K
4
3.10 COMPRESSOR UNLOADER VALVE
The compressor unloader (located on the compressor cylinder head) is controlled by relay UFR and the temperature controller.
a. Checkout Procedure
1. Connect manifold gauges to the compressor suction and discharge service valves and start unit in cooling with the trailer temperature at least 5
_
F (2.8
_
C) above set point and the compressor will be fully loaded (unloader coil de-energized). Note suction pressure.
2. Remove wiring from the unloader coil. Place electrical tape over wire terminals.
3. Set controller upscale (cooler to warmer). This mechanically simulates falling temperature. Approximately 2
_
F (1.1
_
C) below box temperature the unloader coil will energize. Note suction pressure, a rise of approximately 3 psig (0.2 kg/cm
@
) will be noted on the suction pressure gauge.
4. Reconnect wiring on the unloader.
5. Reverse the above procedure to check out compressor loading. Suction pressure will drop with this test.
NOTE
If either unloader coil energizes and the suction pressure does not change, the unloader assembly must be checked.
b. Solenoid Coil Replacement
NOTE
The coil may be removed without pumping the unit down.
1. Disconnect leads. Remove retainer. Lift off coil. (See
Figure 3-10)
2. Verify coil type, voltage and frequency of old and new coil. This information appears on the coil housing.
3. Place new coil over enclosing tube, retainer and connect wiring.
c. Replacing Solenoid Valve Internal Parts
1. Pump down the unit. Frontseat both service valves to isolate the compressor.
2. Remove coil retainer (see Figure 3-10), and coil.
3. Remove enclosing tube collar (item 4) using installation/removal tool supplied with repair kit (item 3).
4. Check plunger for restriction due to: (a) Corroded or worn parts; (b) Foreign material lodged in valve; (c)
Bent or dented enclosing tube.
5. Install new parts. Do not overtighten enclosing tube assembly. Torque to a value of 100 inch pounds
(1.15 mkg).
6. Remove supplied installation/removal tool. Install coil, voltage plate, and retainer.
7. Evacuate and dehydrate the compressor.
8. Start unit and check unloader operation (Refer to section 3.10.a).
62--10808
3-10
1
2
3
6
7
4
5
8
9
12
13
10
11
14
1. Retainer
2. Coil Assembly
3. Installation/Removal
Tool
4. Enclosing Tube
Collar
5. “O” Ring
6. Enclosing Tube
7. Plunger Spring
8. Plunger Assembly
9. Gasket
10. Valve Body
11. Gasket
12. Bolt
13. Gasket, Bolt
14. Piston Ring
Figure 3-10. Unloader Solenoid Valve
3.11 CHECKING AND REPLACING FILTER-DRIER
To Check Filter
Check for a restricted or plugged filter-drier by feeling the liquid line inlet and outlet connections of the drier cartridge. If the outlet side feels cooler than the inlet side, then the filter-drier should be changed.
To Replace Filter-Drier
a. Pump down the unit per section 3.4. Remove bracket, then replace drier.
b. Check refrigerant level. (Refer to section 3.7.2)
3.12 CHECKING AND REPLACING HIGH
PRESSURE SWITCH
3.12.1 Replacing High Pressure Switch
a. Pump down the unit. (Refer to section 3.4.a)
Frontseat both suction and discharge service valves to isolate compressor.
b. Slowly release compressor pressure through the service valve gauge ports to refrigerant recovery device.
c. Disconnect wiring from defective switch. The high pressure switch is located near the top of the compressor. (See Figure 3-9) d. Install new cutout switch after verifying switch settings. (Refer to section 3.12.2) e. Evacuate and dehydrate the compressor. (Refer to section 3.8)
3.12.2 Checking High Pressure Switch
WARNING
Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is approximately 2350 psi (165 kg/cm
@
). Do not use oxygen in or near a refrigerant system as an explosion may occur.
(See
Figure 3-11)
1
4
2
3
5
6
1. Cylinder Valve and Gauge
2. Pressure Regulator
3. Nitrogen Cylinder
4. Pressure Gauge
(0 to 400 psig =
0 to 28 kg/cm
@
)
5. Bleed-Off Valve
6. 1/4 inch Connection
Figure 3-11. Typical Setup for Testing High
Pressure Switch
a. Remove switch as outlined in section 3.12.1.
b. Connect ohmmeter or continuity light across switch terminals. Ohmmeter will indicate resistance and continuity light will be lighted if switch closed after relieving pressure.
c. Connect switch to a cylinder of dry nitrogen. (See
Figure 3-11) d. Set nitrogen pressure regulator higher than cutout point on switch being tested. Pressure switch cutout and cut-in points are shown in section 1.8.
e. Close valve on cylinder and open bleed-off valve.
f. Open cylinder valve. Slowly close bleed-off valve and increase pressure until the switch opens. If light is used, light will go out and if an ohmmeter is used, the meter will indicate open. Open pressure on gauge.
Slowly open bleed-off valve (to decrease pressure) until switch closes (light will light or ohmmeter will move).
3-11 62--10808
3.13 CHECKING CALIBRATION OF THE DEFROST
AIR SWITCH
5
2
3.14 CHECKING AND REPLACING EVAPORATOR
FAN MOTOR BRUSHES & COMMUTATOR
The fan motor commutator and brushes should be checked periodically for cleanliness and wear to maintain proper operation of the the fan motors.
6
4
3
1
2
1
1. Brush Cap
2. Brush
1. Ohmmeter or Continuity Device
2. Adjustment Screw (0.050 socket head size)
3. Low Side Connection
4. Pressure Line or Aspirator Bulb
(P/N 07-00177-01)
5. Magnehelic Gauge (P/N 07-00177)
6. High Side Connection
Figure 3-12. Defrost Air Switch Test Setup
a. Make sure magnehelic gauge is in proper calibration.
NOTE
The magnehelic gauge may be used in any position, but must be re-zeroed if position of gauge is changed from vertical to horizontal or vice versa. USE ONLY IN POSITION FOR
WHICH IT IS CALIBRATED.
b. With air switch in vertical position, connect high pressure side of magnehelic gauge to high side connection of air switch. (See Figure 3-12) c. Install tee in pressure line to high side connection. Tee should be approximately half-way between gauge and air switch or an improper reading may result.
d. Attach an ohmmeter to the air switch electrical contacts to check switch action.
NOTE
Use a hand aspirator (P/N 07-00177-01), since blowing into tube by mouth may cause an incorrect reading.
e. With the gauge reading at zero, apply air pressure very slowly to the air switch. An ohmmeter will indicate continuity when switch actuates.
f. Refer to section 1.3 for switch settings. If switch fails to actuate at correct gauge reading, adjust switch by turning adjusting screw clockwise to increase setting or counterclockwise to decrease setting.
g. Repeat checkout procedure until switch actuates at correct gauge reading.
h. After switch is adjusted, place a small amount of paint or glycerol on the adjusting screw so that vibration will not change switch setting.
62--10808
3-12
Figure 3-13. 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 3-13.
b. Remove brushes (item 2; 2 per motor) and check the length of the brush. If the length is less than 1/4 inch the brushes should be replaced (after checking commutator).
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 emery cloth.
Wipe out any accumulation of greasy material using a clean rag dampened with solvent. Reassemble the motor; install new brushes and replace cap.
3.15 EVAPORATOR COIL CLEANING
The use of recycled cardboard cartons is increasing across the country. The recycled cardboard cartons create much more fiber dust during transport than “new” cartons. The fiber dust and particles are drawn into the evaporator where they lodge between the evaporator fins. If the coil is not cleaned on a regular basis, sometimes as often as after each trip, the accumulation can be great enough to restrict air flow, cause coil icing, repetitive defrosts and loss of unit capacity. Due to the
“washing” action of normal defrost the fiber dust and particles may not be visible on the face of the coil but may accumulate deep within.
It is recommended to clean the evaporator coil on a regular basis, not only to remove cardboard dust, but to remove any grease or oil film which sometimes coats the fins and prevents water from draining into the drain pan.
Cardboard fiber particles after being wetted and dried several times can be very hard to remove. Therefore, several washings may be necessary.
a. Remove rubber check valves (Kazoo) from drain lines.
b. Spray coil with a mild detergent solution such as
Oakite 164 or any good commercial grade automatic dish washer detergent such as Electrosol or Cascade and let the solution stand for a few minutes and re-
verse flush (opposite normal air flow) with clean water at mild pressure. A garden hose with spray nozzle is usually sufficient. Make sure drain lines are clean.
c. Run unit until defrost mode can be initiated to check for proper draining from drain pan.
3.16 CONDENSER COIL CLEANING
Refer to section 3.2.1
3.17 HOT GAS (Three-Way) VALVE
3.17.1 Replacing Solenoid Coil
It is not necessary to pump the unit down to replace the coil for HGS1 (see Figure 3-14). Remove and store charge in evacuated container if servicing HGS2.
a. Remove 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 re--install the coil cover.
d. Recharge system. (Only necessary if servicing
HGS2).
CAUTION
Do not damage or over tighten the enclosing tube assembly. Also make sure all parts are placed on the enclosing tube in proper sequence to avoid premature coil burnout.
1
2
3
4
1. Snap cap
2. Voltage plate
3. Coil assembly
5
6
4. Enclosing tube
5. Plunger assembly
6. Valve body assembly
Figure 3-14 Hot Gas (HGS2) or Condenser
Pressure Control Solenoid
3.18 ADJUSTING THE COMPRESSOR PRESSURE
REGULATING VALVE (CPR)
The CPR valve is factory pre-set and should not need adjustment. If it is necessary to adjust the valve for any reason, proceed with the following outline.
When adjusting the CPR valve, the unit must be running in the high speed heat or defrost. This will ensure a suction pressure above the proper CPR setting.
1 2 3
1. Cap 2. Jam Nut 3. Setting Screw
Figure 3-15. Compressor Pressure Regulating
Valve
To adjust the CPR valve, proceed as follows: a. Install a manifold gauge set.
b. Remove cap (item 1) from CPR valve.
c. With an 8 mm Allen wrench, loosen the jam nut
(Figure 3-15, item 2).
d. Using the 8 mm Allen wrench, adjust the setting screw. To raise the suction pressure turn the setting screw (item 3) clockwise; to lower the suction pressure, turn the setting screw counterclockwise. Refer to section 1.7 for CPR valve setting.
e. When the setting has been adjusted, tighten the jam nut securely against the setting screw (item 3). This will prevent any movement of the setting screw due to vibrations in the unit. Replace the cap.
3.19 THERMOSTATIC EXPANSION VALVE
The thermal expansion valve (see Figure 3-16) 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.
a. Replacing Expansion Valve
1. Pump down the unit. (Refer to section 3.4.a)
2. Remove insulation (Presstite) from expansion valve bulb and then remove bulb from suction line.
3. Loosen flare nut and disconnect equalizer line from expansion valve.
4. Remove flange screws and lift off power assembly.
Then remove the cage assembly. Check for foreign material in valve body.
5. The thermal bulb is located below the center of the suction line (See Figure 3-17). This area must be clean to ensure positive bulb contact. Strap thermal bulb to suction line and insulate both with Presstite.
3-13 62--10808
6. Install new gaskets and insert cage assembly and install power assembly.
7. Fasten equalizer tube to expansion valve.
8. Evacuate by placing vacuum pump on suction service valve.
9. Open King valve and then check refrigerant level.
(Refer to section 3.7.2)
10.Check superheat. (Refer to section 1.7)
1
1.Orifice
2.Strainer
2
Figure 3-16. Thermostatic Expansion Valve b. Adjusting Superheat (See Figure 3-16)
1. Check superheat.
2. Check orifice size, Clean/replace as necessary.
3. Check/clean strainer.
NOTE
It is not recommended adjusting expansion valves unless absolutely necessary. Due to the time involved in adjusting the superheat, replace the valve rather than adjusting it.
4. Replace valve if superheat is incorrect.
c. To Measure Superheat
NOTE
The expansion valve and bulb location are shown in Figure 1-2.
1. Remove insulation from expansion valve bulb and suction line.
2. Loosen one TXV bulb clamp and make sure area under clamp (above TXV bulb) is clean.
3. Place thermocouple above (parallel) TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in
Figure 3-17.
3
2
1
5
4
1. Suction Line
2. TXV Bulb Clamp
3. Nut and Bolt
4. TXV Bulb
5. Thermocouple
Figure 3-17. Thermostatic Expansion Valve Bulb and Thermocouple
NOTE
When conducting this test the suction pressure must be 0.4 kg/cm
@
(6 psig) below expansion valve maximum operating pressure (MOP) of
120 psig.
4. Connect an accurate gauge to the 1/4” port on the suction service valve.
5. Run unit until stabilized. Set controller 10
_
F (5.5
_
C) below box temperature.
6. From the temperature/pressure chart, determine the saturation temperature corresponding to the evaporator outlet pressure.
7. Note the temperature of the suction gas at the expansion valve bulb.
Subtract the saturation temperature determined in Step
6 from the average temperature measured in Step 7.
The difference is the superheat of the suction gas.
3.20 MICROPROCESSOR CONTROLLER
NOTE
The erasable, programmable, read only memory (EPROM) chip (component U3 on the microprocessor logic board) has a label on it listing the revision level of the software.
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.
As mentioned above, some microprocessor inputs operate at voltage levels other than the conventional 12 vdc. Connector points and the associated approximate voltage levels are listed below for reference only. Under no circumstances should 12 vdc be applied at these connection points.
Grounded wrist cuffs are available from Carrier (P/N
07-00304-00). It is recommended that these be worn whenever handling a microprocessor.
62--10808
3-14
Table 3-2. Connection Point Voltage
Connection Point
ATS, CDT, RAS, SAS,
WTS
MP23
Approximate Voltage
2.5 vdc (Variable)
5.0 vdc
Most
CAUTION electronic components are susceptible to damage caused by electrical static discharge (ESD). In certain cases, the human body can have enough static electricity to cause resultant damage to the components by touch. This is especially true of the integrated circuits found on the truck/trailer microprocessor.
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 always 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 trailer, ALL wiring to the microprocessor
MUST be disconnected. When welding is performed on other areas of the trailer, 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.
a. Replacing Key Board
Should damage to the Key Board of the microprocessor occur, it is possible to replace only the Key Board.
b.
Hour Meters
The hour meter can be set to any value via the serial port, if the meter has less then 5 hours on it. This allows a replacement microprocessor to be set to the same hours as the microprocessor it is replacing.
The microprocessor has 2 programmable maintenance hourmeter which are set via the serial port. These maintenance hourmeter are compared to one of the hour meters (diesel, standby, or switch on). If the hour meter is greater than the maintenance hourmeter then the proper service alarm is triggered.
3.21 MICROPROCESSOR REPLACEMENT and
CONFIGURATION
3.21.1 To Remove and Replace
Microprocessor Logic Board:
1. Before removing the microprocessor, disconnect the negative battery cable and attach a grounded
3-15 wrist strap (07-00304-00) to your wrist and ground it to a good unit frame ground.
2. Open the roadside side door of the unit and loosen the 4 bolts holding the cover / microprocessor onto the front of the control box.
3. Unplug the ribbon cable from the logic board but leave it connected to the cab command cable.
4. Take the new microprocessor from the anti-static bag and install in the control box, following steps
2--6 in reverse order.
5. Place the removed microprocessor back into the anti-static bag and part box for return.
NOTE
BEFORE STARTING THE UNIT: When replacing a microprocessor it is important to check that the configurations are compatible for the unit into which it will be installed.
3.21.2 To Reach The Configuration Fields From
The Keypad:
1. Turn the Run/Stop switch to the Stop position.
2. With the unit off, locate the serial port plug behind the control panel. Remove the protective cap to gain access to the wire terminals. Place an insulated
jumper wire
between wires SPA and SPB at the serial port plug.
Caution : Do not allow this wire to touch any ground.
3. Turn the Run/Stop switch to the Run position. The
FAULT light will come on, and the micro display will read “CNF1 TV” or “CNF1 DI”. Remove the jumper
wire from the serial port and reinstall the protective cap
. The configuration screen will now remain available for five minutes. Scroll through the configuration list using the “FUNCTION” key and compare the settings with those shown in the table on the following page. If any of the configurations need to be changed, continue with step 4 below.
4. To change the configuration selection
(refer to Table 3-3):
A. Bring the configuration to be changed onto the display. Press the “ENTER” key to allow change access to the displayed configuration.
B. Press either the “UP” or “DOWN” keys to display available selections for that configuration. Leave the correct selection on the screen. The selection display will flash, warning the operator that the displayed value has not been entered. Press the “ENTER” key to enter the new selection into memory. (The display will revert to the original selection if no further action is taken for the next five seconds.)
C. Continue to scroll through the configuration list by pressing the “FUNCTION” key. Change any other configurations as required.
5. When finished, turn the Run/Stop switch to the Stop position, then back to the Run position to start the unit.
62--10808
SETTINGS
644/744
ON
844
OFF
OFF*
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
CNF22
CNF23
CNF24
CNF25
CNF26
CNF27
CNF28
CNF29
CNF30
CNF31
CNF32
CONFIGURATION DESCRIPTION
DI Long glow cycle
TV Short glow cycle
CNF3
Note 2
OFF 844 Only
ON 644/744 Only
OFF
Max Set Point +86 ° F (30 ° c) (All functions locked)
ON
Max Set Point +90 ° F (32.2C
° )Modified function lock)
OFF Heat Lockout On At 10 ° F (--12.2
° C)
ON Heat Lockout Off
OFF 644/744/844
ON Do Not Turn On!
OFF Do Not Turn Off!
ON Supra Units 644/744/844
OFF Supra Units 644/744/844
CNF9
Note 1
CNF11
Note 2
ON Do Not Turn On!
OFF
Do Not Turn Off!
ON Supra Units 644/744/844
OFF Out--of--range alarm only
ON Out--of--range alarm and unit shut down
OFF
Standby Diesel Backup is disabled.
And All Units Prior to Rev. 3.23
ON
Enables Standby Diesel Backup. Rev. 3.23
and higher
OFF Functions change normally
ON Functions & Start Stop locked
OFF Supra Units 644/744/844
ON Do Not Turn On!
OFF Supra Units 644/744/844
ON Do Not Turn On!
OFF Supra Units 644/744/844
ON Do Not Turn On!
OFF Supra Units 644/744/844
ON Do Not Turn On!
OFF Alt Aux alarm only
ON Alt Aux alarm shuts unit down
OFF Supra Units 644/744/844
ON Do Not Turn On!
OFF SYSTEM CK alarm Off
ON SYSTEM CK alarm On
CNF20
Note 3
OFF OFF All Units
ON Do Not Turn On!
OFF Display Units Unlocked
ON
Display Units Locked (Not applicable with
Revisions lower Than 3.23)
OFF Supra Units 644/744/844
ON Do Not Turn On!
OFF For future use. Do not turn on.
OFF For future use. Do not turn on.
OFF For future use. Do not turn on.
OFF For future use. Do not turn on.
OFF For future use. Do not turn on.
OFF For future use. Do not turn on.
OFF For future use. Do not turn on.
OFF For future use. Do not turn on.
OFF For future use. Do not turn on.
OFF For future use. Do not turn on.
OFF For future use. Do not turn on.
* These settings are optional and can be set to customer specifications, or left at default values. All f g ( )
1.
CNF9 allows selection of how the unit will react under an Out-Of-Range condition.
An
Out-Of-Range condition is described as the box temperature having arrived at setpoint, then drifting away from setpoint. With this CNF in the
OFF position, once the box temperature has been Out Of Range for 15 minutes, the ALARM light will be turned on and the alarm display
“OUT RANGE” will be displayed alternately with the default display of the setpoint and box temperature. With this CNF in the ON position, once the box
O t Of R temperature has f 45 i t th been it ill h t down and the same alarms as described above
2
CNF3 & CNF11
Standard Function Lock allows the Function
Key and the Start/Stop--Continuous Run Key to be locked so that no changes can be made y
Modified Function Lock is the same as
Standard Function Lock except that with the setpoint at or between +32 it ill l
_
F and +42
_
R
F, the
If the setpoint is outside this range either
Start/Stop or Continuous Run can be selected.
controlled via a combination of CNF3 and
CNF11: p bi ti f CNF3 d
3.
CNF20 allows the Fahrenheit / Celsius function to be locked. In order to change the units setting,
CNF20 must be OFF. The units setting can then be changed in the functional parameters list. If
CNF20 is ON, the units setting cannot be
Table 3-3. Configuration Settings For Supra 644/744/844 Truck Units
f
Maximum set p ti
_
F. No l k
Maximum set point 86
_
F.
Standard func tion lock
Maximum set point 90
_
F. No function lock
Maximum set point 90
_
F
Modified func tion lock
62--10808
3-16
3.22 CONTROLLER SENSOR CHECKOUT
An accurate ohmmeter must be used to check resistance values shown in Table 3-4 .
Due to variations and inaccuracies in ohmmeters, thermometers or other test equipment, a reading within 2% of the chart value would indicate a good sensor. If a sensor is bad, the resistance reading will usually be much higher or lower than the resistance values given in
Table 3-4.
At least one lead from the sensor (RAS, terminals D1 and E1 or SAS, terminals D2 and E2) must be disconnected from the unit electrical system before any reading is taken. Not doing so will result in a false reading.
Two preferred methods of determining the actual test temperature at the sensor, is an ice bath at 32
_
F (0
_
C) or a calibrated temperature tester.
3.23 SUCTION PRESSURE TRANSDUCER
Before installing a new suction pressure transducer it must be calibrated.
The calibration will not be performed if the run relay is energized. This prevents the operator from calibrating the unit with the sensor in the system. The reading of the sensor must be at atmospheric pressure (0 psig or 14.7
psi). If the sensor reading is greater than 20 psig (34.7
psi) or less than --6.7 psig (8 psi) it can not be calibrated.
Once the micro is calibrated, the display will readout the actual value.
a. Turn power off and remove starter solenoid wire, then let unit fail to start. This will de-energize run relay.
b. Connect wiring to new suction pressure transducer.
Before installing suction pressure transducer into unit, display the suction pressure via the unit status display. While the suction pressure is being displayed press Enter Key for 3 seconds, the display should read “0”. If display reads “0” install suction pressure transducer into unit.
Temperature
_
F
_
C
--20 --28.9
--10 --23.3
0 --17.8
10 --12.2
20 -- 6.7
30
32
-- 1.1
0
40
50
60
70
77
4.4
10.0
15.6
21.1
25
80
90
26.7
32.2
100 37.8
110 43.3
120 48.9
194 90
212 100
266 130
302 150
325 163
350 177
Table 3-4. Sensor Resistance -- Micro Units
(ATS,CDT, RAS, SAS & WTS)
RAS, SAS &
WTS Resistance
In Ohms
165,300
117,800
85,500
62,400
46,300
34,500
32,700
4,700
3,800
915
680
301
186
--
--
26,200
19,900
15,300
11,900
10,000
9,300
7,300
5,800
CDT
Resistance
In Ohms
1,653,000
1,178,000
855,000
624,000
463,000
345,000
327,000
47,000
38,000
9,150
6,800
3,010
1,860
1,358
1,202
262,000
199,000
153,000
119,000
100,000
93,000
73,000
58,000
3-17 62--10808
Temperature
_
F
_
C
Pressure
Psig Kg/cm
@
Bar
--40 --40
--35 --37
4.5
7.1
--30 --34 9.9
--25 --32 12.9
--20 --29 16.3
--18 --28 17.7
--16 --27 19.2
0.32
0.50
0.70
0.91
1.15
1.24
1.35
0.31
0.49
0.68
0.89
1.12
1.22
1.32
--14 --26 20.7
--12 --24 22.3
1.46
1.57
1.43
1.54
14
16
18
20
6
8
10
12
22
24
26
28
--2
0
2
4
--10 --23 23.9
--8 --22 25.6
--6
--4
--21
--20
27.3
29.1
--19
--18
--17
--16
30.9
32.8
34.8
36.8
--14 38.9
--13 41.1
--12 43.3
--11 45.6
--10 48.0
--9
--8
--7
--6
--4
--3
--2
50.4
52.9
55.5
58.1
60.9
63.7
66.5
30 --1 69.5
2.73
2.89
3.04
3.21
3.37
3.54
3.72
3.90
1.68
1.80
1.92
2.05
2.17
2.31
2.45
2.59
4.08
4.28
4.48
4.68
4.89
2.68
2.83
2.99
3.14
3.31
3.47
3.65
3.83
1.65
1.77
1.88
2.01
2.13
2.26
2.40
2.54
4.01
4.20
4.39
4.59
4.79
Table 3-5. R-404A Temperature--Pressure Chart
46
48
90
95
100
105
110
115
120
125
130
135
140
145
150
70
75
80
85
50
55
60
65
Temperature
36
38
40
42
44
_
F
32
34
Pressure
4
6
2
3
7
_
C Psig Kg/cm
@
Bar
0
1
72.5
75.6
5.10
5.32
5.00
5.21
78.8
82.1
85.5
89.0
92.5
5.54
5.77
6.01
6.26
6.50
5.43
5.66
5.90
6.14
6.38
8
9
96.2
99.9
6.76
7.02
6.63
6.89
10 103.7
7.29
13 115.4
8.11
16 126.1
8.87
18 137.4
9.66
7.15
7.96
8.69
9.47
21 149.4
10.50
10.30
24 162.1
11.40
11.18
27 175.5
12.34
12.10
29 189.6
13.33
13.07
32 204.5
14.38
14.10
35 220.2
15.48
15.18
38 236.8
16.65
16.33
41 254.2
17.87
17.53
43 272.4
19.15
18.78
46 291.6
20.50
20.11
49 311.8
21.92
21.50
52 332.9
23.41
22.95
54 355.0
24.96
24.48
57 378.1
26.58
26.07
60 402.3
28.28
27.74
63 427.6
30.06
29.48
66 454.0
31.92
31.30
62--10808
3-18
SECTION 4
TROUBLESHOOTING
CAUTION
DO NOT attempt to service the microprocessor!
Should a problem develop with the microprocessor, contact your nearest Carrier Transicold dealer for replacement.
REFERENCE
SECTION
INDICATION/
TROUBLE
4.1 DIESEL ENGINE
POSSIBLE CAUSES
4.1.1 Engine Will Not Start
Starter motor will not crank or low cranking speed
Starter motor cranks but engine fails to start
Battery insufficiently charged
Battery terminal post dirty or defective
Bad electrical connections at starter
Starter motor malfunctions
Starter motor solenoid defective
Open starting circuit
Incorrect grade of lubricating oil
No fuel in tank
Air in fuel system
Water in fuel system
Plugged fuel filters
Plugged fuel lines to injector (s)
Fuel control operation erratic
Glow plug(s) defective
Run solenoid defective
Fuel pump (FP) malfunction
Engine lube oil too heavy
Voltage drop in starter cable(s)
Starter cranks, engages, but dies after a few seconds
4.1.2 Engine Starts Then Stops
Engine stops after several rotations
Fuel supply restricted
No fuel in tank
Leak in fuel system
Faulty fuel control operation
Fuel filter restricted
Injector nozzle(s) defective
Injection pump defective
Air cleaner or hose restricted
Safety device open
Open wiring circuit to run solenoid
Fuel pump (FP) malfunction
4.1.3 Starter Motor Malfunction
Starter motor will not crank or turns slowly
Battery insufficiently charged
Battery cable connections loose or oxidized
Battery cables defective
Starter brushes shorted out
Starter brushes hang up or have no contact
Starter solenoid damaged
Run-Stop or Start-Run-Stop switch defective
Engine lube oil too heavy
Check
Check
Check
4.1.3
Engine Manual
4.1.4
1.6
Check
Check
Drain Sump
Replace
Check
Engine Manual
3.2.6
3.2.3
3.2.5
1.6
Check
Check
Fill Tank
Repair
Engine Manual
3.2.5
Engine Manual
Engine Manual
3.2.4
1.10
3.2.3
3.2.5
Check
Check
Replace
Engine Manual
Engine Manual
Engine Manual
3.2.3
1.6
4-1
62--10808
INDICATION/
TROUBLE
POSSIBLE CAUSES
4.1.3 Starter Motor Malfunction (CONTINUED)
Starter motor turns but pinion does not engage
Pinion or ring gear obstructed or worn
Starter motor does not disengage after switch was depressed
Run-Stop or Start-Run-Stop switch defective
Starter motor solenoid defective
Pinion does not disengage after engine is running
Defective starter
4.1.4 Malfunction In the Engine Starting Circuit
No power to starter motor solenoid (SS)
Run solenoid does not energize or does not remain energized
Battery defective
Loose electrical connections
Battery defective
Loose electrical connections
Oil pressure safety switch (OP) defective
Run relay (RR) defective
Water temperature safety switch open
Water temperature sensor (WTS) defective
Run solenoid defective
Run-Stop or Start-Run-Stop switch defective
4.2 ALTERNATOR (AUTOMOTIVE TYPE)
Alternator fails to charge Limited charging system operating time
Battery condition
Alternator belt loose/broken
Loose, dirty, corroded terminals, or broken leads
Excessively worn, open or defective brushes
Open blocking diode
Regulator faulty
Open isolation diode
Open rotor (field coil)
Low or unsteady charging rate
Excessive charging rate
(as evidenced by battery requiring too frequent refilling) or charge indicator shows constant
“charge with engine idling”
Noisy alternator
Alternator belt loose
Loose, dirty, corroded terminals, or broken leads
Excessively worn, sticky or intermittent brushes
Faulty regulator
Grounded or shorted turns in rotor
Open, grounded or shorted turns in stator
Regulator leads loose, dirty, corroded terminals, or wires broken
Defective regulator
Defective or badly worn V-belt
Worn bearing(s)
Misaligned belt or pulley
Loose pulley
REFERENCE
SECTION
Clean both, remove burrs, or replace; apply grease
3.2.3
Engine Manual
Engine Manual
Check
Tighten
Check
Tighten
Replace
Replace
1.6
Replace
3.2.3
Replace
Check
Check
3.3
Check/Repair
Check
Check
Check
Check
Replace
3.3
Check/Repair
Check
Check
Check
Replace
Clean/Repair
Check
3.3
Replace
3.3
Tighten
62--10808
4-2
INDICATION/
TROUBLE
4.3 REFRIGERATION
4.3.1 Unit Will Not Cool
Diesel engine
Compressor malfunction
Refrigeration system
POSSIBLE CAUSES
Malfunction(s)
Compressor drive defective
Compressor defective
Defrost cycle did not terminate
Abnormal pressure
Hot Gas (three-way) valve malfunction
4.3.2 Unit Runs But Has Insufficient Cooling
Compressor Compressor valves defective
Unloader malfunction
Refrigeration system Abnormal pressure
Expansion valve malfunction
No or restricted evaporator airflow
Unloader malfunction
Engine does not develop full rpm
Speed control linkage
Engine malfunction
4.3.3 Unit Operates Long or Continuously in Cooling
Container Hot Load
Refrigeration system
Defective box insulation or air leak
Abnormal pressure
Temperature controller malfunction
Defective Compressor
4.3.4 Unit Will Not Heat or Has Insufficient Heating
Refrigeration Abnormal pressure
Temperature controller malfunction
Hot Gas (three-way) valve malfunction
Compressor
Engine does not develop full rpm
Compressor drive defective
Compressor defective
Speed control linkage
Engine malfunction
REFERENCE
SECTION
4.1
3.8
3.8
4.3.5
4.3.6
4.3.11
3.8
3.10
4.3.6
4.3.10
4.3.9
3.10
3.2.3
4.1
Allow time to pull down
Correct
4.3.6
4.3.8
3.8
4.3.6
4.3.8
4.3.11
3.8
3.8
3.2.3
4.1
4-3
62--10808
INDICATION/
TROUBLE
POSSIBLE CAUSES
4.3.5 Defrost Cycle Malfunction
Will not initiate defrost automatically
Defrost air switch (DA) out of calibration
Defrost thermostats (DTT) open or defective
Defrost air switch (DA) defective
Loose terminal connections
Air sensing tubes defective or disconnected
Defrost timer defective
Will not initiate defrost manually Microprocessor defective
Loose terminal connections
Defrost thermostats (DTT) open or defective
Glow/Defrost switch defective
Initiates but does not defrost
Frequent defrost
Does not terminate or cycles on defrost
Hot Gas (three-way) valve malfunction
Defrost relay (DR) defective
Evaporator Clutch defective
Defrost air switch (DA) out of adjustment
Wet load
Defrost thermostats (DTT) shorted closed
Defrost timer defective
Glow/Defrost switch defective
Defrost air switch (DA) out of adjustment
4.3.6 Abnormal Pressure
4.3.6.1 Cooling
High discharge pressure
Low discharge pressure
High suction pressure
Low suction pressure
Suction and discharge pressures tend to equalize when unit is operating
Quench valve malfunction
Condenser coil dirty
Condenser fan defective
V-belt broken or loose
Discharge check valve restricted
Noncondensibles or refrigerant overcharge
Compressor valves(s) worn or broken
Hot Gas (three-way) valve malfunction
Compressor valves(s) worn or broken
Compressor gasket(s) defective
Hot Gas (three-way) valve malfunction
Suction service valve partially closed
King valve partially closed
Filter-drier partially plugged
Low refrigerant charge
Expansion valve malfunction
No evaporator air flow or restricted air flow
Excessive frost on coil
Compressor valves defective
Hot Gas (three-way) valve malfunction
REFERENCE
SECTION
3.13
Replace
3.13
Tighten
Check
Check/Replace
Replace
Tighten
Replace
Replace
4.3.11
Replace
Replace
3.13
Normal
Replace
Check/Replace
Replace
3.13
Replace
3.16
Check
3.3
Replace
Replace
3.8
3.17
3.8
3.8
3.17
Open
Open
3.11
3.7
4.3.10
4.3.9
Check
3.8
3.17
62--10808
4-4
INDICATION/
TROUBLE
4.3.6.2 Heating
High discharge pressure
POSSIBLE CAUSES
Low discharge pressure
Low suction pressure
Overcharged system
Condenser fan defective
V-belts broken or loose
Noncondensibles in system
Compressor valve(s) worn or broken
Hot Gas (three-way) valve malfunction
Low refrigerant charge
Refrigerant shortage
Compressor pressure regulating valve malfunction
Suction service valve partially closed
4.3.7 Abnormal Noise
Compressor
Condenser or evaporator fan
Loose mounting bolts
Worn bearings
Worn or broken valves
Liquid slugging
Insufficient oil
Loose or striking shroud
Bearings defective
Bent shaft
Cracked or worn V-belts
4.3.8 Control System Malfunction
Will not control Sensor defective
Relay(s) defective
Microprocessor controller malfunction
Solid State controller malfunction
4.3.9 No Evaporator Air Flow or Restricted Air Flow
Evaporator coil blocked Frost on coil
Dirty coil
Fan motor(s) malfunction
No or partial evaporator air flow
V-belt broken or loose
Clutch defective
Evaporator fan loose or defective
Evaporator fan rotating backwards
Evaporator air flow blocked in trailer (box)
Fan motor(s) malfunction
REFERENCE
SECTION
3.7.2
Check
3.3
Check
3.8
3.17
3.7
3.7
3.18
Open
Tighten
3.8
3.8
4.3.10
3.9
Check
Check
Check
3.3
3.22
Check
3.20
Replace
Check
3.15
3.14
3.3
Replace
Check
3.3
Check
3.14
4-5
62--10808
INDICATION/
TROUBLE
POSSIBLE CAUSES
4.3.10 Expansion Valve Malfunction
Low suction pressure with high superheat
Low refrigerant charge
External equalizer line plugged
Ice formation at valve seat
Wax, oil or dirt plugging valve or orifice
Broken capillary
Power assembly failure or partial
Loss of element/bulb charge
Superheat setting too high
Low superheat and liquid slugging in compressor
Fluctuating suction pressure
Superheat setting too low
External equalizer line plugged
Ice holding valve open
Foreign material in valve
Pin and seat of expansion valve eroded or held open by foreign material
Improper bulb location or installation
Low superheat setting
High superheat Broken capillary
4.3.11 Hot Gas (Three-Way) Valve Malfunction
Valve does not function properly No power to valve
Improper wiring or loose connections
Coil defective
Valve improperly assembled
Coil or coil sleeve improperly assembled
Temperature controller malfunction
Valve shifts but refrigerant continues to flow
Movement of plunger restricted due to: a. Corroded or worn parts b. Foreign material lodged in valve c. Bent or dented enclosing tube
Foreign material lodged under seat
Defective seat
4.4 Standby Motor Malfunction
Standby motor fails to start Motor contactor (MC) defective
Motor Overload (OL) open
Improper power supply
Oil pressure switch (OPS) open
Selector switch (SSW) defective
Standby motor starts, then stops Motor Overload (OL) open
High amperage draw
REFERENCE
SECTION
3.5/3.7
Clean
3.6
3.19
3.19
Replace
Replace
3.19
3.19
Open
3.6
Clean
3.19
3.19
3.19
3.19
Check
Check
3.17
3.17
3.17
Replace
3.17
3.17
3.17
Replace
Replace motor
1.8
Check
Replace
1.8
Check
62--10808
4-6
SECTION 5
ELECTRICAL SCHEMATIC WIRING DIAGRAM
5.1 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 fans and V-belts caused by the thermostat and the start/stop cycling of the unit.
WARNING
Under no circumstances should ether or any other starting aids be used to start engine.
CAUTION
Under no circumstances should anyone attempt to repair the Logic or Display Boards! 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.
Reverse polarity will destroy the rectifier diodes in alternator. As a precautionary measure, disconnect positive battery terminal when charging battery in unit. Connecting charger in reverse will destroy the rectifier diodes in alternator.
CAUTION
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 truck/trailer microprocessor.
5-1
62--10808
LOCATION SYMBOL
F1
G1
D1
T10
O10
A8
G5
O2/03/K9
O11
T11
K3
O1O (SHEET 3)
N10 (SHEET 3)
G4
O5
S12/S13
O11/O12P5/Q5/R5
T4
K9/O4
I2
N2
N7
N9
K3/N10
N11
N11/N12/N13
P5
P7
L7 (SHEET 3)
T1/ N7(SHEET 3)
M7 (SHEET 3)
T3
T7
K6/O7
S7
S7
H6
K10/O1
H8
D6
D7/D11/F4 (SHEET 3) MC
F8/F11(SHEET 3)
B2
F3
H3
B11 (SHEET 3)
OL
OP
GP
GPR
HGS1
HGS2
HP1
HR1
MGC
MP
A7
K2/L3
K6/O2
T3
H2
A7
G7/G11 (SHEET 3)
S9
B1
B3
A5
K10/O9
B2
K7
T4/T10
K7O10
T10
A6
SAS
SBM
SCS
SM
SP
SPT
SR
SS
P1
P2
PSR
RAS
RCR
RR
RS
RSS
SSR
SUFR
UFR
UF
WTS
ALT
B
BTY
CC
CCR
CDT
DA
DER
DDR
DDS
DPS
DS
DSR
DTT
DT
EFM 1,2,3
EFMR 1,2,3
EHC
EHR
F1
F3
F4
F5
F2,F6
F7
F8,F9, F10
F11
F12
FH
FHR
FHTH
FP
DESCRIPTION
ALTERNATOR
BUZZER
BATTERY
COMPRESSOR CLUTCH
COMPRESSOR CLUTCH RELAY
COMPRESSOR DISCHARGE TEMPERATURE SENSOR
DEFROST AIR SWITCH
DIESEL ELECTRIC RELAY
DERFROST DAMPER RELAY
DEFROST DAMPER SOLENOID
DETECTOR POWER SUPPLY
DOOR SWITCH
DOOR SWITCH RELAY
DEFROST THERMOSTAT
DEFROST TRANSISTOR
ELECTRIC FAN MOTOR
ELECTRIC FAN MOTOR RELAY
EVAPORATOR HEAT CONTACTOR
EVAPORATOR HEAT RELAY
FUSE (MAXI FUSE 80A)
FUSE 15A
FUSE 3/5A
FUSE 10A
FUSE 5A
FUSE 15A
FUSE 20A
FUSE 5A
FUSE 25A
FUEL HEATER (OPTION)
FUEL HEATER RELAY (OPTION)
FUEL HEATER THERMOSTAT (OPTION)
FUEL PUMP
GLOW PLUG
GLOW PLUG RELAY
HOT GAS SOLENOID
HOT GAS BYPASS SOLENOID
HIGH PRESSURE CUT-OUT SWITCH
HEAT RELAY
MANUAL GLOW/CRANK
MICROPROCESSOR BOARD
MOTOR CONTACTOR
OVERLOAD PROTECTOR
OIL PRESSURE SAFETY SWITCH (NO)
CAB COMMAND PLUG CONNECTOR
MICROPROCESSOR-CAB COMMAND PLUG CONNECTOR
POWER SUPPLY RECEPTACLE
RETURN AIR SENSOR
RUN CONTROL RELAY
RUN RELAY
RUN SOLENOID
RUN STOP SWITCH
SUPPLY AIR SENSOR (OPTIONAL)
STANDBY MOTOR
SPEED CONTROL SOLENOID
STARTER MOTOR
SERIAL PORT
SUCTION PRESSURE TRANSDUCER
SPEED RELAY
STARTER SOLENOID
STARTER SOLENOID RELAY
STANDBY UNLOADER FRONT RELAY
UNLOADER FRONT RELAY
UNLOADER FRONT
WATER TEMPERATURE SENSOR
LOCATION
MID FRAME
CONTROL BOX
CONTROL BOX
CONTROL BOX
COMPRESSOR
FRAME
CONTROL BOX
CONTROL BOX
EVAPORATOR
CONTROL BOX
CONTROL BOX
CONTROL BOX
EVAPORATOR
CONTROL BOX
EVAPORATOR
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
LIGHT BAR
ENGINE
CONTROL BOX
ENGINE
FUEL TANK
ENGINE
CONTROL BOX
FRAME
FRAME
COMPRESSOR
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
ENGINE
CONTROL BOX
CONTROL BOX
EVAPORATOR
CONTROL BOX
CONTROL BOX
ENGINE
CONTROL BOX
EVAPORATOR
FRAME
ENGINE
ENGINE
CONTROL BOX
COMPRESSOR
CONTROL BOX
STARTER
CONTROL BOX
CONTROL BOX
CONTROL BOX
COMPRESSOR
ENGINE
Figure 5-1. Electrical Schematic Wiring Diagram - MICROPROCESSOR CONTROLLER Based On Dwg. No. 62-60925 Rev C (Sheet 1 of 3)
844 ONLY
844 ONLY
844 ONLY
844 ONLY
844 ONLY
844 ONLY
844 ONLY
Figure 5-1. Electrical Schematic Wiring Diagram - Based On Dwg. No. 62-60925 Rev C Sheet 2 of 3
Figure 5-1. Electrical Schematic Wiring Diagram - MICROPROCESSOR CONTROLLER Based On Dwg. No. 62-60925 Rev C Sheet 3 of 3
A
Accumulator , 1-5
Additional Support Manuals, 1-1
Adjusting The Compressor Pressure Regulating
Valve, 3-13
Alarm Display, 2-6
Alarm Reset, 2-4
Alternator , 3-5
Alternator Auxiliary Alarm, 2-7
Alternator V--Belt, 3-6
Alternator: , 1-11
Alternator/Regulator, 1-4, 4--2
Ambient Temperature, 2-6
Auto Start Sequence, 2-13
Auto/Manual Start Operation, 2-4
Automatic Start, 2-11
B
Battery Voltage, 2-6
Belt Tension Gauge, 3-5
C
Changing Lube Oil and Lube Oil Filters, 3-3
Charging The Refrigeration System, 3-8
Checking 05k Compressor Oil level , 3-9
Checking And Replacing Evaporator Fan Motor
Brushes & Commutator, 3-12
Checking And Replacing Filter--drier , 3-11
Checking And Replacing High Pressure Switch, 3-11
Checking Calibration Of The Defrost Air Switch , 3-12
Checking the Refrigerant Charge, 3-9
Clutch Assembly , 1-4
Code Vs English Messages, 2-4
Compartment 2 Air Temperature , 2-6
Compartment 2 Setpoint, 2-4
Compartment 3 Air Temperature , 2-6
INDEX
Compartment 3 Setpoint, 2-4
Compressor, 1-4
Compressor Data, 1-9
Compressor Discharge Temperature, 2-6
Compressor Discharge Temperature Alarm, 2-8
Compressor Discharge Temperature Sensor, 1-10
Compressor Discharge Temperature Sensor Alarm,
2-8
Compressor Pressure Regulating Valve, 1--5, 1--10,
3-13
Compressor Unloader, 1-4, 3--10
Condenser/Subcooler, 1-5
Condensing Section, 1-1
Configuration of Microprocessor, 3-15
Control Circuit Operation -- Engine Drive, 2-11
Control Circuit Operation -- Standby, 2-12
Controller, 3-14
Controller Sensor Checkout , 3-17
Controlling Probe, 2-4
Coolant Temperature Sensor Alarm, 2-8
Cooling Operation, 1-5
Cooling System, 3-3
D
Defective Glow Plug, 3-5
Defrost Air Switch Initiation, 2-10
Defrost Air Switch Setting, 1-10
Defrost Cycle, 2-10
Defrost Interval, 2-4
Defrost Override Alarm, 2-7
Defrost Thermostat, 1-10
Defrost Timer , 1-10
Defrost Timer Initiation, 2-10
Diesel Engine, 4-1
Digital Display, 2-2
Display Alarm, 2-8
Dual Probe Operation, 2-9
Index-1 62--10808
E
Electric and Water Heat, 1-6
Electrical Data , 1-10
Engine, 1-1
Engine Air Cleaner , 3-4
Engine Data, 1-9
Engine Hours, 2-5
Engine Temperature, 2-5
Engine--Compressor V--Belts, 3-6
Evacuation And DehydratioN, 3-7
Evaporator, 1-6
Evaporator Coil Cleaning, 3-12
Evaporator Fan Motors , 1-10
Evaporator Section, 1-6
F
Fail safe Defrost Termination, 2-10
Filter Drier, 1-6
Fuel Heater , 2-9
Fuel Pump , 3-5
Functional Parameters, 2-3
Fuse Alarm, 2-8
G
Glow Plugs, 3-5
H
Heat And Defrost, 1-12
Heat and Defrost Operation, 1-5
Heat Exchanger, 1-6
High Battery Voltage Alarm, 2-7
High Coolant Temperature Alarm, 2-7
High Pressure Alarm, 2-7
High Pressure Cutout Switches, 1-10
HOT GAS (Three--Way) VALVE, 3-13
Hot Gas Bypass Solenoid Valve, 1-6
Hot Gas Solenoid Valve, 1-5
62--10808
INDEX
Hour Meters, 3-15
K
Keypad, 2-2
L
Loaded Operation, 1-4
Low Battery Voltage Alarm, 2-7
Low Oil Pressure Alarm, 2-7
Lubrication System, 1-9
M
Maintenance Hour Meter 1, 2-6
Maintenance Hour Meter 1 Alarm, 2-8
Maintenance Hour Meter 2, 2-6
Maintenance Hour Meter 2 Alarm, 2-8
Maintenance Schedule, 3-1, 3-2
Manual Defrost Initiation, 2-10
Manual Glow Override, 2-4
Manual Start, 2-11
Maximum Off Time, 2-4
Microprocessor Configuration, 2-3
Microprocessor Controller, 3-14
Microprocessor Controller , 2-1
Minimum Off--Time, 2-4
Minimum On--Time, 2-4
Model Chart , 1-1
Modes Of Operation, 2-9
N
No Power for Standby Alarm, 2-8
Null Mode Overrides, 2-9
Index-2
O
Operator Microprocessor Settings, 2-3
Out--Of--Range Alarm, 2-8
Out--of--Range Tolerance, 2-5
P
Pre--trip, 2-8
Pre--trip Inspection, 2-10
Pre--trip Inspection -- Starting , 2-10
Pre--trip Inspection -- Before Starting , 2-10
Pumping The Unit Down, 3-7
R
Receiver, 1-6
Refrigerant Charge, 1-10
Refrigerant Circuit, 1-12
Refrigerant Leak Checking, 3-7
Refrigeration, 4-3
Refrigeration System Data, 1-10
Remote Air Temperature, 2-5
Remote Compartment 2 Out--of--range Alarm, 2-8
Remote Compartment 3 Out--of--range Alarm, 2-8
Removing the Refrigerant Charge, 3-7
Replacing Key Board , 3-15
Replacing The Compressor, 3-9
Replacing The Speed And Run Control solenoids ,
3-3
Return Air Sensor Alarm, 2-7
Return Air Temperature, 2-5
Road Operation, 1-1
INDEX
Standby Hours, 2-6
Standby Motor , 1-4
Standby Motor Overload , 1-11
Standby Motor Overload Alarm, 2-8
Standby Motor--compressor V--belt, 3-6
Standby Motors, 1-10
Standby Operation, 1-1
Start Failure Alarm , 2-7
Starter Motor Alarm, 2-7
Starting -- Standby Motor Drive, 2-11
Startup And Pull Down -- Engine Operation, 2-9
Stopping Instructions, 2-11
Suction Pressure, 2-5
Suction Pressure Transducer, 3-17
Superheat , 3-14
Supply Air Sensor Alarm, 2-8
Supply Air Temperature, 2-5
Switch On Hour Meter, 2-6
Switches And Controls , 1-7
System Check Alarm, 2-8
System Operating Controls And Components, 1-6
T
Tartup And Pull Down -- Standby Operation, 2-9
Thermal Expansion Valve, 1-6
Thermostatic Expansion Valve , 3-13
Thermostatic Expansion Valve Superheat, 1-10
Torque Values, 1-11
S
Safety Devices, 1-11
Sensor Resistance, 3-17
Serial Number Low, 2-6
Serial Number Upper, 2-6
Servicing And Adjusting V--belts, 3-5
Setpoint, 2-3
Software Revision, 2-6
Speed Control, 2-4
Standard Units Select, 2-4
U
Unit Data, 2-5
Unloaded Operation , 1-4
W
Water Pump Belt Tensioner, 3-6
Index-3 62--10808
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
2005 Carrier Corporation
D
Printed in U. S. A. 0305
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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