Carrier 69NT40 551 v2 Operation and Service Manual PDF

1 of 105
1 of 105

Summary of Content for Carrier 69NT40 551 v2 Operation and Service Manual PDF

T--327 Rev C

OPERATION AND SERVICE for

69NT40--551--400 TO 425 Container Refrigeration Units

Container Refrigeration r

OPERATION AND SERVICE MANUAL CONTAINER REFRIGERATION UNIT

Models 69NT40--551--400 to 425

i T-327

TABLE OF CONTENTS

PARAGRAPH NUMBER Page GENERAL SAFETY NOTICES Safety-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIRST AID Safety-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING PRECAUTIONS Safety-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE PRECAUTIONS Safety-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFIC WARNING AND CAUTION STATEMENTS Safety-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 CONFIGURATION IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 OPTION DESCRIPTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1 Battery 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.2 Dehumidification 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.3 Control Box 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.4 Temperature Readout 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.5 Pressure Readout 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.6 USDA 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.7 Interrogator 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.8 Remote Monitoring 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.9 Communications 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.10 Compressor 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.11 Condenser Coil 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.12 Autotransformer 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.13 Temperature Recorder 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.14 Gutters 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.15 Handles 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.16 Thermometer Port 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.17 Water Cooling 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.18 Back Panels 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.19 460 Volt Cable 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.20 230 Volt Cable 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.21 Cable Restraint 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.22 Upper Air (Fresh Air Make Up) 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.23 Lower Air (Fresh Air Make Up) 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.24 Power Correction 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.25 Evaporator 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.26 Labels 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.27 Plate Set 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.28 Controller 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.29 Condenser Grille 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.30 Emergency Bypass 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 GENERAL DESCRIPTION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Refrigeration Unit -- Front Section 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Fresh Air Makeup Vent 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.3 Evaporator Section 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iiT-327

TABLE OF CONTENTS - Continued

PARAGRAPH NUMBER Page 2.1.4 Compressor Section 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.5 Air Cooled Condenser Section 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.6 Water-Cooled Condenser Section 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.7 Control Box Section 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.8 Communications Interface Module 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 REFRIGERATION SYSTEM DATA 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 ELECTRICAL DATA 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 SAFETY AND PROTECTIVE DEVICES 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 REFRIGERATION CIRCUIT 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.1 Standard Operation 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2 Economized Operation 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.3 Unloaded Operation 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.4 Quench/Injection Operation 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MICROPROCESSOR 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Key Pad 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2 Display Module 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.3 Controller 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 CONTROLLER SOFTWARE 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Configuration Software (Variables) 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Operational Software (Function Codes) 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 MODES OF OPERATION 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Temperature Control -- Perishable Mode 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Defrost Interval 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3 Failure Action 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.4 Generator Protection 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.5 Compressor High Temperature, Low Pressure Protection. 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.6 Perishable Mode -- Conventional 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.7 Perishable Mode -- Economy 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.8 Perishable Mode -- Dehumidification 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.9 Perishable, Dehumidification -- Bulb Mode 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.10 Perishable -- System Pressure Regulation 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.11 Temperature Control -- Frozen Mode 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.12 Frozen Mode -- Conventional 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.13 Frozen Mode -- Economy 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.14 Condenser Fan Switch Override 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 CONTROLLER ALARMS 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5. UNIT PRE-TRIP DIAGNOSTICS 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 DataCORDER 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.1 Description 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.2 DataCORDER Software 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.3 Sensor Configuration (dCF02) 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.4 Logging Interval (dCF03) 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.5 Thermistor Format (dCF04) 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii T-327

TABLE OF CONTENTS - Continued

PARAGRAPH NUMBER Page 3.6.6 Sampling Type (dCF05 & dCF06) 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.7 Alarm Configuration (dCF07 -- dCF10) 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.8 DataCORDER Power-Up 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.9 Pre-Trip Data Recording 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.10 DataCORDER Communications 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.11 USDA Cold Treatment 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.12 USDA Cold Treatment Procedure 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.13 DataCORDER Alarms 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.14 ISO Trip Header 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 INSPECTION (Before Starting) 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 CONNECT POWER 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Connection To 380/460 vac Power 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Connection To 190/230 vac Power 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 ADJUST FRESH AIR MAKEUP VENT 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Upper Fresh Air Makeup Vent 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2 Lower Fresh Air Makeup Vent 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.3 Fresh Air Position Sensor 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 CONNECT WATER-COOLED CONDENSER 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1 Water--Cooled Condenser with Water Pressure Switch 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2 Water-Cooled Condenser with Condenser Fan Switch 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 CONNECT REMOTE MONITORINGRECEPTACLE 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 STARTING AND STOPPING INSTRUCTIONS 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Starting the Unit 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.2 Stopping the Unit 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 START--UP INSPECTION 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.1 Physical Inspection 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.2 Check Controller Function Codes 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.3 Start Temperature Recorder 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.4 Complete Inspection 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 PRE-TRIP DIAGNOSIS 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 OBSERVE UNIT OPERATION 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.1 Probe Check 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10 SEQUENCE OF OPERATION 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.1 Sequence Of Operation -- Compressor Phase Sequence 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.2 Sequence Of Operation -- Perishable Mode Cooling 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.3 Sequence Of Operation -- Perishable Mode Heating 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.4 Sequence Of Operation -- Frozen Mode Cooling 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.5 Sequence Of Operation -- Defrost 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.6 Emergency Bypass Operation 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 UNIT WILL NOT START OR STARTS THEN STOPS 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ivT-327

TABLE OF CONTENTS - Continued

PARAGRAPH NUMBER Page 5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 UNIT WILL NOT TERMINATE HEATING 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 UNIT WILL NOT DEFROST PROPERLY 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 ABNORMAL PRESSURES (COOLING) 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 ABNORMAL NOISE OR VIBRATIONS 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 CONTROLLER MALFUNCTION 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.12 AUTOTRANSFORMER MALFUNCTION 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH 5-4. . . . . . . . . . . . . . . . . . . . . . . .

5.14 COMPRESSOR OPERATING IN REVERSE 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.15 ABNORMAL TEMPERATURES 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16 ABNORMAL CURRENTS 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 SECTION LAYOUT 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 MANIFOLD GAUGE SET 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 REFRIGERATION SYSTEM SERVICE 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1 Service Connections 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.2 Pumping Down the Unit 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.3 Refrigerant Leak Checking 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.4 Refrigerant Recovery 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.5 Evacuation and Dehydration 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.6 Refrigerant Charge 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.8 Adding Refrigerant to System (Partial Charge) 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 COMPRESSOR 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4.1 Removal and Replacement of Compressor 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 COMPRESSOR OIL LEVEL 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6 HIGH PRESSURE SWITCH 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.1 Replacing High Pressure Switch 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.2 Checking High Pressure Switch 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 CONDENSER COIL 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 CONDENSER FAN AND MOTOR ASSEMBLY 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 WATER COOLED CONDENSER CLEANING 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10 FILTER-DRIER 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 EXPANSION VALVES 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11.1 Checking Superheat 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11.2 Valve Replacement 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12 EVAPORATOR COIL AND HEATERASSEMBLY 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12.1 Evaporator Coil Replacement 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12.2 Evaporator Heater Replacement 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.13 ECONOMIZER, LIQUID INJECTION AND UNLOADER VALVES 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14 EVAPORATOR FAN AND MOTOR ASSEMBLY 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.1 Replacing The Evaporator Fan Assembly 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.2 Disassemble The Evaporator Fan Assembly 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

v T-327

TABLE OF CONTENTS - Continued

PARAGRAPH NUMBER Page

6.14.3 Assemble The Evaporator Fan Assembly 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15 EVAPORATOR FAN MOTOR CAPACITOR 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15.1 When To Check For A Defective Capacitor 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15.2 Removing The Capacitor 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15.3 Checking The Capacitor 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.16 VALVE OVERRIDE CONTROLS 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.17 SUCTION MODULATION VALVE 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.17.1 Precheck Procedure 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.17.2 Checking The Stepper valve 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.18 AUTOTRANSFORMER 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.19 CONTROLLER 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.19.1 Handling Modules 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.19.2 Controller Troubleshooting 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.19.3 Controller Programming Procedure 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.19.4 Removing and Installing a Module 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.19.5 Battery Replacement 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.20 VENT POSITION SENSOR SERVICE 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.20.1 Vent Position Sensor Calibration 6-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.21 TEMPERATURE SENSOR SERVICE 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.21.1 Sensor Checkout Procedure 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.21.2 Sensor Replacement 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.21.3 Sensor Re--Installation 6-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.22 ELECTRONIC PARTLOW TEMPERATURE RECORDER 6-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.23 MAINTENANCE OF PAINTED SURFACES 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24 COMPOSITE CONTROL BOX REPAIRS 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.1 Introduction 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.2 Cracks 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.3 Chips And Holes 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.4 Inserts 6-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.5 Door Hinge Inserts 6-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.25 COMMUNICATIONS INTERFACE MODULE INSTALLATION 6-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL WIRING SCHEMATICS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 INTRODUCTION 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

viT-327

LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 2-1 Refrigeration Unit -- Front Section 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-2 Evaporator Section 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-3 Compressor Section 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-4 Condenser Section 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-5 Water-Cooled Condenser Section 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-6 Control Box Section 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-7 Refrigeration Circuit Schematic -- Standard Operation 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-8 Refrigeration Circuit Schematic -- Economized Operation 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-9 Refrigeration Circuit Schematic -- Unloaded Operation 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-1 Temperature Control System 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-2 Key Pad 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-3 Display Module 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-4 Control Module 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-5 Standard Configuration Download Report 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-6 Data Reader 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-1 Autotransformer 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-2 Make Up Air Flow Chart 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-3 Controller Operation -- Perishable Mode 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-4 Controller Operation -- Frozen Mode 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-5 Perishable Mode 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-6 Perishable Mode Heating 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-7 Frozen Mode 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-8 Defrost 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-1 Manifold Gauge Set 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-2 R-134a Manifold Gauge/Hose Set 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-3 Service Valve 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-4 Refrigeration System Service Connections 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-5 Compressor Upper Mounting 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-6 Compressor Lower Mounting 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-7 High Pressure Switch Testing 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-8 Water-Cooled Condenser Cleaning -- Forced Circulation 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-9 Water Cooled Condenser Cleaning - Gravity Circulation 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-10 Thermostatic Expansion Valve Bulb 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-11 Hermetic Thermostatic Expansion Valve Brazing Procedure 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-12 Evaporator Expansion Valve 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-13 Quench & Economizer Expansion Valves 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-14 Unloader Solenoid Valve 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-15 Economizer/Liquid Injection Solenoid Valve 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-16 Evaporator Fan Assembly 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-17 Suction Modulation Valve (SMV) 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-18 Controller Section of the Control Box 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-19 Sensor Types 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-20 Sensor and Cable Splice 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-21 Supply Sensor Positioning 6-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-22 Return Sensor Positioning 6-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii T-327

LIST OF ILLUSTRATIONS - Continued FIGURE NUMBER Page

Figure 6-23 Electronic Partlow Temperature Recorder 6-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-24 Door Hinge Repair 6-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-25 Insert Location 6-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-26 Communications Interface Installation 6-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-1 LEGEND 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-2 SCHEMATIC DIAGRAM 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-3 SCHEMATIC DIAGRAM -- TransFRESH and Emergency Bypass 7-3. . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-4 SCHEMATIC DIAGRAM, WIRING DIAGRAM -- Electronic Partlow Recorder 7-4. . . . . . . . . . . . . . .

Figure 7-5 SCHEMATIC DIAGRAM, WIRING DIAGRAM -- Upper and Lower Vent Position Sensors 7-5. . . . .

Figure 7-6 WIRING DIAGRAM 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF TABLES

TABLE NUMBER Page Table 2-1 Safety and Protective Devices 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-1 Key Pad Function 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-2 DataCORDER Configuration Variables 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-3 DataCORDER Standard Configurations 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-4 Controller Configuration Variables 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-5 Controller Function Codes 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-6 Controller Alarm Indications 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-7 Controller Pre-Trip Test Codes 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-8 DataCORDER Function Code Assignments 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-9 DataCORDER Pre-Trip Result Records 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-10 DataCORDER Alarm Indications 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-1 Compressor Kit 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-2 Sensor Temperature/Resistance Chart (+/--.002%) 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-3 Crack, Chip & Hole Repair Kit 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-4 Insert Repair Kit 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-5 Drill Information 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-6 Recommended Bolt Torque Values 6-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-7 R-134a Temperature - Pressure Chart 6-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T--327Safety-1

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions appearing elsewhere in the manual follows the general safety notices.

FIRST AID

An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.

OPERATING PRECAUTIONS

Always wear safety glasses.

Keep hands, clothing and tools clear of the evaporator and condenser fans.

No work should be performed on the unit until all circuit breakers, start-stop switches are turned off, and power supply is disconnected.

Always work in pairs. Never work on the equipment alone.

In case of severe vibration or unusual noise, stop the unit and investigate.

MAINTENANCE PRECAUTIONS

Beware of unannounced starting of the evaporator and condenser fans. Do not open the condenser fan grille or evaporator access panels before turning power off, disconnecting and securing the power plug.

Be sure power is turned off before working on motors, controllers, solenoid valves and electrical control switches. Tag circuit breaker and power supply to prevent accidental energizing of circuit.

Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.

When performing any arc welding on the unit or container, disconnect all wire harness connectors from the modules in both control boxes. Do not remove wire harness from the modules unless you are grounded to the unit frame with a static safe wrist strap.

In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).

SPECIFIC WARNING AND CAUTION STATE- MENTS

To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation is given with the appropriate consequences:

DANGER -- means an immediate hazard which WILL result in severe personal injury or death.

WARNING -- means to warn against hazards or unsafe conditions which COULD result in severe personal injury or death.

CAUTION -- means to warn against potential hazard or unsafe practice which could result in minor personal injury, product or property damage.

The statements listed below are applicable to the refrigeration unit and appear elsewhere in this manual. These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein.

DANGER Never use air for leak testing. It has been de- termined that pressurized, mixtures of re- frigerant and air can undergo combustion when exposed to an ignition source.

WARNING Beware of unannounced starting of the evaporator and condenser fans. The unit may cycle the fans and compressor unex- pectedly as control requirements dictate.

WARNING Do not attempt to remove power plug(s) be- fore turningOFF start-stop switch (ST), unit circuit breaker(s) and external power source.

WARNING Make sure the power plugs are clean and dry before connecting to any power recep- tacle.

Safety-2T--327

WARNING

Make sure that the unit circuit breaker(s) (CB-1 & CB-2) and the START-STOP switch (ST) are in the O (OFF) position before connecting to any electrical power source.

WARNING

Make sure power to the unit is OFF and power plug disconnected before replacing the compressor.

WARNING

Before disassembly of the compressor make sure to relieve the internal pressure verycarefullyby slightly loosening thecou- plings to break the seal.

WARNING

Oakite No. 32 is an acid. Be sure that the acid is slowly added to the water. DO NOT PUT WATER INTO THE ACID -- this will cause spattering and excessive heat.

WARNING

Wear rubber gloves and wash the solution from the skin immediately if accidental contact occurs. Do not allow the solution to splash onto concrete.

WARNING

Always turn OFF the unit circuit breakers (CB-1 & CB-2) and disconnect main power supply before working on moving parts.

WARNING

Make sure power to the unit is OFF and power plug disconnected before removing capacitor(s).

WARNING With power OFF discharge the capacitor before disconnecting the circuit wiring.

WARNING Do not use a nitrogen cylinder without a pressure regulator. Do not use oxygen in or near a refrigeration system as an explosion may occur.

WARNING Do not open the condenser fan grille before turning power OFF and disconnecting power plug.

WARNING TheUnit Power PlugMust BeDisconnected ToRemovePowerFromCircuit BreakerCb1

CAUTION Do not remove wire harnesses from con- troller modules unless you are grounded to the unit frame with a static safe wrist strap.

CAUTION Unplug all controller module wire harness connectors before performing arc welding on any part of the container.

CAUTION Do not attempt to use anML2i PC card in an ML3equippedunit. ThePCcardsarephysi- cally different and will result in damage to the controller.

CAUTION When condenserwater flow is below 11 lpm (3 gpm) or when water-cooled operation is not in use, the CFS switch MUST be set to position 1 or the unit will not operate properly.

T--327Safety-3

CAUTION Pre-trip inspection should not be per- formed with critical temperature cargoes in the container.

CAUTION WhenPre-Trip key ispressed, economy,de- humidification and bulb mode will be deac- tivated. At the completion of Pre-Trip activi- ty, economy, dehumidification and bulb mode must be reactivated.

CAUTION When a failure occurs during automatic testing the unit will suspend operation awaiting operator intervention.

CAUTION When Pre--Trip test Auto 2 runs to comple- tion without being interrupted, the unit will terminate pre-trip and display Auto 2 end. Theunit will suspend operation until the user depresses the ENTER key!

CAUTION To prevent trapping liquid refrigerant in the manifold gaugeset besure set is brought to suction pressure before disconnecting.

CAUTION The scroll compressor achieves low suc- tion pressure very quickly. Do not use the compressor to evacuate the system below zero psig. Never operate the compressor with thesuction ordischargeservicevalves closed (frontseated). Internal damage will result from operating the compressor in a deep vacuum.

CAUTION Use only Carrier Transicold approved Polyol EsterOil (POE) -- EAL 32STcompres- sor oil with R-134a. Buy in quantities of one quart or smaller. When using this hygro- scopic oil, immediately reseal. Do not leave container of oil open or contamination will occur.

CAUTION

Take necessary steps (place plywood over coil or use sling onmotor) to preventmotor from falling into condenser coil.

CAUTION

DONOT disassemble piston fromNEWsuc- tion modulating valve powerhead assem- bly. Doing so may result in damage to pis- ton.

CAUTION

The unit must be OFF whenever a program- ming card is inserted or removed from the controller programming port.

CAUTION

Do not allow moisture to enter wire splice area as this may affect the sensor resis- tance.

CAUTION

Do not allow the recorder stylus to snap back down. The stylus arm base is spring loaded, and damagemayoccur to thechart, or the stylus force may be altered.

CAUTION

The inside mechanism of the recorder, particularly the inside of the element housing should never be oiled, however, control mechanisms should be sprayed periodically (every 60 days) with corrosion inhibiting CRC 3-36a or 6-66 or LPS no. 2.

CAUTION

Recorder element capillary tubing may be bent, but never sharper than 1/2 radius; extra care should be taken when bending adjacent to welds. The bulb should never be bent, as this will affect calibration.

1-1 T-327

SECTION 1

INTRODUCTION

1.1 INTRODUCTION

The Carrier Transicold model 69NT40--551--401 to 425 series units are of lightweight aluminum frame construction, designed to fit in the front of a container and serve as the containers front wall.

They are one piece, self-contained, all electric units which includes cooling and heating systems to provide precise temperature control.

The units are suppled with a complete charge of refrigerant R-134a and compressor lubricating oil and are ready for operation upon installation. Forklift pockets are provided for unit installation and removal.

The base unit operates on nominal 380/460 volt, 3 phase, 50/60 hertz power. An optional autotransformer may be fitted to allow operation on nominal 190/230 , 3 phase, 50/60 hertz power. Power for the control system is provided by a transformer which steps the supply power down to 18 and 24 volts, single phase.

The controller is a Carrier Transicold Micro-Link 3 microprocessor. The controller will operate automatically to select cooling, holding or heating as required to maintain the desired set point temperature within very close limits. The unit may also be equipped with an electronic temperature recorder.

The controller has a keypad and display for viewing or changing operating parameters. The display is also equipped with lights to indicate various modes of operation.

1.2 CONFIGURATION IDENTIFICATION

Unit identification information is provided on a plate located near the compressor. The plate provides the unit model number, the unit serial number and the unit parts identification number (PID). The model number identifies the overall unit configuration while the PID provides information on specific optional equipment, factory provision to allow for field installation of optional equipment and differences in detailed parts.

Configuration identification for the models covered herein are provided in the Carrier Transicold Container Identification Matrix found at the Carrier Web site, www.container.carrier.com.

1.3 OPTION DESCRIPTION

Various options may be factory or field equipped to the base unit. These options are listed in the tables and described in the following subparagraphs.

1.3.1 Battery The refrigeration controller may be fitted with standard replaceable batteries or a rechargeable battery pack. Rechargeable battery packs may be fitted in the standard or in a secure location.

1.3.2 Dehumidification

The unit may be fitted with a humidity sensor. This sensor allows setting of a humidity set point in the controller. In the dehumidification mode the controller will operate to reduce internal container moisture level.

1.3.3 Control Box

Units are equipped with a composite material box and may be fitted with a lockable door.

1.3.4 Temperature Readout

The unit may be fitted with suction and discharge temperature sensors. The sensor readings may be viewed on the controller display.

1.3.5 Pressure Readout

The unit may be fitted with suction and discharge pressure gauges or suction and discharge transducers or no pressure readout. The transducer readings may be viewed on the controller display.

1.3.6 USDA

The unit may be supplied with fittings for additional temperature probes which allow recording of USDA Cold Treatment data by the integral DataCORDER function of the Micro--Link refrigeration controller.

1.3.7 Interrogator

Units that use the DataCORDER function are fitted with interrogator receptacles for connection of equipment to download the recorded data. Two receptacles may be fitted, one accessible from the front of the container and the other mounted inside the container (with the USDA receptacles).

1.3.8 Remote Monitoring

The unit may be fitted with a remote monitoring receptacle. This item allows connection of remote indicators for COOL, DEFROST and IN RANGE. Unless otherwise indicated, the receptacle is mounted at the control box location.

1.3.9 Communications

The unit may be fitted with a communications interface module. The communications interface module is a slave module which allows communication with a master central monitoring station. The module will respond to communication and return information over the main power line. Refer to the ship master system technical manual for further information.

1.3.10 Compressor

The unit is fitted with a scroll compressor, equippedwith suction, discharge and economizer service connections.

1-2T-327

1.3.11 Condenser Coil

The unit is fitted a 4 row coil using 7mm tubing.

1.3.12 Autotransformer

An autotransformer may be provided to allow operation on 190/230, 3 phase, 50/60 hertz power. The autotransformer raises the supply voltage to the nominal 380/460 volt power required by the base unit. The autotransformer may also be fitted with an individual circuit breaker for the 230 volt power.

If the unit is equipped with an autotransformer and communications module, the autotransformer will be fitted with a transformer bridge unit (TBU) to assist in communications.

1.3.13 Temperature Recorder

The units may be fitted with an electronic temperature recording device manufactured by the Partlow Corporation.

1.3.14 Gutters

Rain gutters may be fitted over the control box and recorder section to divert rain away from the controls. The different gutters include standard length bolted gutters, extended length gutters and riveted gutters.

1.3.15 Handles

The unit may be equipped with handles to facilitate access to stacked containers. These handles may include fixed handles (located at the sides of the unit) and/or a hinged handle at the center (attached to the condenser coil cover).

1.3.16 Thermometer Port

The unit may be fitted with ports in the front of the frame for insertion of a thermometer tomeasure supply and/or return air temperature. If fitted, the port(s) will require a cap and chain.

1.3.17 Water Cooling

The refrigeration system may be fitted with a water cooled condenser. The condenser is constructed using copper--nickel tube for sea water applications. The water cooled condenser is in series with the air cooled condenser and replaces the standard unit receiver. When operating on the water cooled condenser, the condenser fan is deactivated by either a water pressure switch or condenser fan switch.

1.3.18 Back Panels

Back panel designs that may be fitted include panels of aluminum and stainless steel. Panels may have access doors and/or hinge mounting.

1.3.19 460 Volt Cable

Various power cable and plug designs are available for the main 460 volt supply. The plug options tailor the cables to each customers requirements.

1.3.20 230 Volt Cable

Units equipped with an autotransformer require an additional power cable for connection to the 230 volt source. Various power cable and plug designs are available. The plug options tailor the cables to each customers requirements.

1.3.21 Cable Restraint

Various designs are available for storage of the power cables. These options are variations of the compressor section front cover.

1.3.22 Upper Air (Fresh Air Make Up)

The unit may be fitted with an upper fresh air makeup assembly. The fresh air makeup assembly is available with a Vent Positioning Sensor (VPS) and may also be fitted with screens.

1.3.23 Lower Air (Fresh Air Make Up)

The unit may be fitted with a lower fresh air makeup assembly and may also be fitted with screens.

1.3.24 Power Correction

The unit may be fitted with a set of power factor correction capacitors to assist in correction of imbalance in current draw by the compressor.

1.3.25 Evaporator

Evaporator section is equipped with a hermetic thermal expansion valve.

1.3.26 Labels

Operating Instruction and Function Code listing labels differ, depending on the options installed. For example, additional operating instructions are required to describe start--up of a unit equipped with an autotransformer. Labels available with additional languages are listed in the parts list.

1.3.27 Plate Set

Each unit is equipped with a tethered set of wiring schematic andwiring diagram plates. The plate sets are ordered using a seven digit base part number and a two digit dash number.

1.3.28 Controller

Two different controllers are available: 1. Remanufactured -- Controller is the equivalent of a new OEM controller and is supplied with a 12 month warranty. 2. Repaired -- Controller has had previous faults repaired and upgraded with the latest software. Note: Repaired controllers are NOT to be used for warranty repairs; only full OEM Remanufactured controllers are to be used. Controllers will be factory equipped with the latest version of operational software, but will NOT be configured for a specific model number and will need to be configured at the time of installation or sale.

1.3.29 Condenser Grille

Two styles of condenser grilles are available: direct bolted grilles and hinged grilles.

1.3.30 Emergency Bypass

The unit may be equipped with switches to allow emergency bypass of the controller. TheEMERGENCY BYPASS switch functions to bypass the controller in the event of controller failure.

T-3272--1

SECTION 2

DESCRIPTION

2.1 GENERAL DESCRIPTION

2.1.1 Refrigeration Unit -- Front Section

The unit is designed so that the majority of the components are accessible from the front, see Figure 2-1. Theupper access panels allowentry into the evaporator section, and the center access panel allows access to the evaporator expansion valve, suction

modulation valve and evaporator coil heaters. The unit model number, serial number and parts identification number can be found on the serial plate to the left of the economizer.

2.1.2 Fresh Air Makeup Vent The function of the upper or lower makeup air vent is to provide ventilation for commodities that require fresh air circulation.

1

2

3

8

4

13

5

14

17

9

18

16

12

15

1011

6 7

1. Access Panel (Evap. Fan #1) 2. Access Panel (Heaters, Suction Modulating

Valve & Evaporator Expansion Valve)

3. Fork Lift Pockets 4. Control Box 5. Compressor 6. Receiver or Water Cooled Condenser 7. Economizer 8. Unit Serial Number, Model Number and

Parts Identification Number (PID) Plate 9. Power Cables and Plug

10. Condenser Fan 11. Autotransformer (Location) 12. TransFRESH Communications Connector 13. Interrogator Connector (Front left) 14. Temperature Recorder 15. Lower Fresh Air Makeup Vent Location

(Blank Cover Shown) 16. TIR (Transports Internationaux Routiers)

Sealing Provisions - Typical All Panels 17. Upper Fresh Air Makeup Vent 18. Access Panel (Evap. Fan #2)

Figure 2-1 Refrigeration Unit -- Front Section

2--2T-327

2.1.3 Evaporator Section

The evaporator section (Figure 2-2) contains the temperature recorder bulb or return recorder sensor, return temperature sensor, evaporator expansionvalve, quenchexpansion valve, suctionmodulation valve, dual speed evaporator fans (EM1 and EM2), evaporator coil and heater, drain pan heater, defrost heaters, defrost temperature sensor, heat termination thermostat and

suction temperature sensor.

The evaporator fans circulate air through the container by pulling it in the top of the unit, directing it through the evaporator coil, where it is heated or cooled, and discharging it at the bottom.

The evaporator components are accessible by removing the upper rear panel (as shown in the illustration) or by removing the front access panels.

16

14

11

13

1

2

3

4

5 6

7

10

17

19

8

23

20 21 22

9

15

18

18141716

12

1. Evaporator Fan Motor #1 2. Return Recorder Sensor/Temperature Sensor 3. Humidity Sensor 4. Evaporator Fan Motor #2 5. Defrost Temperature Sensor 6. Evaporator Coil 7. Evaporator Coil Heaters 8. Evaporator Expansion Valve Bulb 9. Evaporator Expansion Valve 10. Unloader Solenoid Valve 11. Low Side Access Valve 12. Heater Termination Thermostat

13. Suction Modulating Valve 14. To Unloader Solenoid Valve 15. Suction Temperature Sensor 16. To Compressor (suction) 17. From Evaporator Coil 18. Liquid To Evaporator Expansion Valve 19. Interrogator Connector (Rear) 20. USDA Probe Receptacle PR2 21. USDA Probe Receptacle PR1 22. USDA Probe Receptacle PR3 23. Cargo Probe Receptacle PR4

Figure 2-2 Evaporator Section

T-3272--3

2.1.4 Compressor Section The compressor section includes the compressor (with high pressure switch), a discharge pressure transducer and the suction pressure transducers.

The supply temperature sensor, supply recorder sensor and ambient sensor are located at the left side of the compressor.

12 13

1 3

2

5

6

8 9 10

14 7

15

11

Discharge Connection (Hidden)

Economizer Connection

Suction Connection

12

4

17

16

19 18

12

1. Compressor Guard 2. Supply Air Thermometer Port (location) 3. Supply Temperature/Supply Recorder Sensor

Assembly 4. Compressor 5. Oil Drain 6. Compressor Sight Glass 7 Compressor Power Plug 8. Discharge Service Valve 9. High Pressure Switch

10. From Suction Modulating Valve 11. Discharge Temperature Sensor 12. Access Valve 13. Economizer Connection 14. Suction Strainer 15. Suction Pressure Transducer 16. To Liquid Line Service Valve 17. From Economizer 18. To Condenser Coil 19. From Condenser Coil

Figure 2-3 Compressor Section

2--4T-327

2.1.5 Air Cooled Condenser Section The air cooled condenser section (Figure 2-4) consists of the condenser fan, condenser coil, receiver, sight glass/moisture indicator, liquid line service valve, filter-drier, fusible plug, economizer, quench expansion valve, liquid injection valve, economizer expansion valve, and economizer solenoid valve.

The condenser fanpulls air in thebottomof thecoil and it is dischargedhorizontally out through the condenser fan grille.

This section also contains the economizer, economizer solenoid valve, economizer expansion valve and the unloader solenoid valve.

5

6

1

2 43

8 10

22 15

16

14

17

18 19

20 21

97

12

13

11

1. Grille and Venturi Assembly 2. Condenser Fan 3. Key 4. Condenser Fan Motor 5. Condenser Coil 6. Condenser Coil Cover 7. To Evaporator Expansion Valve 8. Economizer 9. Quench Expansion Valve 10. To Unloader Solenoid Valve 11. Liquid Injection Valve 12. From Condenser Coil

13. To Compressor (Economizer) 14. Sight Glass 15. Receiver 16. Sight Glass/Moisture Indicator 17. Fusible Plug 18. Access Valve 19. Liquid Line Service Valve 20. Filter-Drier 21. Economizer Expansion Valve 22. Economizer Solenoid Valve

Figure 2-4 Condenser Section

T-3272--5

2.1.6 Water-Cooled Condenser Section

The water-cooled condenser section (Figure 2-5) consists of a water-cooled condenser, sight glass, rupture disc, filter-drier, water couplings, water pressure switch, economizer, quench expansion valve, liquid injection valve, economizer expansion valve, economizer solenoid valve, and moisture/liquid

indicator.

The water cooled condenser replaces the standard unit receiver.

This section also contains the economizer, economizer solenoid valve, economizer expansion valve, moisture/liquid indicator and the unloader solenoid valve.

10

11

12 131415

16

17

18

19

1

9

2 3 5 7 864

1. To Evaporator Expansion Valve 2. Economizer 3. Quench Expansion Valve 4. To Unloader Solenoid Valve 5. To Compressor Economizer Connection 6. Rupture Disc 7. Liquid Injection Valve 8. From Air Cooled Condenser 9. Water Pressure Switch 10. Coupling (Water In)

11. Self Draining Coupling (Water Out) 12. Water-Cooled Condenser 13. Sight Glass 14. Access Valve 15. Liquid Line Service Valve/Connection 16. Moisture/Liquid Indicator 17. Filter-Drier 18. Economizer Expansion Valve 19. Economizer Solenoid Valve

Figure 2-5 Water-Cooled Condenser Section

2--6T-327

2.1.7 Control Box Section The control box (Figure 2-6) includes the manual operation switches; circuit breaker (CB-1); compressor, fan and heater contactors; control power transformer; fuses; key pad; display module; current sensor module; controller module expansion module and the communications interface module.

2.1.8 Communications Interface Module The communications interface module is a slave module which allow communication with a master central monitoring station. The module will respond to communication and return information over the main power line. Refer to themaster system technicalmanual for further information.

1718 131516

1 2 3 4 5 6

810

7

914 1112

1. Compressor Phase A Contactor 2. Compressor Phase B Contactor 3. Heater Contactor 4. Display Module 5. Communications Interface Module 6. Controller/DataCORDER Module (Controller) 7. Key Pad 8. Remote Monitoring Receptacle 9. Controller Battery Pack (Standard Location)

10. Interrogator Connector (Box Location) 11. Fan Mode Switch 12. Emergency Bypass Switch 13. Control Transformer 14. Evaporator Fan Contactor - High 15. Evaporator Fan Contactor - Low 16. Condenser Fan Contactor 17. Circuit Breaker -- 460V 18. Current Sensor Module

Figure 2-6 Control Box Section

T-3272--7

2.2 REFRIGERATION SYSTEM DATA

a. Compressor/Motor Assembly

Model RSH105

Weight (Dry) 46.5 kg (103 lb) Approved Oil Mobil -- 32ST Oil Charge 2957 ml (100 ounces)

Oil Sight Glass The oil level range, with the compressor off, should be between the bottom and one-eighth level of the sight glass.

b. Evaporator Expansion Valve Superheat

Verify at --18 _C (0 _F) container box temperature

4.4 to 6.7 _C (8 to 12 _F)

c. Economizer Expansion Valve Superheat 4.4 to 11.1 _C (8 to 20 _F)

d. Heater Termination Thermostat Opens 54 ( 3) _C = 130 ( 5) _F

Closes 38 ( 4) _C = 100 ( 7) _F

e. High Pressure Switch Cutout 25 ( 1.0) kg/cm@ = 350 ( 10) psig

Cut-In 18 ( 0.7) kg/cm@ = 250 ( 10) psig

f. Refrigerant Charge

Unit Configuration Charge Requirements -- R-134a

Water-Cooled Condenser

5.56 kg (12.25 lbs)

Receiver 5.22kg (11.5 lbs)

g. Fusible Plug Melting point 99 _C = (210 _F) Torque 6.2 to 6.9 mkg (45 to 50 ft-lbs)

h. Sight Glass/Moisture Indicator Torque 8.9 to 9.7 mkg (65 to 70 ft-lbs)

i. Rupture Disc Bursts at 35 5% kg/cm@ = (500 5% psig) Torque 6.2 to 6.9 mkg (45 to 50 ft-lbs)

j. Unit Weight Refer to unit model number plate.

k. Water Pressure Switch Cut-In 0.5 0.2 kg/cm@ (7 3 psig)

Cutout 1.6 0.4 kg/cm@ (22 5 psig)

2--8T-327

2.3 ELECTRICAL DATA

a. Circuit Breaker

CB-1 Trips at 29 amps CB-2 (50 amp) Trips at 62.5 amps CB-2 (70 amp) Trips at 87.5 amps

b. Compressor Motor Full Load Amps (FLA) 13 amps @ 460 vac

c. Condenser Fan Motor

380 vac, Single Phase, 50 hz

460 vac, Single Phase, 60 hz

Full Load Amps 1.3 amps 1.6 amps Horsepower 0.43 hp 0.75 hp Rotations Per Minute 1425 rpm 1725 rpm

Voltage and Frequency 360 -- 460 vac 2.5 hz 400 -- 500 vac 2.5 hz Bearing Lubrication Factory lubricated, additional grease not required. Rotation Counter-clockwise when viewed from shaft end.

d. Evaporator Coil Heaters

Number of Heaters 6 Rating 750 watts +5/--10% each @ 230 vac Resistance (cold) 66.8 to 77.2 ohms @ 20 _C (68 _F) Type Sheath

e. Evaporator Fan Motor(s)

380 vac/50 hz 460 vac/60 hz Full Load Amps

High Speed 1.6 2.0

Full Load Amps Low Speed 0.8 1.0

Nominal Horsepower High Speed 0.70 0.84

Nominal Horsepower Low Speed 0.09 0.11

Rotations Per Minute High Speed 2850 rpm 3450 rpm

Rotations Per Minute Low Speed 1425 rpm 1750 rpm

Voltage and Frequency 360 -- 460 vac 1.25 hz 400 -- 500 vac 1.5 hz Voltage & Frequency us- ing power autotransformer 180 -- 230 vac 1.25hz 200 -- 250 vac 1.5 hz

Bearing Lubrication Factory lubricated, additional grease not required Rotation CW when viewed from shaft end

f. Fuses

Control Circuit 7.5 amps (F3A,F3B) Controller/DataCORDER 5 amps (F1 & F2) Emergency Bypass 10 amps (FEB) Emergency Defrost 5 amps (FED)

g. Vent Positioning Sensor

Electrical Output 0.5 VDC to 4.5 VDC over 90o range Supply Voltage 5VDC+10% Supply Current 5mA (typical)

T-3272--9

Table 2.3 -- Continued

h. Humidity Sensor

Orange wire Power Red wire Output Brown wire Ground Input voltage 5 vdc Output voltage 0 to 3.3 vdc

Output voltage readings verses relative humidity (RH) percentage: 30% 0.99 V 50% 1.65 V 70% 2.31 V 90% 2.97 V

2.4 SAFETY AND PROTECTIVE DEVICES

Unit components are protected from damage by safety and protective devices listed in the following table. Thesedevicesmonitor theunit operating conditions and open a set of electrical contacts when an unsafe condition occurs.

Open safety switch contacts on either or both of devices

IP-CP or HPS will shut down the compressor.

Open safety switch contacts on device IP-CM will shut down the condenser fan motor.

The entire refrigeration unit will shut down if one of the following safety devices open: (a) Circuit Breaker(s); (b) Fuse (F3A/F3B, 7.5A); or (c) Evaporator Fan Motor Internal Protector(s) -- (IP-EM).

Table 2-1 Safety and Protective Devices

UNSAFE CONDITION DEVICE DEVICE SETTING

Circuit Breaker (CB-1) -- Manual Reset Trips at 29 amps (460 vac)

Excessive current draw Circuit Breaker (CB-2, 50 amp) --Manual Reset Trips at 62.5 amps (230 vac)

Circuit Breaker (CB-2, 70 amp) --Manual Reset Trips at 87.5 amps (230 vac)

Excessive current draw in the control circuit Fuse (F3A & F3B) 7.5 amp rating

Excessive current draw by the controller Fuse (F1 & F2) 5 amp rating

Excessive current draw by the emergency bypass module Fuse (FEB) 10 amp rating

Excessive current draw by the emergency defrost module Fuse (FED) 5 amp rating

Excessive condenser fan mo- tor winding temperature Internal Protector (IP-CM) -- Automatic Reset N/A

Excessive compressor motor winding temperature Internal Protector (IP-CP) -- Automatic Reset N/A

Excessive evaporator fan mo- tor(s) winding temperature Internal Protector(s) (IP-EM) -- Automatic Reset N/A

Abnormal pressures/tempera- tures in the high refrigerant side

Fusible Plug -- Used on the Receiver

Rupture Disc -- Used on the Water-Cooled Con- denser

99 _C = (210 _F)

35 kg/cm@ = (500 psig)

Abnormally high discharge pressure High Pressure Switch (HPS) Opens at 25 kg/cm@

(350 psig)

2--10T-327

2.5 REFRIGERATION CIRCUIT

2.5.1 Standard Operation

Starting at the compressor, (see Figure 2-7, upper schematic) the suction gas is compressed to a higher pressure and temperature.

In the standard mode, both the economizer and unloader solenoid valves (USV) are closed.

The refrigerant gas Flows through the Discharge line and continues into the air-cooled condenser. When operating with the air-cooled condenser active, air flowing across the coil fins and tubes cools the gas to saturation temperature. By removing latent heat, the gas condenses to a high pressure/high temperature liquid and flows to the receiver which stores the additional charge necessary for low temperature operation.

When operating with the water cooled condenser active (see Figure 2-7, lower schematic), the refrigerant gas passes through the air cooled condenser and enters the water cooled condenser shell. The water flowing inside the tubing cools the gas to saturation temperature in the same manner as the air passing over the air cooled condenser. The refrigerant condenses on the outside of the tubes and exits as a high temperature liquid. The water cooled condenser also acts as a receiver, storing excess refrigerant.

The liquid refrigerant continues through the liquid line, the filter-drier (which keeps refrigerant clean and dry) and the economizer (which is not active during standard operation) to the evaporator expansion valve. As the liquid refrigerant passes through the variable orifice of the expansion valve, some of it vaporizes into a gas (flash gas). Heat is absorbed from the return air by the balance of the liquid, causing it to vaporize in the evaporator coil. The vapor then flows through the suction modulation valve to the compressor.

The evaporator expansion valve is activated by the bulb strapped to the suction line near the evaporator outlet. The valve maintains a constant superheat at the coil outlet regardless of load conditions.

On systems fitted with a water pressure switch, the condenser fan will be off when there is sufficient pressure to open the switch. If water pressure drops below the switch cut out setting, the condenser fan will be automatically started. When operating a system fittedwith a condenser fan switch, the condenser fanwill be off when the switch is placed in the O position. The condenser fanwill be onwhen the switch is placed in the I position.

2.5.2 Economized Operation In the economized mode the frozen and pull down capacity of the unit is increased by subcooling the liquid refrigerant entering the evaporator expansion valve. Overall efficiency is increased because the gas leaving the economizer enters the compressor at a higher pressure, therefore requiring less energy to compress it to the required condensing conditions.

During economized operation, flow of refrigerant through the main refrigerant system is identical to the standard mode. (The unloader solenoid valve is de--energized [closed] by the controller.)

Liquid refrigerant for use in the economizer circuit is taken from themain liquid line as it leaves the filter--drier (see Figure 2-8). The flow is activated when the controller energizes the economizer solenoid valve (ESV). The liquid refrigerant flows through the economizer expansion valve and the economizer internal passages absorbing heat from the liquid refrigerant flowing to the evaporator expansion valve. The resultant medium temperature/pressure gas enters the compressor at the economizer line.

2.5.3 Unloaded Operation The system will operate in the unloaded mode; during periods of low load, during periods of requireddischarge pressure or current limiting, and during start--up.

During unloaded operation, flow of refrigerant through the main refrigerant system is identical to the standard mode. (The economizer solenoid valve is de--energized [closed] by the controller.)

In the unloaded mode, a portion of the mid--stage compressed gas is bypassed to decrease compressor capacity. The flow is activatedwhen the controller opens the unloader solenoid valve (see Figure 2-9). Opening of the valve creates a bypass from the economizer service valve through the unloader solenoid valve and into the suction line on the outlet side of the suction pressure modulation valve.

As load on the system decreases, the suction modulating valve decreases flow of refrigerant to the compressor. This action balances the compressor capacity with the load and prevents operation with low coil temperatures.

2.5.4 Quench/Injection Operation The quench valve senses refrigerant condition entering the compressor andwillmodulate as required to provide sufficient liquid refrigerant flow into the suction line for cooling of the compressor motor.

If the compressor dome temperature rises above set point or suction superheat exceeds set point, the controller will open the liquid injection solenoid valve to provide additional compressor cooling.

T-3272--11

STANDARD OPERATION WITH RECEIVER

COMPRESSOR

FILTER DRIER

CONDENSER

DISCHARGE SERVICE VALVE

USV

SUCTION SERVICE VALVE

EVAPORATOR TXV

SMV

QUENCH TXV

RECEIVER

QUENCH TXV BULB

TXV BULB

FUSIBLE PLUG

LIQUID LINE SERVICE VALVE

ECONOMIZER TXV

ESV

ECONOMIZER

ECONOMIZER TXV BULB

EVAPORATOR

SIGHT GLASS

MOISTURE INDICATOR

LIV

STANDARD OPERATION WITH WATER COOLED CONDENSER

COMPRESSOR

FILTER DRIER

CONDENSER

DISCHARGE SERVICE VALVE

USV

SUCTION SERVICE VALVE

SMV

QUENCH TXV

QUENCH TXV BULB

TXV BULB

ECONOMIZER TXV

ESV

ECONOMIZER

ECONOMIZER TXV BULB

EVAPORATOR

LIV

DISCHARGE LIQUID SUCTION

RUPTURE DISC

WATER COOLED CONDENSER

SIGHT GLASS MOISTURE INDICATOR

ECONOMIZER CONNECTION

EVAPORATOR TXV

LIQUID LINE SERVICE VALVE

ECONOMIZER CONNECTION

Figure 2-7 Refrigeration Circuit Schematic -- Standard Operation

2--12T-327

LIQUID ECONOMIZER PRESSURE

ECONOMIZER

ESV

ECONOMIZER TXV

LIQUID LINE SERVICE VALVE

RECEIVER

ECONOMIZER CONNECTION

Figure 2-8 Refrigeration Circuit Schematic -- Economized Operation

LIQUID ECONOMIZER PRESSURE

SUCTION SERVICE VALVE

QUENCH TXV

USV

SUCTION

RECEIVER

QUENCH TXV BULB

ECONOMIZER CONNECTION

Figure 2-9 Refrigeration Circuit Schematic -- Unloaded Operation

3--1 T-327

SECTION 3

MICROPROCESSOR 3.1 TEMPERATURE CONTROL MICROPRO-

CESSOR SYSTEM

The temperature control Micro-Link 3 microprocessor system (see Figure 3-1) consists of a key pad, display module, the control module (controller) and interconnecting wiring. The controller houses the temperature control software and the DataCORDER Software. The temperature control software functions to operate the unit components as required to provide the desired cargo temperature and humidity. The DataCORDER software functions to record unit

operating parameters and cargo temperature parameters for future retrieval. Coverage of the temperature control software begins with paragraph 3.2. Coverage of the DataCORDER software is provided in paragraph 3.6.

The key pad and display module serve to provide user access and readouts for both of the controller functions, temperature control and DataCORDER. The functions are accessed by key pad selections and viewed on the display module. The components are designed to permit ease of installation and removal.

TO DISPLAY

CONTROL MODULE DISPLAY MODULE

KEY PAD

CONFIGURATION SOFTWARE

CONFIGURATION VARIABLE (CnF##)

TEMPERATURE CONTROL SOFTWARE

ALARMS (AL<70)

PRE--TRIP INTERROGATION CONNECTOR

DATAREADER

Computer Device With DataLine

Software

DataCORDER SOFTWARE

OPERATIONAL SOFTWARE

FUNCTION CODE (Cd)

TO DISPLAY

CONFIGURATION SOFTWARE

CONFIGURATION VARIABLE

(dCF## read only)

ALARMS (AL>68)

DATA STORAGE MEMORY

OPERATIONAL SOFTWARE

FUNCTION CODE (dC)

TO DISPLAY

(Scrollback)

DATABANK CARD

Figure 3-1 Temperature Control System

3--2T-327

3.1.1 Key Pad

The key pad (Figure 3-2) is mounted on the right-hand side of the control box. The key pad consists of eleven push button switches that act as the users interface with the controller. Descriptions of the switch functions are provided in Table 3-1.

ENTER

BATTERY POWER

MANUAL DEFROST/ INTERVAL

CODE SELECT

PRE TRIP

ALARM LIST

ALT. MODE

RETURN SUPPLY

_C _F

Figure 3-2 Key Pad

COOL HEAT DEFROST IN RANGEALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

Figure 3-3 Display Module

3.1.2 Display Module

The display module (Figure 3-3) consists of five digit displays and seven indicator lights. The indicator lights include:

1. Cool -- White LED: Energized when the refrigerant compressor is energized.

2. Heat -- OrangeLED: Energized to indicate heaterop- eration in the heat or defrost mode.

3. Defrost -- Orange LED: Energizedwhen the unit is in the defrost mode.

4. In-Range -- Green LED: Energized when the con- trolled temperature probe iswithin specified tolerance of set point.

Table 3-1 Key Pad Function

KEY FUNCTION

Code Select Accesses function codes.

Pre-Trip Displays the pre-trip selection menu. Discontinues pre-trip in progress.

Alarm List Displays alarm list and clears the alarm queue.

Manual Defrost/ Interval

Displays selected defrost mode. De- pressing and holding the Defrost in- terval key for five (5) seconds will ini- tiate defrost using the same logic as if the optional manual defrost switch was toggled on.

Enter Confirms a selection or saves a selection to the controller.

Arrow Up Change or scroll a selection upward Pre-trip advance or test interruption.

Arrow Down Change or scroll a selection down- ward. Pre-trip repeat backward.

Return/ Supply

Displays non-controlling probe tem- perature (momentary display).

_C/_F

Displays alternate English/Metric scale (momentary display). When set to _F, pressure is displayed in psig and vacuum in /hg. P appears after the value to indicate psig and i ap- pears for inches of mercury. When set to _C. pressure readings are in bars. b appears after the val- ue to indicate bars.

Battery Power

Initiate battery backup mode to allow set point and function code selection if AC power is not connected.

ALT. Mode

This key is pressed to switch the functions from the temperature soft- ware to the DataCORDER Software. The remaining keys function the same as described above except the readings or changes are made to the DataCORDER programming.

NOTE The controlling probe in the perishable range will be the SUPPLYair probeand the controlling probe in the frozen range will be the RETURN air probe.

5. Supply -- Yellow LED: Energized when the supply air probe is used for control.When this LED is illuminated, the temperature displayed in the AIRTEMPERATURE display is the reading at the supply air probe. This LED will flash if dehumidification or humidification is en- abled.

6. Return -- Yellow LED: Energized when the return air probe is used for control.When this LED is illuminated, the temperature displayed in the AIRTEMPERATURE display is the reading at the return air probe. This LED will flash if dehumidification or humidification is en- abled.

7. Alarm -- Red LED: Energizedwhen there is an active or an inactive shutdown alarm in the alarm queue.

3--3 T-327

81 2 3 3 3 3 34 5 6 7

1. Mounting Screw 2. Micro-Link 3 Control/DataCORDER Module 3. Connectors 4. Test Points

5. Fuses 6. Control Circuit Power Connection 7. Software Programming Port 8. Battery Pack (Standard Location)

Figure 3-4 Control Module 3.1.3 Controller

CAUTION Do not remove wire harnesses from con- troller modules unless you are grounded to the unit frame with a static safe wrist strap.

CAUTION Unplug all controller module wire harness connectors before performing arc welding on any part of the container.

CAUTION Do not attempt to use anML2i PC card in an ML3equippedunit. ThePCcardsarephysi- cally different and will result in damage to the controller.

NOTE Do not attempt to service the controller mod- ules. Breaking the seal will void the warranty.

The Micro--Link 3 controller is a dual module microprocessor as shown in Figure 3-4. It is fitted with test points, harness connectors and a software card programming port. 3.2 CONTROLLER SOFTWARE The controller software is a custom designed program that is subdivided into the Configuration Software and the Operational Software. The controller software performs the following functions: a. Control supply or return air temperature to required limits, provide modulated refrigeration operation, economized operation, unloaded operation, electric heat control and defrost. Defrost is performed to clear build up of frost and ice and ensure proper air flow across the coil.

b. Providedefault independent readouts of set point and supply or return air temperatures.

c. Provide ability to read and (if applicable) modify the Configuration Software Variables, Operating Soft- ware Function Codes and Alarm Code Indications.

d. Provide a Pre-Trip step-by-step checkout of refrigera- tion unit performance including: proper component operation, electronic and refrigeration control opera- tion, heater operation, probe calibration, pressure limiting and current limiting settings.

e. Provide battery powered ability to access or change selected codes and set point without AC power con- nected.

f. Provide the ability to reprogram the software through the use of a memory card.

3.2.1 Configuration Software (Variables) The Configuration Software is a variable listing of the components available for use by the Operational Software. This software is factory installed in accordance with the equipment fitted and options listed on the original purchase order. Changes to the Configuration Software are required only when a new controller has been installed or a physical change has beenmade to the unit such as the addition or removal of an option. A Configuration Variable list is provided in Table 3-4. Change to the factory installed Configuration Software is achieved via a configuration card or by communications. 3.2.2 Operational Software (Function Codes) The Operational Software is the actual operation programming of the controller which activates or deactivates components in accordancewith current unit operating conditions and operator selected modes of operation. The programming is divided into function Codes. Some of the codes are read only while the remaining codes may be user configured. The value of the user configurable codes can be assigned in accordance with user desired mode of operation. A list of the function codes is provided in Table 3-5. To access the function codes, perform the following: a. Press the CODE SELECT key, then press an arrow key until the left window displays the desired code number.

b. The right window will display the value of this item for five seconds before returning to the normal display mode.

c. If a longer time is desired, press the ENTERkey to ex- tend the time to 30 seconds.

3.3 MODES OF OPERATION The Operational Software responds to various inputs. These inputs come from the temperature and pressure

3--4T-327

sensors, the temperature set point, the settings of the the configuration variables and the function code assignments. The action taken by the Operational Software will change if any one of the inputs changes. Overall interaction of the inputs is describedas a mode of operation. The modes of operation include, perishable (chill) mode and frozen mode. Descriptions of the controller interaction and modes of operation are provided in the following sub paragraphs.

3.3.1 Temperature Control -- Perishable Mode

With configuration variable CnF26 (Heat Lockout Temperature) set to --10_C the perishable mode of operation is active with set points above --10_C (+14_F). With the variable set to --5_C, the perishable mode is active above --5_C (+23_F). Refer to Table 3-4.

When in the perishable mode the controller maintains the supply air temperature at set point, the SUPPLY indicator light will be illuminated on the display module and the default reading on the display window will be the supply temperature sensor reading.

When the supply air temperature enters the in-range temperature tolerance (as selected at function code Cd30), the in-range light will energize.

3.3.2 Defrost Interval

Controller function code Cd27 sets two modes for defrost initiation, either user--selected timed intervals or automatic control. The user--selected values are 3, 6, 9, 12, or 24 hours and the factory default for the timed interval is 12 hours (someunitsmay be configured to allowdefrost to be disabled altogether; in this case a user--selected value of OFF will be available). Refer to Table 3-5.

In perishable mode, perishable--pulldown mode, or frozen--pulldown mode, automatic defrost starts with an initial defrost set to 3 hours and then adjusts the interval to the next defrost based on the accumulation of ice on the evaporator coil. In this way, defrosts are scheduled to occur only when necessary.

Once setpoint has been reached in frozen operation, the automatic selectionwill set the time interval to 12 hours for the first two defrosts once the return probe is reading below the frozen setpoint and then adjust to 24 hours thereafter.

All defrost interval times reflect the number of compressor runtime hours since the last defrost de--ice cycle. The minimum defrost interval under the automatic setting is 3 hours while the maximum is 24. In frozen mode the amount of wall--clock time necessary to accumulate a given amount of defrost interval time will exceed the defrost interval time by a factor of two to three depending on the compressor duty--cycle. Defrost interval time is not accumulated in any mode until the defrost termination sensor reads less than 10_C (50_F).

3.3.3 Failure Action

Function code Cd29 may be operator set to allow continued operation in the event that all of the control sensors are reading out of range. The factory default is full system shutdown. Refer to Table 3-5.

3.3.4 Generator Protection

Function codes Cd31(Stagger Start, Offset Time) and Cd32 (Current Limit) may be operator set to control start up sequence of multiple units and operating current draw. The factory default allows ondemandstarting (nodelay)of units and normal current draw. Refer to Table 3-5.

3.3.5 Compressor High Temperature, Low Pres- sure Protection.

The controller monitors compressor discharge temperature and suction pressure. If discharge pressure or temperature rises above the allowed limit or suction pressure falls below the allowed limit the compressor will be cycled off on a three minute timer. Condenser and evaporator fans continue to operate during the compressor off cycle.

1. If compressor dome temperature exceeds 137.5_C (279_F) continuously for 15 seconds (high dome temperature), the liquid injection solenoid valve will open. When compressor dome temperature then decreases to 122.5_C (252.5_F) or below, the liquid injection solenoid valve will close.

2. If suction superheat exceeds a 55_C range during un- loaded capacity mode operation (suction quench), open liquid injection solenoid valve. When suction superheat decreases below 20_C range, or if unit leaves unloaded capacity mode, the liquid injection solenoid valve will close.

3. If conditions that would require the liquid injection valve to open because high dome temperature occur after the liquid injection valve is already open be- cause of high suction superheat, or vice versa, then close the valve when dome temperature goes below 137.5_C and suction superheat is less than 20_C range.

3.3.6 Perishable Mode -- Conventional The unit is capable of maintaining supply air temperature to within 0.25_C (0.5_F) of set point. Supply air temperature is controlled by positioning of the suction modulation valve (SMV), cycling of the compressor and cycling of the heaters. When cooling from a temperature that is more than 2.5_C (4.5_F) above set point, the system will be in the perishable pull down mode. It will be in economized operation with a target SMV position of 100% open. However, pressure and current limit functions may restrict the valve, if either exceeds the preset value. Once set point is reached, the unit will transition to the perishable steady state mode. This results in unloaded operation with some restriction of the SMV. The SMV will continue to close and restrict refrigerant flow until the capacity of the unit and the load are balanced. If the SMV is at minimum modulation, the controller has determined that cooling is not required, or the controller logic determines suction pressure is at the low pressure limit, the unit will transition to the perishable idle mode. The compressor is turned off and the evaporator fans continue to run to circulate air throughout the container. If temperature rises above set point +0.2_C, the unit will transition back to the perishable steady state mode. If the temperature drops to 0.5_C (0.9_F) below set point, the unit will transition to the perishable heating mode and the heaters will be energized . The unit will transition back to the perishable idle mode when the temperature rises to 0.2_C (0.4_F) below the set point and the heaters will de-energize. 3.3.7 Perishable Mode -- Economy The economy mode is an extension of the conventional mode. The mode is activated when the setting of function code Cd34 is ON. Economy mode is provided for power saving purposes. Economy mode could be utilized in the transportation of temperature tolerant cargo or non-respiration items which do not require high

3--5 T-327

airflow for removing respiration heat. There is no active display indicator that economy mode has been activated. To check for economy mode, perform a manual display of code Cd34.

In order to achieve economy mode, a perishable set point must be selected prior to activation. When economy mode is active, the evaporator fans will be controlled as follows:

At the start of each cooling or heating cycle, the evaporator fans will be run in high speed for three minutes. They will then be switched to low speed any time the supply air temperature is within 0.25_C (0.45_F) of the set point and the return air temperature is less than or equal to the supply air temperature + 3_C (5.4_F). The fans will continue to run in low speed for one hour. At the end of the hour, the evaporator fans will switch back to high speed and the cycle will be repeated. If bulb mode is active, the economy fan activity will be overwritten.

3.3.8 Perishable Mode -- Dehumidification The dehumidification mode is provided to reduce the humidity levels inside the container. The mode is activated when a humidity value is set at at function code Cd33. The display module SUPPLY led will flash ON and OFF every second to indicate that the dehumidification mode is active. Once the Mode is active and the following conditions are satisfied, the controller will activate the heat relay to begin dehumidification.

1. The humidity sensor reading is above the set point.

2. The unit is in the perishable steady state mode and supply air temperature is less than 0.25_C above set point.

3. The heater debounce timer (three minutes) has timed out.

4. Heater termination thermostat (HTT) is closed.

If the above conditions are true the evaporator fans will switch from high to low speed operation. The evaporator fan speed will switch every hour thereafter as long as all conditions are met (see Bulb Mode section for different evaporator fan speed options). If any condition except for item (1) becomes false OR if the relative humidity sensed is 2% below the dehumidification set point, the high speed evaporator fans will be energized.

In the dehumidification mode power is applied to the defrost heaters. This added heat load causes the controller to open the suction modulating valve to match the increased heat load while still holding the supply air temperature very close to the set point.

Opening the modulating valve reduces the temperature of the evaporator coil surface, which increases the rate at which water is condensed from the passing air. Removing water from the air reduces the relative humidity. When the relative humidity sensed is 2% below the set point , the controller de-energizes the heat relay. The controller will continue to cycle heating to maintain relative humidity below the selected set point. If the mode is terminated by a condition other than the humidity sensor, e.g., an out-of-range or compressor shutdown condition, the heat relay is de-energized immediately.

Two timers are activated in the dehumidification mode to prevent rapid cycling and consequent contactorwear. They are:

1. Heater debounce timer (three minutes). 2. Out-of-range timer (five minutes). The heater debounce timer is started whenever the heater contactor status is changed. The heat contactor remains energized (or de-energized) for at least three minutes even if the set point criteria are satisfied. The out-of-range timer is started to maintain heater operation during a temporary out-of-range condition. If the supply air temperature remains outside of the user selected in-range setting for more than fiveminutes, the heaters will be de-energized to allow the system to recover. The out-of-range timer starts as soon as the temperature exceeds the in-range tolerance value set by function code Cd30. 3.3.9 Perishable, Dehumidification -- Bulb Mode Bulbmode is an extension of the dehumidificationmode which allows changes to the evaporator fan speed and/or defrost termination set points. Bulbmode is activewhenconfiguration codeCd35 is set to Bulb. Once thebulbmode is activated, the usermay then change the dehumidification mode evaporator fan operation from the default (speed alternates from low to high each hour) to constant low or constant high speed. This is done by toggling function code Cd36 from its default of alt to Lo or Hi as desired. If low speed evaporator fan operation is selected, this gives the user the additional capability of selecting dehumidification set points from 60 to 95% (instead of the normal 65 to 95%). In addition, if bulb mode is active, function code Cd37 may be set to override the previous defrost termination thermostat settings. (Refer to paragraph 4.10.5.) The temperature at which thedefrost termination thermostat will be considered open may be changed [in 0.1_C (0.2_F) increments] to any value between 25.6_C (78_F) and 4_C (39.2_F) . The temperature at which the defrost termination thermostat is considered closed for interval timer start or demand defrost is 10_C for open values from 25.6_C (78_F) down to a 10_C setting. For open values lower than 10_C, the closed values will decrease to the same value as the open setting. Bulb mode is terminated when: 1. Bulb mode code Cd35 is set to Nor. 2. Dehumidification code Cd33 is set to Off. 3. The user changes the set point to one that is in the

frozen range. When bulb mode is disabled by any of the above, the evaporator fan operation for dehumidification reverts to alt and the DTS termination setting resets to the value determined by controller configuration variable CnF41. 3.3.10 Perishable -- System Pressure Regulation In perishable mode, system pressures may need to be regulated at ambient temperatures of 20_C (68_F) and below. Once below this ambient temperature, the condenser fan may cycle on and off based on limits imposed for discharge pressure. For extremely cold ambient temperatures, --18_C (~0_F), heater cycling may occur within normal system operation based on discharge pressure limits. For ambient temperatures below --29_C (--20.2_F) the SMV may regulate to a higher percent opening based on discharge pressure output. 3.3.11 Temperature Control -- Frozen Mode With configuration variable CnF26 (Heat Lockout Temperature) set to --10_C the frozenmodeof operation

3--6T-327

is active with set points at or below --10_C (+14_F).With the variable set to --5_C, the frozen mode is active at or below --5_C (+23_F).

When in the frozen mode the controller maintains the return air temperature at set point, the RETURN indicator light will be illuminated on the display module and the default reading on the display windowwill be the return air probe reading.

When the return air temperature enters the in-range temperature tolerance as selected at function code Cd30, the in-range light will energize.

3.3.12 Frozen Mode -- Conventional

Frozen range cargos are not sensitive to minor temperature changes. The method of temperature control employed in this range takes advantageof this to greatly improve the energy efficiency of the unit. Temperature control in the frozen range is accomplished by cycling the compressor on and off as the load demand requires.

When cooling from a temperature that is more than 2.5_C (4.5_F) above set point, the system will be in the frozen pull down mode. It will transition to economized operation with a target SMV position of 100% open. However, pressure and current limit functions may restrict the valve, if either exceeds the preset value.

Once set point is reached, the unit will transition to the frozen steady state mode. (Economized operation with maximum allowed suction modulating valve opening.)

When temperature drops to set point minus 0.2_C and the compressor has run for at least fiveminutes, theunit will transition to the frozen idlemode. The compressor is turned off and the evaporator fans continue to run to circulate air throughout the container. If temperature rises above set point +0.2_C, the unit will transition back to the frozen steady state mode.

If the temperature drops 10_C below set point, the unit will transition to the frozen heating mode. In the frozen heating mode the evaporator fans are brought to high speed. The unit will transition back to the frozen steady state mode when the temperature rises back to the transition point.

3.3.13 Frozen Mode -- Economy

In order to activate economy frozen mode operation, a frozen set point temperature must be selected. The economymode is active when function codeCd34 is set to ON. When economy mode frozen is active, the system will perform normal frozen mode operations except that the entire refrigeration system, excluding the controller, will be turned off when the control temperature is less than or equal to the set point -- 2_C. After an off-cycle period of 60 minutes, the unit will turn on high speed evaporator fans for three minutes, and then check the control temperature. If the control temperature is greater than or equal to the set point + 0.2_C., the unit will restart the refrigeration system and continue to cool until the previously mentioned off-cycle temperature criteria are met. If the control temperature is less than the set point + 0.2_C, the unit will turn off the evaporator fans and restart another 60minute off-cycle.

3.3.14 Condenser Fan Switch Override

When configuration variable CnF15 (Discharge Temperature Sensor) is set to In and CnF48 (Condenser Fan Switch Override) is set to On the

condenser fan switch override logic is activated. If condenser cooling water pressure is sufficient to open the Water Pressure Switch (de--energizing the condenser fan) when water flow or temperature conditions are not maintaining discharge temperature the logic will energize the condenser fan as follows:

1. If the Discharge Temperature Switch reading is valid and discharge temperature is greater than 115_C (240_F) the condenser fan is energized.

2. When discharge temperature falls to 90.5_C (195_F) the condenser fan is de--energized.

3. If the system is running on condenser fan override and the High Pressure Switch opens twice, within a sevenminute period, the condenser fan is energized and will remain energized until the system is power cycled. Alarm 58 (Compressor High Pressure Safe- ty) will be triggered.

3.4 CONTROLLER ALARMS

Alarm display is an independent controller software function. If an operating parameter is outside of expected range or a component does not return the correct signals back to the controller an alarm is generated. A listing of the alarms is provided in Table 3-6, page 3--17.

The alarm philosophy balances the protection of the refrigeration unit and that of the refrigerated cargo. The action takenwhen anerror is detected always considers the survival of the cargo. Rechecks aremade to confirm that an error actually exists.

Some alarms requiring compressor shutdown have time delays before and after to try to keep the compressor on line. An example is alarm code LO, (low main voltage), when a voltage drop of over 25% occurs, an indication is given on the display, but the unit will continue to run.

When an Alarm Occurs:

a. The red alarm light will illuminate for alarm code num- bers 13, 15, 17, 20, 21, 22, 23, 24, 25, 26, and 27.

b. If a detectable problem is found to exist, its alarm codewill be alternately displayedwith the set point on the left display.

c. Theuser should scroll through thealarm list to deter- mine what alarms exist or have existed. Alarms must bediagnosedandcorrectedbefore theAlarm List can be cleared.

To Display Alarm Codes:

a. While in the Default Display mode, press the ALARM LIST key. This accesses theAlarmList DisplayMode, which displays any alarms archived in the Alarm Queue.

b. The alarm queue stores up to 16 alarms in the se- quence in which they occurred. The user may scroll through the list by depressing an ARROW key.

c. The left display will show AL##, where ## is the alarm number sequentially in the queue.

d. The right display will show the actual alarm code. AA## will display for an active alarm, where ## is the alarm code. Or IA## will display for an inactive alarm, See Table 3-6, page 3--17,

e. END is displayed to indicate the end of the alarm list if any alarms are active.

3--7 T-327

f. CLEAr is displayed if all alarms are inactive. The alarmqueuemay than be cleared by pressing theEN- TER key. The alarm list will clear and -- -- -- -- -- will be displayed.

Note: AL26 is active when all of the sensors are not responding. Check the connector at the back of the controller, if it is loose or unplugged, recon- nect it. Then run a pretrip test (P5) to clear AL26.

3.5. UNIT PRE-TRIP DIAGNOSTICS

Pre--Trip Diagnostics is an independent controller function which will suspend normal refrigeration controller activities and provide preprogrammed test routines. The test routines include Auto Mode testing, which automatically preforms a pre programmed sequenced of tests, or Manual Mode testing, which allows the operator to select and run any of the individual tests.

CAUTION Pre-trip inspection should not be per- formed with critical temperature cargoes in the container.

CAUTION WhenPre-Trip key ispressed, economy,de- humidification and bulb mode will be deac- tivated. At the completion of Pre-Trip activi- ty, economy, dehumidification and bulb mode must be reactivated.

Testing may be initiated by use of the Key Pad or via communication, but when initiated by communication the controller will execute the entire battery of tests (auto mode).

At the end of a pre-trip test, the message P, rSLts (pretest results) will be displayed. Pressing the ENTER key will allow the user to see the results for all subtests. The results will be displayed as PASS or FAIL for all the tests run to completion.

A detailed description of thepre-trip tests and test codes is provided in Table 3-7, page 3--21. detailed operating instructions are provided in paragraph 4.8.

3.6 DataCORDER

3.6.1 Description

The Carrier Transicold DataCORDER, software is integrated into the controller and serves to eliminate the temperature recorder and paper chart. The DataCORDER functions may be accessed by key pad selections and viewedon thedisplaymodule. The unit is also fitted with interrogation connections (see Figure 3-1) which may be used with the Carrier Transicold Data Reader to down load data. A personal computer with Carrier Transicold DataView/DataLine software may also be used to download data and configure settings. The DataCORDER consists of:

Configuration Software Operational Software Data Storage Memory Real Time Clock (with internal battery backup) Six thermistor inputs Interrogation Connections Power supply (battery pack).

The DataCORDER performs the following functions:

a. Logs data at 15, 30, 60 or 120 minute intervals and stores twoyears of data (basedonone hour interval).

b. Records and displays alarms on the display module.

c. Records results of pre--trip testing.

d. Records DataCORDER and temperature control software generated data and events as follows: Container ID Change Software Upgrades Alarm Activity Battery Low (Battery Pack) Data Retrieval Defrost Start and End Dehumidification Start and End Power Loss (w/wo battery pack) Power Up (w/wo battery pack) Remote Probe Temperatures in the Container (USDA Cold treatment and Cargo probe recording) Return Air Temperature Set Point Change Supply Air Temperature Real TimeClock Battery (Internal Battery) Replace- ment Real Time Clock Modification Trip Start ISO Trip Header (When entered via Interrogation program) Economy Mode Start and End Auto 1/Auto 2/Auto3 Pre-Trip Start and End Bulb Mode Start Bulb Mode changes Bulb Mode End USDA Trip Comment Humidification Start and End USDA Probe Calibration Fresh Air Vent Position

3.6.2 DataCORDER Software

The DataCORDER Software is subdivided into the Configuration Software, Operational Software and the Data Memory.

a. Operational Software

The Operational Software reads and interprets inputs for use by the Configuration Software. The inputs are labeled Function Codes. There are controller functions (see Table 3-8, page 3--25) which the operator may access to examine the current input data or stored data. To access these codes, do the following:

1. Press the ALT. MODE & CODE SELECT keys.

2. Press an arrow key until the left window displays the desired code number. The right window will display the value of this item for five seconds before returning to the normal display mode.

3--8T-327

Table 3-2 DataCORDER Configuration Variables

CONFIGURATION NO. TITLE DEFAULT OPTION dCF01 (Future Use) ---- ---- dCF02 Sensor Configuration 2 2,5,6,9,54,64,94 dCF03 Logging Interval (Minutes) 60 15,30,60,120 dCF04 Thermistor Format Short Long dCF05 Thermistor Sampling Type A A,b,C dCF06 Controlled Atmosphere/Humidity Sampling Type A A,b dCF07 Alarm Configuration USDA Sensor 1 A Auto, On, Off dCF08 Alarm Configuration USDA Sensor 2 A Auto, On, Off dCF09 Alarm Configuration USDA Sensor 3 A Auto, On, Off

dCF10 Alarm Configuration Cargo Sensor A Auto, On, Off

3. If a longer time is desired, press the ENTERkey to ex- tend the time to 30 seconds.

b. Configuration Software The configuration software controls the recording and alarm functions of the DataCORDER. Reprogramming to the factory installed configuration is achieved via a configuration card. Changes to the unit DataCORDER configuration may be made made using the DataView/DataLine interrogation software. A listing of the configuration variables is provided in Table 3-2. Descriptions of DataCORDER operation for each variable setting are provided in the following paragraphs. 3.6.3 Sensor Configuration (dCF02) Two modes of operation may be configured, the Standard Mode and the Generic Mode. a. Standard Mode In the standard mode, the user may configure the DataCORDER to record data using one of seven standard configurations. The seven standard configuration variables, with their descriptions, are listed in Table 3-3. Table 3-3 DataCORDER Standard Configurations

Standard Config. Description

2 sensors (dCF02=2) 2 thermistor inputs(supply & return)

5 sensors (dCF02=5)

2 thermistor inputs(supply & return) 3 USDA thermistor inputs

6 sensors (dCF02=6)

2 thermistor inputs(supply & return) 3 USDA thermistor inputs 1 humidity input

9 sensors (dCF02=9) Not Applicable

6 sensors (dCF02=54)

2 thermistor inputs(supply & return) 3 USDA thermistor inputs 1 cargo probe (thermistor input)

7 sensors (dCF02=64)

2 thermistor inputs(supply & return) 3 USDA thermistor inputs 1 humidity input 1 cargo probe (thermistor input)

10 sensors (dCF02=94)

2 thermistor inputs(supply & return) 3 USDA thermistor inputs 1 humidity input 1 cargo probe (thermistor input) 3 C.A. inputs (NOT APPLICABLE)

The inputs of the six thermistors (supply, return, USDA #1, #2, #3 and cargo probe) and the humidity sensor input will be generated by the DataCORDER. See Figure 3-5.

NOTE The DataCORDER software uses the supply and return recorder sensors (SRS,RRS). The temperature control software uses the supply and return temperature sensors (STS,RTS) .

b. Generic Mode The generic recordingmode allows user selection of the network data points to be recorded. Theuser may select up to a total of eight data points for recording. A list of the data points available for recording follows. Changing the configuration to generic and selectingwhich data points to recordmay be doneusing theCarrier TransicoldData Retrieval Program.

1. Control mode 2. Control temperature 3. Frequency 4. Humidity 5. Phase A current 6. Phase B current 7. Phase C current 8. Main voltage 9. Suction modulation valve percentage 10. Discrete outputs (Bit mapped -- require special

handling if used) 11. Discrete inputs (Bit mapped -- require special

handling if used) 12. Ambient sensor 13. Compressor suction sensor 14. Compressor discharge sensor 15. Return temperature sensor (RTS) 16. Supply temperature sensor (STS) 17. Defrost temperature sensor 18. Discharge pressure transducer 19. Suction pressure transducer 20. Condenser pressure transducer 21. Vent position sensor (VPS)

3--9 T-327

Raw Data Report for ABC1234567 May 31, 2001 to Jun 04, 2001

System Configuration at the Time of Interrogation:

Interrogated On Sept 05, 2001 Extracted by DataLine Rev 1.0.0

Controller Software: 5120 Controller Serial #: 04163552

Bill of Lading #: 1 Origin: Origin Date: Destination: Discharge Date: Comment: DataLine Tool

Probe Calibration Readings: USDA1: 0.0 USDA2: 0.0 USDA3: 0.0 Cargo: 0.0 Temperature Units: Centigrade ________________________________________________________________________________________

May 31, 2001

Setpoint: 1.66, Container : Serial : 04189552

9 Sensors Logged at 15 Minute Interval

Sensor Format Resolution

Figure 3-5 Standard Configuration Download Report

3--10T-327

3.6.4 Logging Interval (dCF03) The user may select four different time intervals between data recordings. Data is logged at exact intervals in accordance with the real time clock. The clock is factory set at Greenwich Mean Time (GMT).

3.6.5 Thermistor Format (dCF04) The user may configure the format in which the thermistor readings are recorded. The short resolution is a 1 byte format and the long resolution is a 2 byte format. The short requires less memory and records temperature in 0.25C (0.45F) steps when in the perishable mode or 0.5C (0.9F) steps when in the frozen mode. The long records temperature in 0.01C (0.02F) steps for the entire range.

3.6.6 Sampling Type (dCF05 & dCF06) Three types of data sampling are available, average, snapshot and USDA. When configured to average, the average of readings taken every minute over the recording period is recorded. When configured to snapshot, the sensor reading at the log interval time is recorded. When USDA is configured the supply and return temperature readings are averaged and the 3 USDA probe readings are snapshot.

3.6.7 Alarm Configuration (dCF07 -- dCF10) The USDA and cargo probe alarms may be configured to OFF, ON or AUTO. If a probe alarm is configured to OFF, then the alarm for this probe is always disabled. If a probealarm is configured toON, then theassociated alarm is always enabled. If the probes are configured to AUTO, they act as a group. This function is designed to assist users who keep their DataCORDER configured for USDA recording, but donot install the probes for every trip. If all the probes are disconnected, no alarms are activated. As soon as one of the probes is installed , then all of the alarms are enabled and the remaining probes that are not installed will give active alarm indications.

3.6.8 DataCORDER Power-Up The DataCORDER may be powered up in any one of four ways:

1. Normal AC power: The DataCORDER is powered up when the unit is turned on via the stop-start switch.

2. Controller DC battery pack power: If a battery pack is installed, theDataCORDERwill power up for commu- nication when an interrogation cable is plugged into an interrogation receptacle.

3. External DC battery pack power: A 12 volt battery pack may also be plugged into the back of the interrogation cable, which is then plugged into an interrogation port. No controller battery pack is required with this method.

4. Real Time Clock demand: If the DataCORDER is equipped with a charged battery pack and AC power is not present, the DataCORDER will power up when the real time clock indicates that a data recording should take place. When the DataCORDER is fin- ished recording, it will power down.

During DataCORDER power-up, while using battery-pack power, the controller will perform a hardware voltage check on the battery. If the hardware check passes, theController will energize and performa software battery voltage check before DataCORDER logging. If either test fails, the real time clock battery power-up will be disabled until the next AC power cycle.

Further DataCORDER temperature logging will be prohibited until that time. An alarm will be generated when the battery voltage transitions from good to bad indicating that the battery pack needs recharging. If the alarm condition persists for more than 24 hours on continuous AC power, the battery pack needs replacement. 3.6.9 Pre-Trip Data Recording The DataCORDER will record the initiation of a pre-trip test (refer to paragraph 3.5) and the results of each of the tests included in pre--trip. The data is time-stamped and may be extracted via the Data Retrieval program. Refer to Table 3-9 for a description of the data stored in theDataCORDER for each correspondingPre-Trip test. 3.6.10 DataCORDER Communications Data retrieval from the DataCORDER can be accomplished by using one of the following; DataReader, DataLine/DataView or a communications interface module.

NOTE A DataReader, DataLine/DataView or a com- munications interface module display of Com- munication Failed is caused by faulty data transfer between the Datacorder and the data retrieval device. Common causes include:

1. Bad cable or connection between DataCORDER and data retrieval device.

2. PC communication port(s) unavailable or misassigned.

3. Chart Recorder Fuse (FCR) blown . Configuration identification for the models covered herein may be obtained on the Container Products Group Information Center by authorized Carrier Transicold Service Centers.

a. DataReader The Carrier Transicold Data Reader (see Figure 3-6) is a simple to operate hand held device designed to extract data from the DataCORDER and upload it to a PC. The Data Reader has the ability to store multiple data files. Refer to Data Retrieval manual 62-02575 for a more detailed explanation of the DataReader

DataReader

Figure 3-6 Data Reader b. DataView The DataView software for a personal computer is supplied on a floppy disk. This software allows interrogation, configuration variable assignment, screen view of the data, hard copy report generation, cold treatment probe calibration, cold treatment

3--11 T-327

initialization and file management. Refer to Data Retrieval manual 62-02575 for a more detailed explanation of the DataView interrogation software.

c. Communications Interface Module

The communications interface module is a slave module which allows communication with a master central monitoring station. The module will respond to communication and return information over the main power line.

With a remotemonitoring unit installed, all functions and selectable features that are accessible at the unit may be performed at the master station. Retrieval of all DataCORDER reports may also be performed. Refer to the master system technical manual for further information.

d. DataLine

The DataLINE software for a personal computer is supplied on both floppy disks and CD. This software allows interrogation, configuration variable assignment, screen view of the data, hard copy report generation, cold treatment probe calibration and file management. Refer to Data Retrieval manual 62-10629 for a more detailed explanation of the DataLINE interrogation software. TheDataLinemanualmay be foundon thenet at www.container.carrier.com

3.6.11 USDA Cold Treatment

Sustained cold temperature has been employed as an effective postharvest method for the control of Mediterranean and certain other tropical fruit flies. Exposing infested fruit to temperatures of 2.2 degrees Celsius (36_F) or below for specific periods results in the mortality of the various stages of this group of insects.

In response to the demand to replace fumigation with this environmentally sound process, Carrier has integrated Cold Treatment capability into its microprocessor system. These units have the ability to maintain supply air temperature within one-quarter degree Celsius of setpoint and record minute changes in product temperature within the DataCORDER memory, thus meeting USDA criteria. Information on USDA is provided in the following subparagraphs

a. USDA Recording

A special type of recording is used for USDA cold treatment purposes. Cold treatment recording requires three remote temperature probes be placed at prescribed locations in the cargo. Provision is made to connect these probes to the DataCORDER via receptacles located at the rear left-hand side of the unit. Four or five receptacles are provided. The four three-pin receptacles are for the probes. The five pin receptacle is the rear connection for the Interrogator. The probe receptacles are sized to accept plugs with tricam coupling locking devices. A label on the back panel of the unit shows which receptacle is used for each probe.

The standard DataCORDER report displays the supply and return air temperatures. The cold treatment report displays USDA #1, #2, #3 and the supply and return air temperatures. Cold treatment recording is backed upby a battery so recording can continue if AC power is lost.

b. USDA/ Message Trip Comment

A special feature is incorporated in DataLine/DataView which allows the user to enter a USDA (or other)

message in the header of a data report. The maximum message length is 78 characters. Onlyonemessagewill be recorded per day.

3.6.12 USDA Cold Treatment Procedure The following is a summary of the steps required to initiate a USDA Cold Treatment:

a. Calibrate the three USDA probes by ice bathing the probes and performing the calibration function with the DataReader, DataView or DataLine. This calibra- tion procedure determines the probe offsets and stores them in the controller for use in generating the cold treatment report. Refer to the Data Retrieval manual 62-02575 for more details.

b. Pre-cool the container to the treatment temperature or below.

c. Install the DataCORDERmodule battery pack (if not already installed).

d. Place the three probes. The probes are placed into the pulp of the product (at the locations defined in the following table) as the product is loaded.

Sensor 1 Place in pulp of the product located next to the return air intake.

Sensor 2

Place in pulp of the product five feet from the end of the load for 40 foot con- tainers, or three feet from the end of the load for 20 foot containers. This probe should be placed in a center carton at one-half the height of the load.

Sensor 3

Place in pulp of product five feet from the end of the load for 40 foot containers or three feet from the end of the load for 20 foot containers. This probe should be placed in a carton at a side wall at one-- half the height of the load.

e. To initiate USDA Recording, connect the personal computer and perform the configuration as follows, using either the Data View or Data Line software:

1. Enter ISO header information.

2. Enter a trip comment if desired.

3. Configure theDataCORDER for five probes (s, r, P1, P2, P3) (dcf02=5)

4. Configure the logging interval for one hour.

5. Set the sensor configuration to USDA.

6. Configure for two byte memory storage format (dcf04=LONG).

7. Perform a trip start.

3.6.13 DataCORDER Alarms The alarm display is an independent DataCORDER function. If an operating parameter is outside of the expected range or a component does not return the correct values back to the DataCORDER an alarm is generated. TheDataCORDER contains a buffer of up to eight alarms. A listing of the DataCORDER alarms is provided in Table 3-10, page 3--27. Refer to paragraph 3.6.7 for configuration information.

To display alarm codes:

a. While in the Default Display mode, press the ALT. MODE&ALARMLISTkeys. Thisaccesses theData- CORDER Alarm List Display Mode, which displays any alarms stored in the Alarm Queue.

3--12T-327

b. To scroll to the end of the alarm list press the UP AR- ROW. Depressing the DOWNARROWkey will scroll the list backward.

c. The left display will show AL# where # is the alarms number in the queue. The right display will show AA##, if the alarm is active, where ## is the alarm number. IA##, will show if the alarm is inactive

d. END is displayed to indicate the end of the alarm list if any alarms are active. CLEAr is displayed if all the alarms in the list are inactive.

e. If no alarms are active, the Alarm Queue may be cleared. The exception to this rule is the DataCORD- ER Alarm Queue Full alarm (AL91) , which does not have to be inactive in order to clear the alarm list. To Clear the Alarm List:

1. Press the ALT. MODE & ALARM LIST keys.

2. Press the UP/DOWN ARROW key until CLEAr is displayed.

3. Press the ENTER key. The alarm list will clear and -- -- -- -- -- will be displayed.

4. Press the ALARM LIST key. AL will show on the left display and -- -- -- -- -- on the right display when there are no alarms in the list.

5. Upon clearing of the AlarmQueue, the Alarm light will be turned off.

3.6.14 ISO Trip Header DataLine provides the user with an interface to view/modify current settings of the ISO trip header through the ISO Trip Header screen. The ISO Trip Header screen is displayed when the user clicks on the ISO Trip Header button in the Trip Functions Group Box on the System Tools screen.

F9 function -- Provides the user with a shortcut for manually triggering the refresh operation.Before sending modified parameter values, the user must ensure that a successful connection is established with the Controller.

If the connection is establishedwith theDataCorder, the current contents of the ISO Trip Header from the DataCorder will be displayed in each field. If the connection is not established with the DataCorder, all fields on the screen will be displayed as Xs.If at any time during the display of the ISO Trip Header screen the connection is not established or is lost, the user is alerted to the status of the connection.

After modifying the values and ensuring a successful connection has been made with the DataCorder, click on the Send button to send the modified parameter values.

The maximum allowed length of the ISO Trip Header is 128 characters.If the user tries to refresh the screen or close the utility without sending the changes made on the screen to the DataCorder, the user is alerted with a message.

3--13 T-327

Table 3-4 Controller Configuration Variables CONFIGURATION

NUMBER TITLE DEFAULT OPTION

CnF01 Bypass Valve Enable In Out CnF02 Evaporator Fan Speed dS (Dual) SS (Single) CnF03 Control Sensors FOUr duAL CnF04 Dehumidification Mode On OFF CnF05 Reserved for future use ---------- n/a CnF06 Condenser Fan Speed Select OFF (Single) On (Variable) CnF07 Unit Selection, 20FT/ 40FT/45FT 40ft 20ft,45 CnF08 Single Phase/Three Phase Motor 1Ph 3Ph CnF09 Refrigerant Selection r134a r12, r22, bLEnd CnF10 Two Speed Compressor Logic Out (Single) In (Dual) CnF11 Defrost Off Selection noOFF OFF CnF12 TXV/Solenoid Quench Valve Out (TXV) In (Solenoid) CnF13 Unloader Out In CnF14 Condenser Pressure Control (CPC) In Out CnF15 Discharge Temperature Sensor Out In CnF16 DataCORDER Present On (Yes) (Not Allowed) CnF17 Discharge Pressure Sensor Out (No) In (Yes) CnF18 Heater Old (Low Watt) nEW (High Watt) CnF19 Controlled Atmosphere Out (No) In (Yes) CnF20 Suction Pressure Sensor Out (No) In (Yes) CnF21 Autotransformer Out In CnF22 Economy Mode Option OFF Std, Full CnF23 Defrost Interval Timer Save Option noSAv SAv CnF24 Advanced Pre-Trip Enhanced Test Series Option Auto Auto2, Auto 3 CnF25 Pre-Trip Test Points/Results Recording Option rSLtS dAtA CnF26 Heat Lockout Change Option Set to --10_C Set to --5_C CnF27 Suction Temperature Display Option Out In CnF28 Bulb Mode Option NOr bULb CnF29 Arctic Mode Out In CnF30 Compressor Size 41 CFM 37 CFM CnF31 Probe Check Option Std SPEC CnF32 Single Evaporator Fan Option 2EF0 1EF0 CnF33 Snap Freeze Option OFF SnAP CnF34 Degree Celsius Lockout Option bOth _F CnF35 Humidification Mode OFF On CnF36 SMV Type 1 (standard) 2, 3 (stepper) CnF37 Electronic Temperature Recorder rEtUR SUPPL, bOth CnF38 Quench Bypass Valve Out In CnF39 Expanded Current Limit Range Out In CnF40 Demand Defrost Out In CnF41 Lower DTT Setting Out In CnF42 Auto Pre--trip Start Out In CnF47 Fresh Air Vent Position Sensor OFF UPP,LOW,CUStOM

CnF48 CFS Override OFF On CnF49 Datacorder Configuration Restore OFF On CnF50 Enhanced Bulb Mode Selection OFF Bulb, dEHUM CnF51 Timed Defrost Disable 0 0--out, 1--in CnF52 Oil Return Algorithm 1 0--out, 1--in

CnF53 Water Cool Oil Return Logic 0 0--out, 1--in Note: Configuration numbers not listed are not used in this application. These items may appear when loading configura- tion software to the controller but changes will not be recognized by the controller programming.

3--14T-327

Table 3-5 Controller Function Codes (Sheet 1 of 3)

Code No. TITLE DESCRIPTION

Note: If the function is not applicable, the display will read -- -- -- -- --

Display Only Functions

Cd01 Suction Modulation Valve Opening (%)

Displays the SMV percent open. The right display reads 100% when the valve is fully open. The valve will usually be at 10% on start up of the unit except in very high ambient temperatures.

Cd02 Not Applicable Not used

Cd03 Compressor Motor Current

The current sensor measures current draw in lines L1 & L2 by all of the high voltage components. It also measures current draw in compressor motor leg T3. The compressor leg T3 current is displayed.

Cd04

Cd05

Cd06

Line Current, Phase A

Line Current, Phase B

Line Current, Phase C

The current sensor measures current on two legs. The third unmeasured leg is calculated based on a current algorithm. The current measured is used for control and diagnostic purposes. For control processing, the highest of the Phase A and B current values is used for current limiting purposes. For diagnostic processing, the current draws are used to monitor component energization. Whenever a heater or a motor is turned ON or OFF, the current draw increase/reduction for that activity is measured. The current draw is then tested to determine if it falls within the expected range of values for the component. Failure of this test will result in a pre-trip failure or a control alarm indication.

Cd07 Main Power Voltage The main supply voltage is displayed.

Cd08 Main Power Fre- quency

The value of the main power frequency is displayed in Hertz. The frequency displayed will be halved if either fuse F1 or F2 is bad (alarm code AL21).

Cd09 Ambient Tempera- ture The ambient sensor reading is displayed.

Cd10 Compressor Suction Temperature Compressor suction temperature sensor reading is displayed.

Cd11 Compressor Dis- charge Temperature Compressor discharge temperature sensor reading is displayed.

Cd12 Compressor Suction Pressure Compressor suction pressure transducer reading is displayed.

Cd13 Not Applicable Not used

Cd14 Compressor Dis- charge Pressure Compressor discharge pressure transducer reading is displayed.

Cd15 Unloader Valve The status of the valve is displayed (Open - Closed).

Cd16 Compressor Motor Hour Meter

Records total hours of compressor run time. Total hours are recorded in incre- ments of 10 hours (i.e., 3000 hours is displayed as 300).

Cd17 Relative Humidity (%)

Humidity sensor reading is displayed. This code displays the relative humidity, as a percent value.

Cd18 Software Revision # The software revision number is displayed.

Cd19 Battery Check

This code checks the Controller/DataCORDER battery pack. While the test is running, btest will flash on the right display, followed by the result. PASS will be displayed for battery voltages greater than 7.0 volts. FAIL will be displayed for battery voltages between 4.5 and 7.0 volts, and -- -- -- -- -- will be displayed for battery voltages less than 4.5 volts. After the result is displayed for four se- conds, btest will again be displayed, and the user may continue to scroll through the various codes.

Cd20 Config/Model # This code indicates the dash number of the model for which the Controller is configured (i.e., if the unit is a 69NT40-551-100, the display will show 51100).

Cd21 Economizer Valve The status of the valve is displayed (Open - Closed).

Cd22 Compressor State The status of the compressor is displayed (Off, On).

Cd23 Evaporator Fan Displays the current evaporator fan state (high, low or off).

Cd24 Controlled Atmosphere State Not used in this application

3--15 T-327

Table 3-5 Controller Function Codes (Sheet 2 of 3)

Cd25 Compressor Run Time Remaining Un- til Defrost

This code displays the time remaining until the unit goes into defrost (in tenths of an hour). This value is based on the actual accumulated compressor running time.

Cd26 Defrost Temperature Sensor Reading Defrost temperature sensor reading is displayed.

Configurable Functions

NOTE Function codes Cd27 through Cd37 are user-selectable functions. The operator can change the value of these functions to meet the operational needs of the container.

Cd27 Defrost Interval (Hours or Automatic)

There are two modes for defrost initiation, either user--selected timed intervals or automatic control. The user--selected values are (OFF), 3, 6, 9, 12, or 24 hours while the factory default is 12 hours. Automatic defrost starts with an initial defrost at 3 hours and then adjusts the interval to the next defrost based on the accumulation of ice on the evaporator coil. Following a start--up or after termina- tion of a defrost, the time will not begin counting down until the defrost tempera- ture sensor (DTS) reading falls below set point. If the reading of DTS rises above set point any time during the timer count down, the interval is reset and the countdown begins over. If DTS fails, alarm code AL60 is activated and control switches over to the the return temperature sensor. The controller will act in the same manner as with the DTS except the return temperature sensor reading will be used. Defrost Interval Timer Value (Configuration variable CnF23): If the software is configured to SAv (save) for this option, then the value of the defrost interval timer will be saved at power down and restored at power up. This option prevents short power interruptions from resetting an almost expired defrost interval, and possibly delaying a needed defrost cycle.

NOTE The defrost interval timer counts only during compressor run time.

Cd28 Temperature Units (_C or _F)

This code determines the temperature units (_C or _F) which will be used for all temperature displays. The user selects _C or _F by selecting function code Cd28 and pushing the ENTER key. The factory default value is Celsius units.

NOTE This function code will display --- --- --- --- --- ifConfiguration Variable CnF34 is set to _F.

Cd29 Failure Action (Mode)

If all of the control sensors are out of range (alarm code AL26) or there is a probe circuit calibration failure (alarm code AL27), the unit will enter the shutdown state defined by this setting. The user selects one of four possible actions as follows: A -- Full Cooling (Compressor is on, economized operation. SMV subject to pressure and current limit.)

B -- Partial Cooling (Compressor is on, standard operation. SMV subject to pressure and current limit.)

C -- Evaporator Fan Only (Evaporator fans on high speed, not applicable with frozen set points.

D -- Full System Shutdown -- Factory Default (Shut down every component in the unit)

Cd30 In-Range Tolerance

The in-range tolerance will determine the band of temperatures around the set point which will be designated as in-range. If the control temperature is in-range, the in-range light will be illuminated. There are four possible values: 1 = 0.5_C ( 0.9_F) 2 = 1.0_C ( 1.8_F) 3 = 1.5_C ( 2.7_F) 4 = 2.0_C ( 3.6_F) -- Factory Default

Cd31 Stagger Start Offset Time (Seconds)

The stagger start offset time is the amount of time that the unit will delay at start-up, thus allowing multiple units to stagger their control initiation when all units are powered up together. The eight possible offset values are: 0 (Factory Default), 3, 6, 9, 12, 15, 18 or 21 seconds

3--16T-327

Table 3-5 Controller Function Codes (Sheet 3 of 3)

Cd32 Current Limit (Amperes)

The current limit is the maximum current draw allowed on any phase at any time. Limiting the units current reduces the load on the main power supply. This is accomplished by reducing the SMV position until current draw is reduced to the set point. When desirable, the limit can be lowered. Note, however, that capacity is also reduced. The five values for 460vac operation are: 15, 17, 19, 21 (Factory Default), 23

Cd33 Perishable Mode Dehumidification Control (% RH)

Relative humidity set point is available only on units configured for dehumidifica- tion. When the mode is activated, the control probe LED flashes on and off every second to alert the user. If not configured, the mode is permanently deactivated and -- -- -- -- -- will display. The value can be set to OFF. TEST, or a range of 65 to 95% relative humidity in increments of 1%. [If bulb mode is active (code Cd35) and Lo speed evaporator motors are selected (code Cd36) then set point ranges from 60 to 95%.] When TEST is selected or test set point is entered, the heat LED should illuminate, indicating that dehumidification mode is activated. After a period of five minutes in the TEST mode has elapsed, the previously selected mode is reinstated.

Cd34 Economy Mode (On--Off)

Economy mode is a user selectable mode of operation provided for power saving purposes.

Cd35 Bulb Mode

Bulb mode is a user selectable mode of operation that is an extension of dehu- midification control (Cd33). If dehumidification is set to Off, code Cd35 will display Nor and the user will be unable to change it. After a dehumidification set point has been selected and entered for code Cd33, the user may then change code Cd35 to bulb. After bulb has been selected and entered, the user may then utilize function codes Cd36 and Cd37 to make the desired changes.

Cd36 Evaporator Speed Select

This code is enabled only if in the dehumidification mode (code Cd33) and bulb mode (Cd35) has been set to bulb. If these conditions are not met, alt will be displayed (indicating that the evaporator fans will alternate their speed) and the display cannot be changed. If a dehumidification set point has been selected along with bulb mode then alt may be selected for alternating speed, Lo for low speed evaporator fan only, or Hi for high speed evaporator fan only. If a setting other than alt has been selected and bulb mode is deactivated in any manner, then selection reverts back to alt.

Cd37 Defrost Termination Temperature Setting (Bulb Mode)

This code, as with function code Cd36, is used in conjunction with bulb mode and dehumidification. If bulb mode is active, this code allows the user to change the temperature above which defrost will terminate. It allows the user to change the setting within a range of 4_C to 25.6_C in 0.1_C (0.2_F) increments. This value is changed using the UP/DOWN ARROW keys, followed by the ENTER key when the desired value is displayed. If bulb mode is deactivated, the DTS setting returns to the default.

Display Only Functions - Continued

Cd38 Secondary Supply Temperature Sensor

Code Cd38 will display the current secondary supply temperature sensor reading for units configured for four probes. If the unit is configured with a DataCORDER, Cd38 will display -- -- -- -- -- . If the DataCORDER suffers a failure, (AL55) Cd38 will display the supply recorder sensor reading.

Cd39 Secondary Return Temperature Sensor

Code Cd39 will display the current secondary return temperature sensor reading for units configured for four probes. If the unit is configured with a DataCORDER, Cd39 will display -- -- -- -- -- . If the DataCORDER suffers a failure, (AL55) Cd39 will display the return recorder sensor reading.

Cd40 Container Identifica- tion Number

Code Cd40 is configured at commissioning to read a valid container identification number. The reading will not display alpha characters, only the numeric portion of the number will display.

Cd41 Valve Override SERVICE FUNCTION: This code is used for troubleshooting and allows manual positioning of the economizer, unloader, suction modulation and oil return valves. Refer to paragraph 6.16 for operating instructions.

Cd45 Fresh Air Vent Position Sensor

The fresh air flow (CMH/CFM) is displayed. Unless AL50 is active or CnF47 is OFF. This function code will automatically activate for 30 seconds and display when a vent position change occurs.

Cd46 Cd47 Cd48

Not Applicable Not used

Cd49 Days Since Last Successful Pre--trip Code Cd49 will display the time period (days) since the last successful pre--trip.

3--17 T-327

Table 3-6 Controller Alarm Indications (Sheet 1 of 4)

Code No. TITLE DESCRIPTION

AL05 Manual Defrost Switch Failure

Alarm 05 is triggered if the controller detects continuous Manual Defrost Switch action for 5 minutes or more. The alarm will only trigger off when the unit is power cycled.

AL06 Keypad or Harness Failure

Alarm 06 is triggered if the controller detects continuous keypad button activity for 5 minutes or more. The alarm will only trigger off when the unit is power cycled.

AL07 Fresh Air Vent Open with Frozen Setpoint

Alarm 07 is triggered if the VPS is reading greater than 0 CMH based on the function code display value and a frozen setpoint is active. If AL 50 is active AL 07 will not be generated. The alarm will go inactive if the VPS reading transitions to 0 CMH, the setpoint transitions to the perishable range, or an AL50 is active.

AL08 High Compressor Pressure Ratio

Alarm 08 is triggered when the controller detects discharge pressure :suction pressure ratio is too high. This is a display alarm and has no associated failure action.

AL10 CO2 Sensor Failure Alarm 10 is a display only alarm triggered when the controller a CO2 sensor is out of range. This is a display alarm and has no associated failure action.

AL14 Phase Sequence Failure -- Electronic

Alarm 14 is triggered if the electronic phase detection system is unable to deter- mine the correct phase relationship. DIRCHECK will be displayed while the relationship is determined. If the system is unable to determine the proper rela- tionship alarm 14 will remain active. Additional information on phase detection may be displayed at Function Code Cd41. If the right most digit of Code Cd41 is 3 or 4, this indicates incorrect motor or sensor wiring. If the right most digit is 5, this indicates a failed current sensor assembly.

AL15 Loss of Cool

Alarm 15 is activated when SMV is greater than 15%, unit is in economized or standard operating modes and Return -- Supply Temperature Difference is less than 0.5C after 4 minutes of compressor run time. The alarm triggers failure action C ( evaporator fan only) or D ( all machinery off ) if in perishable mode and failure action D ( all machinery off ) if a frozen set point has been selected.. The alarm remains active until the unit is power cycled.

AL16 Compressor Current High

Alarm 16 is triggered if compressor current draw is 15% over calculated maxi- mum for 10 minutes out of the last hour. The alarm is display only and will trigger off when the compressor operates for one hour without over current.

AL17 Phase Sequence Failure -- Pressure

Alarm 17 is triggered if a compressor start in both directions fails to generate sufficient pressure differential. The controller will attempt restart every twenty minutes and deactivate the alarm if successful. This alarm triggers failure action C (evaporator fan only) or D (all machinery off) of Function Code Cd29 if the unit has a perishable set point. Failure action D (all machinery off) is triggered if the unit has a frozen set point

AL18 Discharge Pressure High

Alarm 18 is triggered if discharge pressure is 10% over calculated maximum for 10 minutes within the last hour. The alarm is display only and will trigger off when the compressor operates for one hour without overpressure.

AL19 Discharge Tempera- ture High

Alarm 19 is triggered if discharge temperature exceeds 135_C (275_F) for 10 minutes within the last hour. The alarm is display only and will trigger off when the compressor operates for one hour without over temperature.

AL20 Control Circuit Fuse Open (24 vac)

Alarm 20 is triggered by control power fuse (F3A, F3B) opening and will cause the software shutdown of all control units. This alarm will remain active until the fuse is replaced.

AL21 Micro Circuit Fuse Open (18 vac)

Alarm 21 is triggered by one of the fuses (F1/F2) being opened on 18 volts AC power supply to the Controller. The suction modulation valve (SMV) will be opened and current limiting is halted. Temperature control will be maintained by cycling the compressor.

AL22 Evaporator Fan Mo- tor Safety

Alarm 22 responds to the evaporator motor internal protectors. The alarm is triggered by opening of either internal protector. It will disable all control units until the motor protector resets and the unit is power cycled.

3--18T-327

Table 3-6 Controller Alarm Indications (Sheet 2 of 4)

AL23 Loss of Phase B

Alarm 23 is triggered if low current draw is detected on phase B and IPCP, HPS or IPEM is not tripped. If the compressor should be running, the controller will initiate a start up every five minutes and trigger off, if current reappears. If the evaporator fan motors only should be running, the alarm will trigger off is current reappears. This alarm triggers failure action C (evaporator fan only) or D (all machinery off) of Function Code Cd29 if the unit has a perishable set point. Failure action D (all machinery off) is triggered if the unit has a frozen set point

AL24 Compressor Motor Safety

Alarm 24 is triggered when compressor is not drawing any current. It also triggers failure action C or D set by function Code 29 for perishable setpoint, or D for frozen setpoint. If the compressor should be running, the controller will initiate a start up every five minutes and trigger off, if current reappears. This alarm will remain active until compressor draws current.

AL25 Condenser Fan Mo- tor Safety

Alarm 25 is triggered by the opening of the condenser motor internal protector and will disable all control units except for the evaporator fans. This alarm will remain active until the motor protector resets. This alarm triggers failure action C (evaporator fan only) or D (all machinery off) of Function Code Cd29 if the unit has a perishable set point. Failure action D (all machinery off) is triggered if the unit has a frozen set point

AL26

All Supply and Re- turn temperature Control Sensors Failure

Alarm 26 is triggered if the Controller determines that all of the control sensors are out-of-range. This can occur for box temperatures outside the range of --50_C to +70_C (--58_F to +158_F). This alarm triggers the failure action code set by Function Code Cd29.

AL27 A/D Accuracy Fail- ure

The Controller has a built-in Analog to Digital (A-D) converter, used to convert analog readings (i.e. temperature sensors, current sensors, etc.) to digital read- ings. The Controller continuously performs calibration tests on the A-D converter. If the A-D converter fails to calibrate for 30 consecutive seconds, this alarm is activated.This alarm will be inactivated as soon as the A-D converter calibrates.

AL28 Low Suction Pres- sure

Alarm 28 is triggered if suction pressure is below 2 psia and alarm 66 (Suction Pressure Transducer Failure) is not active. This alarm will be inactivated when suction pressure rises above 2 psia for three continuous minutes. This alarm triggers failure action C (evaporator fan only) or D (all machinery off) as deter- mined by User Selectable Failure Response if the unit has a perishable set point; Failure action D (all machinery off) if the unit has a frozen set point. Reset SMV.

AL50 Fresh Air Position Sensor (VPS)

Alarm 50 is activated whenever the sensor is outside the valid range. There is a 4 minute adjustment period where the user can change the vent position without generating an alarm event. The sensor requires 4 minutes of no movement to confirm stability. If the vent position changes at any point beyond the 4 minute adjustment period, the sensor will generate an alarm event. The alarm is trig- gered off when the unit power cycles and the sensor is within valid range.

AL51 Alarm List Failure

During start-up diagnostics, the EEPROM is examined to determine validity of its contents. This is done by testing the set point and the alarm list. If the contents are invalid, Alarm 51 is activated. During control processing, any operation involving alarm list activity that results in an error will cause Alarm 51 to be activated. Alarm 51 is a display only alarm and is not written into the alarm list. Pressing the ENTER key when CLEAr is displayed will result in an attempt to clear the alarm list. If that action is successful (all alarms are inactive), Alarm 51 will be reset.

AL52 Alarm List Full

Alarm 52 is activated whenever the alarm list is determined to be full; at start-up or after recording an alarm in the list. Alarm 52 is displayed, but is not recorded in the alarm list. This alarm can be reset by clearing the alarm list. This can be done only if all alarms written in the list are inactive.

AL53 Battery Pack Failure

Alarm 53 is caused by the battery pack charge being too low to provide sufficient power for battery-backed recording. If this alarm occurs on start up, allow a unit fitted with rechargeable batteries to operate for up to 24 hours to charge re- chargeable batteries sufficiently to deactivate the alarm

3--19 T-327

Table 3-6 Controller Alarm Indications (Sheet 3 of 4)

AL54 Primary Supply Tem- perature Sensor Failure (STS)

Alarm 54 is activated by an invalid primary supply temperature sensor reading that is sensed outside the range of --50 to +70_C (--58_F to +158_F) or if the probe check logic has determined there is a fault with this sensor. If Alarm 54 is activated and the primary supply is the control sensor, the secondary supply sensor will be used for control if the unit is so equipped. If the unit does not have a secondary supply temperature sensor, and AL54 is activated, the primary return sensor reading, minus 2_C will be used for control.

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm

AL55 I/O Failure This alarm activates to indicate I/O functions have failed and require replace- ment.

AL56 Primary Return Tem- perature Sensor Failure (RTS)

Alarm 56 is activated by an invalid primary return temperature sensor reading that is outside the range of --50 to +70_C (--58_F to +158_F). If Alarm 56 is activated and the primary return is the control sensor, the secondary return sensor will be used for control if the unit is so equipped. If the unit is not equipped with a secondary return temperature sensor or it fails, the primary supply sensor will be used for control.

NOTE The P5 Pre-Trip test must be run to inactivate the alarm.

AL57 Ambient Tempera- ture Sensor Failure

Alarm 57 is triggered by an ambient temperature reading outside the valid range from --50_C (--58_F) to +70_C (+158_F).

AL58 Compressor High Pressure Safety

Alarm 58 is triggered when the compressor high discharge pressure safety switch remains open for at least one minute. This alarm will remain active until the pressure switch resets, at which time the compressor will restart.

AL60 Defrost Temperature Sensor Failure

Alarm 60 is an indication of a probable failure of the defrost temperature sensor (DTS). It is triggered by the opening of the heat termination thermostat (HTT) or the failure of the DTS to go above set point within two hours of defrost initiation. After one-half hour with a frozen range set point, or one-half hour of continuous compressor run time, if the return air falls below 7_C (45_F), the Controller checks to ensure the DTS reading has dropped to 10_C or below. If not, a DTS failure alarm is given and the defrost mode is operated using the return tempera- ture sensor. The defrost mode will be terminated after one hour by the Controller.

AL61 Heaters Failure

Alarm 61 is triggered by detection of improper amperage resulting from heater activation or deactivation. Each phase of the power source is checked for proper amperage.This alarm is a display alarm with no resulting failure action, and will be reset by a proper amp draw of the heater.

AL62 Compressor Circuit Failure

Alarm 62 is triggered by improper current draw increase (or decrease) resulting from compressor turn on (or off). The compressor is expected to draw a mini- mum of 2 amps; failure to do so will activate the alarm. This is a display alarm with no associated failure action and will be reset by a proper amp draw of the compressor.

AL63 Current Over Limit

Alarm 63 is triggered by the current limiting system. If the compressor is ON and current limiting procedures cannot maintain a current level below the user se- lected limit, the current limit alarm is activated. This alarm is a display alarm and is inactivated by power cycling the unit, changing the current limit via the code select Cd32, or if the current decreases below the activation level.

AL64 Discharge Tempera- ture Over Limit

Alarm 64 is triggered if the discharge temperature sensed is outside the range of --60_C (--76_F) to 175_C (347_F), or if the sensor is out of range. This is a display alarm and has no associated failure action.

AL65 Discharge Pressure Transducer Failure

Alarm 65 is triggered if a compressor discharge transducer is out of range. This is a display alarm and has no associated failure action.

AL66 Suction Pressure Transducer Failure Alarm 66 is triggered if a suction pressure transducer is out of range.

AL67 Humidity Sensor Failure

Alarm 67 is triggered by a humidity sensor reading outside the valid range of 0% to 100% relative humidity. If alarm AL67 is triggered when the dehumidification mode is activated, then the dehumidification mode will be deactivated.

AL68 Condenser Pressure Sensor

Alarm 68 is triggered when the Condenser Pressure Sensor is out of range. This is a display alarm and has no associated failure action.

3--20T-327

Table 3-6 Controller Alarm Indications (Sheet 4 of 4)

AL69 Suction Pressure Sensor

Alarm 69 is triggered when the Suction Pressure Sensor is out of range. This is a display alarm and has no associated failure action.

NOTE If the Controller is configured for four probes without a DataCORDER, the DataCORDERalarms AL70 and AL71 will be processed as Controller alarms AL70 and AL71. Refer to Table 3-10, page 3--27.

ERR #

Internal Microprocessor Failure

The Controller performs self-check routines. if an internal failure occurs, an ERR alarm will appear on the display. This is an indication the Controller needs to be replaced.

ERROR DESCRIPTION

ERR 0 -- RAM failure Indicates that the Controller working memory has failed.

ERR 1 -- Program Memory failure Indicates a problem with the Controller program.

ERR 2 -- Watchdog time--out

The Controller program has entered a mode where- by the Controller program has stopped executing.

ERR 3 -- N/A N/A ERR 4 -- N/A N/A

ERR 5 -- A-D failure The Controllers Analog to Digital (A-D) converter has failed.

ERR 6 -- IO Board failure Internal program/update failure. ERR 7 -- Controller failure Internal version/firmware incompatible. ERR 8--DataCorder failure Internal DataCorder memory failure. ERR -- 9 Controller failure Internal controller memory failure. In the event that a failure occurs and the display cannot be updated, the status LED will indicate the appropriate ERR code using Morse code as shown below.

E R R 0 to 9 ERR0 = . .--. .--. ---------- ERR1 = . .--. .--. . -------- ERR2 = . .--. .--. . . ------ ERR3 = . .--. .--. . . . ---- ERR4 = . .--. .--. . . . . -- ERR5 = . .--. .--. . . . . . ERR6 = . .--. .--. --. . . . ERR7 = . .--. .--. ----. . . ERR8 = . .--. .--. ------. . ERR9 = . .--. .--. -------- .

Entr StPt

Enter Setpoint (Press Arrow & Enter)

The Controller is prompting the operator to enter a set point.

LO

Low Main Voltage (Function Codes Cd27--38 disabled and NO alarm stored.)

This message will be alternately displayed with the set point whenever the supply voltage is less than 75% of its proper value.

3--21 T-327

Table 3-7 Controller Pre-Trip Test Codes (Sheet 1 of 4)

Code No. TITLE DESCRIPTION

NOTE Auto or Auto1 menu includes the: P0, P1, P2, P3, P4, P5, P6 and rSLts. Auto2 menu includes P0, P1, P2, P3, P4, P5, P6, P7, P8, P9, P10 and rSLts.

P0--0 Pre-Trip Initiated All lights and display segments will be energized for five seconds at the start of the pre-trip. Since the unit cannot recognize lights and display failures, there are no test codes or results associated with this phase of pre-trip.

P1-0 Heaters Turned On Setup: Heater must start in the OFF condition, and then be turned on. A current draw test is done after 15 seconds. Pass/Fail Criteria: Passes if current draw change is within the range specified.

P1-1 Heaters Turned Off Setup: Heater must start in the ON condition, and then be turned off. A current draw test is done after 10 seconds. Pass/Fail Criteria: Passes if current draw change is within the range specified.

P2-0 Condenser Fan On

Requirements: Water pressure switch or condenser fan switch input must be closed. Setup: Condenser fan is turned ON, a current draw test is done after 15 sec- onds. Pass/Fail Criteria: Passes if current draw change is within the range specified.

P2-1 Condenser Fan Off Setup: Condenser fan is turned OFF, a current draw test is done after 10 sec- onds. Pass/Fail Criteria: Passes if current draw change is within the range specified.

P3 Low Speed Evapo- rator Fans

Requirements: The unit must be equipped with a low speed evaporator fan, as determined by the Evaporator Fan speed select configuration variable.

P3-0 Low Speed Evapo- rator Fan Motors On

Setup: The high speed evaporator fans will be turned on for 10 seconds, then off for two seconds, then the low speed evaporator fans are turned on. A current draw test is done after 60 seconds. Pass/Fail Criteria: Passes if change in current draw is within the range speci- fied. Fails if AL11 or AL12 activates during test for units operating with single fan only.

P3-1 Low Speed Evapo- rator Fan Motors Off

Setup: The low speed Evaporator Fan is turned off, a current draw test is done after 10 seconds. Pass/Fail Criteria: Passes if change in current draw is within the range speci- fied. Fails if AL11 or AL12 activates during test for units operating with single fan only.

P4-0 High Speed Evapo- rator Fan Motors On

Setup: The high speed Evaporator Fan is turned on, a current draw test is done after 60 seconds. Pass/Fail Criteria: Passes if change in current draw is within the range speci- fied. Fails if AL11 or AL12 activates during test for units operating with single fan only.

P4-1 High Speed Evapo- rator Fan Motors Off

Setup: The high speed Evaporator Fan is turned off, a current draw test is done after 10 seconds. Pass/Fail Criteria: Passes if change in current draw is within the range speci- fied. Fails if AL11 or AL12 activates during test.

P5-0 Supply/Return Probe Test

Setup: The High Speed Evaporator Fan is turned on and run for eight minutes, with all other outputs de-energized. Pass/Fail Criteria: A temperature comparison is made between the return and supply probes.

NOTE If this test fails, P5-0 and FAIL will be displayed. If both Probe tests (this test and the PRIMARY/ SECONDARY) pass, the display will read P5 PASS.

3--22T-327

Table 3-7 Controller Pre-Trip Test Codes (Sheet 2 of 4)

P5-1 Supply Probe Test

Requirements: For units equipped with secondary supply probe only. Pass/Fail Criteria: The temperature difference between primary and secondary probe (supply) is compared.

NOTE If this test fails, P5-1 and FAIL will be displayed. If both Probe tests (this and the SUPPLY/ RETURN TEST) pass, because of themultiple tests, the display will read P 5 PASS.

P5-2 Return Probe Test

Requirements: For units equipped with secondary return probe only. Pass/Fail Criteria: The temperature difference between primary and secondary probe (return) is compared.

NOTES

1. If this test fails, P5-2 and FAIL will be displayed. If both Probe tests (this test and the SUPPLY/ RETURN) pass, because of the multiple tests, the display will read P 5, PASS.

2. The results of Pre-Trip tests 5-0, 5-1 and 5-2 will be used to activate or clear control probe alarms.

P6

Refrigerant Probes, Compressor

and Refrigeration valves

Setup: The system is operated through a sequence of events to test the compo- nents. The sequence is: Step 1, de--energize all outputs; Step 2, start unit with unloader valve open. Open then close the suction modulation valve. Monitor suction pressure; Step 3, open suction modulation valve to a known position; Step 4, close suction modulation valve to a know position; Step 5, open econo- mizer valve; Step 6, close unloader valve; Step 7, open unloader valve; Step 8, close economizer valve; Step 9, de--energize all outputs.

P6-0 Discharge Thermistor Test

If alarm 64 is activated any time during the first 45 second period of Step 1, the test fails.

P6-1 Suction Thermistor Test

Alarm is activated if suction temperature is outside of the valid range of --60_C (--76_F) to 150_C (302_F) any time during the first 45 second period of Step 1, the test fails.

P6-2 Discharge Pressure Sensor Test

If alarm 65 is activated any time during the first 45 second period of Step 1, the test fails.

P6-3 Suction Pressure Sensor Test

If alarm 66 is activated any time during the first 45 second period of Step 1, the test fails.

P6-4 Compressor Current Draw Test

Compressor current is tested before and after start up. If current does not in- crease, the test fails.

P6-5 Suction Modulation Valve Test

Suction pressure is measured before and after the valve opens. If suction pres- sure does not increase, the test fails.

P6-6 Economizer Valve Test

Suction pressure is measured during Steps 4 and 5. If suction pressure does not increase, the test fails.

P6-7 Unloader Valve Test Suction pressure is measured during Steps 6 and 7. If suction pressure does not increase, the test fails.

3--23 T-327

Table 3-7 Temperature Controller Pre-Trip Test Codes (Sheet 3 of 4)

NOTE P7--0 & P8 are included with Auto2 & Auto 3 only. P9--0 through P10 are included with Auto2 only

P7-0 High Pressure Switch Closed

NOTE This test is skipped if the sensed ambient temperature is less than 7_C (45_F), the return air temperature is less than --17.8_C (0_F), the water pressure switch is open or the condenser fan switch is open.

Setup: With the unit running, the condenser fan is de-energized, and a 15 minute timer is started. Pass/Fail Criteria: The test fails if high pressure switch fails to open in 15 minutes.

P7-1 High Pressure Switch Open

Requirements: Test P7-0 must pass for this test to execute. Setup: The con- denser fan is started and a 60 second timer is started. Pass/Fail Criteria: Passes the test if the high pressure switch (HPS) closes within the 60 second time limit, otherwise, it fails.

P8-0 Perishable Mode Heat Test

Setup: If the container temperature is below 15.6C (60_F), the set point is changed to 15.6C, and a 180 minute timer is started. The left display will read P8-0. The control will then heat the container until 15.6C is reached. If the container temperature is above 15.6C at the start of the test, then the test proceeds immediately to test P8-1 and the left display will change to P8-1. Pass/Fail Criteria: The test fails if the 180 minute timer expires before the control temperature reaches set point. The display will read P8-0, FAIL.

P8-1 Perishable Mode Pull Down Test

Requirements: Control temperature must be at least 15.6C (60_F). Setup: The set point is changed to 0C (32_F), and a 180 minute timer is started. The left display will read P8-1, the right display will show the supply air temperature. The unit will then start to pull down the temperature to the 0C set point. Pass/Fail Criteria: The test passes if the container temperature reaches set point before the 180 minute timer expires.

P8-2 Perishable Mode Maintain Tempera-

ture Test

Requirements: Test P8-1 must pass for this test to execute. This test is skipped if the dataCORDER is not configured or available. Setup: The left display will read P8-2, and the right display will show the supply air temperature. A two hour timer is started. The unit will be required to maintain the temperature to within + or -- 0.5_C (0.9_F) of set point until a DataCORDER recording is executed. The recorder supply probe temperature running total (and its associated readings counter) will be zeroed out for the remainder of the recording period at the start of this test, so that the actual value recorded in the DataCORDER will be an average of only this tests results. Once a recording interval is complete, the average recorder supply temperature will be recorded in the DataCORDER, as well as stored in memory for use in applying the test pass/fail criteria. Pass/Fail Criteria: If the recorded temperature is within +/-- 0.5_C. of set point from test start to DataCORDER recording, the test passes. If the average tem- perature is outside of the tolerance range at the recording, the test fails and will auto--repeat by starting P8--0 over.

P9-0 Defrost Test

Setup: The defrost temperature sensor (DTS) reading will be displayed on the left display. The right display will show the supply air temperature. The unit will run FULL COOL for 30 minutes maximum until the DTT is considered closed. Once the DTT is considered closed, the unit simulates defrost by running the heaters for up to two hours, or until the DTT is considered open. Pass/Fail Criteria: The test fails if: the DTT is not considered closed after the 30 minutes of full cooling, HTT opens when DTT is considered closed or if return air temperature rises above 49/50_C (120/122_F).

3--24T-327

Table 3-7 Controller Pre-Trip Test Codes (Sheet 4 of 4)

P10-0 Frozen Mode Heat Test

Setup: If the container temperature is below 7.2_C (45_F), the set point is changed to 7.2_C and a 180 minute timer is started. The control will then be placed in the equivalent of normal heating. If the container temperature is above 7.2_C at the start of the test, then the test proceeds immediately to test 10--1. During this test, the control temperature will be shown in the right display. Pass/Fail Criteria: The test fails if the 180 minute timer expires before the control temperate reaches set point --0.3_C (0.17_F). If the test fails it will not auto--repeat. There is no pass display for this test, once the control temperature reaches set point, the test proceeds to test 10--1

P10-1 Frozen Mode Pull Down Test

Requirements: Control temperature must be at least 7.2_C (45_F) Setup: The set point is changed to --17.8_C (0_F). The system will then attempt to pull don the Control temperature to set point using normal frozen mode cool- ing. During this test, the control temperate will be shown on the right display Pass/Fail Criteria: If the control temperature does not reach set point --0.3_C (0.17_F) before the 180 minute timer expires the test fails and will auto--repeat by starting P10--0 over.

P10-2 Frozen Mode Maintain

Temperature Test

Requirements: Test P10-1 must pass for this test to execute. This test is skipped if the dataCORDER is not configured or available. Setup: During this test, the left display will read P10-2, and the right display will show the supply air temperature. A two hour timer is started. The unit will be required to maintain the temperature to within + 0.5_C (0.9_F)/--1.3_C (2.3_F) of set point until a DataCORDER recording is executed. The recorder supply probe temperature running total (and its associated readings counter) will be zeroed out for the remainder of the recording period at the start of this test, so that the actual value recorded in the DataCORDER will be an average of only this tests results. Once a recording interval is complete, the average recorder supply temperature will be recorded in the DataCORDER, as well as stored in memory for use in applying the test pass/fail criteria. Pass/Fail Criteria: If the recorded temperature is within +0.5_C (0.9_F)/--1.3_C (2.3_F) of set point from test start to DataCORDER recording, the test passes. If the average temperature is outside of the tolerance range at the recording, the test fails and will auto--repeat by starting P10--0 over.

3--25 T-327

Table 3-8 DataCORDER Function Code Assignments

NOTE Inapplicable Functions Display -- -- -- -- --

To Access: Press ALT. MODE key Code No. TITLE DESCRIPTION

dC1 Recorder Supply Temperature Current reading of the supply recorder sensor.

dC2 Recorder Return Temperature Current reading of the return recorder sensor.

dC3-5 USDA 1,2,3 Temper- atures Current readings of the three USDA probes.

dC6-13 Network Data Points 1-8

Current values of the network data points (as configured). Data point 1 (Code 6) is generally the humidity sensor and its value is obtained from the Control- ler once every minute.

dC14 Cargo Probe 4 Tem- perature Current reading of the cargo probe #4.

dC15-19 Future Expansion These codes are for future expansion, and are not in use at this time.

dC20-24 Temperature Sen- sors 1-5 Calibration

Current calibration offset values for each of the five probes: supply, return, USDA #1, #2, and #3. These values are entered via the interrogation pro- gram.

dC25 Future Expansion This code is for future expansion, and is not in use at this time.

dC26,27 S/N, Left 4, Right 4

The DataCORDER serial number consists of eight characters. Function code dC26 contains the first four characters. Function code dC27 contains the last four characters. (This serial number is the same as the Controller serial number)

dC28 Minimum Days Left An approximation of the number of logging days remaining until the Data- CORDER starts to overwrite the existing data.

dC29 Days Stored Number of days of data that are currently stored in the DataCORDER.

dC30 Date of last Trip start

The date when a Trip Start was initiated by the user. In addition, if the system goes without power for seven continuous days or longer, a trip start will automatically be generated on the next AC power up. Press and hold EN- TER key for 5 seconds to initiate a Trip Start.

dC31 Battery Test Shows the current status of the optional battery pack. PASS: Battery pack is fully charged. FAIL: Battery pack voltage is low.

dC32 Time: Hour, Minute Current time on the real time clock (RTC) in the DataCORDER.

dC33 Date: Month, Day Current date (month and day) on the RTC in the DataCORDER.

dC34 Date: Year Current year on the RTC in the DataCORDER.

dC35 Cargo Probe 4 Calibration

Current calibration value for the Cargo Probe. This value is an input via the interrogation program.

3--26T-327

Table 3-9 DataCORDER Pre-Trip Result Records Test No. TITLE DATA

1-0 Heater On Pass/Fail/Skip Result, Change in current for Phase A, B and C 1-1 Heater Off Pass/Fail/Skip Result, Change in currents for Phase A, B and C

2-0 Condenser Fan On Pass/Fail/Skip Result, Water pressure switch (WPS) -- Open/Closed, Change in currents for Phase A, B and C

2-1 Condenser Fan Off Pass/Fail/Skip Result, Change in currents for Phase A, B and C

3-0 Low Speed Evaporator Fan On Pass/Fail/Skip Result, Change in currents for Phase A, B and C

3-1 Low Speed Evaporator Fan On Pass/Fail/Skip Result, Change in currents for Phase A, B and C

4-0 High Speed Evaporator Fan On Pass/Fail/Skip Result, Change in currents for Phase A, B and C

4-1 High Speed Evaporator Fan On Pass/Fail/Skip Result, Change in currents for Phase A, B and C

5-0 Supply/Return Probe Test Pass/Fail/Skip Result, STS, RTS, SRS and RRS 5-1 Secondary Supply Probe Test Pass/Fail/Skip

5-2 Secondary Return Probe Test Pass/Fail/Skip 6-0 Discharge Thermistor Test Pass/Fail/Skip 6-1 Suction Thermistor Test Pass/Fail/Skip

6-2 Discharge Pressure Sensor Test Pass/Fail/Skip

6-3 Suction Pressure Sensor Test Pass/Fail/Skip

6-4 Compressor Current Draw Test Pass/Fail/Skip

6-5 Suction Modulation valve Test Pass/Fail/Skip 6-6 Economizer Valve Test Pass/Fail/Skip 6-7 Unloader Valve Test Pass/Fail/Skip

7-0 High Pressure Switch Closed Pass/Fail/Skip Result, AMBS, DPT or CPT (if equipped) Input values that component opens

7-1 High Pressure Switch Open Pass/Fail/Skip Result, STS, DPT or CPT (if equipped) Input values that component closes

8-0 Perishable Mode Heat Test Pass/Fail/Skip Result, STS, time it takes to heat to 16_C (60_F)

8-1 Perishable Mode Pull Down Test Pass/Fail/Skip Result, STS, time it takes to pull down to 0_C (32_F)

8-2 Perishable Mode Maintain Test

Pass/Fail/Skip Result, Averaged DataCORDER supply temperature (SRS) over last recording interval.

9-0 Defrost Test Pass/Fail/Skip Result, DTS reading at end of test, line voltage, line frequency, time in defrost.

10-0 Frozen Mode Heat Test Pass/Fail/Skip Result, STS, time unit is in heat. 10-1 Frozen Mode Pull Down Test Pass/Fail/Skip Result, STS, time to pull down unit to --17.8_C (0_F).

10-2 Frozen Mode Maintain Test Pass/Fail/Skip Result, Averaged DataCORDER return temperature (RRS) over last recording interval.

3--27 T-327

Table 3-10 DataCORDER Alarm Indications

To Access: Press ALT. MODE key Code No. TITLE DESCRIPTION

dAL70 Recorder Supply Tem- perature Out of Range

The supply recorder sensor reading is outside of the range of --50_C to 70_C (--58_F to +158_F) or, the probe check logic has determined there is a fault with this sensor.

NOTE The P5 Pre-Trip test must be run to inactivate the alarm.

dAL71 Recorder Return Tem- perature Out of Range

The return recorder sensor reading is outside of the range of --50_C to 70_C (--58_F to +158_F) or, the probe check logic has determined there is a fault with this sensor.

NOTE The P5 Pre-Trip test must be run to inactivate the alarm.

dAL72-74 USDA Temperatures 1, 2, 3 Out of Range

The USDA probe temperature reading is sensed outside of --50 to 70C (--58 to 158F) range.

dAL75 Cargo Probe 4 Out of Range

The cargo probe temperature reading is outside of --50 to 70C (--58 to 158F) range.

dAL76, 77 Future Expansion These alarms are for future expansion, and are not in use at this time.

dAL78-85 Network Data Point 1 -- 8 Out of Range

The network data point is outside of its specified range. The DataCORD- ER is configured by default to record the supply and return recorder sen- sors. The DataCORDER may be configured to record up to 8 additional network data points. An alarm number (AL78 to AL85) is assigned to each configured point. When an alarm occurs, the DataCORDER must be interrogated to identify the data point assigned. When a humidity sensor is installed, it is usually assigned to AL78.

dAL86 RTC Battery Low The Real Time Clock (RTC) backup battery is too low to adequately main- tain the RTC reading.

dAL87 RTC Failure An invalid date or time has been detected. This situation may be corrected by changing the Real Time Clock (RTC) to a valid value using the Data- View.

dAL88 DataCORDER EEPROM Failure A write of critical DataCORDER information to the EEPROM has failed.

dAL89 Flash Memory Error An error has been detected in the process of writing daily data to the non-volatile FLASH memory.

dAL90 Future Expansion This alarm is for future expansion, and is not in use at this time.

dAL91 Alarm List Full The DataCORDER alarm queue is determined to be full (eight alarms).

T-3274--1

SECTION 4 OPERATION

4.1 INSPECTION (Before Starting)

WARNING Beware of unannounced starting of the evaporator and condenser fans. The unit may cycle the fans and compressor unex- pectedly as control requirements dictate.

a. If container is empty, check inside for the following:

1. Check channels or T bar floor for cleanliness. Channels must be free of debris for proper air cir- culation.

2. Check container panels, insulation and door seals for damage. Effect permanent or temporary repairs.

3. Visually check evaporator fan motor mounting bolts for proper securement (refer to paragraph 6.14).

4. Check for dirt or grease on evaporator fan or fan deck and clean if necessary.

5. Check evaporator coil for cleanliness or obstruc- tions. Wash with fresh water.

6. Check defrost drain pans and drain lines for obstruc- tions and clear if necessary. Wash with fresh water.

7. Check panels on refrigeration unit for loose bolts and condition of panels. Make sure T.I.R. devices are in place on access panels.

b. Check condenser coil for cleanliness. Wash with fresh water.

c. Opencontrol box door. Check for loose electrical con- nections or hardware.

d. Check color of moisture-liquid indicator.

e. Check oil level in compressor sight glass.

4.2 CONNECT POWER

WARNING Do not attempt to remove power plug(s) be- fore turningOFF start-stop switch (ST), unit circuit breaker(s) and external power source.

WARNING Make sure the power plugs are clean and dry before connecting to power receptacle.

4.2.1 Connection To 380/460 vac Power

1. Make sure start-stop switch (ST, on control panel) and circuit breaker (CB-1, in the control box) are in position 0 (OFF).

2. Plug the 460 vac (yellow) cable into a de-energized 380/460 vac, 3-phase power source. Energize the power source. Place circuit breaker (CB-1) in position I (ON). Close and secure control box door.

4.2.2 Connection To 190/230 vac Power

An autotransformer (Figure 4-1) is required to allow operation on nominal 230 volt power. It is fitted with a 230 vac cable and a receptacle to accept the standard 460 vac power plug. The 230 volt cable is black in color while the 460 volt cable is yellow. The transformer may also be equipped with a circuit breaker (CB-2). The transformer is a step up transformer that will provide 380/460 vac, 3-phase, 50/60 hertz power to the unit when the 230 vac power cable is connected to a 190/230 vac, 3-phase power source.

1. Make sure that the start-stop switch (ST, on control panel) and circuit breakers CB-1 (in the control box and CB-2 (on the transformer) are in position 0 (OFF). Plug in and lock the 460 vac power plug at the receptacle on the transformer.

2. Plug the 230 vac (black) cable into a de-energized 190/230 vac, 3-phase power source. Energize the power source. Set circuit breakers CB-1 and CB2 to position I (ON). Close and secure control box door.

1

32

1. Dual Voltage Modular Autotransformer

2. Circuit Breaker (CB-2) 230V

3. 460 vac Power Receptacle

Figure 4-1 Autotransformer

4.3 ADJUST FRESH AIR MAKEUP VENT

The purpose of the fresh air makeup vent is to provide ventilation for commodities that require fresh air circulation. The ventmust be closed when transporting frozen foods.

Air exchange depends on static pressure differential, which will vary depending on the container and how the container is loaded.

Units may be equipped with a Vent Position Sensor (VPS). The VPS determines the position of the fresh air vent and sends data to the controller display.

T-327 4--2

4.3.1 Upper Fresh Air Makeup Vent

Two slots and a stop are designed into the disc for air flow adjustments. The first slot allows for a 0 to 30% air flow, and the second slot allows for a 30 to 100%air flow. To adjust the percentage of air flow, loosen the wing nut and rotate the disc until the desired percentage of air flow matches with the arrow. Tighten the wing nut. To clear thegapbetween the slots, loosen thewing nut until the disc clears the stop. Figure 4-2 gives air exchange values for an empty container. Higher values can be expected for a fully loaded container.

0

30

60

90

120

150

180

210

240

0 10 20 30 40 50 60 70 80 90 100

AIR FLOW (CMH)

1-!/2

PERCENT OPEN

50HZ T-BAR

2-%/8

3 T-BAR

T-BAR

0

40

80

120

160

200

240

280

0 10 20 30 40 50 60 70 80 90 100

AIR FLOW (CMH) 1-!/2

PERCENT OPEN

T-BAR

2-%/8

3 T-BAR

T-BAR

60HZ

Figure 4-2 Make Up Air Flow Chart

4.3.2 Lower Fresh Air Makeup Vent

a. Full Open or Closed Positions

Maximum air flow is achieved by loosening the wing nuts and moving the cover to the maximum open

position (100% position). The closed position is 0% air flow position.The operator may also adjust the opening to increase or decrease the air flow volume to meet the required air flow.

b. Reduced Flow for Fresh Air Makeup

On some models the air slide is supplied with two adjustable air control disks. The freshairmakeup canbe adjusted for (15, 35, 50 or 75) cubic meters per hour (CMH). The air flow has been established at 60HZ power and 2 1/2 inch T bar andwith 15mm (.6 inch)H2O external static above free blow.

Loosen the hex nut and adjust each disk to the required air flow and tighten hex nut.

NOTE The main air slide is in the fully closed position during reduced air flow operation.

c. Adjustment

The air slide is supplied with two adjustable air control discs. The fresh air makeup can be adjusted for 15, 35, 50and75cubicmeters per hour (CFM). Theair flowhas been established at 60Hz power, and a 2 1/2 inch T bar, with 15 mm (0.6 inch) H2O external static above free blow.

NOTE

The main air slide is in the fully closed position during reduced air flow operation.

d. Air Sampling for Carbon Dioxide (CO2) Level

Loosen hex nuts and move the cover until the arrow on the cover is alignedwith the atmosphere sampling port label. Tighten the hex nuts and attach a 3/8 hose to the sampling port.

If the internal atmosphere content has reached an unacceptable level, the operator may adjust the disc opening tomeet the required air flow volume to ventilate the container.

4.3.3 Fresh Air Position Sensor

The VPS allows the user to determine position of the fresh air vent via function code 45. This function code is accessible via the code select key.

The vent position will display for 30 seconds whenever motion corresponding to 5 CMH (3 CFM) or greater is detected. It will scroll in intervals of 5 CMH (3 CFM). Scrolling to Function Code 45 will display the Fresh Air Vent Position.

Data Recording of the Sensor Position -- The position of the vent will be recorded in the DataCorder whenever the unit is running under AC power and any of the following:

Trip start On every power cycle Midnight Manual change greater than 5 CMH (3 CFM) and remains in that position for 4 minutes.

T-3274--3

NOTE The user has 4 minutes to make necessary ad- justments to the vent setting. This time begins on the initial movement of the sensor. The vent can be moved to any position within the 4 min- utes. On completion of the first 4 minutes, the vent is required to remain in stable for the next 4 minutes. If vent position changes are detected during the 4 minutes stability period, an alarm will be generated. This provides the user with the ability to change the vent setting without generating multiple events in the DataCorder.

4.4 CONNECT WATER-COOLED CONDENSER

The water-cooled condenser is used when cooling water is available and heating the surrounding air is objectionable, such as in a ships hold. If water cooled operation is desired, connect in accordance with the following subparagraphs.

4.4.1 Water--Cooled Condenser with Water Pres- sure Switch

a. Connect the water supply line to the inlet side of con- denser and the discharge line to the outlet side of the condenser. (See Figure 2-5.)

b. Maintain a flow rate of 11 to 26 liters per minute (3 to 7 gallons per minute). The water pressure switch will open to de-energize the condenser fan relay. The condenser fanmotor will stop andwill remain stopped until the water pressure switch closes.

c. To shift to air-cooled condenser operation,disconnect thewater supply and the discharge line to thewater-- cooled condenser. The refrigeration unit will shift to air-cooled condenser operation when the water pres- sure switch closes.

4.4.2 Water-Cooled Condenser with Condenser Fan Switch

a. Connect the water supply line to the inlet side of con- denser and the discharge line to the outlet side of the condenser. (See Figure 2-5.)

b. Maintain a flow rate of 11 to 26 lpm (3 to 7 gpm).

c. Set the condenser fan switch to position O. This will de-energize the condenser fan relay. The condenser fan motor will stop and remain stopped until the CFS switch is set to position I.

CAUTION When condenserwater flow is below 11 lpm (3 gpm) or when water-cooled operation is not in use, the CFS switch MUST be set to position 1 or the unit will not operate properly.

d. To shift to air-cooled condenser operation, stop the unit, set the CFS switch to position I and restart the unit. Disconnect the water lines to the water-cooled condenser.

4.5 CONNECT REMOTE MONITORING RECEPTACLE

If remote monitoring is required, connect remote monitor plug at unit receptacle. When the remote monitor plug is connected to the remote monitoring receptacle, the following remote circuits are energized:

CIRCUIT FUNCTION Sockets B to A Energizes remote cool light Sockets C to A Energizes remote defrost light Sockets D to A Energizes remote in-range light

4.6 STARTING AND STOPPING INSTRUCTIONS

WARNING Make sure that the unit circuit breaker(s) (CB-1 & CB-2) and the START-STOP switch (ST) are in the O (OFF) position before connecting to any electrical power source.

4.6.1 Starting the Unit a. With power properly applied, the fresh air damper set and (if required) the water cooled condenser con- nected, (refer to paragraphs 4.2, 4.3 & 4.4) place the START-STOP switch to I (ON).

NOTE Within the first 30 seconds the electronic phase detection system will check for proper com- pressor rotation. If rotation is not correct, the compressor will be stopped and restarted in the opposite direction. If the compressor is produc- ing unusually loud and continuous noise after the first 30 seconds of operation, stop the unit and investigate.

b Continue with Start Up Inspection, paragraph 4.7. 4.6.2 Stopping the Unit To stop the unit, place the START-STOP switch in position 0 (OFF).

4.7 START--UP INSPECTION 4.7.1 Physical Inspection a. Check rotation of condenser and evaporator fans. b. Check compressor oil level. (Refer to paragraph 6.5.) 4.7.2 Check Controller Function Codes Check and, if required, reset controller Function Codes (Cd27 through Cd39) in accordance with desired operating parameters. Refer to paragraph 3.2.2. 4.7.3 Start Temperature Recorder Partlow Recorders a. Open recorder door and wind mechanical clock or check battery of electronic recorder. Be sure key is re- turned to storage clip of mechanical recorder.

b. Lift stylus (pen) by pulling the marking tip outward un- til the stylus arm snaps into its retracted position.

c. Install new chart making sure chart is under the four corner tabs. Lower the stylus until it hasmadecontact with the chart. Close and secure door.

T-327 4--4

DataCORDER

a. Check and, if required, set theDataCORDERConfig- uration in accordance with desired recording parame- ter. Refer to paragraph 3.6.3.

b. Enter a Trip Start. To enter a trip Start, do the fol- lowing:

1. Depress the ALT MODE key and scroll to Code dC30.

2. Depress and hold the ENTER key for five seconds.

3. The Trip Start event will be entered in the Data- CORDER.

4.7.4 Complete Inspection

Allow unit to run for 5minutes to stabilize conditions and perform a pre--trip diagnosis in accordance with the following paragraph.

4.8 PRE-TRIP DIAGNOSIS

CAUTION Pre-trip inspection should not be per- formed with critical temperature cargoes in the container.

CAUTION WhenPre-Trip key ispressed, economy,de- humidification and bulb mode will be deac- tivated. At the completion of Pre-Trip activi- ty, economy, dehumidification and bulb mode must be reactivated.

Pre-Trip diagnosis provides automatic testing of theunit components using internal measurements and comparison logic. The program will provide a PASS or FAIL display to indicate test results.

The testing begins with access to a pre-trip selection menu. The user may have the option of selecting one of two automatic tests. These tests will automatically perform a series of individual pre--trip tests. The user may also scroll down to select any of the individual tests. When only the short sequence is configured it will appear as AUtO in the display, otherwise AUtO1 will indicate the short sequence and AUtO2 will indicate the long sequence. The test short sequence will run tests P0 through P6. The long test sequence will run tests P0 through P10.

A detailed description of the pre-trip test codes is listed in Table 3-7, page 3--21. If no selection is made, the pre-trip menu selection process will terminate automatically. However, dehumidification and bulb mode must be reactivated manually if required.

Scrolling down to the rSLts code and pressing ENTER will allow the user to scroll through the results of the last pre--trip testing run. If no pre--testing has been run (or an individual test has not been run) since the unit was powered up -------- will be displayed.

To start a pre--trip test, do the following:

NOTE

1. Prior to starting tests, verify that unit voltage (Function Code Cd 07) is within tolerance and unit amperage draw (Function Codes Cd04, Cd05, Cd06) are within expected limits. Otherwise, tests may fail incorrectly.

2. All alarms must be rectified and cleared before starting tests.

3. Pre-trip may also be initiated via communications. The operation is the same as for the key pad initiation described below except that should a test fail, the pre-trip mode will automatically terminate. When initiated via communications, a test may not be interrupted with an arrow key, but the pre-trip mode can be terminated with the PRE-TRIP key.

a. Press the PRE-TRIP key. This accesses a test selec- tion menu.

b. TO RUN AN AUTOMATIC TEST: Scroll through the selections by pressing the UP ARROW or DOWN ARROW keys to display AUTO, AUTO 1, AUTO 2 or AUTO 3 as desired and then press the AUTO key.

1. The unit will execute the series of tests without any need for direct user interface. These tests vary in length, depending on the component under test.

2. While tests are running, P#-# will appear on the left display, where the #s indicate the test number and sub-test. The right displaywill showacountdown time in minutes and seconds, indicating how much time there is left remaining in the test.

CAUTION When a failure occurs during automatic testing the unit will suspend operation awaiting operator intervention.

When anautomatic test fails, it will be repeated once . A repeated test failure will cause FAIL to be shown on the right display, with the corresponding test num- ber to the left. The user may then press the DOWN ARROW to repeat the test, theUP ARROW to skip to the next test or the PRE--TRIP key to terminate test- ing. The unit will wait indefinitely, until the user manu- ally enters a command.

CAUTION When Pre--Trip test Auto 2 runs to comple- tion without being interrupted, the unit will terminate pre-trip and display Auto 2 end. Theunit will suspend operation until the user depresses the ENTER key!

When an Auto 1 runs to completion without a failure, the unit will exit the pre-trip mode, and return to nor- mal control operation. However, dehumidification and bulb mode must be reactivated manually if required.

T-3274--5

c. TO RUN AN INDIVIDUAL TEST: Scroll through the selections by pressing the UP ARROW or DOWN ARROW keys to display an individual test code. Pressing ENTER when the desired test code is dis- played.

1. Individually selected tests, other than the LED/Dis- play test, will perform the operations necessary to verify the operation of the component. At the conclu- sion, PASS or FAIL will be displayed. This message will remain displayed for up to three minutes, during which time a user may select another test. If the three minute time period expires, the unit will termi- nate pre-trip and return to control mode operation.

2. While thetestsarebeingexecuted, theusermayter- minate the pre-trip diagnostics by pressing and hold- ingthePRE-TRIPkey.Theunitwill then resumenor- mal operation. If the user decides to terminate a test but remain at the test selection menu, the user may press theUPARROWkey.When this is done all test outputs will be de-energized and the test selection menu will be displayed.

3. Throughout the duration of any pre-trip test except the P-7 high pressure switch tests, the current and pressure limiting processes are active.

d. Pre-Trip Test Results

At the end of the pre-trip test selection menu, the message P, rSLts (pre--trip results) will be displayed. Pressing the ENTER key will allow the user to see the results for all subtests (i.e., 1-0, 1-1, etc). The resultswill be displayed as PASS or FAIL for all the tests run to completion since power up. If a test has not been run since power up, -- -- -- -- -- will be displayed. Once all pre--test activity is completed, dehumidification and bulb mode must be reactivated manually if required.

4.9 OBSERVE UNIT OPERATION

4.9.1 Probe Check

If the DataCORDER is off or in alarm the controller will revert to a four probe configuration which includes the DataCORDER supply and return air probes as the secondary controller probes. The controller continuously performs probe diagnosis testing which compares the four probes. If the probe diagnosis result indicates a probe problem exists, the controller will perform a probe check to identify the probe(s) in error.

a. Probe Diagnostic Logic -- Standard

If the probe check option (controller configuration code CnF31) is configured for standard, the criteria used for comparison between the primary and secondary control probes is:

1_C (1.8_F) for perishable set points or 2_C (3.6_F) for frozen set points.

If 25 or more of 30 readings taken within a 30minute period are outside of the limit, then a defrost is initi- ated and a probe check is performed.

In this configuration, a probe check will be run as a part of every normal (time initiated) defrost.

b. Probe Diagnostic Logic -- Special

If the probe check option is configured for special the above criteria are applicable. A defrost with probe check will be initiated if 25 of 30 readings or 10 consecutive readings are outside of the limits

In this configuration, a probe check will not be run as a part of a normal defrost, but only as a part of a defrost initiated due to a diagnostic reading outside of the limits.

c.The 30 minute timer will be reset at each of the follow- ing conditions:

1. At every power up.

2. At the end of every defrost.

3. After every diagnostic check that does not fall out- side of the limits as outlined above.

d. Probe Check

A defrost cycle probe check is accomplished by energizing just the evaporator motors for eight minutes at the end of the normal defrost. At the end of the eight minute period the probes will be compared to a set of predetermined limits. The defrost indicator will remain on throughout this period.

Any probe(s) determined to be outside the limits will cause the appropriate alarm code(s) to be displayed to identify which probe(s) needs to be replaced. The P5 Pre-Trip test must be run to inactivate alarms.

4.10 SEQUENCE OF OPERATION General operation sequences for cooling, heating and defrost are provided in the following subparagraphs. Schematic representation of controller action are provided in Figure 4-3 and Figure 4-4. Refer to Section 3 for detailed descriptions of special events and timers that are incorporated by the controller in specific modes of operation.

4.10.1 SequenceOfOperation -- CompressorPhase Sequence

The controller logic will check for proper compressor rotation. If the compressor is rotating in the wrong direction, the controller will energize or de--energize relay T6 as required (see Figure 4-5). Energizing relay T6 will switch operation from compressor contactor PA to compressor contactor PB. De--energizing relay T6 will switch operation from compressor contactor PB to compressor contactor PA. Compressor contactorsPA is wired to run the compressor on L1, L2, and L3. Compressor contactor PB is wired to run the compressor on L2, L1 and L3 thus providing reverse rotation .

T-327 4--6

SET POINT

PULL DOWN RISING

TEMPERATURE

--0.5_C (0.9_F)

--0.20_C

+.20_C

HEATINGHEATING

AIR CIRCULATION

+2.5_C (4.5_F)

UNLOADED OPERATION

MODULATED COOLING UNLOADED

AIR CIRCULATION

SET POINT

+.20_C

HEATING

+2.5_C (4.5_F)

FALLING TEMPERATURE

MODULATED COOLING UNLOADED

--0.5_C (0.9_F)

AIR CIRCULATION

NOTE: TEMPERATURES INDICATIONS ARE ABOVE OR BELOW SET POINT

START UNLOADED, TRANSITION TO ECONOMIZED OPERATION

--0.20_C

Figure 4-3 Controller Operation -- Perishable Mode

SET POINT

FALLING TEMPERATURE

RISING TEMPERATURE

--0.20_C

+.20_C

COOLING ECONOMIZED

AIR CIRCULATION

START UNLOADED, TRANSITION TO ECONOMIZED OPERATION

NOTE: TEMPERATURES INDICATIONS ARE ABOVE OR BELOW SET POINT

AIR CIRCULATION

Figure 4-4 Controller Operation -- Frozen Mode

T-3274--7

CONTROL TRANSFORMER

POWER TO CONTROLLER

SIGNAL TO CONTROLLER

ENERGIZED DE--ENERGIZED

FOR FULL DIAGRAM AND LEGEND, SEE SECTION 7

NOTE: HIGH SPEED EVAPORATOR FAN SHOWN. FOR LOW SPEED CONTACT TE IS DE--ENERGIZED AND CONTACT TV IS ENERGIZED

TD T6 PA PB

T6 PB PA

USV

ESV

TU

TS

Figure 4-5 Perishable Mode

4.10.2 Sequence Of Operation -- Perishable Mode Cooling

NOTE In the Conventional Perishable Mode of opera- tion the evaporator motors run in high speed. In the Economy PerishableMode the fan speed is varied.

a. With supply air temperature above set point and de- creasing, the unit will be cooling with the condenser fanmotor (CF), compressor motor (PA or PB), evapo- rator fanmotors (EF) energizedand theCOOL light il- luminated. (See Figure 4-5.) Also, if current or pres- sure limiting is not active, the controller will energize relay TS to open the economizer solenoid valve (ESV) and place the unit in economized operation.

b. When the air temperature decreases to a predeter- mined tolerance above set point, the in-range light is illuminated.

c. As the air temperature continues to fall, modulating cooling starts at approximately 2.5_C (4.5_F) above set point. (See Figure 4-3.) At set point, relay TS is de--energized to close the economizer solenoid valve and relay TU is energized to open the unloader sole- noid valve changing from economized operation to unloaded operation. (As shown in Figure 4-5)

d. The controller monitors the supply air. Once the sup- ply air falls below set point the controller periodically records the supply air temperature, set point and time. A calculation is then performed to determine temperature drift from set point over time.

e. If the calculation determines cooling is no longer re- quired, contacts TD and TN are opened to de-ener- gize compressor motor and condenser fan motor. The cool light is also de-energized.

f. Theevaporator fanmotors continue to run to circulate air throughout the container. The in-range light re-

mains illuminated as long as the supply air is within tolerance of set point.

g. If the supply air temperature increases to 0.2_C (0.4_F) above set point and the three minute off time has elapsed, relays TD, TU and TN are energized to restart the compressor and condenser fan motors in unloaded operation. The cool light is also illuminated.

CONTROL TRANSFORMER

POWER TO CONTROLLER

SIGNAL TO CONTROLLER

ENERGIZED DE--ENERGIZED

FOR FULL DIAGRAM AND LEGEND, SEE SECTION 7

NOTE: HIGH SPEED EVAPORATOR FAN SHOWN. FOR LOW SPEED CONTACT TE IS DE--ENERGIZED AND CONTACT TV IS ENERGIZED

TD T6 PA PB

T6 PB PA

USV

ESV

TU

TS

Figure 4-6 Perishable Mode Heating

4.10.3 Sequence Of Operation -- Perishable Mode Heating

a. If the air temperature decreases 0.5_C (0.9_F) below set point, the system enters the heating mode. (See Figure 4-3). The controller closes contacts TH (see Figure 4-6) to allow power flow through the heat ter- mination thermostat (HTT) to energize the heaters (HR). The HEAT light is also illuminated. The evapo- rator fans continue to run to circulate air throughout the container.

b. When the temperature rises to 0.2_C (0.4_F) above set point, contact TH opens to de--energize the heat- ers. The HEAT light is also de--energized. The evapo- rator fans continue to run to circulate air throughout the container.

c. A safety heater termination thermostat (HTT), at- tached to an evaporator coil support, will open the heating circuit if overheating occurs.

T-327 4--8

4.10.4 SequenceOfOperation -- FrozenModeCool- ing

a. With supply air temperature above set point and de- creasing, the unit will transition to economized cool- ing with the condenser fan motor (CF), compressor motor (CH), economizer solenoid valve (ESV), low speed evaporator fan motors (ES) energized and the COOL light illuminated. (See Figure 4-7)

b.When the air temperature decreases to a predeter- mined tolerance above set point, the in-range light is illuminated.

CONTROL TRANSFORMER

POWER TO CONTROLLER

SIGNAL TO CONTROLLER

ENERGIZED DE--ENERGIZED

FOR FULL DIAGRAM AND LEGEND, SEE SECTION 7

TD T6 PA PB

T6 PB PA

USV

ESV

TU

TS

Figure 4-7 Frozen Mode

c. When the return air temperature decreases to 0.2_C (0.4_F) below set point, contacts TD, TS and TN are opened to de-energize the compressor, economizer solenoid valve and condenser fan motors. The cool light is also de-energized.

d. The evaporator fan motors continue to run in low speed to circulate air throughout the container. The in-range light remains illuminated as long as the re- turn air is within tolerance of set point.

e. When return air temperature is 10_C (18_F) or more below set point, the evaporator fans are brought to high speed.

f. When the return air temperature increases to 0.2_C (0.4_F) above set point and the three minute off time has elapsed, relays TD, TS and TN are energizes to restart the compressor and condenser fan motors. The cool light is illuminated.

4.10.5 Sequence Of Operation -- Defrost The defrost cycle may consist of up to three distinct operations. The first is de-icing of the coil, the second is a probe check cycle and the third is snap freeze.

Defrost may be initiated by any one of the following methods:

1. The manual defrost function (also manual defrost switch function if equipped) is initiated and ended by the user. Through the use of the keypad or manual defrost switch (if equipped).

NOTE The Manual Defrost / Interval key can be used to initiate a manual defrost. MinimumSoftware release version #5126 is required in order for to use this function.

Manual Defrost/Interval key operation:

Depressing and holding the Defrost Interval key for five (5) seconds will initiate defrost. If the defrost in- terval key is released in less than five (5) seconds, defrost interval (code 27) shall be displayed.

2. The user sends a defrost command by communica- tions.

3. The defrost interval timer (controller function code Cd27) reaches the defrost interval set by the user.

4. The controller probediagnostic logic determines that a probe check is necessary based on the tempera- ture values currently reported by the supply and re- turn probes.

5. If the controller is programmed with the Demand De- frost option (Future) and the option is set to IN the unit will enter defrost if it has been in operation for over 2.5 hours without reaching set point.

CONTROL TRANSFORMER

POWER TO CONTROLLER

SIGNAL TO CONTROLLER

ENERGIZED DE--ENERGIZED

FOR FULL DIAGRAM AND LEGEND, SEE SECTION 7

TD T6 PA PB

T6 PB PA

USV

ESV

TU

TS

Figure 4-8 Defrost

T-3274--9

Defrost may be initiated any time the defrost temperature sensor reading falls below the controller defrost termination thermostat set point. Defrost will terminate when the defrost temperature sensor reading rises above thedefrost termination thermostat set point. The defrost termination thermostat is not a physical component. It is a controller setting that acts as a thermostat, closing (allowingdefrost) when thedefrost temperature sensor reading is below the set point and opening (terminating or preventing defrost) when the sensor temperature reading is above set point. When the unit is operating in bulb mode (refer to paragraph 3.3.9), special settings may be applicable. If the controller is programmed with the Lower DTT setting option the defrost termination thermostat set point may be configured to the default of 25.6_C (78_F) or lowered to 18_C (64_F). Whena request for defrost is made by use of the manual defrost switch, communications or probe check the unit will enter defrost if the defrost temperature thermostat reading is at or below the defrost termination thermostat setting. Defrost will terminate with the defrost temperature sensor reading rises above the defrost termination thermostat setting. When a request for defrost is made by the defrost intermale timer or by demand defrost, the defrost temperature setting settingmust be below 10_C (50_F). When the defrost mode is initiated the controller opens contacts TD, TN and TE (or TV) to de-energize the compressor, condenser fan and evaporator fans. The COOL light is also de--energized. The controller then closes TH to supply power to the heaters. The defrost light is illuminated. When the defrost temperature sensor reading rises to the defrost termination thermostat setting, the de--icing operation is terminated. If defrost does not terminate correctly and temperature reaches the set point of the heat termination thermostat (HTT) the thermostat will open to de--energize the heaters. If termination does not occur within 2.0 hours, the controller will terminate defrost. An alarm will be given of a possible DTS failure. If probe check (controller function code CnF31) is configured to special, the unit will proceed to the next operation (snap freeze or terminate defrost). If the code is configured to standard, the unit will perform a probe check. The purpose of the probe check is to detect malfunctions or drift in the sensed temperature that is too small to be detected by the normal sensor out of range tests. The system will run for eight minutes in this condition. At the end of the eight minutes, probe alarms will be set or cleared based on the conditions seen. When the return air falls to 7_C (45_F), the controller checks to ensure the defrost temperature sensor (DTS) reading has dropped to 10_C or below. If it has not, a DTS failure alarm is given and the defrost mode is operated by the return temperature sensor (RTS). If controller function code CnF33 is configured to snap freeze, the controller will sequence to this operation. The snap freeze consists of running the compressor without the evaporator fans in operation for a period of four minutes with the suction modulation valve fully open. When the snap freeze is completed, defrost is formally terminated.

4.10.6 Emergency Bypass Operation Toplace the unit in theemergency bypassmode, cut the wire tie installed at the switch mounting and place the EMERGENCY BYPASS switch in the ON position which will in turn activate the Emergency Bypass System (EBS) control module. To operate the fans only the MODE switch must be in the FANS ONLY position and the EMERGENCY BYPASS Switch must be in the ON position. TheEBSmodule uses the systems safety devices (high pressure switch, motor internal protectors, and heat termination thermostat) to protect the system while in Emergency Bypass Mode.

CAUTION

Theunit will remain in the full coolingmode as long as the emergency bypass switch is in the BYPASS position and the MODE SWITCH is in the FULL COOL position. If the cargo may be damaged by low tempera- tures, the operator must monitor container temperature and manually cycle operation as required to maintain temperature within required limits.

In the ON position the EBS will be enabled. With the MODE SWITCH in the FULL COOL MODE. The following will occur simultaneously:

1. The EBS switch will enable EBS input.

2. The phase detection circuit will detect the phase rotation and close to provide power to the compres- sor contactor.

3. The condenser fan contact will close to energize the condenser contactor and provide power to the con- denser fan motor.

4. The evaporator fan contact will close to energize the high speed evaporator contactor and provide power to the evaporator fan motor.

5. The EBS electronic module will open the SMV to 100%.

To return the unit to normal operation, place the EBS switch in the NORMAL OPERATION position. When emergency operation is no longer required, re--install the wire tie at the switch mounting.

5--1 T-327

SECTION 5 TROUBLESHOOTING

CONDITION POSSIBLE CAUSE REMEDY/

REFERENCE SECTION

5.1 UNIT WILL NOT START OR STARTS THEN STOPS

No power to unit

External power source OFF Turn on Start-Stop switch OFF or defective Check Circuit breaker tripped or OFF Check Autotransformer not connected 4.2.2

Loss of control power

Circuit breaker OFF or defective Check Control transformer defective Replace Fuse (F3A/F3B) blown Check Start-Stop switch OFF or defective Check

Component(s) Not Operating

Evaporator fan motor internal protector open 6.14 Condenser fan motor internal protector open 6.8 Compressor internal protector open 6.4 High pressure switch open 5.7 Heat termination thermostat open Replace Loss of communication with expansion module Check Wiring Malfunction of current sensor Replace

Compressor hums, but does not start

Low line voltage Check Single phasing Check Shorted or grounded motor windings 6.4 Compressor seized 6.4

5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING

Container Hot load Normal Defective box insulation or air leak Repair

Refrigeration System

Shortage of refrigerant 6.3 Evaporator coil covered with ice 5.6 Evaporator coil plugged with debris 6.12 Evaporator fan(s) rotating backwards 6.12/6.14 Defective evaporator fan motor/capacitor 6.15 Air bypass around evaporator coil Check Controller set too low Reset Compressor service valves or liquid line shutoff valve par- tially closed

Open valves completely

Dirty condenser 6.7 Compressor worn 6.4 Current limit (function code Cd32) set to wrong value 3.3.4 Suction modulation valve lost track of step count Power cycle Suction modulation valve malfunction 6.17 Economizer solenoid valve or TXV malfunction 6.11, 6.16 Unloader valve stuck open 6.16

5--2T-327

CONDITION POSSIBLE CAUSE REMEDY/

REFERENCE SECTION

5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING

Refrigeration System

Abnormal pressures 5.7 Abnormal temperatures 5.15 Abnormal currents 5.16 Controller malfunction 5.9 Evaporator fan or motor defective 6.14 Shortage of refrigerant 6.3 Suction modulation valve lost track of step count Power cycle Suction modulation valve malfunction 6.17 Compressor service valves or liquid line shutoff valve par- tially closed

Open valves completely

Economizer solenoid valve or TXV malfunction 6.11, 6.16 Unloader valve stuck open 6.16 Frost on coil 5.10

5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING

No operation of any kind

Start-Stop switch OFF or defective Check Circuit breaker OFF or defective Check External power source OFF Turn ON

No control power

Circuit breaker or fuse defective Replace Control Transformer defective Replace Evaporator fan internal motor protector open 6.14 Heat relay defective Check Heater termination thermostat open 6.12

Unit will not heat or has insuffi- cient heat

Heater(s) defective 6.12 Heater contactor or coil defective Replace Evaporator fan motor(s) defective or rotating backwards 6.12/6.14 Evaporator fan motor contactor defective Replace Controller malfunction 5.9 Defective wiring Replace Loose terminal connections Tighten Low line voltage 2.3

5.5 UNIT WILL NOT TERMINATE HEATING

Unit fails to stop heating

Controller improperly set Reset Controller malfunction 5.9 Heater termination thermostat remains closed along with the heat relay 6.12

5.6 UNIT WILL NOT DEFROST PROPERLY

Will not initiate defrost automatically

Defrost timer malfunction (Cd27) Table 3-5 Loose terminal connections Tighten/ Defective wiring Replace Defrost temperature sensor defective or heat termination thermostat open Replace

Heater contactor or coil defective Replace

5--3 T-327

CONDITION POSSIBLE CAUSE REMEDY/

REFERENCE SECTION

5.6 UNIT WILL NOT DEFROST PROPERLY -- Continued

Will not initiate defrost manually

Manual defrost switch defective Replace Defrost temperature sensor open 4.10.5

Initiates but relay (DR) drops out Low line voltage 2.3

Initiates but does not defrost Heater contactor or coil defective Replace Heater(s) burned out 6.12

Frequent defrost Wet load Normal

5.7 ABNORMAL PRESSURES (COOLING)

High discharge pressure

Condenser coil dirty 6.7 Condenser fan rotating backwards 6.8 Condenser fan inoperative 6.8 Refrigerant overcharge or noncondensibles 6.3 Discharge service valve partially closed Open Suction modulation valve malfunction 6.17

Low suction pressure

Faulty suction pressure transducer Replace Suction service valve partially closed Open Filter-drier partially plugged 6.10 Low refrigerant charge 6.3 Expansion valve defective 6.11 No evaporator air flow or restricted air flow 6.12 Excessive frost on evaporator coil 5.6 Evaporator fan(s) rotating backwards 6.14.3 Suction modulation valve malfunction 6.17

Suction and discharge pres- sures tend to equalize when unit is operating

Compressor operating in reverse 5.14

Compressor cycling/stopped Check

5.8 ABNORMAL NOISE OR VIBRATIONS

Compressor

Compressor start up after an extended shutdown Normal

Brief chattering when manually shut down Compressor operating in reverse 5.14 Loose mounting bolts or worn resilient mounts Tighten/Replace Loose upper mounting 6.4.1 step o. Liquid slugging 6.11 Insufficient oil 6.5

Condenser or Evaporator Fan

Bent, loose or striking venturi Check Worn motor bearings 6.8/6.14 Bent motor shaft 6.8/6.14

5--4T-327

CONDITION POSSIBLE CAUSE REMEDY/

REFERENCE SECTION

5.9 CONTROLLER MALFUNCTION

Will not control

Defective Sensor 6.21 Defective wiring Check Stepper motor suction modulation valve circuit malfunction 6.17 Low refrigerant charge 6.3

5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW

Evaporator coil blocked Frost on coil 5.6 Dirty coil 6.12

No or partial evaporator air flow

Evaporator fan motor internal protector open 6.14 Evaporator fan motor(s) defective 6.14 Evaporator fan(s) loose or defective 6.14 Evaporator fan contactor defective Replace

5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION

Low suction pressure with high superheat

Low refrigerant charge 6.3 External equalizer line plugged Open Wax, oil or dirt plugging valve or orifice Ice formation at valve seat 6.11

Superheat not correct 6.12.1 Power assembly failure

6.11 Loss of element/bulb charge Broken capillary Foreign material in valve

High suction pressure with low superheat

Superheat setting too low 6.11 External equalizer line plugged Ice holding valve open Open Foreign material in valve 6.11

Liquid slugging in compressor Pin and seat of expansion valve eroded or held open by foreign material

6.11 Fluctuating suction pressure

Improper bulb location or installation Low superheat setting

5.12 AUTOTRANSFORMER MALFUNCTION

Unit will not start

Circuit breaker (CB-1 or CB-2) tripped Check Autotransformer defective 6.18 Power source not turned ON Check 460 VAC power plug is not inserted into the receptacle 4.2.2

5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH

High discharge pressure Dirty coil

6.9 Noncondensibles

Condenser fan starts and stops Water pressure switch malfunction Check Water supply interruption Check

5--5 T-327

CONDITION POSSIBLE CAUSE REMEDY/

REFERENCE SECTION

5.14 COMPRESSOR OPERATING IN REVERSE

NOTE It is normal for the compressor to run in reverse for 15 seconds when the compressor has been off for 6 hours or more.

CAUTION Allowing thescroll compressor to operate in reverse formore than twominuteswill result in internal compressor damage. Turn the start--stop switch OFF immediately.

Electrical

Incorrect wiring of compressor

CheckIncorrect wiring of compressor contactor(s) Incorrect wiring of current sensor

5.15 ABNORMAL TEMPERATURES

High discharge temperature

Discharge temperature sensor drifting high Replace Failed economizer, TXV or solenoid valve Replace Plugged economizer, TXV or solenoid valve Replace Loose or insufficiently clamped sensor Replace

Low suction temperature

Discharge temperature sensor drifting low Replace Loose or insufficiently clamped sensor Replace Liquid injection valve failure Replace

5.16 ABNORMAL CURRENTS

Unit reads abnormal currents Current sensor wiring Check

6--1 T-327

SECTION 6

SERVICE

NOTE To avoid damage to the earths ozone layer, use a refrigerant recovery system whenever removing refriger- ant. When working with refrigerants you must comply with all local government environmental laws. In the U.S.A., refer to EPA section 608.

WARNING Never use air for leak testing. It has been de- termined that pressurized, mixtures of re- frigerant and air can undergo combustion when exposed to an ignition source.

6.1 SECTION LAYOUT

Service procedures are provided herein beginning with refrigeration system service, then refrigeration system component service, electrical system service, temperature recorder service and general service. Refer to the Table of Contents to locate specific topics.

6.2 MANIFOLD GAUGE SET

The manifold gauge set (see Figure 6-1) is used to determine system operating pressure, add refrigerant charge, and to equalize or evacuate the system.

OPENED (Backseated ) HAND VALVE

CLOSED (Frontseated) HAND VALVE

SUCTION PRESSURE GAUGE

DISCHARGE PRESSURE GAUGE

A B C

A. CONNECTION TO LOW SIDE OF SYSTEM B. CONNECTION TO EITHER:

REFRIGERANT CYLINDER OR OIL CONTAINER

C. CONNECTION TO HIGH SIDE OF SYSTEM

Figure 6-1 Manifold Gauge Set

When the suction pressure hand valve is frontseated (turned all the way in), the suction (low) pressure can be checked. When the discharge pressure hand valve is frontseated, the discharge (high) pressure can be checked. When both valves are open (all the way out), high pressure vapor will flow into the low side. When the suction pressure valve is open and the discharge pressure valve shut, the systemcan becharged. Oil can also be added to the system.

A R-134a manifold gauge/hose set with self-sealing hoses (see Figure 6-2) is required for service of the models covered within this manual. The manifold gauge/hose set is available from Carrier Transicold. (Carrier Transicold part number 07-00294-00, which includes items 1 through 6, Figure 6-2.) To perform service using the manifold gage/hose set, do the following:

a. Preparing Manifold Gauge/Hose Set For Use

1. If the manifold gauge/hose set is new or was exposed to the atmosphere it will need to be eva- cuated to remove contaminants and air as follows:

2. Back seat (turn counterclockwise )both field service couplings (see Figure 6-2) and midseat both hand valves.

3. Connect the yellow hose to a vacuum pump and re- frigerant 134a cylinder.

OPENED (Backseated ) HAND VALVE

CLOSED (Frontseated) HAND VALVE

SUCTION PRESSURE GAUGE

DISCHARGE PRESSURE GAUGE

To Low Side Access Valve

To High Side Access Valve

Red KnobBlue Knob

1

4 3

YELLOW

2

4 56

3 RED

3 BLUE

2

1. Manifold Gauge Set 2. Hose Fitting (0.5-16 Acme) 3. Refrigeration and/or Evacuation Hose . (SAE J2196/R-134a) 4. Hose Fitting w/O-ring (M14 x 1.5) 5. High Side Field Service Coupling 6. Low Side Field Service Coupling

Figure 6-2 R-134a Manifold Gauge/Hose Set

7. Evacuate to 10 inches of vacuum and then charge with R-134a to a slightly positive pressure of 0.1 kg/- cm@ (1.0 psig).

8. Front seat both manifold gauge set valves and dis- connect from cylinder. The gauge set is now ready for use.

6--2T-327

6.3 REFRIGERATION SYSTEM SERVICE

6.3.1 Service Connections

Thecompressor suction, compressor dischargeand the liquid line service valves (see Figure 6-3) are provided with a double seat and an access valve which enable servicing of the compressor and refrigerant lines. Turning the valve stem clockwise (all the way forward) will frontseat the valve to close off the line connection and open a path to the access valve. Turning the stem counterclockwise (all the way out) will backseat the valve to open the line connection and close off the path to the access valve.

With the valve stem midway between frontseat and backseat, both of the service valve connections are open to the access valve path.

For example, the valve stem is first fully backseated when connecting a manifold gauge to measure pressure. Then, the valve is opened 1/4 to 1/2 turn to measure the pressure.

VALVE FRONTSEATED (Clockwise)

VALVE BACKSEATED (Counterclockwise)

5

1

2 3

4

1. Line Connection 2. Access Valve 3. Stem Cap

4. Valve stem 5. Compressor Or Filter

Drier Inlet Connection

Figure 6-3 Service Valve

To connect the manifold gauge/hose set for reading pressures, do the following:

1. Remove service valve stem cap and check to make sure it is backseated. Remove access valve cap. (See Figure 6-3)

2. Connect the field service coupling (see Figure 6-2) to the access valve.

3. Turn the field service coupling knob clockwise, which will open the system to the gauge set.

4. To read system pressures: slightly midseat the ser- vice valve.

5. Repeat the procedure to connect the other side of the gauge set.

CAUTION To prevent trapping liquid refrigerant in the manifold gaugeset besure set is brought to suction pressure before disconnecting.

b. Removing the Manifold Gauge Set

1. While the compressor is still ON, backseat the high side service valve.

2. Midseat both hand valves on the manifold gauge set and allow the pressure in the manifold gauge set to be drawn down to low side pressure. This returns any liquid that may be in the high side hose to the system.

3. Backseat the low side service valve. Backseat both field service couplings and frontseat both manifold hand valves. Remove the couplings from the access valves.

4. Install both service valve stem caps and service port caps (finger-tight only).

6.3.2 Pumping Down the Unit

To service the filter-drier, economizer, high pressure switch, expansion valves, suction modulation valve, economizer solenoid valve, unloader solenoid valve or evaporator coil, pump the refrigerant into the high side as follows:

CAUTION The scroll compressor achieves low suc- tion pressure very quickly. Do not operate the compressor in a deep vacuum, internal damage will result.

a. Attach manifold gauge set to the compressor suction anddischarge service valves. Refer to paragraph6.2.

b. Start the unit and run in the frozen mode (controller set below --10 degrees C (14 degrees F) for 10 to 15 minutes.

c. Check function codeCd21 (refer to paragraph 3.2.2). The economizer solenoid valve should be open. If not, continue to run until the valve opens.

d. Frontseat the liquid line service valve. Place start-- stop switch in the OFF position when the suction reaches a positive pressure of 0.1 kg/cm@ (1.0 psig).

e. Run unit until the controller shuts the compressor down due to low pressure. Place the START/STOP switch in the OFF position and close the discharge valve when discharge pressure reaches 1--2 psi. The refrigerant will be trapped between the compressor discharge service valves and the liquid line valve.

f. Before opening up any part of the system, a slight positive pressure should be indicatedon thepressure gauge. If a vacuum is indicated, emit refrigerant by cracking the liquid line valvemomentarily to build upa slight positive pressure.

g. 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.

h. After repairs have been made, be sure to perform a refrigerant leak check (refer to paragraph 6.3.3), and evacuate and dehydrate the low side (refer to para- graph 6.3.5).

i. Check refrigerant charge (refer to paragraph 6.3.6).

6--3 T-327

6.3.3 Refrigerant Leak Checking

WARNING Never use air for leak testing. It has been determined that pressurized, air-rich mix- tures of refrigerants and air can undergo combustion when exposed to an ignition source.

a. The recommended procedure for finding leaks in a system is with a R-134a electronic leak detector. Testing joints with soapsuds is satisfactory only for locating large leaks.

b. If the system iswithout refrigerant, charge the system with refrigerant 134a to build uppressure between2.1 to 3.5 kg/cm@ (30 to 50 psig). To ensure complete pressurization of the system, refrigerant should be charged at the compressor suction valves and the liq- uid line service valve. Also, the area between the suc- tion modulating valve and evaporator expansion valvemay not beopen to these charging points. Pres- sure between these components may be checked at the low side access valve (item 11, Figure 2-2) or by checking that the suction modulating valve is more than 10% open at controller function code Cd01. The suction modulating valve may be opened by use of the controller function code Cd41 valve override con- trol (refer to paragraph 6.16). Remove refrigerant cyl- inder and leak-check all connections.

NOTE Only refrigerant 134a should be used to pres- surize the system. Any other gas or vapor will contaminate the system, which will require additional purging and evacuation of the sys- tem.

c. If required, remove refrigerant using a refrigerant recovery system and repair any leaks. Check for leaks.

d. Evacuate anddehydrate theunit. (Refer to paragraph 6.3.5.)

e. Charge unit per paragraph 6.3.6.

6.3.4 Refrigerant Recovery To remove the refrigerant for service, do the following:

a. Connect the three access valves (discharge, liquid and suction) to the refrigerant recovery unit as shown inFigure 6-4. Following the refrigerant recov- ery unit manufacturers instructions, start the recov- ery process.

b. Toensure complete removal of refrigerant, check that the suction modulating valve is more than 10% open at controller function code Cd01. If required, the suc- tion modulating valve may be opened by use of con- troller function code Cd41 valve override control.

c. Break the vacuum and bring the system to a slight positive pressure using dry nitrogen. When refriger- ant is fully recovered, remove the refrigerant recovery unit.

d. Perform repairs as required and then leak test, evac- uate, charge and reseal unit in accordance with the following paragraphs.

6.3.5 Evacuation and Dehydration

General

Moisture is detrimental to refrigeration systems. The presence of moisture in a refrigeration system can have many undesirable effects. The most common are copper plating, acid sludge formation, freezing-up of metering devices by free water, and formation of acids, resulting in metal corrosion.

Preparation

a. Evacuate anddehydrate only after pressure leak test.

b. Essential tools to properly evacuate and dehydrate any system include a vacuum pump (8 m3/hr = 5 cfm volume displacement) and an electronic vacuum gauge. (The pump and gauge are available fromCar- rier Transicold. The pump is part number 07-00176-11 and the gauge is part number 07--414--00 .)

c. If possible, keep the ambient temperature above 15.6 degrees C (60 degrees F) to speed evaporation of moisture. If the ambient temperature is lower than 15.6 degrees C (60 degrees F), icemight form before moisture removal is complete. Heat lamps or alter- nate sources of heat may be used to raise the system temperature.

d. Additional time may be saved during a complete sys- tem pump down by replacing the filter-drier with a section of copper tubing and the appropriate fittings. Installation of a new drier may be performed during the charging procedure.

4

DS

10 8

9 6

7

1

5

32

1. Liquid Service Con- nection. 2. Receiver or Water

Cooled Condenser 3. Compressor 4. Discharge Service

Connection

5. Suction Service Con- nection 6. Vacuum Pump 7. Electronic Vacuum

Gauge 8. Manifold Gauge Set 9. Refrigerant Cylinder 10. Reclaimer

Figure 6-4 Refrigeration System Service Connections

6--4T-327

Procedure - Complete system

NOTE Refer to Partial System procedure for informa- tion pertaining to partial system evacuation and dehydration.

a. Remove all refrigerant using a refrigerant recovery system.

b. The recommended method to evacuate and dehy- drate the system is to connect evacuation hoses at the compressor suction, discharge port and liquid line service valve (see Figure 6-4). Be sure the service hoses are suited for evacuation purposes.

c. The area between the suction modulating valve and evaporator expansion valve may not be open to the access valves. To ensure evacuation of this area, check that the suction modulating valve is more than 10% open at controller function code Cd01. If re- quired, the suction modulating valve may be opened by use of the controller function code Cd41 valve override control. If power is not available to open the valve, the area may be evacuated by connecting an additional hose at the low side access valve (item 11, Figure 2-2).

d. Test the evacuation setup for leaks by backseating the unit service valves and drawing a deep vacuum with the vacuum pump and gauge valves open. Shut off the pump and check to see if the vacuum holds. Repair leaks if necessary.

e. Midseat the refrigerant system service valves.

f. Open the vacuum pump and electronic vacuum gauge valves, if they are not already open. Start the vacuum pump. Evacuate unit until the electronic vac- uum gauge indicates 2000 microns. Close the elec- tronic vacuum gauge and vacuum pump valves. Shut off the vacuum pump. Wait a few minutes to be sure the vacuum holds.

g. Break the vacuum with clean dry refrigerant 134a gas.Raisesystempressure toapproximately 0.2kg/- cm@ (2 psig), monitoring it with the compound gauge.

h. Remove refrigerant using a refrigerant recovery sys- tem.

i. Repeat steps f.and g. one time.

j. Remove the copper tubing and change the filter-drier. Evacuate unit to 500 microns. Close the electronic vacuumgaugeandvacuumpumpvalves. Shut off the vacuum pump. Wait five minutes to see if vacuum holds. This procedure checks for residual moisture and/or leaks.

k. With a vacuum still in the unit, the refrigerant charge may be drawn into the system from a refrigerant con- tainer on weight scales.

Procedure - Partial System

a. If refrigerant charge has been removed from the low side only, evacuate the low side by connecting the evacuation set--upat the compressor suction anddis- charge service valves and the liquid service valve ex- cept leave the service valves frontseated until evacu- ation is completed.

b. Once evacuation has been completed and the pump has been isolated, fully backseat the service valves to

isolate the service connections and then continue with checking and, if required, adding refrigerant in accordance with normal procedures.

6.3.6 Refrigerant Charge Checking the Refrigerant Charge

NOTE To avoid damage to the earths ozone layer, use a refrigerant recovery system whenever remov- ing refrigerant. When working with refrigerants youmust complywith all local government envi- ronmental laws. In the U.S.A., refer to EPA sec- tion 608.

a. Connect the gauge manifold to the liquid and suction access valves. For units operating on a water cooled condenser, change over to air cooled operation.

b. Bring the container temperature to approximately --17.8 degrees C (0 F). Then set the controller set point to --25 degreesC (--13degrees F) to ensure that the suctionmodulation valve is fully open. Also, check function codeCd21. The economizer valve should be open. If ambient is between 16 degrees C (60 de- grees F) and 49 degrees C (120 degrees F), proceed to step d.

c. If ambient is below 16 degrees C (60 degrees F), par- tially block the condenser coil inlet air. Increase the area blocked until the compressor discharge pres- sure is raised to approximately 12 kg/cm@ (175 psig).

d. On units equippedwith a receiver, the level should be between the glasses. On units equipped with a water cooled condenser, the level should be at the center of the glass. If the refrigerant level is not correct, contin- ue with the following paragraphs to add or remove re- frigerant as required.

6.3.7 Adding Refrigerant to System (Full Charge) a. Evacuate unit and leave in deep vacuum.

b. Place cylinder of R-134a on scale and connect charg- ing line from cylinder to liquid line valve. Purge charg- ing line at liquid line valve and then note weight of cyl- inder and refrigerant.

c. Open liquid valve on cylinder and allow the liquid refrigerant to flow into theunit until the correct amount of refrigerant has been added.

d. Close liquid valve on cylinder.

e. Start unit in coolingmode. Runapproximately 10min- utes and check the refrigerant charge.

f. On units equippedwith a receiver, the level should be between the glasses. On units equipped with a water cooled condenser, the level should be at the center of the glass. If the refrigerant level is not correct, go to section 6.3.8.

6.3.8 Adding Refrigerant to System (Partial Charge)

a. Examine the unit refrigerant system for any evidence of leaks. Repair as necessary.

b. Maintain the conditions outlined in paragraph 6.4.5.

c. Connect charging line between suction line and cylin- der of refrigerant R-134a. Open VAPOR valve.

d. Slowly add charge until the liquid appears at theprop- er level.

6--5 T-327

6.4 COMPRESSOR

WARNING Make sure power to the unit is OFF and power plug disconnected before replacing the compressor.

WARNING Before disassembly of the compressor make sure to relieve the internal pressure verycarefullyby slightly loosening thecou- plings to break the seal.

CAUTION The scroll compressor achieves low suc- tion pressure very quickly. Do not use the compressor to evacuate the system below zero psig. Never operate the compressor with thesuction ordischargeservicevalves closed (frontseated). Internal damage will result from operating the compressor in a deep vacuum.

6.4.1 Removal and Replacement of Compressor

NOTE Service compressor contains a nitrogen charge. Due to thehygroscopic nature of theoil, time the compressor is left open to the atmo- sphere should be minimized as much as pos- sible.

a. Procure a replacement compressor kit. A list of items contained in the compressor kit is provided in Table 6-1.

Table 6-1 Compressor Kit Item Component Qty 1 Compressor 1 2 Service Connection Seal 3 3 Mylar Washers 4 4 Wire Tie 2 5 Resilient Mount 4 6 Upper Shock Mount Ring 1 7 Upper Shock Mount Bushing 1 8 Compressor Power Plug O--Ring 1 9 SST Washers 8 10 Oil --Mobil 32ST (32 oz can) 2 11 Oil Charge Warning Tag 1 12 Schrader valve/ valve body* 1 13 Mylar Protector 1

* Schrader valve is not used on all units

b. Turn the unit start--stop switch (ST) and unit circuit breaker (CB--1) OFF. Using a refrigerant reclaim sys- tem, remove the refrigerant charge. Refer to section 6.3.4.

c. Make sure power to the unit is OFF and unit power plug disconnected. Disconnect the power plug from the compressor.

d. Loosen and break the seal at fittings from the suction, discharge and the economizer service connections. Remove fittings and discard service valve seals, re- tain oil fitting O--ring.

NOTE Use an oil catch can or basin to minimize spillage when removing the compressor oil drain port on units with semi--hermetic refrigerant circuits.

e. Remove the entire compressor upper mounting bracket assembly,(see Figure 6-5) by removing the four cap screws attaching it to theunit and the32--mm bolt from the compressor mounting bracket.

Upper Shock Mount Bushing (Kit Item 7)

Upper Shock Mount Ring (Kit Item 6)

Shoulder Bolt

32mm Bolt

Mylar Protector (Kit Item 13 )

9.5 mm

(0.375 in)

Figure 6-5 Compressor Upper Mounting f. Replace the uppermounting bracket shockmount ring , Mylar protector and bushing (kit items 6, 13 and 7). Re- assemble the bracket in the samemanner as the origi- nal and torque the shoulder bolt to 2.8 mkg (20 ft--lbs).

Resilient Mount (Kit Item 5)

Mylar Washer (Kit Item 3)

Mylar Protector (Retain)

Base Plate (Retain)

Mylar Protector (Retain)

SST Washer (Kit Item 9)

SST Washer (Kit Item 9)

Figure 6-6 Compressor Lower Mounting g. Remove the lower mounting bolts and hardware (see Figure 6-6). Using plugs from replacement compres-

6--6T-327

sor, plug connections on old compressor. Remove the old compressor from the unit. Refer to paragraph 2.2 for compressor weight. Return plugs to replace- ment compressor.

NOTE Schrader valve should be installed on the new compressor, ONLY if the old (removed) com- pressor was equipped with a Schrader valve.

h. The replacement compressor is shipped with an oil charge of 591ml (20 ounces). Before sliding the new compressor in theunit, remove the oil sight glass plug and (using a small funnel) charge the compressor with an additional 1893ml (64 ounces) Mobil 32ST (POE oil). Reassemble the oil sight glass plug, Torque to 2.5--3.0 mkg (18--22 ft--lbs).

i. Secure the base plate and Mylar protectors to the compressor with wire ties (kit item 4), and place the compressor in the unit by tilting it to the right.

j. Cut and remove the wire ties that were used to hold the base plate and protectors to the compressor. Us- ing new resilient mounts, SST washers and Mylar washers (kit items 3, 5 & 9). Install the four mounting screws loosely.

k. Place the new service seals, the compressor service ports, connect the three service fittings loosely.

l. Torque the four resilient mount screws to 6.2 mkg (45 ft--lbs).

m.Torque the three compressor fittings to: Connection Type Torque

Suction or Discharge Service Valve

11 to 13.8 mkg (80 to 100 ft--lbs.)

Economizer Fitting 6.9 to 8.3 mkg (50 to 60 ft--lbs.)

n. Reassemble the top mounting bracket (see Figure 6-5) by hand tightening the32--mm (1 --inch) bolt and torquing the four mounting screws to 0.9 mkg (6.5 ft--lbs). Align the mounting so that the ring and bushing assembly are freewith no compression.

o. Torque the 32mm bolt to 1.5 mkg (11 ft--lbs.). While maintaining the free movement of the shock mount, torque the four mounting screws to 0.9 mkg (6.5 ft--- lbs.).

p. Ensure theO--Ring in the compressor power plug is in place. If necessary, replace the power plug O--Ring with new ring (kit item 8). Insert the power plug into the compressor fitting. Be sure plug is fully seated into the fitting and then thread the coupling nut aminimum of 5 turns.

q. Leak check and evacuate the unit. Charge the unit per sections 6.3.5 and 6.3.6.

r. Run the unit for at least 15 minutes and check the oil and refrigerant levels.

6.5 COMPRESSOR OIL LEVEL

CAUTION Use only Carrier Transicold approved Polyol Ester Oil (POE) -- Mobil 32ST com- pressor oil with R-134a. Buy in quantities of one quart or smaller. When using this hygroscopic oil, immediately reseal. Do not leave container of oil open or contamina- tion will occur.

NOTE Use an oil catch can or basin to minimize spill- age when removing the compressor oil drain port.

a. Checking the Oil Level in the Compressor 1 Ideally, ambient temperature should be between

4.4 and 37.8 degrees C (40 and 100 degrees F).

2 Operate the unit in cooling mode for at least 20 min- utes.

3 Check the controller function code Cd1 for the suc- tion modulation valve (SMV) position. It should be at least 20% open.

4 Locate the oil sight glass on the side of the compres- sor (item 6, Figure 2-3). Oil level must be visible in the sight glass. If it is not visible, oil must be added to the compressor.

b. Adding Oil with Compressor in System 1. Remove refrigerant charge. Add oil using an oil

pump at the suction connection.

2. Leak check, evacuate and recharge system

3. Run unit for 20 minutes and check oil level in the sight glass.

c. Removing Oil from the Compressor 1. If the oil level is above the sight glass, oil must be

removed from the compressor.

2. Remove the refrigerant charge.

3. Remove the oil plug, and drain oil until a level can be seen in the sight glass. Evacuate and recharge unit.

4. Run unit for 20 minutes in cooling mode. Check oil level at the compressor sight glass.

6.6 HIGH PRESSURE SWITCH

6.6.1 Replacing High Pressure Switch a. Pump down the unit (refer to paragraph 6.3.2).

Remove the refrigerant from the unit (refer to para- graph 6.3.4).

b. Disconnect wiring from defective switch. The high pressure switch is located on the discharge service valve and is removed by turning counterclockwise. (See Figure 2-3)

c. Install a new high pressure switch after verifying switch settings. (Refer to paragraph 6.6.2)

d. Evacuate, dehydrate and recharge.

e. Start unit, verify refrigeration charge and oil level.

6--7 T-327

6.6.2 Checking High Pressure Switch

WARNING Do not use a nitrogen cylinder without a pressure regulator. Do not use oxygen in or near a refrigeration system as an explosion may occur.

NOTE The high pressure switch is non-adjustable.

a. Remove switch as outlined in paragraphs 6.6.1.

b. Connect ohmmeter or continuity light across switch terminals. Ohm meter will indicate no resistance or continuity light will be illuminated if the switch closed after relieving compressor pressure.

c. Connect hose to a cylinder of dry nitrogen. (See Figure 6-7.)

1. Cylinder Valve and Gauge

2. Pressure Regulator 3. Nitrogen Cylinder 4. Pressure Gauge

(0 to 36 kg/cm@ = 0 to 400 psig)

5. Bleed-Off Valve 6. 1/4 inch Connection

1

2

3

4

5

6

Figure 6-7 High Pressure Switch Testing

d. Set nitrogen pressure regulator at 26.4 kg/cm@ (375 psig) with bleed-off valve closed.

e. Close valve on cylinder and open bleed-off valve.

f. Open cylinder valve. Slowly close bleed-off valve to increase pressure on switch. The switch should open at a static pressure up to 25 kg/cm@ (350 psig). If a light is used, light will go out. If an ohmmeter is used, the meter will indicate open circuit.

g. Slowly open bleed-off valve to decrease the pres- sure. The switch should close at 18 kg/cm@ (250 psig).

6.7 CONDENSER COIL

The condenser consists of a series of parallel copper tubes expanded into copper fins. The condenser coil must be cleanedwith freshwater or steamso theair flow is not restricted. To replace the coil, do the following:

WARNING Do not open the condenser fan grille before turning power OFF and disconnecting power plug.

a. Usinga refrigerant reclaim system, remove the refrig- erant charge.

b. Remove the condenser coil guard.

c. Unsolder discharge line and remove the line to the receiver or water-cooled condenser.

d. Remove coil mounting hardware and remove the coil.

e. Install replacement coil and solder connections.

f. Leak-check the coil connections per paragraph para- graph 6.3.3. Evacuate the unit then charge the unit with refrigerant.

6.8 CONDENSER FAN AND MOTOR ASSEMBLY

WARNING Do not open condenser fan grille before turning power OFF and disconnecting power plug.

The condenser fan rotates counter-clockwise (viewed from front of unit), pulls air through the the condenser coil, and discharges horizontally through the front of the unit. To replace motor assembly:

a. Open condenser fan screen guard.

b. Loosen two square head set screws on fan. (Thread sealer has been applied to set screws at installation.) Disconnect wiring from motor junction box.

CAUTION Take necessary steps (place plywood over coil or use sling onmotor) to preventmotor from falling into condenser coil.

c. Remove motor mounting hardware and replace the motor. It is recommended that new locknuts be used when replacing motor. Connect wiring per wiring dia- gram.

d. Install fan loosely on motor shaft (hub side in). DO NOTUSEFORCE. If necessary, tap thehub only, not the hub nuts or bolts. Install venturi. Apply Loctite H to fan set screws. Adjust fanwithin venturi so that the outer edge of the fan is within 2.0 +/-- 0.07 mm (0.08 +/-- 0.03) from the outside of the orifice open- ing. Spin fan by hand to check clearance.

e. Close and secure condenser fan screen guard.

f. Apply power to unit and check fan rotation. If fan motor rotates backward, reverse wire numbers 5 and 8.

6.9 WATER COOLED CONDENSER CLEANING

The water-cooled condenser is of the shell and coil type with water circulating through the cupro-nickel coil. The refrigerant vapor is admitted to the shell side and is condensed on the outer surface of the coil.

Rust, scale and slime on the water-cooling surfaces inside of the coil interfere with the transfer of heat, reduce system capacity, cause higher head pressures and increase the load on the system.

By checking the leaving water temperature and the actual condensing temperature, it can be determined if the condenser coil is becoming dirty. A larger than

6--8T-327

normal difference between leaving condensing water temperature and actual condensing temperature, coupled with a small difference in temperature of entering and leaving condensing water, is an indication of a dirty condensing coil.

To find the approximate condensing temperature, with the unit running in the cooling mode, install a gauge 0 to 36.2 kg/cm@ (0 to 500 psig) on the compressor discharge service valve.

Example: Discharge pressure is 10.3 kg/cm@ (146.4 psig). Referring to Table 6-7 (R-134a pressure/ temperature chart), the 10.3 kg/cm@ (146.4 psig) value converts to 43 degrees C (110 degrees F).

If the water-cooled condenser is dirty, it may be cleaned and de-scaled by the following procedure:

a. Turn unit off and disconnect main power.

b. Disconnect water pressure switch tubing by loosen- ing the two flare nuts. Install one-quarter inch flare cap on water-cooled condenser inlet tube (replaces tubing flare nut). De-scale tubing if necessary.

What You Will Need:

1. Oakite composition No. 22, available as a powder in 68 kg (150 lb) and 136 kg (300 lb) containers.

2. Oakite composition No. 32, available as a liquid in cases, each containing 3.785 liters (4 U.S. gallon) bottles and also in carboys of 52.6 kg (116 lbs) net.

3. Fresh clean water.

4. Acid proof pump and containers or bottles with rub- ber hose.

NOTE When Oakite compound No. 32 is being used for the first time, the localOakite Technical Ser- vice representative should be called in for their suggestions in planning the procedure. They will advise the reader onhow to do theworkwith a minimum dismantling of equipment: how to estimate the time and amount of compound required; how to prepare the solution; how to control and conclude the de-scaling operation by rinsing and neutralizing equipment before putting it back into service. Their knowledge of metals, typesofscale,waterconditionsandde-- scaling techniques will be highly useful .

Summary of Procedure:

a. Drain water from condenser tubing circuit. Clean water tubes with Oakite No. 22 to remove mud and slime.

b. Flush.

c. De-scale water tubes with Oakite No. 32 to remove scale.

d. Flush.

e. Neutralize.

f. Flush.

g. Put unit back in service under normal load and check head (discharge) pressure.

Detailed Procedure: 1. Drain and flush the water circuit of the condenser

coil. If scale on the tube inner surfaces is accompa- nied by slime, a thorough cleaning is necessary before de-scaling process can be accomplished.

2. To removeslimeormud, useOakite compositionNo. 22. Mixed 170 grams (6 ounces) per 3.785 liters (1 U.S. gallon) of water. Warm this solution and circu- late through the tubes until all slime and mud has been removed.

3. After cleaning, flush tubes thoroughly with fresh clean water.

4. Prepare a 15% by volume solution for de-scaling, by diluting Oakite compound No. 32 with water. This is accomplishedby slowly adding0.47 liter (1 U.S. pint) of the acid (Oakite No. 32) to 2.8 liters (3 U.S. quarts) of water.

WARNING Oakite No. 32 is an acid. Be sure that the acid is slowly added to the water. DO NOT PUT WATER INTO THE ACID -- this will cause spattering and excessive heat.

WARNING Wear rubber gloves and wash the solution from the skin immediately if accidental con- tact occurs. Do not allow the solution to splash onto concrete.

5. Fill the tubes with this solution by filling from the bot- tom. See Figure 6-8. Important: be sure to provide a vent at the top for escaping gas.

Centrifugal pump 30 GPM at 35 head

Pump

Suction

Pump support

Tank

Fine mesh screen

Return

Remove water regulating valve

Condenser

Globe valves

Vent Close vent pipe valve when pump is running.Priming

connection

Figure 6-8 Water-Cooled Condenser Cleaning -- Forced Circulation

6. Allow the Oakite No. 32 solution to soak in the tube coils for several hours, periodically pump-circulating it with an acid-proof pump.

An alternate method may be used whereby a pail (see Figure 6-9) filled with the solution and attached to the coils by ahose can serve the same purposeby

6--9 T-327

filling and draining. The solution must contact the scale at every point for thorough de-scaling. Air pockets in the solution should be avoided by regu- larly opening the vent to release gas. Keep flames away from the vent gases.

7. The time required for de-scalingwill vary, depending upon the extent of the deposits. One way to deter- mine when de-scaling has been completed is to titrate the solution periodically, using titrating equip- ment provided free by the Oakite Technical Service representative. As scale is being dissolved, titrate readings will indicate that the Oakite No. 32 solution is losing strength. When the reading remains constant for a reasonable time, this is an indication that scale has been dissolved.

Fill condenser with clean- ing solution. Do not add solution more rapidly than vent can exhaust gases caused by chemical action.

Condenser

Vent pipe

1 Pipe

5 Approximate

3 to 4

Figure 6-9 Water Cooled Condenser Cleaning - Gravity Circulation

8. When de-scaling is complete, drain the solution and flush thoroughly with water.

9. Following the water flush, circulate a 56.7 gram (2 ounce) per 3.785 liter (1 U.S. gallon) solution of Oakite No. 22 thru the tubes to neutralize. Drain this solution.

10.Flush the tubes thoroughly with fresh water.

NOTE If the condenser coolingwater is not beingused as drinking water or is not re-circulated in a closed or tower system, neutralizing is not nec- essary.

11 Put the unit back in service and operate under nor- mal load. Check theheadpressure. If normal, a thor- ough de-scaling has been achieved.

What You Can Do For Further Help:

Contact the Engineering and Service Department of the OAKITE PRODUCTS CO., 675 Central Avenue, New Providence, NJ 07974 U.S.A. (or visit www.oakite.com) for the name and address of the service representative in your area.

6.10 FILTER-DRIER

On units equipped with a water-cooled condenser, if the sight glass appears to be flashing or bubbles are constantly moving through the sight glass when the suctionmodulation valve is fully open, theunit may have a low refrigerant charge or the filter-drier could be partially plugged.

a. To Check Filter-Drier

1. Test for a restricted or plugged filter-drier by feeling the liquid line inlet and outlet connections of the drier cartridge. If the outlet side feels cooler than the inlet side, then the filter-drier should be changed.

2. Check the moisture-liquid indicator if the indicator shows a high level of moisture, the filter-drier should be replaced.

b. To Replace Filter-Drier

1. Pump down the unit (refer to paragraph 6.3.2). Then replace filter-drier.

2. Evacuate the low side in accordance with paragraph 6.3.5.

3. After unit is in operation, inspect for moisture in sys- tem and check charge.

6.11 EXPANSION VALVES

Three expansion valves are used, the evaporator expansion valve (item 8, Figure 2-2), the quench expansion valve (item 10, Figure 2-2) and the economizer expansion valve (item 21, Figure 2-4). The expansion valves are automatic devices whichmaintain constant superheat of the refrigerant gas leaving at the point of bulb attachment regardless of suction pressure.

The valve functions are:

1. Automatic control of the refrigerant flow to match the load.

2. Prevention of liquid refrigerant entering the com- pressor.

Unless the valve is defective, it seldom requires maintenance other than periodic inspection to ensure that the thermal bulb is tightly secured to the suction line and wrapped with insulating compound. (See Figure 6-10)

1

2

3

4

1. Suction Line 2. TXV Bulb Clamp 3. Nut and Bolt 4. TXV Bulb

Figure 6-10 Thermostatic Expansion Valve Bulb

6--10T-327

Copper Tube (Apply heat for 10-15 seconds)

Bi-metallic Tube Connection (Apply heat for 2-5 seconds) Use of a wet cloth is not neces-

sary due to rapid heat dissipation of the bi--metallic connections

Braze Rod (Sil-Phos = 5.5% Silver, 6% Phosphorus)

Figure 6-11 Hermetic Thermostatic Expansion Valve Brazing Procedure

6.11.1 Checking Superheat

NOTE Proper superheat measurement for the evapo- rator expansion valve should be completed at --18 degrees C (0 F) container box tempera- ture where possible. If the economizer or quench valve is suspect, it should be replaced.

a. Open the heater access panel (see Figure 2-1) to ex- pose the evaporator expansion valve.

b. Attach a temperature sensor near the expansion valve bulb and insulate. Make sure the suction line is clean and that firm contact is made with the sensor.

c. Connect an accurate gauge to the service port direct- ly upstream of the suction modulating valve.

d. Set the temperature set point to --18degreesC (0 F), and run unit until conditions stabilize.

e. The readings may cycle from a high to a low reading. Take readings of temperature and pressure every three to five minutes for a total of 5 or 6 readings

f. From the temperature/pressure chart (Table 6-7), de- termine the saturation temperature corresponding to the evaporator outlet test pressures at the suction modulation valve.

g. Subtract the saturation temperatures determined in step f. from the temperatures measured in step e.. The difference is the superheat of the suction gas. Determine the average superheat It should be 4.5 to 6.7 degrees C (8 to 12 degrees F).

6.11.2 Valve Replacement a. Removing the Expansion Valve

NOTES

The TXVs are hermetic valves and do not have adjustable superheat.

All connections on the evaporator TXV are bi--- metallic, copper on the inside and stainless on the outside. When brazing, bi--metallic connec- tions heat up very quickly.

1

6

5

4 3

2

1. Evaporator Expansion Valve 2. Non-adjustable Superheat Stem 3. Equalizer Connection 4. Inlet Connection 5. Outlet Connection 6. Expansion Valve Bulb

Figure 6-12 Evaporator Expansion Valve

INLET

OUTLET

Figure 6-13 Quench & Economizer Expansion Valves

1. Pump down the unit per paragraph 6.3.2.

2. Removecushion clamps locatedon the inlet andout- let lines.

3. Unbraze the equalizer connection (if applicable), the outlet connection and then the inlet connection.

4. Remove insulation (Presstite) from expansion valve bulb.

6--11 T-327

5. Unstrap the bulb, located below the center of the suction line (4 oclock position), and remove the valve.

b. Installing the Expansion Valve

1. Clean the suction line with sandpaper before instal- ling bulb to ensure proper heat transfer. Apply ther- mal grease to the indentation in the suction line.

2. Strap the thermal bulb to the suction line, making sure bulb is placed firmly into the suction line. See Figure 6-10 for bulb placement.

3. Insulate the thermal bulb.

4. The economizer and quench valves should be wrapped in a soaked cloth for brazing. For the evap- orator valve, see Figure 6-11. Braze inlet connection to inlet line.

5. Braze outlet connection to outlet line.

6. Reinstall the cushion clamps on inlet and outlet lines.

7. If applicable, braze the equalizer connection to the equalizer line.

8. Check superheat (refer to step 6.11.1).

6.12 EVAPORATOR COIL AND HEATER ASSEMBLY

The evaporator section, including the coil, should be cleaned regularly. The preferred cleaning fluid is fresh water or steam. Another recommended cleaner is Oakite 202 or similar, following manufacturers instructions.

The two drain pan hoses are routed behind the condenser fan motor and compressor. The drain pan line(s) must be open to ensure adequate drainage.

6.12.1 Evaporator Coil Replacement

a. Pump unit down. (Refer to paragraph 6.3.2.)

b. With power OFF and power plug removed, remove the screws securing the panel covering the evapora- tor section (upper panel).

c. Disconnect the defrost heater wiring.

d. Disconnect the defrost temperature sensor (see Figure 2-2 from the coil.

e. Remove middle coil support.

f. Remove the mounting hardware from the coil.

g. Unsolder the two coil connections, one at the distribu- tor and the other at the coil header.

h. After defective coil is removed from unit, remove defrost heaters and install on replacement coil.

i. Install coil assembly by reversing above steps.

j. Leak check connections. Evacuate and add refriger- ant charge.

6.12.2 Evaporator Heater Replacement

a. Before servicingunit, makesure theunit circuit break- ers (CB-1 & CB-2) and the start-stop switch (ST) are in theOFFposition, and that thepower plugandcable are disconnected.

b. Remove the lower access panel (Figure 2-1) by removing the T.I.R. locking device lockwire and mounting screws.

c. Determine which heater(s) need replacing by check- ing resistance on each heater. Refer to paragraph2.3 for heater resistance values.

d. Remove hold-down clamp securing heaters to coil.

e. Lift the bent end of the heater (with the opposite end down and away from coil). Move heater to the side enough to clear the heater end support and remove.

6.13 ECONOMIZER, LIQUID INJECTION AND UN- LOADER VALVES

a. Replacing the Coil

NOTE The coil may be replaced without removing the refrigerant.

1. Be sure electrical power is removed from the unit. Disconnect leads. Remove top screw and washer. Lift off coil. (See Figure 6-14 or Figure 6-15).

2. Verify coil type, voltageand frequency of old andnew coil. This information appears on the coil housing.

b. Replacing Valve Internal Parts (Unloader Solenoid Only)

1. Pump down the unit. Refer to paragraph 6.3.2. Eva- cuate if unit is not equipped with service valves. Re- fer to paragraph 6.4.4.

2. Be sure electrical power is removed from the unit. Disconnect leads. Remove top screw and washer. Lift off coil. (See Figure 6-14)

3. Remove the top screw (see Figure 6-14), washer, and coil assembly.

4. Loosen the enclosing tube locknut.

5. Remove enclosing tube and locknut assembly. The gasket is inside the enclosing tube.

6. Remove seat disc from inside of body and check for obstructions and foreign material.

7. Place theseat disc into thevalvebodywith thesmall- er diameter end facing up.

8. Install stem and plunger.

9. Place the enclosing tube locknut over the enclosing tube. Install spacer over enclosing tube making sure it is seated properly in the enclosing tube locknut. Tighten enclosing tube locknut to a torque value of 2.78 mkg (20 ft-lb). Do not overtighten.

10.Install coil assembly, washer and top screw.

11.Evacuate and dehydrate the system. Charge unit with refrigerant per section 6.3.6.

12.Start unit and check operation.

c. Replacing Valve

1. To replace the unloader or economizer valve, pump down the unit. Refer to paragraph 6.3.2.

2. Be sure electrical power is removed from the unit. Disconnect leads. Remove top screw and washer. Lift off coil. (See Figure 6-14 or Figure 6-15)

3. Unbraze valve from unit and braze new valve in place

4. Install coil. Evacuate low side and place unit back in operation. Check charge

6--12T-327

1

9

8

7

6

5

4

3

2

1. Top Screw 2. Washer 3. Coil 4. Locknut 5. Enclosing Tube

6. Gasket 7. Stem and Plunger 8. Seat Disc 9. Body

Figure 6-14 Unloader Solenoid Valve

1

2

3

4

1. Slotted Screw 2. Washer 3. Coil 4. Enclosing Tube and Body

Figure 6-15 Economizer/Liquid Injection Solenoid Valve

6.14 EVAPORATOR FAN AND MOTOR ASSEMBLY

The evaporator fans circulate air throughout the container by pulling air in the top of the unit. The air is forced through the evaporator coil where it is either heated or cooled and then discharged out the bottom of the refrigeration unit into the container. The fan motor bearings are factory lubricated and do not require additional grease.

6.14.1 Replacing The Evaporator Fan Assembly

WARNING

Always turn OFF the unit circuit breakers (CB-1 & CB-2) and disconnect main power supply before working on moving parts.

a. Remove upper access panel (see Figure 2-2) by removing mounting bolts and T.I.R. locking device. Reach inside of unit and remove the Ty-Rap securing the wire harness loop. Then unplug the connector by twisting to unlock and pulling to separate.

b. Loosen four 1/4-20 clampbolts that are locatedon the underside of the fan deck at the sides of the of the fan assembly. Slide the loosened clamps back from the fan assembly.

c. Slide the fan assembly out from the unit and place on a sturdy work surface.

6.14.2 Disassemble The Evaporator Fan Assembly a. Attach a spanner wrench to the two 1/4-20 holes located in the fan hub. Loosen the 5/8-18 shaft nut by holding the spanner wrench stationary and turning the 5/8-18 nut counter-clockwise (see Figure 6-16).

NOTE When removing the black nylon evaporator fan blade, care must be taken to assure that the blade is not damaged. In the past, it was a com- mon practice to insert a screwdriver between the fan blades to keep it from turning. This prac- tice canno longer beused, as theblade ismade up of a material that will damage. It is recom- mended that an impact wrench be used when removing the blade. Do not use the impact wrench when reinstalling, as galling of the stain- less steel shaft can occur.

b. Remove the spanner wrench. Use a universal wheel puller and remove the fan from the shaft. Remove the washers and key.

c. Remove the four 1/4-20 x 3/4 long bolts that are located under the fan that support the motor and sta- tor housing. Remove the motor and plastic spacer.

6.14.3 Assemble The Evaporator Fan Assembly a. Assemble the motor and plastic spacer onto the sta- tor.

b. Apply loctite to the 1/4-20 x 3/4 long bolts and torque to 0.81 mkg (70 inch-pounds).

c. Place one 5/8 flat washer on the shoulder of the fan motor shaft. Insert the key in the keyway and lubricate the fan motor shaft and threads with a graphite-oil solution (such as Never-seez).

d. Install the fan onto the motor shaft. Place one 5/8 flat washer with a5/8-18 locknut onto themotor shaft and torque to 40 foot-pounds.

e. Install the evaporator fan assembly in reverse order of removal. Torque the four 1/4-20 clampbolts to 0.81 mkg (70 inch-pounds) Apply power momentarily to check for proper fan rotation (refer to paragraph 2.3). If fan spins backward, then motor wiring or motor is defective.

6--13 T-327

f. Replace access panel making sure that panel does not leak. Make sure that the T.I.R. locking device is lockwired.

1

2

3

4 5

6

5

7

8

9

1. Stator 2. Flat washer, 1/4 3. Bolt, 1/4-20 x 3/4 4. Locknut, 5/8-18 5. Flat washer, 5/8

6. Impeller Fan 7. Key 8. Mylar Protector 9. Evaporator Motor

Figure 6-16 Evaporator Fan Assembly

6.15 EVAPORATOR FAN MOTOR CAPACITOR

The evaporator fan motors are of the permanent-split capacitor type. The motor is equipped with one capacitor.

6.15.1 When To Check For A Defective Capacitor

a. Fanmotor will not change speed. For example: in the conventional perishablemode, themotors should run in high speed. In the economy perishable mode they should switch speeds and in the frozenmode, themo- tors should run in low speed.

NOTE The evaporator fan motors will always start in high speed.

b. Motor running in wrong direction (after checking for correct wiring application).

c. Motor will not start, and IP-EMs are not open.

6.15.2 Removing The Capacitor

WARNING Make sure power to the unit is OFF and power plug disconnected before removing capacitor(s).

The capacitor is located on the motor and above the evaporator fan deck they may be removed by two methods:

1 If container is empty, open upper rear panel of the unit. The capacitor may be serviced after discon- necting power plug.

2 If container is full, turn the unit power OFF and dis- connect power plug. Remove the evaporator fan motor access panel. (See Figure 2-1). For removal of theevaporator fanassembly, refer to section 6.14.

WARNING With power OFF discharge the capacitor before disconnecting the circuit wiring.

6.15.3 Checking The Capacitor If the capacitor is suspected of malfunction, you may choose to simply replace it. Direct replacement requires a capacitor of the same value. Two methods for checking capacitor function are: 1. Volt-ohmmeter set on RX 10,000 ohms:

Connect ohmmeter leads across the capacitor terminals and observe themeter needle. If the capacitor is good, the needle will make a rapid swing toward zero resistance and then gradually swing back toward a very high resistance reading.

If the capacitor has failed open, the ohmmeter needle will not move when the meter probes touch the terminals. If the capacitor is shorted, the needle will swing to zero resistance position and stay there.

2. Capacitor analyzer: The function of the analyzer is to read the microfarad value of a capacitor and to detect insulation breakdown under load conditions. The important advantages of a analyzer are its ability to locate capacitors that have failed to hold their microfarad ratings, or those that are breaking down internally during operation. It is also useful in identifying capacitors when their microfarad rating marks have become unreadable. 6.16 VALVE OVERRIDE CONTROLS

Controller function code Cd41 is a configurable code that allows timed operation of the automatic valves for troubleshooting. Three test sequences are provided. The first, capacity mode (CAP), allows alignment of the unloader and economizer solenoid valves in the standard, unloaded and economized operating configurations. The second, SMV % Setting (SM) allows opening of the suction modulating valve to various percentages. A third selection is also provided to enter a time periodof up to three minutes, during which the override(s) are active. If the timer is active, valve override selectionswill take place immediately. If the timer is not active, changes will not take place for a few seconds after the

6--14T-327

timer is started. When the timer times out, override function is automatically terminated and the valves return to normal machinery control. To operate the override, do the following:

a. Press the CODE SELECT key then press an AR- ROW key until Cd41 is displayed in the left window. The right window will display a controller communica- tions code.

b. Press theENTERkey. The left display will show a test name alternating with the test setting or time remain- ing. Use an ARROW key to scroll to the desired test. Press the ENTER key and SELCt will appear in the left display.

c. Use an ARROW key to scroll to the desired setting, and then press the ENTER key. Selections available for each of the tests are provided in the following table.

d. If the timer is not operating, follow the above proce- dure to display the timer. UseanARROWkey toscroll to the desired time interval and press ENTER to start the timer.

e. The above described sequence may be repeated during the timer cycle to change to another override. Right Display Available Selections

CAP (Capacity Mode)

AUtO (Normal Control)

UnLd (Unloader = Open

Economizer = Closed) Std

(Unloader = closed Economizer = closed)

ECOn (Unloader = closed Economizer = open)

SM (SMV % Setting)

AUtO (Normal Control)

3 4 6 12 25 50 100

LIV (Liquid Valve Setting,

if applicable)

AUto (Normal Control)

CLOSE OPEn

tIM (Timer)

0 00 (0 minutes/0 Seconds) In 30 second increments to 3 00 (3 minutes/ 0 seconds)

6.17 SUCTION MODULATION VALVE

On start up of the unit, the valve will reset to a known open position. This is accomplished by assuming the valve was fully open, driving it fully closed, resetting the percentage open to zero, then opening to a known 10% staging position.

2-1/8 inch Nut FROM COIL

FROM UNLOADER/QUENCH TO COMPRESSOR

Figure 6-17 Suction Modulation Valve (SMV)

6.17.1 Precheck Procedure

a. Check unit for abnormal operation.

b. Check charge. If refrigerant is low repair as required and again check operation.

c. If sufficient capacity cannot be maintained or unit is tripping excessively on high pressure switch (HPS) in high ambients, check coils and clean if required.

d. If capacity or control cannot be maintained turn unit OFF, then back ON. This will reset the valve in the event the controller lost communication with the valve, and may correct the problem.

NOTE Carefully listen to the valve. During reset, the valve will make a ratcheting noise that may be heard or felt as it is attempting to close. If this can be heard or felt, it indicates that the control- ler and drivemodule are attempting to close the valve, and may serve as a quick indication that the drive is in working order.

e. Operation of the valve may be checked using the con- troller valve override program, function code Cd41. Refer to paragraph 6.16 for valve override test in- structions.

6.17.2 Checking The Stepper valve

a. Checking with ohmmeter:

Disconnect the four pin connector to the stepper SMV. With a reliable digital ohmmeter, check the winding resistance. In normal ambient, the valve should have72 to 84 ohms measured on the red/green (a-b terminals) andon thewhite/black (c-d terminals) leads. If an infinite or zero reading occurs, check connections and replace the motor.

b. Checking with SMA-12 portable stepper drive tester:

The SMA-12 portable stepper drive tester (Carrier Transicold part number 07-00375-00) is a battery operated stepper drive which will open and close the SMV, allows a more thorough check of the operating mechanism.

6--15 T-327

To check operation:

1. Stop the unit, disconnect the four pin connector from the stepper module to the valve and attach the SMA-12 stepper drive to the connector going to the valve.

2. Set the SMA-12 pulse per second (PPS) to one PPS and either open or close valve. Each LED should light sequentially until all four are lit. Any LED failing to light indicates an open on that leg which indicates a poor connection or an open coil. Repair or replace as required to achieve proper operation.

CAUTION

The scroll compressor achieves low suc- tion pressure very quickly. Do not operate the compressor in a deep vacuum, internal damage will result.

3. Restart unit, set the step rate to 200PPS onSMA-12 for the valve, and close stepper valvewhile watching the suction gauge. Within one minute the suction pressure will go into a vacuum. This is an indication that the valve is moving.

4. If no change in suction pressure is detected, check for resistance (refer to step 6.17.2), and check con- nections for proper continuity and retest. If the valve is functioning and all connections and motor resist- ance are good, check the controller.

CAUTION

DONOT disassemble piston fromNEWsuc- tion modulating valve powerhead assem- bly. Doing so may result in damage to pis- ton.

5. If the valve is determined as faulty after completing the above steps, perform a low side pump down (units with standard piping) or remove charge (units with semi--hermetic piping).

Remove valve powerhead assembly, and replace with a NEW valve powerhead assembly, torque nut to 35 ft-lb.

For units with standard piping: Evacuate low side, open all service valves and leak test unit.

For units with semi--hermetic piping: Leak test unit, evacuate, dehydrate and recharge.

6.18 AUTOTRANSFORMER

If the unit does not start, check the following:

a. Make sure the 460 vac (yellow) power cable is plugged into the receptacle (item 3, Figure 4-1) and locked in place.

b. Make sure that circuit breakers CB-1 and CB-2 are in the ON position. If the circuit breakers donot hold in, check voltage supply.

c. There is no internal protector for this transformer design, therefore, no checking of the internal protec- tor is required.

d. Using a voltmeter, and with the primary supply circuit ON, check the primary (input) voltage (460 vac). Next, check the secondary (output) voltage (230 vac). The transformer is defective if output voltage is not available.

6.19 CONTROLLER

6.19.1 Handling Modules

CAUTION Donot removewire harnesses frommodule unless you are grounded to the unit frame with a static safe wrist strap.

CAUTION Unplug all module connectors before per- forming arc welding on any part of the con- tainer.

The guidelines and cautions provided herein should be followed when handling the modules. These precautions and procedures should be implemented when replacing a module, when doing any arc welding on the unit, or when service to the refrigeration unit requires handling and removal of a module.

a. Obtain a grounding wrist strap (Carrier Transicold part number 07--00--304--00) and a static dissipation mat (Carrier Transicold part number 07--00304--00). The wrist strap, when properly grounded, will dissi- pate any potential buildup on the body. The dissipa- tion mat will provide a static-free work surface on which to place and/or service the modules.

b. Disconnect and secure power to the unit.

c. Place strap on wrist and attach the ground end to any exposed unpainted metal area on the refrigeration unit frame (bolts, screws, etc).

d. Carefully remove themodule. Do not touch any of the electrical connections if possible. Place the module on the static mat.

e. The strap should be worn during any service work on a module, even when it is placed on the mat.

6--16T-327

1 2 3

4

1. Controller Software Programming Port 2. Mounting Screw 3. Controller 4. Test Points

Figure 6-18 Controller Section of the Control Box

6.19.2 Controller Troubleshooting

Agroupof test points (TP, seeFigure 6-18) are provided on the controller for trouble-shooting electrical circuits (see schematic diagram, Section 7). A description of the test points follows:

NOTE Use a digital voltmeter to measure ac voltage between TPs and ground (TP9), except for TP8.

TP1

This test point enables the user to check if the controller unloader solenoid valve relay (TU) is open or closed.

TP2

This test point enables the user to check if the high pressure switch (HPS) is open or closed.

TP3

This test point enables the user to check if the water pressure switch (WP) contact is open or closed.

TP 4

This test point enables the user to check if the internal protector for the condenser fanmotor(IP-CM) is openor closed.

TP 5

This test point enables the user to check if the internal protectors for the evaporator fan motors (IP-EM1 or IP-EM2) are open or closed.

TP 6

This test point is not used in this application.

TP 7

This test point enables the user to check if the controller economizer solenoid valve relay (TS) is open or closed

TP 8

This test point enables the user to check power to the suction modulator valve.

TP 9

This test point is the chassis (unit frame) ground connection.

TP 10

This test point enables the user to check if the heat termination thermostat (HTT) contact is open or closed.

6.19.3 Controller Programming Procedure

To load new software into themodule, the programming card is inserted into the programming/software port.

CAUTION The unit must be OFF whenever a program- ming card is inserted or removed from the controller programming port.

a. Procedure for loading Operational Software

1. Turn unit OFF, via start-stop switch (ST).

2. Insert software/programming PCMCIA card contain- ing the following (example) files into the program- ming/software port. (See Figure 6-18):

menuDDMM.ml3, this file allows the user to select a file/program to upload into the controller.

cfYYMMDD.ml3, multi--configuration file

3. Turn unit ON, via start-stop switch (ST).

4. The Display module will display the message ruN COnFG. (If a defective card is being used the Dis- play will blink the message bAd CArd. Turn start-- stop switch OFF and remove the card.)

5. Press the UP or DOWN arrow key until display reads, LOAd 55XX for Scroll.

6. Press the ENTER key on the keypad.

The Display will alternate to between PrESS EntR and rEV XXXX

6. Press the ENTER key on the keypad.

7. The Display will show the message Pro SoFt. This message will last for up to one minute.

6. Press the ENTER key on the keypad.

8. The Display module will go blank briefly, then read Pro donE when the software loadinghas loaded. (If a problemoccurswhile loading the software: theDis- play will blink the message Pro FAIL or bad 12V. Turn start-stop switch OFF and remove the card.)

9. Turn unit OFF, via start-stop switch (ST).

10.Remove the PCMIA card from the programming/- software port and return the unit to normal operation by placing the start-stop switch in the ON position.

11.Turn power on, and wait 15 seconds -- The status LED will flash quickly, and there will be no display. The controller is loading the new software into memory. This takes about 15 seconds.

Whencomplete the controller will reset andpowerup normally.

6--17 T-327

12.Wait for default display, setpoint on the left, and con- trol temperature on the right.

13.Confirm software is correct using keypad code se- lect 18 to view Cd18 XXXX.

14.Turn power off. Operational Software is loaded.

b. Procedure for loading Configuration Software

1. Turn unit OFF using start-stop switch (ST).

2. Insert software/programming PCMCIA card contain- ing the following (example) files into the program- ming/software port. (See Figure 6-18):

menuDDMM.ml3, this file allows the user to select the file/program to upload into the controller.

cfYYMMDD.ml3, multi--configuration file

scrll55XX.ml3, controller software program for scroll units.

3. Turn unit ON using start-stop switch (ST).

4. The Display module will display the message ruN COnFG. (If a defective card is being used the Dis- play will blink the message bAd CArd. Turn start-- stop switch OFF and remove the card.)

5. Press the ENTER key on the keypad.

6. TheDisplaymodulewill go blank briefly and thendis- play 551 00. Based on the operational software installed.

7. Press the UP or DOWN ARROW key to scroll through the list to obtain the proper model dash num- ber. (If a defective card is being used, theDisplaywill blink the message bAd CArd. Turn start-stop switch OFF and remove the card.)

8. Press the ENTER key on the keypad.

9. When the software loading has successfully com- pleted, the Display will show the message EEPrM donE. (If a problem occurs while loading the soft- ware, the Display will blink the message Pro FAIL or bad12V. Turn start-stop switchOFFand remove the card.)

10.Turn unit OFF using start-stop switch (ST).

11.Remove the PCMIA card from the programming/- software port and return the unit to normal operation by placing the start-stop switch in the ON position.

12.Confirm correct model configuration using the key- pad to choose function code 20 (Cd20). The model displayed should match the unit serial number plate.

6.19.4 Removing and Installing a Module

a. Removal:

1. Disconnect all front wire harness connectors and move wiring out of way.

2. The lower controller mounting is slotted, loosen the top mounting screw (see Figure 6-18) and lift up and out.

3. Disconnect the back connectors and remove mod- ule.

4. When removing the replacement module from its packaging , note how it is packaged. When returning the old module for service, place it in the packaging in the same manner as the replacement. The pack-

aging has been designed to protect the module from both physical and electrostatic discharge damage during storage and transit.

b.Installation: Install the module by reversing the removal steps. Torque values for mounting screws (item 2, see Figure 6-18) are 0.23 mkg (20 inch-pounds). Torque value for the connectors is 0.12 mkg (10 inch-pounds). 6.19.5 Battery Replacement Standard Battery Location (Standard Cells): a. Turn unit power OFF and disconnect power supply. b. Slide bracket out, remove old batteries. (See Figure 3-4, Item 8.)

c. Install new batteries, slide bracket into control box slot.

CAUTION Use care when cutting wire ties to avoid nicking or cutting wires.

Standard Battery Location (Rechargeable Cells): a. Turn unit power OFF and disconnect power supply. b. Disconnect battery wire connector from control box. c. Slide out and remove old battery and bracket. (See Figure 3-4, Item 8.)

d. Slide new battery pack and bracket into the control box slot.

e. Reconnect battery wire connector to control box and replace wire ties that were removed.

Secure Battery Option (Rechargeable Cells Only): a. Turn unit power OFF and disconnect power supply. b. Opencontrol box door and removeboth thehigh volt- age shield and clear plastic rain shield (if installed).

c. Disconnect the battery wires from the KA plug posi- tions 14, 13, 11.

d. Using Driver Bit, Carrier Transicold part number 07--00418--00, remove the 4 screws securing the dis- playmodule to the control box. Disconnect the ribbon cable and set the display module aside.

NOTE The battery wires must face toward the right.

e. Remove the old battery from the bracket and clean bracket surface. Remove the protective backing from the new battery and assemble to the bracket. Secure battery by inserting the wire tie from the back of the bracket around the battery, and back through the bracket.

f. Reconnect the ribbon cable to display and re--install the display.

g. Route thebatterywires from thebattery along thedis- play harness and connect the red battery wire and one end of the red jumper to KA14, the other end of the red jumper wire to KA11, and the black wire to KA13.

h. Replace wire ties that were removed.

6.20 VENT POSITION SENSOR SERVICE

The fresh air vent position sensor alarm (AL50) will occur if the sensor reading is not stable for 4minutes or if

6--18T-327

the sensor is outside of its valid range (shorted or open). This can occur if the vent is loose or the panel is defective. To confirm a defective panel, assure that the wing nut is secure and then power cycle the unit. If the alarm immediately reappears as active, the panel should be replaced.

The alarm should immediately go inactive, check the 4--minute stability requirement. If the alarm reoccurs after the four minutes and the panel was known to have been stable, then the sensor should be replaced.

In order to replace the Upper VPS, the panel must be removed and replaced with another upper fresh air panel equipped with VPS.

Lower VPS replacement is accomplished by removing the temperature recorder, if equipped, or the recorder blank panel and replacing the sensor potentiometer.

6.20.1 Vent Position Sensor Calibration

NOTE Sensors are calibrated at the factory and do not need to be recalibrated in the field. Calibration is only necessary after a new sensor is installed or, in the case of Lower VPS, if the gears have been disengaged.

Units equipped with Upper VPS Option:

1. Check the alarm list for an active AL50. If there is no active AL50, go to step 5.

2. If there is an active AL50, power cycle to clear it. If there is no active AL50, go to step 5.

3. If there is still an active AL50, the sensor is consid- ered invalid. Check to make sure the sensor is plugged in andwired correctly thengoback to step1.

4. If the wiring is correct, the sensor is plugged in, and there is still an active AL50, the sensor is bad. Re- place the sensor and go back to step 1.

5. With the unit ON Rotate the vent to the 0 CMH/CFM position.

6. With CD45 displayed, press and hold the ENTER key until the word CAL is displayed (more than 5 seconds).

7. Press and hold the ALT Mode key until a numeric value returns to the right side display (more than 5 seconds). 0 CMH/CFM should now be displayed.

8. Check the alarm list for an active AL50. If there is no active AL50, end.

9. If there is an active AL50, the sensor was out of cal- ibration range when the calibration was attempted. The valid calibration range is 0.25V to 0.75V mea- suredbetweenSignal (Terminal3)andGround(Ter- minal 1). Make sure the Sensor is locked at the 0 CMH/CFM position and repeat the calibration at- tempt by going back to step 2 (Power Cycle).

10.If there is still an active AL50, the sensor is out of cal- ibration range. Replace the sensor and go back to step 1.

Units equipped with Lower VPS Option:

1. Check the alarm list for an active AL50. If there is no active AL50, go to step 5.

2. If there is an active AL50, power cycle to clear it. If there is now no active AL50, go to step 5.

3. If there is still an active AL50, the sensor is consid- ered invalid. Check to make sure the sensor is plugged in and wired correctly all the way to the con- troller. After a fix, go back to step 1.

4. If the wiring is correct, the sensor is plugged in, and there is still an active AL50, the sensor is bad. Re- place the sensor and go back to step 1.

5. Remove the slide assembly.

6. Disconnect the harness plug (this will generate ac- tive AL50 if unit is left powered on, but this is not a problem) and connect the test leads from themulti- meter to terminals 2 and 3 in the sensor. Set multi- meter to 200k ohms.

7. Turn the shaft fully counter clockwise. Reading should be 100k ohms +/-- 3%.

8. Turn shaft fully clockwise. Reading should be close to 0 ohm (several hundred ohms or less) +/-- 3%.

9. Turn shaft counter clockwise until approximately 6.5k ohms shows on the meter.

10.Leave the meter attached to the sensor and re--- install slide assembly in the fully closed position. Make sure the gear teeth are fully messed. If the reading on the meter remains between 5k ohms and 10k ohms, this is a good assembly and will calibrate successfully. If not, readjust the sensor position until a value in this range is achieved.

11.Disconnect multimeter and re--connect harness (if the unit has been left poweredonwith anactiveAL50 due to the sensor being unplugged, this will inacti- vate the AL50).

12.Turn unit ON if it is not. Check the alarm list to verify there is no active AL50. If there is, go back to step 2.

13.Select Code 45, press and hold the ENTER key until the word CAL is displayed (more than 5 seconds).

14.Press the ALT Mode key until a numeric value re- turns to the right side display (more than 5 seconds). 0 CMH/CFM should now be displayed.

15.Check the alarm list for an active AL50. If there is no active AL50, end.

16.If there is an active AL50, the sensor was out of cal- ibration range when the calibration was attempted. The valid calibration range is 4.5k ohm to 10.5k ohm measured between Terminal 2 and Terminal 3. Re- peat the calibration attempt by going back to step 2 (Power Cycle), verifying the Resistance measure- ment at the 0 CMH/CFM position.

17.If there is still an active AL50, the sensor is out of cal- ibration range. Replace the sensor and go back to step 1.

1. Rotate the vent to the 0 CMH/ CFM position.

2. Code select 45 will automatically display. Press the Enter key and hold until the display reads CAL.

3. Press the ALT MODE key and hold until the display reads 0 CMH/CFH.

4. If the ALT key is not held down long enough, the dis- play will read FAIL , indicating that the calibration procedure was performed incorrectly and should be repeated.

6--19 T-327

6.21 TEMPERATURE SENSOR SERVICE

Procedures for service of the Return Recorder, Return Temperature, Supply Recorder, Supply Temperature, Ambient, Defrost Temperature, Compressor Discharge and Compressor Suction temperature sensors are provided in the following sub paragraphs.

6.21.1 Sensor Checkout Procedure

To check a sensor reading, do the following:

a. Remove the sensor andplace in a0 C(32degreesF) ice-water bath. The ice-water bath is prepared by fill- ing an insulated container (of sufficient size to com- pletely immerse bulb) with ice cubes or chipped ice, then filling voids between ice with water and agitating until mixture reaches 0 C (32 degrees F) measured on a laboratory thermometer.

b. Start unit and check sensor reading on the control panel. The reading should be 0 C (32 degrees F). If the reading is correct, reinstall sensor; if it is not, con- tinue with the following.

c. Turn unit OFF and disconnect power supply.

d. Refer to paragraph6.19and removecontroller to gain access to the sensor plugs.

Table 6-2 Sensor Temperature/Resistance Chart (+/--.002%)

Temperature Resistance

_C _F (Ohms) AMBS, CPSS, DTS, RTS, RRS,

STS, SRS

CPDS

--30 --22 177,000 1,770,000 --25 --13 130,400 1,340,000

--20 --4 97,070 970,700 --15 5 72,900 729,000 --10 14 55,330 553,000 --5 23 43,200 423,300 0 32 32,650 326,500 5 41 25,390 253,900 10 50 19,900 199,000 15 59 15,700 157,100 20 68 12,490 124,900 25 77 10,000 100,000

30 86 8,060 80,600 35 95 6,530 65,300 40 104 5,330 53,300 45 113 4,370 43,700 50 122 3,600 36,000 55 131 2,900 29,000 60 140 2,490 24,900 65 149 2,080 20,800 65 158 1,750 17,500

e. Using the plug connector marked EC, that is con- nected to the back of the controller, locate the sensor wires (RRS, RTS, SRS, STS, AMBS, DTS, CPDS

ORCPSSas required). Follow thosewires to the con- nector and using the pins of the plug, measure the resistance. Values are provided in Table 6-2. Due to the variations and inaccuracies in ohmmeters, thermometers or other test equipment, a reading within 2% of the chart value would indicate a good sensor. If a sensor is defective, the resistance read- ingwill usually bemuch higher or lower than the resis- tance values given.

6.21.2 Sensor Replacement a. Turn unit power OFF and disconnect power supply. b. Cut cable 5 cm (2 inches) from shoulder of defective sensor and discard thedefective probeonly. Slide the cap and grommet off a bulb type sensor and save for reuse. Do not cut the grommet.

c. Cut one wire of existing cable 40 mm (1-1/2 inch) shorter than the other wire.

d. Cut one replacement sensor wire (opposite color) back 40 mm (1-1/2 inch). (See Figure 6-19)

e. Strip back insulation on all wiring 6.3 mm (1/4 inch).

Sensor 40 mm (1 1/2 inch)

6.3 mm (1/4 inch)

Mounting Stud Type

Sensor 40 mm (1-1/2 inches)

6.3 mm (1/4 inch) Bulb Type

Figure 6-19 Sensor Types f. Slide a large piece of heat shrink tubing over the cable, and place the two small pieces of heat shrink tubing, one over each wire, before adding crimp fit- tings as shown in Figure 6-20.

Sensor (Typical)

Cable Heat Shrink Tubing (2)

Large Heat Shrink Tubing (1)

Figure 6-20 Sensor and Cable Splice g. If required, slide the cap and grommet assembly onto the replacement sensor.

h. Slip crimp fittings over dressed wires (keeping wire colors together). Make sure wires are pushed into crimp fittings as far as possible and crimp with crimp- ing tool.

i. Solder spliced wires with a 60% tin and 40% lead Rosincore solder.

6--20T-327

j. Slide heat shrink tubing over splice so that ends of tubing cover both ends of crimp as shown in Figure 6-20.

k. Heat tubing to shrink over splice.Make sure all seams are sealed tightly against the wiring to prevent mois- ture seepage.

l. Slide large heat shrink tubing over both splices and shrink.

CAUTION Do not allow moisture to enter wire splice area as this may affect the sensor resis- tance.

m.Position sensor in unit as shown in Figure 6-21 and re--check sensor resistance.

n. Reinstall sensor, refer to paragraph 6.21.3.

NOTE The P5 Pre-Trip test must be run to inactivate probe alarms (refer to paragraph 4.8).

6.21.3 Sensor Re--Installation

a. Sensors STS and SRS

Toproperly position a supply sensor, the sensor must be fully inserted into the probe holder. This positioning will give the sensor the optimum amount of exposure to the supply air stream, and will allow the Controller to operate correctly. Insufficient probe insertion into the probe holder will result in poor temperature control due to the lack of air flow over the sensor.

It is also necessary to ensure that the probe tip does not contact the evaporator back panel. The design minimum clearance of 6 mm (1/4 inch) should be maintained (see Figure 6-21).

Cap and Grommet Assembly

Probe Holder

Supply Sensor

Sensor Wires

Supply Air Stream

Evaporator Back Panel

6 mm (1/4 inch)

Figure 6-21 Supply Sensor Positioning

b. Sensors RRS and RTS

Reinstall the return sensor as shown in Figure 6-22. For proper placement of the return sensor, be sure to position the enlarged positioning section of the sensor against the the side of the mounting clamp.

Evaporator Grille Return Sensor

Mounting ClampEnlarged Positioning

(Plastic) Section

Figure 6-22 Return Sensor Positioning

c. Sensor DTS

The DTS sensor must have insulating material placed completely over the sensor to insure the coil metal temperature is sensed.

6.22 ELECTRONIC PARTLOW TEMPERATURE RECORDER

The microprocessor based temperature recorder is designed to interface with the DataCORDER to log temperature with time. The electronic recorder will automatically record the return air, supply air, or both, based on the setting of temperature controller configuration code CnF37, refer to Table 3-4. The recorder reads and records data from the Controller in present time, under normal operating conditions.

If the power has beenOFF for more than thirty days, the recorder will NOT re--synchronize (the chart will not advance to present time), the pen tip will move to the currently recorded temperature, and the recorder will resume normal temperature recording.

If using the Electronic Partlow Recorder CTD part number 12-00464-xx Wherexx= an evennumber (example:12--00464--08)

The recorder will STOPwhen the power is OFF, and the pen tip will remain at the last recorded temperature on the chart. When power is applied, and the power off period is less than thirty days; the recorder will retrieve the logged data from the DataCORDER for the power off period and record it onto the chart, thereafter, the recorder will resume normal temperature recording.

If the optionalDataCORDERbattery pack is beingused, and the charge is too low to enable recording during the power off period of less than thirty days, the pen tip will move to below the inner chart ring for the period when NO data was recorded by the DataCORDER.

If the power has beenOFF for more than thirty days, the recorder will NOT re--synchronize (the chart will not advance to present time), the pen tip will move to the currently recorded temperature, and the recorder will resume normal temperature recording.

6--21 T-327

6.22.1Replacing the Recorder

a. Turn power to the unit OFF.

b. Open the recorder door (item 1, see Figure 6-23).

c. Locate the connector below the recorder, and squeeze the ears together to disconnect the plug, (item 6).

d. Remove the four mounting screws (item 8), and remove the recorder.

e. Install the new recorder by reversing the above steps.

6.22.2Changing the Chart

NOTE To prevent recorder corrosion, it is important to assure the door is securely closed at all times after completing the chart change.

a. Lift the stylus (item 5, Figure 6-23) by grasping the arm near the base, and pull the arm away from the chart until it snaps into its retracted position.

b. Remove the chart retaining nut (item 10), remove the used chart, and record todays date on the old chart.

c. Press the Change Chart button (item 2).

NOTE

Failure to press the change chart button, when changing a chart with the power OFF, may result in the chart advancing when power is applied.

d. Install a new chart, make sure the chart center hole is placed over the center hub, and the chart edges are behind the four hold down tabs (item 9).

e. Mark todays date, container number, and other required information on the new chart and install under hold down tabs.

f. Replace the chart nut loosely, rotate the chart until the correct day is aligned with the start arrow, and hand tighten the chart nut.

g. Gently lower the stylus arm until the pen tip (item 4) comes in contact with the chart.

CAUTION

Do not allow the recorder stylus to snap back down. The stylus arm base is spring loaded, and damagemayoccur to thechart, or the stylus force may be altered.

DO NOT move the stylus arm up and down on the chart face. This will result in damage to the stylus motor gear.

6.22.3Adjusting the Recorder Stylus

Proper stylus force upon the chart paper is important. Factory adjustment is 113 to 127 grams (4 to 4.5 ounces). To measure the force, use a spring type gage, and attach it under the stylus as close as possible to the pen tip (item 4). Exert pull on the gage perpendicular to the chart surface. The measured force should be noted just as the pen tip leaves the surface.

NOTE

The two coil springs near the base of the stylus are NOT involved in establishing chart contact force. They serve only to hold the stylus in its retracted position.

Correct adjustment is made by carefully bending the portion of the stylus arm between the bend near the pen tip, and the first bend towards the stylus arm base. If the force is too low, the stylus trace will be light and difficult to read. If the force is too great, wrinkling, or tearing of the paper chart may occur.

6--22T-327

1

2

3

4

5

6

7

8

9

10

1. Recorder Door 2. Change Chart

Button 3. Recorder Box 4. Pen Tip 5. Stylus Arm 6. Connector 7. Calibration Button

(Located underneath) 8. Mounting Screws,

#10-24 x 7/16 inches long 9. Hold Down Tab 10. Chart Retaining Nut

Figure 6-23 Electronic Partlow Temperature Recorder

6--23 T-327

6.22.4Rezeroing the Recording Thermometer

For Electronic Partlow Recorder CTD part number 12-00464-xx Where xx= an odd number (example: 12--00464--03 )

NOTE

Use chart CTD part number 09-00128-00 ( F) part number 09-00128-01 ( C).

a. Press the Calibration button (item 7, Figure 6-23) on the bottom of the recorder. The pen tip will drive fully downscale, thenmoveupscale to the chart ring at --29 degrees C (--20 degrees F), and stop.

b. If the tip of the pen (item 4) is on the --29 degrees C (--20 degrees F) chart ring the recorder is in calibration, proceed to step c. If the tip of the pen is NOT on the --29 degrees C (--20 degrees F) chart ring, theoperatormust loosen the twoscrews on the bottom of the stylus arm to adjust the pen tip manually to the --29 degrees C (--20 degrees F) chart ring. Tighten the screws when adjustment is complete.

c. Press the calibration buttonand thepenwill position itself to the correct temperature reading.

For Electronic Partlow Recorder CTD part number 12-00464-xx Wherexx= an evennumber (example:12--00464--08)

NOTE

Use chart CTD part number 09-00128-00 ( F) part number 09-00128-01 ( C).

a. Press the Calibration button (item 7, Figure 6-23) on the bottom of the recorder. The pen tip will drive fully downscale, thenmoveupscale to the chart ring at 0 C (32 degrees F), and stop.

b. If the tip of the pen (item 4) is on the 0C (32degrees F) chart ring the recorder is in calibration, proceed to step c. If the tip of the pen is NOT on the 0 C (32 degrees F) chart ring, the operator must loosen the two screws on the bottom of the stylus arm to adjust thepen tipmanually to the 0C (32 degreesF) chart ring. Tighten the screws when adjustment is complete.

c. Press the calibration buttonand thepenwill position itself to the correct temperature reading.

6.23 MAINTENANCE OF PAINTED SURFACES

The refrigeration unit is protected by a special paint system against the corrosive atmosphere in which it normally operates. However, should the paint system be damaged, the base metal can corrode. In order to protect the refrigeration unit from the highly corrosive sea atmosphere, or if the protective paint system is scratched or damaged, clean area to baremetal using a wire brush, emery paper or equivalent cleaningmethod. Immediately following cleaning, apply 2--part epoxy paint to the area and allow to dry. After the first coat dries, apply a second coat.

6.24 COMPOSITE CONTROL BOX REPAIRS

6.24.1 Introduction

This procedure provides instructions for repair of the Carrier Transicold composite control box. Damage to the control box may be in the form of a chip or hole, a crack, a damaged thread insert or damage to the door hinge inserts. Generally, the object of the repair must be to ensure sufficient strength is restored to the damaged area and the repair must keep the box water tight. Informationon repair kits and repair procedures foreach type of damage is provided in the following paragraphs. Ambient temperature must be above 7 degrees C (45 degrees F) for proper curing of epoxy repairs.

6.24.2 Cracks

Cracks in the control box are repaired using a fiberglass patch over the damaged area. Materials required are included in the Fiberglass Patch Kit supplied with Crack Repair Kit, Carrier Transicold part number 76-00724-00SV (see Table 6-3).

a. The surface must be clean and dry. Roughen the sur- face with sandpaper to ensure a good bond.

b. Cut the fiberglass cloth to allow a 25mm (1--inch) overlap around the area to be repaired.

c. Stretch and position the cloth over the area to be re- paired and secure it with masking tape.

d. Make up sufficient epoxy glue to cover the cloth by mixingequal parts of resin andhardener. Saturate the cloth with the epoxy glue, spreading evenly.

e. Remove the tape and overlap the edge of the cloth approximately 6 to 12 mm (1/4 to 1/2) with glue.

f. Epoxy will dry in 45--60 minutes. When completely cured (12 hours), use sandpaper to smooth edges of the patch.

6.24.3 Chips And Holes

Chips and holes in the control box are repaired using a piece of aluminum or stainless steel to cover the damaged area. The material can be cut to suit and riveted in place. An adhesive sealant must be used to make the repair watertight. The adhesive sealant (Sikaflex 221) is included in Crack Repair Kit Carrier Transicold part number 76-00724-00SV (see Table 6-3). Do not use an acetone based silicone sealant (Which can be identified by a vinegar--like odor).

a. To make up the patch, cut a piece of aluminum or stainless steel so that it will overlap thedamagedarea by at least 40 mm (1 1/2) on all sides.

b. Choose rivet locations and drill the rivet holes in the corresponding locations on the control box and patch piece.

c. Apply theadhesive sealant around the damagedarea to form a seal between the control box and the patch piece.

d. Rivet the patch piece in place.

e. File smooth any rough edges (including rivets) that may come into contact with wires.

6--24T-327

6.24.4 Inserts

The threaded brass inserts that are molded into the control box will need to be replaced if the threads become stripped, or if the insert becomes loose. The inserts and epoxy are contained in repair kit, Carrier Transicold part number 76-50084-00 (see Table 6-4). There are 6 different inserts used in the control box. Refer to Figure 6-25 for the locations of the various inserts.

NOTE An epoxy application gun is also needed (Carrier Transicold part number07--00391--00).

The damaged insert must be removed from the control box. Table 6-5 identifies thedrill size and drill depth to be used for each insert. A stop ring should be used on the drill bit to limit the depth.

a. Center the drill bit on the insert and drill to the pre- scribed depth.

b. Remove the chips from the drilled hole.

c. Mix the two component epoxy and fill the hole 1/2way to the top with epoxy.

d. Press the insert in until it is flush with the surface.

e. Wipe away any excess epoxy. The part is ready for service after the bond material has hardened and is tack free (approximately 20 minutes).

6.24.5 Door Hinge Inserts

If the door hinges have been pulled from the control box drill and reinstall the hinge as shown in Figure 6-24 and described in the following steps:

Figure 6-24 Door Hinge Repair Materials needed:

1. Cut two square pieces of 3 mm thick (1/8 inch) aluminum or stainless steel approximately 40 mm (15/8) square. These squareswill serveas backing plates.

2. Two nuts, bolts (10 -- 24 x 1) and washers for each insert that needs repair.

a. Drill a 1/4 hole in the center of each square backing plate.

b. Pass the bolts through the bolts holes in the door hinge, then through the control box at the location where the hinge insert pulled out.

c. From inside the control box, slide the backing plates over the bolts and secure in place with the washers and nuts.

6--25 T-327

Table 6-3 Crack, Chip & Hole Repair Kit ITEM DESCRIPTION PART NUMBER Qty

1 Crack Repair Kit -- Includes 76--00724--00SV 1

2 Fiberglass Patch Kit (Loctite FK--98 or 80265). . . 76--00724--00Z 10

3 Sikaflex 221 Adhesive Sealant (Sikaflex 232--361). . . 02--00067--02Z 10

4 Instruction Sheet. . . 98--02339--00 10

Table 6-4 Insert Repair Kit ITEM DESCRIPTION PART NUMBER Qty

1 Insert Repair Kit -- Includes 76--50084--00 1

2 Insert - 17.53 x 9.91 mm (.690 x .390 in) 1/4--20 Threads. . . 34--06231--01 10

3 Insert - 15.88 x 6.35 mm (.625 x .250 in) 10-24 Threads. . . 34--06231--03 10

4 Insert - 25.15 x 7.54 mm (.990 x .297 in) 10-24 Threads. . . 34--06231--04 10

5 Insert - 10.16 x 9.53 mm (.400 x .375 in) 10-24 Threads. . . 34--06231--05 10

6 Insert - 12.7 x 9.91 mm (.5 x .390 in) 1/4--20 Threads. . . 34--06231--06 10

7 Insert - 9.53 x 6.76 mm (.375 x .266 in) 10-24 Threads. . . 34--06231--07 10

8 Durabond Epoxy E20--HP (Loctite 29314). . . 02--0082--00 1

9 Static Mixing Tube (Loctite 983440). . . 07--00390--00 1

10 Instruction Sheet. . . 98--02338--00 1

Note: Insert repair procedures require use of an ApplicationGun, Carrier part number 07--00391--00 (Loctite 983435)

Table 6-5 Drill Information

Item Insert part number Drill size and depth 1 34- 06231- 01 10.3 mm x 17.8 mm deep (.404 in. x .700 in. deep) 2 34- 06231- 03 6.8 mm x 16.3 mm deep (.266 in. x .640 in. deep) 3 34- 06231- 04 7.9 mm x 25.4 mm deep (.3125 in. x 1.0 in. deep) 4 34- 06231- 05 6.9 mm (.270 in.) Drill completely through. 5 34- 06231- 06 10.3 mm (.404 in.) Drill completely through. 6 34- 06231- 07 6.8 mm (.266 in.) Drill completely through.

6--26T-327

03

04

01

07

05

06

IN S E R T P A R T N U M B E R S 34 --0 62 31 --# # W H E R E T H E ##

IS A S IN D IC A T E D03

03

03

03

04

05

07

Figure 6-25 Insert Location

6--27 T-327

6.25 COMMUNICATIONS INTERFACE MODULE INSTALLATION

Communications interface Module

CB1

Figure 6-26 Communications Interface Installation

Units with communication interface module provision have the required wiring installed. The provision wiring kit (part number 76--00685--00), includes three pre--addressed wires installed between the circuit breaker and communication interfacemodule locations. These wires are to be connected to the module and circuit breaker to allow themodule to communicate over the power system. To install the module, do the following:

WARNING Unit power plug must be disconnected to remove power from Circuit Breaker Cb1.

a. CB1 is connected to the power system, see wiring schematic. Ensure that the unit power is off AND that the unit power plug is disconnected.

b. Open control box, see Figure 6-26 and remove low voltage shield. Open high voltage shield.

c. Remove the circuit breaker panel, with circuit breaker, from the control box.

d. Locate, wires CB21/CIA3, CB22/CIA5 and CB23/CIA7 that have been tied back in the wire harness. Remove the protective heat shrink from the ends of the wires.

e. Attach the three wires as addressed to the LOAD side of the circuit breaker.

f. Refit the circuit breaker panel.

g. Fit the new RMU into the unit.

h. Remove plugs CIA, CIB and CID from the wiring harness and attach to the module.

i. Replace the low voltage shield.

Table 6-6 Recommended Bolt Torque Values

BOLT DIA. THREADS TORQUE Nm FREE SPINNING

#4 #6 #8 #10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4

40 32 32 24 20 18 16 14 13 12 11 10

5.2 in-lbs 9.6 in-lbs 20 in-lbs 23 in-lbs 75 in-lbs 11 ft-lbs 20 ft-lbs 31 ft-lbs 43 ft-lbs 57 ft-lbs 92 ft-lbs 124 ft-lbs

0.6 1.1 2.0 2.5 8.4 15 28 42 59 78 127 171

NONFREE SPINNING (LOCKNUTS ETC.) 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4

20 18 16 14 13 12 11 10

82.5 in-lbs 145.2 in-lbs 22.0 ft-lbs 34.1 ft-lbs 47.3 ft-lbs 62.7 ft-lbs 101.2 ft-lbs 136.4 ft-lbs

9.3 16.4 23 47 65 86 139 188

6--28T-327

Table 6-7 R-134a Temperature - Pressure Chart

Temperature Vacuum

_F _C /hg cm/hg kg/cm@ bar

--40 --40 14.6 49.4 37.08 0.49

--35 --37 12.3 41.6 31.25 0.42

--30 --34 9.7 32.8 24.64 0.33

--25 --32 6.7 22.7 17.00 0.23

--20 --29 3.5 11.9 8.89 0.12

--18 --28 2.1 7.1 5.33 0.07

--16 --27 0.6 2.0 1.52 0.02

Temperature Pressure

_F _C psig kPa kg/cm@ bar

--14 --26 0.4 1.1 0.03 0.03

--12 --24 1.2 8.3 0.08 0.08

--10 --23 2.0 13.8 0.14 0.14

--8 --22 2.9 20.0 0.20 0.20

--6 --21 3.7 25.5 0.26 0.26

--4 --20 4.6 31.7 0.32 0.32

--2 --19 5.6 36.6 0.39 0.39

0 --18 6.5 44.8 0.46 0.45

2 --17 7.6 52.4 0.53 0.52

4 --16 8.6 59.3 0.60 0.59

6 --14 9.7 66.9 0.68 0.67

8 --13 10.8 74.5 0.76 0.74

10 --12 12.0 82.7 0.84 0.83

12 --11 13.2 91.0 0.93 0.91

14 --10 14.5 100.0 1.02 1.00

16 --9 15.8 108.9 1.11 1.09

18 --8 17.1 117.9 1.20 1.18

20 --7 18.5 127.6 1.30 1.28

22 --6 19.9 137.2 1.40 1.37

24 --4 21.4 147.6 1.50 1.48

26 --3 22.9 157.9 1.61 1.58

Temperature Pressure

_F _C psig kPa kg/cm@ bar

28 --2 24.5 168.9 1.72 1.69

30 --1 26.1 180.0 1.84 1.80

32 0 27.8 191.7 1.95 1.92

34 1 29.6 204.1 2.08 2.04

36 2 31.3 215.8 2.20 2.16

38 3 33.2 228.9 2.33 2.29

40 4 35.1 242.0 2.47 2.42

45 7 40.1 276.5 2.82 2.76

50 10 45.5 313.7 3.20 3.14

55 13 51.2 353.0 3.60 3.53

60 16 57.4 395.8 4.04 3.96

65 18 64.1 441.0 4.51 4.42

70 21 71.1 490.2 5.00 4.90

75 24 78.7 542.6 5.53 5.43

80 27 86.7 597.8 6.10 5.98

85 29 95.3 657.1 6.70 6.57

90 32 104.3 719.1 7.33 7.19

95 35 114.0 786.0 8.01 7.86

100 38 124.2 856.4 8.73 8.56

105 41 135.0 930.8 9.49 9.31

110 43 146.4 1009 10.29 10.09

115 46 158.4 1092 11.14 10.92

120 49 171.2 1180 12.04 11.80

125 52 184.6 1273 12.98 12.73

130 54 198.7 1370 13.97 13.70

135 57 213.6 1473 15.02 14.73

140 60 229.2 1580 16.11 15.80

145 63 245.6 1693 17.27 16.93

150 66 262.9 1813 18.48 18.13

155 68 281.1 1938 19.76 19.37

7--1 T-327

SECTION 7

ELECTRICAL WIRING SCHEMATICS

7.1 INTRODUCTION

This section contains the Electrical Schematics and Wiring Diagrams. The diagrams are presented as follows: Figure 7-1 provides the legend for use with all figures. Figure 7-2 provides the basic schematic diagram. Figure 7-3 supplements the basic schematic diagram and provides schematics for TransFRESH and Emergency

Bypass. Figure 7-4 provides the schematic and wiring diagrams for the Electronic Partlow Recorder. Figure 7-5 provides the schematic and wiring diagrams for Upper and Lower Vent Position Sensors. Figure 7-6 provides the basic wiring diagram for the unit. Sequence of operation descriptions for the various modes of operation are provided in paragraph 4.10

SYMBOL DESCRIPTION (Schematic Location)

AMBS AMBIENT SENSOR (C--21)

BM BYPASS MODULE (E--8)

CB1 CIRCUIT BREAKER -- 460 VOLT (J--1)

CB2 CIRCUIT BREAKER -- AUTOTRANSFORMER (C--1)

CF CONDENSER FAN CONTACTOR (M--12, N--5)

CFS CONDENSER FAN SWITCH (L--12)

CI COMMUNICATIONS INTERFACE MODULE (A--3)

CL COOL LIGHT (J--8)

CM CONDENSER FAN MOTOR (H--12)

CP COMPRESSOR MOTOR (T--1)

CPDS COMPRESSOR DISCHARGE SENSOR (A--21)

CPSS COMPRESSOR SUCTION SENSOR (C--21)

CR CHART RECORDER [TEMPERATURE RECORDER]

CS CURRENT SENSOR (M--1)

DHBL DEFROST HEATER -- BOTTOM LEFT (T--4)

DHBR DEFROST HEATER -- BOTTOM RIGHT (R--4)

DHTL DEFROST HEATER -- TOP LEFT (T--4)

DHTR DEFROST HEATER -- TOP RIGHT (R--4)

DL DEFROST LIGHT (J--7)

DPH DRAIN PAN HEATER (P--4)

DPT DISCHARGE PRESSURE TRANSDUCER (L--21)

DTS DEFROST TEMPERATURE SENSOR (B--21)

DVM DUAL VOLTAGE MODULE (D--1)

DVR DUAL VOLTAGE RECEPTACLE (E--1)

EF EVAPORATOR FAN CONTACTOR [HIGH] (L--13,L--14,P--7,P--10)

EM EVAPORATOR FAN MOTOR (E--13,G--13,T--8,T--11)

ES EVAPORATOR FAN CONTACTOR [LOW] (M--14,P--7,P--10)

ESV ECONOMIZER SOLENOID VALVE (J--17)

F FUSE (C--5,D--20,E--20,H--5)

FT FUSE -- TransFRESH (H--5)

HPS HIGH PRESSURE SWITCH (G--11)

HR HEATER CONTACTOR (M--15, N--3)

HS HUMIDITY SENSOR (F--21)

HTT HEAT TERMINATION THERMOSTAT (G--15)

IC INTERROGATOR CONNECTOR [FRONT/REAR] (P--22,P--21)

IP INTERNAL PROTECTOR (E--13,G--13,H--12)

IRL IN RANGE LIGHT (J--9)

LIV LIQUID INJECTION VALVE (K--12)

SYMBOL DESCRIPTION (Schematic Location)

MDS MANUAL DEFROST SWITCH (E--18)

PA COMPRESSOR PHASE CONTACTOR (L--11,M--10,P--1)

PB COMPRESSOR PHASE CONTACTOR (L--10,M--11,P--2)

PR PROBE RECEPTACLE [USDA] D--21,L--22,M--22,N--22)

RM REMOTE MONITORING RECEPTACLE (J--7,J--8,J--9,K--8)

RRS RETURN RECORDER SENSOR (K--21)

RTS RETURN TEMPERATURE SENSOR (B--21)

SMV SUCTION MODULATING VALVE (K--24)

SPT SUCTION PRESSURE TRANSDUCER (M--21)

SRS SUPPLY RECORDER SENSOR (K--22)

ST START -- STOP SWITCH (K--4)

STS SUPPLY TEMPERATURE SENSOR (A--21)

TBU TRANSFORMER BRIDGING UNIT

TCC TransFRESH COMMUNICATIONS CONNECTOR (D--5)

TE CONTROLLER RELAY -- HIGH SPEED EVAPORATOR FANS (K--13)

TFC TransFRESH CONTROLLER (G--5)

TH CONTROLLER RELAY -- HEATING (K--15)

TN CONTROLLER RELAY -- CONDENSER FAN (K--12)

TP TEST POINT (D--20,G--12,G--17,H--11,H--16,J--12, J--13,J--15,M--18)

TR TRANSFORMER (M--2)

TRANS AUTO TRANSFORMER 230/460 (D--1)

TRC TransFRESH REAR CONNECTOR (E--5)

TS CONTROLLER RELAY -- ECONOMIZER SOLENOID VALVE (E--17)

TT CONTROLLER RELAY (C--11)

TU CONTROLLER RELAY -- UNLOADER SOLENOID VALVE (E--16)

TV CONTROLLER RELAY -- LOW SPEED EVAPORATOR FANS (K--14)

TL CONTROLLER RELAY -- RM COOL (G--8)

TF CONTROLLER RELAY -- RM DEFROST (G--7)

TI CONTROLLER RELAY -- RM IN RANGE (G--9)

TCP CONTROLLER RELAY -- COMPRESSOR PHASE SEQUENCING (K--10, K--11)

USV UNLOADER SOLENOID VALVE (K--18)

VPS VENT POSITION SENSOR

WP WATER PRESSURE SWITCH (E--12)

LEGEND

Figure 7-1 LEGEND

7--2T-327

Figure 7-2 SCHEMATIC DIAGRAM

7--3 T-327

TO KB7

TransFRESH CONTROLLER

ST SEE FIGURE

7--2

TR SEE FIGURE

7--2

Emergency Bypass

To QC1

To F3A

To F3B

To F3B

CONTROLLER

Figure 7-3 SCHEMATIC DIAGRAM -- TransFRESH and Emergency Bypass

7--4T-327

NOTE: STANDARD CONTROLLER JUMPERS: MA3 TO MA7 AND MA9 TO MA11 (SEE Figure 7-2) ARE REMOVED IN THIS APPLICATION

CR8

CR2

CR3 CR4

CR6

CR5

NOTE: STANDARD CONTROLLER JUMPERS: MA3 TO MA7 AND MA9 TO MA11 (SEE Figure 7-2 ) ARE REMOVED IN THIS APPLICATION

Figure 7-4 SCHEMATIC DIAGRAM, WIRING DIAGRAM-- Electronic Partlow Recorder

7--5 T-327

NOTE: JUMPER: MA1 TO MB13 AND REMOVE WIRE FROM ECM1 AND CONNECT WIRE TO ECT1 FOR CD45 USE IN BATTERY MODE

LOWER VENT POSITION SENSOR

UPPER VENT POSITION SENSOR

Figure 7-5 SCHEMATIC DIAGRAM, WIRING DIAGRAM-- Upper and Lower Vent Position Sensors

7--6T-327

NOTE: WHEN CFS OR BM ARE INSTALLED, WIRE DESTINATIONS CHANGE. ADDRESSES FOR THE CHANGED DESTINATIONS ARE SHOWN IN BRACKETS [XXX].

KE2 [BM1A]

KE3 [BM1B]

KE4 [BM2A]

KE5 [BM2B]

[B M T2]

[B M T3]

[B M T1]

RMA [BMA2]

Figure 7-6 WIRING DIAGRAM (Sheet 1 of 2)

7--7 T-327

NOTE: WHEN CFS IS INSTALLED, WIRE DESTINATIONS CHANGE FROM THE STANDARD. ADDRESSES FOR THE CHANGED DESTINATIONS ARE SHOWN IN BRACKETS [XXX].

CFS

KA6

CFA1SMVD [BM2B] SMVC [BM1B] SMVB [BM2A] SMVA [BM1A]

Figure 7-6 WIRING DIAGRAM (Sheet 2 of 2)

Index--1 T-327

INDEX

A Adding Refrigerant to System, 6-4

Air Cooled Condenser Section, 2-4

Alarm, 3-6, 3-10, 3-11, 3-12, 3-17, 3-27

Autotransformer, 6-15

B Battery Replacement, 6-17

C Capacitors, 6-13

Checking Superheat, 6-9

Communications Interface Module, 3-11, 6-27

Compressor, 6-5

Compressor Phase Sequence, 4-5

Compressor Section, 2-3

Condenser Coil, 6-7

Condenser Fan, 6-7

Condenser Pressure Control, 3-6

Configuration Software, 3-3, 3-8

Configuration Variables, 3-13

Control Box, 6-23

Controller, 3-3, 6-15

Controller Software, 3-3

Controller Troubleshooting, 6-16

D DataCORDER, 3-7, 3-10, 4-4

DataCORDER Communications, 3-10

DataCORDER Software, 3-7

DataReader, 3-10

DataView, 3-10

Defrost Interval, 3-4

Defrost Mode, 4-8

Display Module, 3-2

E Emergency Bypass, 4-9

Evacuation, 6-3

Evaporator, 6-11

Evaporator Fan, 6-12

Evaporator Section, 2-2

Expansion Valves, 6-9

F Failure Action, 3-4

Filter--Drier, 6-9

Fresh Air Makeup, 2-1, 4-1

Frozen Mode, 4-8

Frozen Mode -- Conventional, 3-6

Frozen Mode -- Economy, 3-6

Function Code, 3-14, 3-25

G General Description, 2-1

Generator Protection, 3-4

H Heat Lockout, 3-4, 3-5

Heater, 6-11

Heating Mode, 4-7

High Pressure Switch, 6-6

I Inspection, 4-1, 4-3

Introduction, 1-1

K Key Pad, 3-2

Index--2 T-327

L Logging Interval, 3-10

Lower Air, 1-2

M Manifold Gauge Set, 6-1

Microporcessor System, 3-1

Modes Of Operation, 3-3

O Oil, 6-6

Operational Software, 3-3, 3-7

P Painted Surfaces, 6-23

Perishable-- System Pressure Regulation, 3-5

Perishable Mode -- Bulb, 3-5

Perishable Mode -- Conventional, 3-4

Perishable Mode -- Dehumidification, 3-5

Perishable Mode -- Economy, 3-4

Power, 4-1

Pre--Trip, 3-7, 3-10, 3-21, 3-26, 4-4

Probe Check, 4-5

Pumping Down, 6-2

R Refrigerant Charge, 6-4

Refrigerant Leak, 6-3

Refrigerant Recovery, 6-3

Refrigeration Circuit, 2-10

Refrigeration System Data, 2-7

Refrigeration Unit -- Front Section, 2-1

S Safety and Protective Devices, 2-9

Sampling Type, 3-10

Section Layout, 6-1

Sensor Configuration, 3-8

Sequence Of Operation, 4-5

Service Connections, 6-2

Solenoid Valves, 6-11

Starting, 4-3

Stopping, 4-3

Suction Modulating Valve, 6-14

T Temperature Control, 3-4, 3-5

Temperature Recorder, 4-3, 6-20

Temperature Sensor, 6-17, 6-19

Thermistor Format, 3-10

Torque Values, 6-27

U Upper Air, 1-2

USDA, 3-11

V Valve Override Controls, 6-13

W Water Cooled Condenser, 6-7

Water--Cooled Condenser Section, 2-5

Wiring Schematic, 7-1

2005 Carrier Corporation D Printed in U. S. A. 09/07

Carrier Transicold Division, Carrier Corporation Container Products Group P.O. Box 4805 Syracuse, N.Y. 13221 U.S A

www.carrier.transicold.com

A member of the Un

Manualsnet FAQs

If you want to find out how the 69NT40 551 Carrier works, you can view and download the Carrier 69NT40 551 v2 Operation and Service Manual on the Manualsnet website.

Yes, we have the Operation and Service Manual for Carrier 69NT40 551 as well as other Carrier manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Operation and Service Manual should include all the details that are needed to use a Carrier 69NT40 551. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Carrier 69NT40 551 v2 Operation and Service Manual is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This Carrier 69NT40 551 v2 Operation and Service Manual consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download Carrier 69NT40 551 v2 Operation and Service Manual free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print Carrier 69NT40 551 v2 Operation and Service Manual, simply download the document to your computer. Once downloaded, open the PDF file and print the Carrier 69NT40 551 v2 Operation and Service Manual as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.