Carrier 69NT40-561-200 to 299 Operation Manual EN PDF

Container Refrigeration

OPERATIONS AND SERVICE MANUAL

For

PrimeLINE 69NT40-561-200 to 299 69NT40-561-500 to 599

PrimeLINE ONE 69NT40-565-200 to 299 69NT40-565-500 to 599 Container Refrigeration Units

T-362 Rev I

TM

2021 Carrier Corporation Printed in USA January 2021

OPERATIONS AND SERVICE MANUAL

For PrimeLINE

69NT40-561-200 to 299 69NT40-561-500 to 599

PrimeLINE ONE 69NT40-565-200 to 299 69NT40-565-500 to 599 Container Refrigeration Units

i T-362

TABLE OF CONTENTS PARAGRAPH NUMBER PAGE

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.1 GENERAL SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.2 FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.3 OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.4 MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.5 SPECIFIC HAZARD STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.2 REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3 CONFIGURATION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.4 FEATURE DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.4.1 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.4.2 Temperature Readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.4.3 Pressure Readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.4.4 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.5 Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.6 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.7 Evaporator Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.8 Plate Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.5 OPTION DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.5.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.5.2 Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.5.3 USDA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.5.4 Interrogator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.5.5 Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.5.6 Communications Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.5.7 Autotransformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.8 Gutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.9 Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.10 Thermometer Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.11 Water Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.12 Back Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.13 460 Volt Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.14 230 Volt Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.15 Cable Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.16 Upper Air (Fresh Air Make Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.17 Lower Air (Fresh Air Make Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.18 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.19 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.5.20 Condenser Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.5.21 Emergency Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.5.22 eAutoFresh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.5.23 XtendFRESH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.5.24 TripWise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.5.25 FuelWise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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2.5.26 QUEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.1.1 Refrigeration Unit - Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.1.2 Fresh Air Makeup Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3.1.3 Evaporator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3.1.4 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3.1.5 Air-Cooled Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3.1.6 Water-Cooled Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 3.1.7 Control Box Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3.1.8 Communications Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.2 REFRIGERATION SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 3.3 ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 3.4 SAFETY AND PROTECTIVE DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 3.5 REFRIGERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

3.5.1 Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 3.5.2 Economized Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 3.5.3 Electronic Expansion Valve (EEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

MICROPROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.1 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.1.1 Display Module and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.1.2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.2 CONTROLLER SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 4.2.1 Configuration Software (CnF Variables) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 4.2.2 Operational Software (Cd Function Codes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.3 MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 4.3.1 Start Up - Compressor Phase Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 4.3.2 Start Up - Compressor Bump Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 4.3.3 Perishable Mode Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 4.3.4 Perishable Pulldown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 4.3.5 Perishable Steady State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 4.3.6 Perishable Idle, Air Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 4.3.7 Perishable Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 4.3.8 Perishable Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 4.3.9 Perishable Dehumidification - Bulb Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 4.3.10 Perishable Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 4.3.11 Perishable Mode Cooling - Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 4.3.12 Perishable Mode Heating - Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 4.3.13 Perishable Mode - Trim Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.3.14 Frozen Mode - Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.3.15 Frozen Steady State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.3.16 Frozen Idle Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.3.17 Frozen Heat Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 4.3.18 Frozen Economy Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 4.3.19 Frozen Mode Cooling - Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 4.3.20 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 4.3.21 Defrost Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 4.3.22 Defrost Related Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

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4.3.23 Evaporator Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.3.24 Failure Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.3.25 Generator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.3.26 Compressor High Temperature Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.3.27 Compressor Low Pressure Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.3.28 Perishable Mode - System Pressure Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.3.29 Condenser Fan Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414

4.4 QUEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 4.5 CONTROLLER ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 4.6 PRE-TRIP DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415 4.7 DATACORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415

4.7.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415 4.7.2 DataCORDER Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416 4.7.3 Sensor Configuration (dCF02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 4.7.4 Logging Interval (dCF03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 4.7.5 Thermistor Format (dCF04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 4.7.6 Sampling Type (dCF05 & dCF06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 4.7.7 Alarm Configuration (dCF07 - dCF10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 4.7.8 DataCORDER Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 4.7.9 Pre-Trip Data Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 4.7.10 DataCORDER Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 4.7.11 USDA Cold Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 4.7.12 USDA Cold Treatment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 4.7.13 DataCORDER Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 4.7.14 ISO Trip Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424

4.8 CONTROLLER CONFIGURATION VARIABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 4.9 CONTROLLER FUNCTION CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 4.10 CONTROLLER ALARM INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 4.11 CONTROLLER PRE-TRIP TEST CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.2 CONNECT POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.2.1 Connecting to 380/460 VAC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.2.2 Connecting to 190/230 VAC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.3 ADJUST FRESH AIR MAKEUP VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 5.3.1 Upper Fresh Air Makeup Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 5.3.2 Lower Fresh Air Makeup Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.3.3 Vent Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.4 EAUTOFRESH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 5.5 XTENDFRESH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 5.6 CONNECT WATER-COOLED CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.6.1 Water-Cooled Condenser with Water Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 5.6.2 Water-Cooled Condenser with Condenser Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.7 CONNECT REMOTE MONITORING RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 5.8 STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.8.1 Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 5.8.2 Stopping the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.9 START-UP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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5.9.1 Physical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 5.9.2 Check Controller Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 5.9.3 Start Temperature Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 5.9.4 Complete Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5.10 PRE-TRIP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 5.10.1 Prior to Starting a Pre-Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 5.10.2 Starting a Pre-Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 5.10.3 Displaying Pre-Trip Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.11 PROBE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 5.12 EMERGENCY BYPASS OPERATION (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 5.13 TRIPWISE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510

5.13.1 Checking TripWise Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 5.13.2 Enabling or Disabling TripWise Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 5.13.3 TripWise Status Event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511

5.14 AUTOMATIC COLD TREATMENT (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 5.15 AUTOMATIC SETPOINT CHANGE (ASC) CD53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 6.1 UNIT WILL NOT START OR STARTS THEN STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 6.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . 61 6.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 6.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 6.5 UNIT WILL NOT TERMINATE HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 6.6 UNIT WILL NOT DEFROST PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 6.7 ABNORMAL PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 6.8 ABNORMAL NOISE OR VIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 6.9 MICROPROCESSOR MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 6.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . 64 6.11 EAUTOFRESH NOT OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 6.12 ELECTRONIC EXPANSION VALVE MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 6.13 AUTOTRANSFORMER MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 6.14 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . 65 6.15 COMPRESSOR OPERATING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 6.16 ABNORMAL TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 6.17 ABNORMAL CURRENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 7.1 SECTION LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 7.2 MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

7.2.1 Evacuating the Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 7.3 SERVICE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

7.3.1 Connecting the Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 7.3.2 Removing the Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

7.4 PUMP DOWN THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 7.4.1 Automatic Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 7.4.2 Manual Pump Down: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.5 REFRIGERANT LEAK CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 7.6 EVACUATION AND DEHYDRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

7.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 7.6.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 7.6.3 Evacuate and Dehydrate - Complete System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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7.6.4 Evacuate and Dehydrate - Partial System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 7.7 REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

7.7.1 Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 7.7.2 Adding Refrigerant to System - Full Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 7.7.3 Adding Refrigerant to System - Partial Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

7.8 CONVERTING TO R-513A REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 7.9 COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

7.9.1 Removing and Replacing the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 7.10 HIGH PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710

7.10.1 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 7.10.2 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711

7.11 CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 7.11.1 Condenser Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 7.11.2 Condenser Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 7.11.3 Condenser Coil Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712 7.11.4 Condenser Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712 7.11.5 Micro Channel Heat Exchanger (MCHE) Repair Instructions . . . . . . . . . . . . . . . . . . . . . . 713

7.12 CONDENSER FAN AND FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717 7.12.1 Condenser Fan Motor Remove/Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717

7.13 WATER-COOLED CONDENSER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718 7.13.1 Cleaning Supplies Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718 7.13.2 Cleaning Procedure Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718 7.13.3 Cleaning Procedure Detailed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718

7.14 FILTER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 7.14.1 Checking the Filter Drier: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 7.14.2 Replacing the Filter Drier: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720

7.15 EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 7.15.1 Evaporator Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721

7.16 EVAPORATOR HEATERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 7.16.1 Megger Testing the Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722

7.17 EVAPORATOR FAN AND MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 7.17.1 Replacing the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 7.17.2 Disassemble the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 7.17.3 Assemble the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724

7.18 EVAPORATOR SECTION CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 7.18.1 Cleaning Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 7.18.2 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726

7.19 ELECTRONIC EXPANSION VALVE (EEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 7.19.1 Removing an EEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 7.19.2 Installing an EEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727

7.20 HUMIDITY SENSOR (HS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727 7.20.1 Checking the Operation of the Humidity Sensor (HS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727

7.21 ECONOMIZER SOLENOID VALVE (ESV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 7.21.1 Removing a Solenoid Valve Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 7.21.2 Removing the Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 7.21.3 Installing the Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 7.21.4 Installing the Solenoid Valve Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729

7.22 ECONOMIZER EXPANSION VALVE (EXV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730

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7.22.1 Removing the Economizer Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730 7.22.2 Installing the Economizer Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730

7.23 TROUBLESHOOTING P6-7 (DUV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730 7.24 DIGITAL UNLOADER VALVE (DUV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731

7.24.1 Removing the DUV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731 7.24.2 Installing the DUV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732

7.25 VALVE OVERRIDE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732 7.26 AUTOTRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733 7.27 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734

7.27.1 Controller Module Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734 7.27.2 Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735 7.27.3 Controller Programming Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 736 7.27.4 Removing and Installing a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738 7.27.5 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738

7.28 TEMPERATURE SENSOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 739 7.28.1 Ice Bath Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 739 7.28.2 Sensor Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 7.28.3 GDP Supply and Return Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742 7.28.4 Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748 7.28.5 Supply Sensor (STS/SRS) Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 7.28.6 Return Sensor (RRS/RTS) Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 7.28.7 Defrost Temperature Sensor (DTS) Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751 7.28.8 Evaporator Temperature Sensor (ETS1/ETS2) Reinstallation . . . . . . . . . . . . . . . . . . . . . . 751 7.28.9 Compressor Discharge Temperature Sensor (CPDS) Reinstallation . . . . . . . . . . . . . . . . . 751

7.29 VENT POSITION SENSOR (VPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752 7.30 EAUTOFRESH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752 7.31 XTENDFRESH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752 7.32 MAINTENANCE OF PAINTED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752 7.33 COMMUNICATIONS INTERFACE MODULE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 753

7.33.1 Installing the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753 ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX1

vii T-362

LIST OF ILLUSTRATIONS FIGURE NUMBER Page

Figure 3.1 Refrigeration Unit - Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Figure 3.2 Evaporator Section - PrimeLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Figure 3.3 Evaporator Section - PrimeLINE ONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Figure 3.4 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Figure 3.5 Air-Cooled Condenser Section with C Shape Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Figure 3.6 Air Cooled Condenser Section with Micro Channel Heat Exchanger (MCHE) . . . . . . . . . . . . . . . 36 Figure 3.7 Tube In Shell Water-Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 3.8 Brazed Plate Water-Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Figure 3.9 Control Box Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Figure 3.10 Refrigeration Circuit Schematic - Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Figure 3.11 Refrigeration Circuit Schematic - Economized Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Figure 3.12 Refrigeration Circuit Schematic - Water-Cooled Condenser (Tube In Shell) . . . . . . . . . . . . . . 316 Figure 3.13 Refrigeration Circuit Schematic - Water-Cooled Condenser (Brazed Plate) . . . . . . . . . . . . . . . 317 Figure 4.1 Temperature Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Figure 4.2 Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Figure 4.3 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Figure 4.4 Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Figure 4.5 Controller Operation - Perishable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Figure 4.6 Perishable Mode Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Figure 4.7 Perishable Mode Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Figure 4.8 Controller Operation - Frozen Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Figure 4.9 Frozen Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 Figure 4.10 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412 Figure 4.11 Standard Configuration Download Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418 Figure 4.12 DataCORDER Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 Figure 4.13 DataCorder Probe Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422 Figure 4.14 DataCorder Probe Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 Figure 4.15 DataCorder Systems Tool Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 Figure 4.16 Alarm Troubleshooting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 Figure 5.1 Autotransformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Figure 5.2 Upper Fresh Air Make Up Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Figure 5.3 Diagram of Emergency Bypass Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Figure 5.4 TripWise Status in DataCorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 Figure 5.5 Generating TripWise Summary Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 Figure 5.6 TripWise Summary Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512 Figure 7.1 Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Figure 7.2 Manifold Gauge / Hose Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Figure 7.3 Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Figure 7.4 Refrigeration System Service Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Figure 7.5 Compressor Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Figure 7.6 High Pressure Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 Figure 7.7 Condenser Fan Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713

T-362 viii

Figure 7.8 Water-Cooled Condenser Cleaning - Forced Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719 Figure 7.9 Water-Cooled Condenser Cleaning - Gravity Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 Figure 7.10 Heater Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 Figure 7.11 Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724 Figure 7.12 Access Panel Torque Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 Figure 7.13 Electronic Expansion Valve (EEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 Figure 7.14 Coil View of Economizer Solenoid Valve (ESV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 Figure 7.15 Economizer Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730 Figure 7.16 Adapter and O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731 Figure 7.17 View of Digital Unloader Valve (DUV) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732 Figure 7.18 Autotransformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734 Figure 7.19 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735 Figure 7.20 Supply Sensors - Cover Assembly and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743 Figure 7.21 Removing Front Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744 Figure 7.22 Removing Evaporator Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744 Figure 7.23 Return Sensors - Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744 Figure 7.24 Return Sensors - Cutting Wire Ties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745 Figure 7.25 DataLINE - Probe Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745 Figure 7.26 DataLINE - Calibrate Sensors Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746 Figure 7.27 DataLINE - Enter Service Center Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746 Figure 7.28 Ice Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747 Figure 7.29 DataLINE - Start Cal Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747 Figure 7.30 DataLINE - Calibration Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748 Figure 7.31 Sensor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749 Figure 7.32 Sensor and Cable Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749 Figure 7.33 STS/SRS Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 Figure 7.34 RRS/RTS Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 Figure 7.35 ETS1/ETS2 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751 Figure 7.36 Compressor Discharge Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751 Figure 7.37 Communications Interface Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753 Figure 8.1 LEGEND - Standard Unit Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Figure 8.2 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Figure 8.3 Unit Wiring Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Figure 8.4 Unit Wiring Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Figure 8.5 Legend - Unit With Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Figure 8.6 Schematic Diagram - Unit With Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Figure 8.7 Unit Wiring Diagram - Unit With Autotransformer (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Figure 8.8 Unit Wiring Diagram - Unit With Transformer (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

ix T-362

LIST OF TABLES TABLE NUMBER Page

Table 31 Refrigeration System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Table 32 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Table 33 Safety and Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Table 41 Display Module LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Table 42 Keypad Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Table 43 DataCORDER Configuration Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418 Table 44 DataCORDER Standard Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 Table 45 Controller Configuration Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 Table 46 Controller Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 Table 47 Controller Pre-Trip Test Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452 Table 48 DataCORDER Function Code Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458 Table 49 DataCORDER Pre-Trip Result Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459 Table 410 DataCORDER Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 Table 71 Valve Override Control Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733 Table 72 Test Point Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735 Table 73 Sensor Resistance - AMBS, DTS, ETS, RRS, RTS, SRS, STS . . . . . . . . . . . . . . . . . . . . . . . . . 741 Table 74 Sensor Resistance - PrimeLINE CPDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742 Table 75 R-134a Refrigerant Pressure Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754 Table 76 R-513A Refrigerant Pressure Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 757 Table 77 Recommended Bolt Torque Values (Dry, Non-Lubricated for 18-8 Stainless Steel) . . . . . . . . . . 760

11 T-362

SECTION 1 SAFETY SUMMARY

1.1 General Safety Notices Installation and servicing of refrigeration equipment can be hazardous due to system pressures and electrical com- ponents. Only trained and qualified service personnel should install, repair, or service refrigeration equipment. When working on refrigeration equipment, observe all potential Danger, Warning and Caution hazards, including those shown below and on hazard labels attached to the unit.

The following general safety notices supplement specific warnings and cautions appearing elsewhere in this man- ual. 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.

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

1.3 Operating Precautions Always wear safety glasses.

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

Wear appropriate personal protective equipment for the work being undertaken.

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

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

1.4 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 mod- ules in 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).

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

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

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

CAUTION - means to warn against potential hazard or unsafe practice that could result in 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.

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WARNING! EXPLOSION HAZARD: Failure to follow this WARNING can result in death, serious personal injury and / or property damage. Never use air or gas mixtures containing oxygen (O2) for leak testing or operating the product. Charge only with refrigerants R-134a or R-513A as specified for the unit model number: Refrigerant must conform to AHRI Standard 700 specification.

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

WARNING! Do not attempt to remove power plug(s) before turning OFF the Start-Stop switch (ST), unit cir- cuit breaker(s) and external power source.

WARNING! Make sure the power plugs are clean and dry before connecting to power receptacle.

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, be sure to relieve the internal pressure very carefully by slightly loosening the couplings to break the seal.

WARNING! Do not use a nitrogen cylinder without a pressure regulator.

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

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.

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

WARNING! Installation requires wiring to the main unit circuit breaker, CB-1. Make sure the power to the unit is off and power plug disconnected before beginning installation.

WARNING! Before powering on the unit, it is important to ensure that all dismantling work is done and tools are away and service personnel are not working on the unit at the time of power on.

WARNING! Before removing the Supply or Return air sensors from the unit, turn the ON/OFF switch and circuit breaker to the OFF position. Disconnect the power plug from the unit. Follow proper lockout/tagout procedures to ensure the power cannot inadvertently be energized. It is important that all dismantling work is done and tools and personnel are away from the unit before powering on the unit for calibration.

WARNING! When performing the Return Air Sensor calibration, disconnect both evaporator motors.

CAUTION! When charging the unit with R-513A refrigerant, charge as a liquid only. R-513A is an azeotrope blend containing R-1234yf and R-134a. Charging or topping off as a vapor will result in an incor- rect mixture of blend in the system.

CAUTION! Charge water-cooled condenser or receiver according to nameplate specifications to ensure optimal unit performance.

CAUTION! Do not remove wire harnesses from circuit boards unless you are grounded to the unit frame with a static safe wrist strap or equivalent static drain device.

CAUTION! Remove the controller module and unplug all connectors before performing any arc welding on any part of the container.

CAUTION! Do not attempt to use an ML2i PC card in an ML3 equipped unit. The PC cards are physically different and will result in damage to the controller.

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

CAUTION! When PRE-TRIP key is pressed, economy, dehumidification and bulb mode will be deactivated. At the completion of pre-trip activity, economy, dehumidification and bulb mode must be reacti- vated.

CAUTION! When condenser water 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.

CAUTION! When a failure occurs during automatic testing, the unit will suspend operation awaiting opera- tor intervention.

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

CAUTION! The unit will remain in the full cooling mode as long as the EB switch is in the On position and the Mode Switch is in the Full Cool position. If the cargo can be damaged by low temperatures, the operator must monitor container temperature and manually cycle operation as required to maintain temperature within required limits.

CAUTION! Allowing the scroll compressor to operate in reverse for more than two minutes will result in internal compressor damage. Turn the Start-Stop switch OFF immediately.

CAUTION! To prevent trapping liquid refrigerant in the manifold gauge set, make sure set is brought to suction pressure before disconnecting.

CAUTION! The scroll compressor achieves low suction pressure very quickly. Do not use the compressor to evacuate the system below 0 psig. Never operate the compressor with the suction or dis- charge service valves closed (front seated). Internal damage will result from operating the com- pressor in a deep vacuum.

CAUTION! Take necessary steps (place plywood over coil or use sling on motor) to prevent motor from falling into condenser coil.

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CAUTION! Do not remove wire harnesses from module unless you are grounded to the unit frame with a static safe wrist strap.

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

CAUTION! The unit must be OFF whenever a programming card is inserted or removed from the controller programming port.

CAUTION! Use care when cutting wire ties to avoid nicking or cutting wires.

CAUTION! Do not allow moisture to enter wire splice area as this may affect sensor resistance.

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SECTION 2 INTRODUCTION

2.1 Introduction The Carrier Transicold PrimeLINE models 69NT40-561-200 to 299 and 69NT40-561-500 to 599 are units of lightweight aluminum frame construction, designed to be bolted on to the front of a container and serve as the containers front wall. Forklift pockets are provided for unit installation and removal.

The Carrier Transicold PrimeLINE ONE models 69NT40-565-200 to 299 and 69NT40-565-500 to 599 are units of lightweight aluminum frame construction, designed to be directly installed on-site onto a welded front wall of a container.

PrimeLINE units are self-contained, all electric units, which include cooling and heating systems to provide precise temperature control. The units are supplied with a complete charge of refrigerant and compressor lubricating oil, and are ready for operation upon installation.

The base unit operates on nominal 380/460 volt, 3-phase, 50/60 hertz (Hz) power. An optional autotransformer may be fitted to allow operation on nominal 190/230, 3-phase, 50/60 Hz power. Control system power 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 operates 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.

2.2 Refrigerant PrimeLINE models 69NT40-561-200 to 299 and PrimeLINE ONE models 69NT40-565-200 to 299 are units designed to only be charged with R-134a refrigerant.

PrimeLINE models 69NT40-561-500 to 599 and PrimeLINE ONE models 69NT40-565-500 to 599 are R-513A- ready units. They are supplied with a complete charge of R-134a refrigerant. But, they are capable of being field converted to R-513A refrigerant at a later date as requested by the unit owner. R-513A is an azeotrope blend containing R-1234yf and R-134a. All information in this manual pertaining to R-513A is only applicable to 561-500 to 599 or 565-500 to 599 model units that have either been converted or are being converted to R-513A.

To convert a R-513A-ready unit to R-513A refrigerant, refer to the procedure in Section 7.8 of the Service chapter.

2.3 Configuration Identification Unit identification information is provided on a unit nameplate (see Figure 3.1) located on the back wall of the condenser section. The nameplate provides the unit model number, serial number and parts identification number (PID). The model number identifies the overall unit configuration, while the PID number provides information on specific optional equipment, factory provisioned to allow for field installation of optional equipment and differences in detailed parts.

2.4 Feature Descriptions

2.4.1 Control Box Units are equipped with an aluminum control box, and may be fitted with a lockable door.

2.4.2 Temperature Readout The unit is fitted with suction and discharge refrigerant temperature sensors. The sensor readings may be viewed on the controller display.

2.4.3 Pressure Readout The unit is fitted with an evaporator, suction, and discharge pressure transducers. The transducer readings may be viewed on the controller display.

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2.4.4 Compressor

The unit is fitted with either an R-134a or an R-513A scroll compressor equipped with suction and discharge service connections. To identify an R-513A-ready compressor in the field, a green dot is located on the top of the compressor on the DUV fitting.

2.4.5 Condenser Coil

Units may be fitted either with a C shape condenser coil, or a U shape micro-channel heat exchanger (MCHE) condenser coil.

2.4.6 Evaporator

The evaporator section is equipped with an electronic expansion valve (EEV).

2.4.7 Evaporator Fan Operation

Units are equipped with three-phase evaporator fan motors. Opening of an evaporator fan internal protector will shut down the unit.

2.4.8 Plate Set

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

2.5 Option Descriptions Various options may be factory or field equipped to the base unit. These options are described in the following sub- paragraphs.

2.5.1 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 location or in a secure location.

2.5.2 Dehumidification

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

2.5.3 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.

2.5.4 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 is accessible from the front of the container and the other is mounted inside the container (with the USDA receptacles).

2.5.5 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.

2.5.6 Communications Interface Module

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.

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2.5.7 Autotransformer

An autotransformer may be provided to allow operation on 190/230, 3-phase, 50/60 Hz 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.

2.5.8 Gutters

Rain gutters may be fitted over the control box and recorder section to divert rain away from the controls.

2.5.9 Handles

The unit may be equipped with handles to facilitate access to stacked containers. These fixed handles are located on either side of the unit.

2.5.10 Thermometer Port

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

2.5.11 Water Cooling

The refrigeration system may be provisioned for a water-cooled condenser. The condenser is constructed using copper nickel tube for sea water applications. Refer to Section 3.1.6 for a more detailed description of the water- cooled condenser.

2.5.12 Back Panels

Aluminum back panels may have access doors and/or hinge mounting.

2.5.13 460 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.

2.5.14 230 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.

2.5.15 Cable Restraint

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

2.5.16 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.

2.5.17 Lower Air (Fresh Air Make Up)

The unit may be fitted with a lower fresh air makeup assembly. The fresh air makeup assembly is available with a vent positioning sensor (VPS) and may also be fitted with screens.

2.5.18 Labels

Safety Instruction and Function Code listing labels differ depending on the options installed. Labels available with additional languages are listed in the parts list.

2.5.19 Controller

Two replacement controllers are available:

1. Re-manufactured - Controller is equivalent of a new OEM controller, supplied with a 12-month warranty.

2. Repaired - Controller has had previous faults repaired and is upgraded with the latest software.

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NOTE Repaired controllers are NOT to be used for warranty repairs; only full OEM Re-manufactured control- lers 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.

2.5.20 Condenser Grille

Condenser grilles are direct bolted.

2.5.21 Emergency Bypass

The optional Emergency Bypass switch (EB) functions to bypass the controller in the event of controller failure.

2.5.22 eAutoFresh

The optional eAutoFresh venting system moderates the atmospheric level inside the container unit in response to cargo respiration.

Procedures and technical information related to the eAutoFresh venting system can be found in the T-342 eAutoFresh Manual, located in the Literature section of the Container Refrigeration website. To find the manual from the Literature section, click on Options > eAutoFresh.

2.5.23 XtendFRESH

XtendFRESH is an OEM option that helps slow the ripening process by removing ethylene and simultaneously controlling CO2 and O2 levels in multiple combinations.

Procedures and technical information related to the XtendFRESH controlled atmosphere system can be found in the T-366 XtendFRESH Manual, located in the Literature section of the Container Refrigeration website. To find the manual from the Literature section, click on Options > XtendFRESH.

2.5.24 TripWise

TripWise is a new premium option available for PrimeLINE units. TripWise is software logic that runs in the background during every voyage and will let you know whenever a standard pre-trip inspection (PTI) is needed. Refer to Section 5.13 for more detail on the TripWise option.

2.5.25 FuelWise

FuelWise is a power-saving option available for PrimeLINE units. FuelWise software works by dynamically cycling the refrigeration system on and off to save energy while still maintaining temperature within +/- 0.25 degrees Celsius of setpoint on an hourly average.

2.5.26 QUEST

QUEST (Quality and Energy Efficiency in Storage and Transport) power-saving mode available for PrimeLINE units. QUEST reduces energy requirements by up to 50 percent while reducing emissions related to power consumption.

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SECTION 3 DESCRIPTION

3.1 General Description 3.1.1 Refrigeration Unit - Front Section

The unit is designed so that the majority of the components are accessible from the front (see Figure 3.1). The unit model number, serial number and parts identification number can be found on the unit nameplate on the back wall under the condenser fan.

Figure 3.1 Refrigeration Unit - Front Section

1) Upper Fresh Air Makeup Vent Panel. Located inside are: Evaporator Fan #2, Defrost Tempera- ture Sensor (DTS)

2) Access Panel. Located inside are: Evaporator Fan #1, Electronic Expansion Valve (EEV), Heat Termi- nation Thermostat (HTT)

3) Fork Lift Pockets 4) Control Panel 5) Unit Display 6) Keypad 7) Remote Monitoring Receptacle (if equipped)

8) Start-Stop Switch (ST) 9) Compressor 10) Access Panel for Supply Temperature Sensor

(STS) / Supply Recorder Sensor (SRS) 11) Ambient Temperature Sensor (AMBS) 12) Economizer Heat Exchanger 13) Options Label 14) Unit Nameplate 15) Power Cables and Plug 16) Autotransformer location (if equipped) 17) Condenser Fan

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3.1.2 Fresh Air Makeup Vent

The function of the upper or lower fresh air makeup air vent is to provide ventilation for commodities that require fresh air circulation. A manually operated venting system is located in the upper left access panel.

3.1.3 Evaporator Section The evaporator section is shown in Figure 3.2. The evaporator fans circulate air through the container by pulling it into the top of the unit, directing it through the evaporator coil to be heated or cooled, and discharging it at the bottom.

Most evaporator components are accessible by removing the upper rear panel or by removing the evaporator fan access panels.

Figure 3.2 Evaporator Section - PrimeLINE

1) Evaporator Fan #1 2) Return Recorder Sensor (RRS) / Return Tempera-

ture Sensor (RTS) 3) Humidity Sensor (HS) - PIDs prior to NT2750 4) Humidity Sensor (HS) - PIDs NT2750 and up 5) Evaporator Fan #2 6) Evaporator Coil 7) Evaporator Coil Heaters 8) Defrost Temperature Sensor (DTS)

9) Heat Termination Thermostat (HTT) 10) Electronic Expansion Valve (EEV) 11) Evaporator Temperature Sensors (ETS1 & ETS2) 12) Interrogator Connector Rear (ICR) 13) USDA Probe Receptacle PR2 14) USDA Probe Receptacle PR1 15) USDA Probe Receptacle PR3 16) Cargo Probe Receptacle PR4

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Figure 3.3 Evaporator Section - PrimeLINE ONE

1) Evaporator Fan #1 2) Evaporator Fan #2 3) Return Recorder Sensor (RRS) / Return Tempera-

ture Sensor (RTS) 4) Humidity Sensor (HS) 5) Evaporator Coil 6) Evaporator Coil Heaters

7) Defrost Temperature Sensor (DTS) 8) Heat Termination Thermostat (HTT) 9) Electronic Expansion Valve (EEV) 10) Evaporator Temperature Sensors (ETS1 & ETS2) 11) Interrogator Connector Rear (ICR) 12) USDA Probe Receptacles (PR1, PR2, PR3, PR4)

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3.1.4 Compressor Section

The compressor section (see Figure 3.4) includes the compressor, digital unloader valve (DUV), high pressure switch, discharge pressure transducer (DPT), evaporator pressure transducer (EPT) and the suction pressure transducer (SPT). The supply temperature sensor (STS) and supply recorder sensor (SRS) are located to the left of the compressor.

Figure 3.4 Compressor Section

1) Compressor 2) Compressor Discharge Temperature Sensor

(CPDS) location 3) Discharge Connection 4) Suction Connection location 5) Compressor Terminal Box 6) Oil Drain location 7) Economizer Connection 8) Discharge Pressure Transducer (DPT)

9) Digital Unloader Valve (DUV) 10) Suction Pressure Transducer (SPT) 11) Evaporator Pressure Transducer (EPT) 12) High Pressure Switch (HPS) 13) Discharge Service Valve 14) Suction Service Valve 15) Supply Temperature Sensor (STS) / Supply

Recorder Sensor (SRS) 16) Warning Label

- - - - -

3.1.5 Air-Cooled Condenser Section

The air-cooled condenser section (see Figure 3.5) consists of the condenser fan, condenser coil, receiver, liquid line service valve, filter drier, fusible plug, economizer, economizer expansion valve (EXV), economizer solenoid valve (ESV), and sight glass / moisture indicator. The condenser fan pulls air from around the coil and discharges it horizontally through the condenser fan grille.

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Figure 3.5 Air-Cooled Condenser Section with C Shape Coil

1) Condenser Coil 2) Grille and Venturi Assembly 3) Condenser Fan 4) Condenser Coil Cover 5) Condenser Fan Motor 6) Receiver 7) Receiver Sight Glass

8) Receiver Moisture & Liquid Indicator 9) Fusible Plug 10) Filter Drier 11) Economizer 12) Economizer Solenoid Valve (ESV) 13) Economizer Expansion Valve (EXV) 14) Service Access Valve

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Figure 3.6 Air Cooled Condenser Section with Micro Channel Heat Exchanger (MCHE)

1) MCHE Coil 2) Grille and Venturi Assembly 3) Condenser Fan 4) Condenser Coil Cover 5) Condenser Fan Motor 6) Receiver 7) Receiver Sight Glass*

8) Receiver Moisture & Liquid Indicator* 9) Fusible Plug 10) Filter Drier 11) Economizer 12) Economizer Solenoid Valve (ESV) 13) Economizer Expansion Valve (EXV) 14) Service Access Valve

- - - - -

* Not visible in view, located behind Filter Drier

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3.1.6 Water-Cooled Condenser Section

The unit may contain a water-cooled condenser (WCC) installed as an option. When operating on the water-cooled condenser, the condenser fan is deactivated by a water pressure switch or condenser fan switch. There are two types of water-cooled condensers available and both are described below.

Tube in Shell Water-Cooled Condenser

The tube in shell water-cooled condenser section (see Figure 3.7) consists of a water-cooled condenser, sight glass, rupture disc, filter drier, water couplings, water pressure switch, economizer, economizer expansion valve (EXV), economizer solenoid valve (ESV), and moisture / liquid indicator. The water-cooled condenser is in series with the air-cooled condenser and replaces the standard unit receiver.

Figure 3.7 Tube In Shell Water-Cooled Condenser

1) Water-Cooled Condenser (WCC) 2) Rupture Disc 3) Moisture / Liquid Indicator 4) Filter Drier 5) Economizer 6) Economizer Solenoid Valve (ESV)

7) Economizer Expansion Valve (EXV) 8) Coupling - Water In 9) Liquid Line Service Valve / Connection 10) Self Draining Coupling - Water Out 11) Water Pressure Switch (WPS) 12) Sight Glass

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32 4 5

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Brazed Plate Water-Cooled Condenser The brazed plate water-cooled condenser section (see Figure 3.8) consists of the brazed plate water-cooled condenser (WCC), water couplings, a water pressure switch and a fusible plug. The receiver is retained in this configuration and the brazed plate heat exchanger is placed between the air-cooled condenser and the receiver.

Figure 3.8 Brazed Plate Water-Cooled Condenser

1) Water-Cooled Condenser (WCC) 2) Coupling - Water In

3) Self Draining Coupling - Water Out 4) Water Pressure Switch (WPS)

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3.1.7 Control Box Section

The control box (see Figure 3.9) includes: the manual operation switches, circuit breaker (CB-1), compressor, fan and heater contactors, control power transformer, fuses, keypad, display module, current sensor module, controller module and the communications interface module.

Figure 3.9 Control Box Section

1) Compressor Contactor (CH) 2) Unit Phase A Contactor (PA) 3) Unit Phase B Contactor (PB) 4) Heater Contactor (HR) 5) Controller / DataCORDER Module 6) Remote Monitoring Receptacle (RM) 7) Start-Stop Switch (ST)

8) Controller Battery Pack (standard location) 9) Control Transformer (TS) 10) Evaporator Fan Contactor High Speed (EF) 11) Evaporator Fan Contactor Low Speed (ES) 12) Condenser Fan Contactor (CF) 13) Circuit Breaker 460V (CB1) 14) Current Sensor Module

- - - - -

3.1.8 Communications Interface Module

The unit may be equipped with an optional communications interface module, which is a slave module that allows communication between the refrigeration unit and a ship system master central monitoring station. The module will respond to communication and return information over the ships main power line. If equipped, this module is located next to the Controller. See the master system technical manual for further information.

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3.2 Refrigeration System Data Table 31 Refrigeration System Data

Compressor / Motor Assembly

Model Number ZMD26KVE-TFD-272 Weight (With Oil) 42.9 kg (95 lb) Approved Oil Uniqema Emkarate RL-32-3MAF Oil Charge 1774 ml (60 ounces)

Electronic Expansion Valve (EEV) Superheat Evaporator

Verify at - 18C (0F) container box temperature 4.4 to 6.7C (8 to 12F)

Economizer Expansion Valve (EXV) Superheat

Verify at - 18C (0F) container box temperature 4.4 to 11.1C (8 to 20F)

Heater Termination Thermostat (HTT)

Opens 54 (+/- 3) C = 130 (+/- 5) F Closes 38 (+/- 4) C = 100 (+/- 7) F

High Pressure Switch (HPS) Cut-Out 25 (+/- 1.0) kg/cm2 = 350 (+/- 10) psig Cut-In 18 (+/- 0.7) kg/cm2 = 250 (+/- 10) psig

WARNING! EXPLOSION HAZARD: Failure to follow this WARNING can result in death, serious personal injury and / or property damage. Never use air or gas mixtures containing oxygen (O2) for leak testing or operating the product. Charge only with refrigerants R-134a or R-513A as specified for the unit model number: Refrigerant must conform to AHRI Standard 700 specification.

Refrigerant R-134a / R-513A Conforming to AHRI standard 700 specifications.

CAUTION! Charge water-cooled condenser or receiver according to nameplate specifications to ensure optimal unit performance.

Refrigerant Charge PIDs Prior to NT2800: WCC Tube-In-Shell 4.99 kg (11 lbs) WCC Brazed Plate 4.85 kg (10.7 lbs) Receiver 4.54 kg (10 lbs) PIDs NT2800 and Up: WCC Brazed Plate 4.58 kg (10.1 lbs) Receiver 4.26 kg (9.4 lbs)

Fusible Plug Melting point 99C = (210F) Torque 6.2 to 6.9 mkg (45 to 50 ft-lbs)

Rupture Disc Bursts at 35 +/- 5% kg/cm2 = (500 +/- 5% psig) Torque 6.2 to 6.9 mkg (45 to 50 ft-lbs)

Unit Weight Refer to unit model number plate.

Water Pressure Switch (WPS) Cut-In 0.5 +/- 0.2 kg/cm2 (7 +/- 3 psig) Cut-Out 1.6 +/- 0.4 kg/cm2 (22 +/- 5 psig)

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3.3 Electrical Data Table 32 Electrical Data

Circuit Breaker CB-1 (25 amp) Trips at 29 amps CB-2 (50 amp) Trips at 62.5 amps CB-2 (70 amp) Trips at 87.5 amps

Compressor Motor (CP) Full Load Amps (FLA) 13 amps @ 460 VAC

Condenser Fan Motor (CM)

Nominal Supply 380 VAC / 3 Phase / 50 Hz 460 VAC / 3 Phase / 60 Hz Full Load Amps .71 amps .72 amps Horsepower 0.21 hp 0.36 hp Rotations Per Minute 1450 rpm 1750 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.

Evaporator Coil Heaters

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

Evaporator Fan Motors (EM)

380 VAC / 3 Phase / 50 Hz 460 VAC / 3 Phase / 60 Hz Full Load Amps High Speed 1.07 .9

Full Load Amps Low Speed 0.47 0.47

Nominal Horsepower High Speed 0.36 0.63

Nominal Horsepower Low Speed 0.05 0.8

Rotations Per Minute High Speed 2850 rpm 3450 rpm

Rotations Per Minute Low Speed 1425 rpm 1725 rpm

Voltage and Frequency 360 - 460 VAC +/- 1.25 Hz 400 - 500 VAC +/- 1.5 Hz Bearing Lubrication Factory lubricated, additional grease not required Rotation CW when viewed from shaft end

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

Vent Position Sensor (VPS)

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

Economizer Solenoid Valve (ESV) Coils 24 VDC

Nominal Resistance @ 77F (25C) 7.7 ohms +/- 5%

Maximum Current Draw 0.7 amps

Digital Unloader Valve (DUV) Coils 12 VDC

Nominal Resistance @ 77F (20C) 14.8 ohms +/- 5%

Maximum Current Draw 929 mA

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3.4 Safety and Protective Devices Unit components are protected from damage by safety and protective devices listed in Table 33. These devices monitor the unit 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).

Electronic Expansion Valve (EEV) Nominal Resistance

Coil Feed to Ground (Gray Wire) 47 ohms

Coil Feed to Coil Feed 95 ohms

Humidity Sensor (HS)

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

Controller Setpoint Range -35 to +30C (-31 to +86F)

Table 33 Safety and Protective Devices

Unsafe Condition Device Device Setting

Excessive current draw Circuit Breaker (CB-1, 25 amp) - Manual Reset Trips at 29 amps (460 VAC) 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 condenser fan motor 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 motor(s) winding temperature Internal Protector(s) (IP-EM) - Automatic Reset N/A

Abnormal pressures / temperatures in the high refrigerant side

Fusible Plug - Used on the Receiver Rupture Disc - Used on the Water-Cooled Condenser

99C = (210F) 35 kg/cm2 = (500 psig)

Abnormally high discharge pressure High Pressure Switch (HPS) Opens at 25 kg/cm2

(350 psig)

Table 32 Electrical Data (Continued)

313 T-362

3.5 Refrigeration Circuit 3.5.1 Standard Operation

Starting at the compressor, (see Figure 3.10) the suction gas is compressed to a higher pressure and temperature.

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 3.12, Figure 3.13), 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 refrigerant for low temperature operation.

The liquid refrigerant continues through the liquid line, the filter drier (which keeps refrigerant clean and dry) and the economizer (not active during standard operation) to the electronic expansion valve (EEV).

As the liquid refrigerant passes through the variable orifice of the EEV, the pressure drops to suction pressure. In this process some of the liquid vaporizes to a gas (flash gas), removing heat from the remaining liquid. The liquid exits as a low pressure, low temperature, saturated mix. Heat is then 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 tube back to the compressor.

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 automatically start.

During the standard mode of operation, the normally closed digital unloader valve (DUV) controls the system refrigerant flow and capacity by loading and unloading the compressor in frequent discrete time intervals. If the system capacity has been decreased to the lowest allowable capacity with the DUV, the unit will enter a trim heat mode of operation, during which the controller will pulse the evaporator heaters in sequence with the compressor digital signal in order to absorb the excess capacity.

3.5.2 Economized Operation

In the economized mode, (see Figure 3.11) the frozen and pull down capacity of the unit is increased by sub- cooling the liquid refrigerant entering the electronic 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.

Liquid refrigerant for use in the economizer circuit is taken from the main liquid line as it leaves the filter drier. The flow is activated when the controller energizes the economizer solenoid valve (ESV).

The liquid refrigerant flows through the ESV to the expansion valve internal passages, absorbing heat from the liquid refrigerant flowing to the electronic expansion valve. The resultant medium temperature/pressure gas enters the compressor at the economizer port fitting.

When the control air temperature falls to 2.0C (3.6F) above setpoint, the DUV unloads the compressors scroll and begins to reduce the capacity of the unit. Percentage of the unit capacity is accessed through code select 01 (Cd01). For example, if Cd01 displays 70, it indicates that the compressor is operating unloaded with the DUV engaged 30% of the time.

3.5.3 Electronic Expansion Valve (EEV)

The microprocessor controls the superheat leaving the evaporator via the electronic expansion valve (EEV), based on inputs from the evaporator pressure transducer (EPT). The microprocessor transmits electronic pulses to the EEV stepper motor, which opens or closes the valve orifice to maintain the superheat setpoint.

T-362 314

Figure 3.10 Refrigeration Circuit Schematic - Standard Operation

1) Compressor 2) Discharge Service Valve 3) Discharge Pressure Transducer (DPT) 4) Condenser 5) Receiver 6) Receiver Sight Glass 7) Fusible Plug 8) Receiver Liquid Level / Moisture Indicator 9) Liquid Line Service Valve 10) Filter Drier 11) Economizer 12) Economizer Solenoid Valve (ESV)

13) Economizer Expansion Valve (EXV) 14) Economizer Expansion Valve (EXV) Sensing Bulb 15) Economizer Connection 16) Electronic Expansion Valve (EEV) 17) Evaporator 18) Evaporator Temperature Sensor (ETS1) 19) Evaporator Temperature Sensor (ETS2) 20) Digital Unloader Valve (DUV) 21) Evaporator Pressure Transducer (EPT) 22) Suction Pressure Transducer (SPT) 23) Suction Service Valve

- - - - -

18

19

1617

4 6 5

8 9

3

20

2

21

22

15

14

12

13

11

23

7

10

1

Discharge Vapor

Liquid Saturated Mixture

Suction Vapor

315 T-362

Figure 3.11 Refrigeration Circuit Schematic - Economized Operation

1) Compressor 2) Discharge Service Valve 3) Discharge Pressure Transducer (DPT) 4) Condenser 5) Receiver 6) Receiver Sight Glass 7) Fusible Plug 8) Receiver Liquid Level / Moisture Indicator 9) Receiver Liquid Line Service Valve 10) Filter Drier 11) Economizer 12) Economizer Solenoid Valve (ESV)

13) Economizer Expansion Valve (EXV) 14) Economizer Expansion Valve (EXV) Sensing Bulb 15) Economizer Connection 16) Electronic Expansion Valve (EEV) 17) Evaporator 18) Evaporator Temperature Sensor (ETS1) 19) Evaporator Temperature Sensor (ETS2) 20) Digital Unloader Valve (DUV) 21) Evaporator Pressure Transducer (EPT) 22) Suction Pressure Transducer (SPT) 23) Suction Service Valve

- - - - -

18

19

1617

4 6

5

8

10

9

3

20

2

21

22

23

15

1411

13

12 1

7

Discharge Vapor

Liquid Saturated Mixture

Suction Vapor

T-362 316

Figure 3.12 Refrigeration Circuit Schematic - Water-Cooled Condenser (Tube In Shell)

1) Compressor 2) Discharge Service Valve 3) Discharge Pressure Transducer (DPT) 4) Condenser 5) Rupture Disk 6) Water-Cooled Condenser 7) Sight Glass 8) Coupling (Water In) 9) Water Pressure Switch (WPS) 10) Coupling (Water Out) 11) Moisture Indicator 12) Liquid Line Service Valve 13) Filter Drier

14) Economizer Solenoid Valve (ESV) 15) Economizer Expansion Valve (EXV) 16) Economizer Expansion Valve (EXV) Sensing Bulb 17) Economizer 18) Economizer Connection 19) Electronic Expansion Valve (EEV) 20) Evaporator 21) Evaporator Temperature Sensor (ETS1) 22) Evaporator Temperature Sensor (ETS2) 23) Digital Unloader Valve (DUV) 24) Evaporator Pressure Transducer (EPT) 25) Suction Pressure Transducer (SPT) 26) Suction Service Valve

- - - - -

21

22

1920

3

23

2

5 16

1 13

1411

6

7 10

12

15 8 17

4

24

25

26

18 9

Discharge Vapor

Liquid Saturated Mixture

Suction Vapor

317 T-362

Figure 3.13 Refrigeration Circuit Schematic - Water-Cooled Condenser (Brazed Plate)

1) Compressor 2) Discharge Service Valve 3) Discharge Pressure Transducer 4) Condenser 5) Water-Cooled Condenser 6) Coupling (Water In) 7) Water Pressure Switch 8) Coupling (Water Out) 9) Receiver 10) Fusible Plug 11) Receiver Sight Glass 12) Receiver Sight Glass / Moisture Indicator 13) Liquid Line Service Valve 14) Filter Drier

15) Economizer Solenoid Valve (ESV) 16) Economizer Expansion Valve (EXV) 17) Economizer Expansion Valve (EXV) Sensing Bulb 18) Economizer 19) Economizer Connection 20) Electronic Expansion Valve (EEV) 21) Evaporator 22) Evaporator Temperature Sensor (ETS1) 23) Evaporator Temperature Sensor (ETS2) 24) Digital Unloader Valve (DUV) 25) Evaporator Pressure Transducer (EPT) 26) Suction Pressure Transducer (SPT) 27) Suction Service Valve

- - - - -

22

23

2021 3

4 11

10

14 9

12

13

24

17

1

19 18

15

16

6

5

7

8

2

25

26

27

Discharge Vapor

Liquid Saturated Mixture

Suction Vapor

41 T-362

SECTION 4 MICROPROCESSOR

4.1 Temperature Control Microprocessor System The temperature control Micro-Link 3 microprocessor system (see Figure 4.1) consists of a keypad, display module, control module (controller) and interconnecting wiring. The controller houses the temperature control software and the DataCORDER software. The temperature control software (see Section 4.2) functions to operate the unit components as required to provide the desired cargo temperature and humidity. The DataCORDER software (see Section 4.7) functions to record unit operating parameters and cargo temperature parameters for future retrieval.

Figure 4.1 Temperature Control System

4.1.1 Display Module and Keypad

The display module and keypad are mounted on the control box door and serve to provide user access and readouts for both of the controller functions, temperature control and DataCORDER. The functions are accessed by keypad selections and viewed on the display module.

The display module (see Figure 4.2) consists of two 5-digit displays and seven indicator lights. The indicator lights are described in Table 41. The keypad (see Figure 4.3) consists of eleven push button switches that act as the users interface with the controller. The switch functions are described in Table 42.

T-362 42

Figure 4.2 Display Module Figure 4.3 Keypad

Table 41 Display Module LEDs

Light Function COOL (White / Blue)

Energized when the refrigerant compressor is energized.

HEAT (Orange)

Energized to indicate heater operation in heat mode, defrost mode, or dehumidification.

DEFROST (Orange)

Energized when the unit is in defrost mode.

IN RANGE (Green)

Energized when the controlled temperature probe is within specified tolerance of setpoint. The controlling probe in perishable range is the SUPPLY air probe and in frozen range is the RETURN air probe.

SUPPLY (Yellow)

Energized when the supply air probe is used for control. When this LED is illuminated, the temperature displayed in the AIR TEMPERATURE display is the reading at the supply air probe. This LED will flash if dehumidification or humidification is enabled.

RETURN (Yellow)

Energized when the return air probe is used for control. When this LED is illuminated, the temperature displayed in the AIR TEMPERATURE display is the reading at the return air probe.

ALARM (Red)

Energized when an active or inactive shutdown alarm is in the alarm queue.

Table 42 Keypad Function

Key Function CODE SELECT Access function codes.

PRE-TRIP Display Pre-Trip selection menu. Discontinue pre-trip in progress.

ALARM LIST Display alarm list and clear alarm queue.

MANUAL DEFROST / INTERVAL

Display selected defrost mode. Press and hold this key for five seconds to initiate defrost using same logic as if the optional manual defrost switch was toggled on.

ENTER Confirm a selection or save a selection to the controller.

Arrow Up Change or scroll a selection up. Pre-trip advance or test interrupt.

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

RETURN / SUPPLY

Display non-controlling probe temperature (momentary display).

C / F Display 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 appears for inches of mercury. When set to C, pressure readings are in bars. b appears after the value to indicate bars.

BATTERY POWER

Initiate battery backup mode to allow setpoint & function code selection if AC power is not connected.

ALT MODE Switch the functions from temperature software to DataCORDER software. The remaining keys function the same as described above except the readings or changes are made to the DataCORDER programming.

CODE SELECT

PRE TRIP

ALARM LIST

MANUAL DEFROST/ INTERVAL

ENTER

BATTERY POWER

ALT MODE

RETURN SUPPLY

C F

43 T-362

4.1.2 Controller

CAUTION! Do not remove wire harnesses from circuit boards unless you are grounded to the unit frame with a static safe wrist strap or equivalent static drain device.

CAUTION! Remove the controller module and unplug all connectors before performing any arc welding on any part of the container.

CAUTION! Do not attempt to use an ML2i PC card in an ML3 equipped unit. The PC cards are physically different and will result in damage to the controller.

NOTE Do not attempt to service the controller modules. Breaking the seal will void the warranty.

The control module (see Figure 4.4) is fitted with test points, harness connectors and a software card programming port.

Figure 4.4 Control Module

1) Micro-Link 3 Controller / DataCORDER Module 2) Mounting Screw 3) Connectors 4) Test Points

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

- - - - -

4.2 Controller Software The controller software is a custom designed program that is subdivided into configuration software and operational software. The controller software performs the following functions:

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 buildup of frost and ice to ensure proper air flow across the evaporator coil.

Provide default independent readouts of setpoint and supply or return air temperatures.

Provide ability to read and (if applicable) modify the configuration software variables, operating software function codes and alarm code indications.

Provide a pre-trip step-by-step checkout of refrigeration unit performance including: proper component operation, electronic and refrigeration control operation, heater operation, probe calibration, pressure limiting and current limiting settings.

Provide battery-powered ability to access or change selected codes and setpoint without AC power connected.

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

M A CONTROLLER

Micro-Link3 With

DataCORDERM B

M C F2 (5 A

)

TP F1 (5 A

)

F3 A

(7 .5

A )

F3 B

(7 .5

A )

K H

O C

1

K A

EN12830 CARRIER S/N: 0491162 T B C1 KE

REV 5147 YYWW: KD

1035 KC

12-00579-00 59980

K B

1

2 3 4 5 3 6 3 8 37

T-362 44

4.2.1 Configuration Software (CnF Variables)

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 been made to the unit such as the addition or removal of an option. A configuration variable list is described in Table 45. Change to the factory-installed configuration software is achieved via a configuration card or by communications.

4.2.2 Operational Software (Cd Function Codes)

The operational software is the actual operation programming of the controller which activates or deactivates components in accordance with current unit operating conditions and 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 described in Table 46.

Accessing Function Codes on the Display

1. Press the CODE SELECT key on the keypad.

2. Press an Arrow key until the left window displays the desired function code.

3. The right window will display the selected function code value for five seconds before returning to normal display mode.

4. If additional time is required, pressing the ENTER key will extend the display time to 30 seconds.

4.3 Modes of Operation General operation sequences for cooling, heating and defrost are described in the following sub-paragraphs. Schematic representation of controller operation is provided in Figure 4.6, Figure 4.7 and Figure 4.8.

Operational software responds to various inputs. These inputs come from the temperature sensors and pressure transducers, the temperature setpoint, the settings of the configuration variables and the function code assignments. The action taken by the operational software changes as the input values change. Overall interaction of the inputs is described as 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.

4.3.1 Start Up - Compressor Phase Sequence At start up, the controller logic checks for proper phase sequencing and compressor rotation. If incorrect sequencing is causing the compressor and three-phase evaporator fan motors to rotate in the wrong direction, the controller will energize or de-energize relay TCP as required. Relay TCP will switch its contacts, energizing or de- energizing relays PA and PB. Relay PA is wired to energize the circuits on L1, L2 and L3. Relay PB is wired to energize the circuits on L3, L2, and L1, thus providing reverse rotation.

4.3.2 Start Up - Compressor Bump Start At start up, the controller logic will initiate a compressor bump start procedure to clear liquid refrigerant from the compressor. If suction and discharge pressures have equalized, the compressor will perform three compressor bump starts. A compressor bump start may also occur after a defrost cycle has been completed.

During bump start, the EEV will close. Relays TS, TQ, TN, TE, and TV will be de-energized (opened). The result of this action will close the ESV and shut all fans off. The compressor will start for 1 second, then pause for five seconds. This sequence will be repeated two more times. After the final bump start, the unit will pre-position the EEV to the correct starting position, pause and then start up.

4.3.3 Perishable Mode Temperature Control In Perishable mode, the controller maintains the supply air temperature at setpoint, the SUPPLY indicator light is illuminated and the default reading on the display window is the supply temperature sensor reading.

When the supply air temperature enters the in-range temperature tolerance (Cd30), the green IN-RANGE light will energize. When CnF26 (Heat Lockout Temperature) is set to -10C, Perishable mode is active with setpoints above -10C (+14F). When CnF26 is set to -5C, Perishable mode is active with setpoints above -5C (+23F).

45 T-362

4.3.4 Perishable Pulldown When the system is in Perishable Pulldown mode, the highest priority is given to bringing the container down to setpoint. When cooling from a temperature that is more than 2.5C (4.5F) above setpoint, the system will be in Perishable Pulldown mode in economized operation. However, pressure and current limit functions may restrict the valve if either exceeds the preset value.

4.3.5 Perishable Steady State In Perishable Steady State mode, the control temperature is maintained near a setpoint that is above the heat lockout temperature. Once setpoint is reached, the unit will transition to Perishable Steady State mode. This results in unloaded operation by cycling the DUV to limit capacity and maintain steady temperature control.

The unit is capable of maintaining supply air temperature to within +/- 0.2C (+/- 0.36F) of setpoint. Supply air temperature is controlled by positioning of the electronic expansion valve (EEV), cycling of the digital unloader valve (DUV), cycling of the compressor, and cycling of the heaters.

4.3.6 Perishable Idle, Air Circulation When it is unnecessary to run the compressor to maintain control temperature, the system enters Perishable Idle mode. If 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 Perishable Idle mode. During Perishable Idle mode, the compressor is turned off, but the evaporator fans continue to run to circulate air throughout the container. If temperature rises +0.2C (0.4F) above setpoint, the unit will transition back to Perishable Steady State mode.

4.3.7 Perishable Heating When it is necessary to raise the control temperature, the system will enter Perishable Heating mode. If the temperature drops to 0.5C (0.9F) below setpoint, the unit will transition to Perishable Heating mode, and the heaters will be energized. The unit will transition back to Perishable Idle mode when the temperature rises to 0.2C (0.4F) below the setpoint, and the heaters will de-energize.

Figure 4.5 Controller Operation - Perishable Mode

Controller Set Point ABOVE -10 C (+14 F), or -5 C (+23 F) optionally

Air Circulation

Air Circulation

Heating

Cooling, Enconomized

Pull DownPerishable Mode

Set Point Set

Point

-0.20 C-0.20 C

-0.50 C

+2.5 C (+4.5 F)

-0.50 C

+0.20 C

-0.25 C

Falling Temperature

Rising Temperature

Cooling, Unloaded

Cooling, Unloaded

(Only Applicable to Perishable Mode) Controller Set Point ABOVE -10 C (+14 F),

or -5 C (+23 F) optionally

Air Circulation

Heating

-0.20 C

T-362 46

4.3.8 Perishable Dehumidification Dehumidification is provided to reduce the humidity levels inside the container. The dehumidification setpoint range is from 50% to 95%. Dehumidification is activated when a humidity value is set at Cd33. The yellow SUPPLY LED will flash ON and OFF every second to indicate that Dehumidification is active. Once Dehumidification 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 humidity setpoint (Cd33).

2. The unit is in Perishable Steady State and supply air temperature is less than 0.25C (0.45F) above setpoint.

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

4. Heater Termination Thermostat (HTT) is closed.

If the above conditions are true for at least one hour, the evaporator fans will switch from high speed to low speed. Evaporator fan speed will then switch every hour, as long as the four conditions are met. See Bulb mode, Section 4.3.9, for different evaporator fan speed options.

If any condition except item (1) becomes false OR if the relative humidity sensed is 2% below the dehumidification setpoint, the high speed evaporator fans will be energized.

During dehumidification, power is applied to the defrost heaters. This added heat load causes the controller to open the EEV to match the increased heat load while still holding the supply air temperature very close to the setpoint.

Opening the EEV reduces the temperature of the evaporator coil surface, which increases the rate at which water is condensed and removes water from the passing air. Removing water from the air reduces the relative humidity. When the relative humidity sensed is 2% below setpoint, the controller de-energizes the heat relay. The controller will continue to cycle heating to maintain relative humidity below the selected setpoint. If dehumidification 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 during dehumidification to prevent rapid cycling and consequent contactor wear:

1. Heater debounce timer (three 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 setpoint criteria are satisfied.

2. Out-of-range timer (five minutes) - The out-of-range timer is started to maintain heater operation during a temporary out-of-range condition. If supply air temperature remains outside of the user selected in-range setting for more than five minutes, the heaters will be de-energized to allow the system to recover. The out- of-range timer starts as soon as temperature exceeds in-range tolerance value set by Cd30.

4.3.9 Perishable Dehumidification - Bulb Mode

Bulb mode is an extension of dehumidification which allows changes to the evaporator fan speed and/or defrost termination setpoints.

Bulb mode is active when Cd35 is set to Bulb. Once Bulb mode is activated, the user may then change dehumidification 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 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 setpoints from 50 to 95%.

In addition, if Bulb mode is active, Cd37 may be set to override the previous defrost termination thermostat (DTT) settings. The temperature at which the DTT will be considered open may be changed [in 0.1C (0.2F) increments] to any value between 25.6C (78F) and 4C (39.2F). The temperature at which the DTT is considered closed for interval timer start or demand defrost is 10C (50F) for open values from 25.6C (78F) down to a 10C (50F) setting. For open values lower than 10C, 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 setpoint to one that is in the frozen range.

When Bulb mode is disabled by any of the above conditions, evaporator fan operation for dehumidification reverts to alt and the DTS termination setting resets to the value determined by CnF41.

47 T-362

4.3.10 Perishable Economy

Economy Fan mode is an extension of the Perishable mode, and is provided for power saving purposes. Economy Fan mode is activated when Cd34 (also used for Frozen Economy mode) is set to ON. Economy Fan mode is used in the transportation of temperature-tolerant cargo or non-respiration items which do not require high airflow for removing respiration heat.

There is no active display that indicates that Economy Fan mode has been initiated. To check for Economy Fan mode, perform a manual display of Cd34.

In order to initiate Economy Fan mode, a perishable setpoint must be selected prior to activation. When Economy Fan mode is active, the evaporator fans will be controlled as follows:

a. At the start of each cooling or heating cycle, the evaporator fans will run in high speed for three minutes.

b. They will then be switched to low speed any time the supply air temperature is within +/- 0.2C (0.36F) of the setpoint and the return air temperature is less than or equal to the supply air temperature + 3C (5.4F).

c. The fans will continue to run in low speed for one hour.

d. 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, Economy Fan mode will be overridden.

4.3.11 Perishable Mode Cooling - Sequence of Operation

NOTE In Standard Perishable mode, the evaporator motors run in high speed. In Economy Fan mode, the fan speed is varied.

a. When supply air temperature is above setpoint and decreasing, the unit will cool with the condenser fan motor (CF), compressor motor (CH), and evaporator fan motors (EF) energized, and the white COOL light illuminated (see Figure 4.6). Also, if current or pressure limiting is not active, the controller will close contacts TS to open the economizer solenoid valve (ESV) and place the unit in economized operation.

Figure 4.6 Perishable Mode Cooling

b. When supply air temperature decreases to a predetermined tolerance above setpoint (Cd30), the green IN RANGE light is illuminated.

c. As air temperature continues to fall, unloaded cooling starts (DUV pulses opens) as the supply air temperature approaches setpoint (see Figure 4.5).

24 VOLT POWER

ENERGIZED DE-ENERGIZED

TN

ST F

HPS CH

IP-CM

TC

CF

TEIP-EM1 EFIP-EM2

HTT TH HR

ESVTS

TV EF ES

T-362 48

d. When unloaded cooling starts, EEV control will transition from a full cool superheat setpoint to a lower modulated cool superheat setpoint. Once unloading starts, the EEV controls evaporator superheat based on the system duty cycle where instantaneous superheat will vary.

e. When the supply air temperature has fallen to within 1.9C (3.4F) of setpoint temperature and the average capacity of the system has fallen below 70%, the unit will open contacts TS to close the ESV and take the unit out of economized operation.

f. The controller continuously monitors supply air temperature. Once the supply air temperature falls below setpoint, the controller periodically records supply air temperature, setpoint and time. A calculation is then performed to determine temperature drift from setpoint over time. If the calculation determines that cooling is no longer required, contacts TC and TN are opened to de-energize the compressor motor and the condenser fan motor. In addition the controller will close the EEV.

g. The evaporator fan motors continue to run to circulate air throughout the container. The green IN RANGE light remains illuminated as long as the supply air temperature is within tolerance of the setpoint.

h. If the supply air temperature increases to 1.0C (1.8F) above setpoint and three minutes have elapsed, contacts TC and TN close to restart the compressor and condenser fan motors in standard mode (non- economized) operation. The white COOL light is also illuminated.

i. If the average system capacity has risen to 100% during unloaded cooling and three minutes off time has elapsed, relay TS will energize to open the ESV, placing the unit in economized mode.

j. If the supply air increases more than 2.5C (4.5F) above setpoint temperature, the microprocessor will transition the evaporator superheat control from modulation back to full cool control.

4.3.12 Perishable Mode Heating - Sequence of Operation a. If the supply air temperature decreases 0.5C (0.9F) below setpoint, the system enters the heating mode

(see Figure 4.5). The controller closes contacts TH (see Figure 4.7) to allow power flow through the heat termination thermostat (HTT) to energize the heaters (HR). The orange HEAT light is also illuminated. The evaporator fans continue to run to circulate air throughout the container.

b. When the supply air temperature rises to 0.2C (0.4F) below setpoint, contact TH opens to de-energize the heaters. The orange HEAT light is also de-energized. The evaporator fans continue to run to circulate air throughout the container.

c. The safety heater termination thermostat (HTT) is attached to an evaporator coil circuit and will open the heating circuit if overheating occurs.

Figure 4.7 Perishable Mode Heating

NOTE The EEV and DUV are independently operated by the microprocessor. For full diagrams and legend, see Section 8.

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TN

ST F

HPS CH

IP-CM

TC

CF

TEIP-EM1 EFIP-EM2

HTT TH HR

ESVTS

TV EF ES

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4.3.13 Perishable Mode - Trim Heat If the system capacity has been decreased to the lowest allowable capacity and conditions exist that warrant maximum temperature stability the controller will pulse the HR relay to energize the evaporator heaters in sequence with the compressor digital signal.

4.3.14 Frozen Mode - Temperature Control In Frozen mode, the controller maintains the return air temperature at setpoint, the yellow RETURN indicator light is illuminated, and the default reading on the display window is the return temperature sensor (RTS) reading.

When the return air temperature enters the in-range temperature tolerance (Cd30), the green IN-RANGE light will energize.

When CnF26 (Heat Lockout Temperature) is set to -10C, frozen mode is active with setpoints below -10C (+14F). When CnF26 is set to -5C, frozen mode is active with setpoints below -5C (+23F).

When the system is in Frozen mode, the highest priority is given to bringing the container down to setpoint, the system will remain in economized operation.

4.3.15 Frozen Steady State Frozen cargos are not sensitive to minor temperature changes, and the frozen temperature control system takes advantage of this to greatly improve the energy efficiency of the unit. Frozen range temperature control is accomplished by cycling the compressor on and off as the load demand requires.

Once the frozen setpoint is reached, the unit will transition to frozen steady state (economized operation).

4.3.16 Frozen Idle Mode When temperature drops to setpoint minus 0.2C (0.4F) and the compressor has run for at least five minutes, the unit will transition to the Frozen Idle mode. The compressor is turned off and the evaporator fans continue to run to circulate air throughout the container. If temperature rises above setpoint +0.2C, (0.4F) the unit will transition back to the frozen steady state mode.

Figure 4.8 Controller Operation - Frozen Mode

Controller Set Point at or BELOW 10 C (+14 F), or 5 C (+23 F) optionally

.20 C

+.20 C

Air Circulation

Cooling, Economized

Set Point

+2.5 C (+4.5 F)

Frozen Mode

Falling Temperature

Rising Temperature

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4.3.17 Frozen Heat Mode

If the temperature drops 10C (18F) below setpoint, the unit will transition to the Frozen Heating mode. The evaporator fans are brought to high speed, and the heat from the fans is circulated through the container. The unit will transition back to Frozen Steady State when the temperature rises back to the transition point.

4.3.18 Frozen Economy Mode In order to activate Frozen Economy mode, a frozen setpoint temperature must be selected, and Cd34 (Economy Mode) set to ON. When economy mode 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 setpoint -2C (4F).

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 frozen setpoint +0.2C (0.4F), the unit will restart the refrigeration system and continue to cool until the off-cycle temperature criteria are met. If the control temperature is less than the frozen setpoint +0.2C (0.4F) the unit will turn off the evaporator fans and restart another 60 minute off-cycle.

4.3.19 Frozen Mode Cooling - Sequence of Operation a. When the return air temperature is above setpoint and decreasing, the unit will transition to economized

cooling with the condenser fan motor (CF), compressor motor (CH), economizer solenoid valve (ESV), low speed evaporator fan motors (ES) energized and the white COOL light illuminated (see Figure 4.9).

b. When the return air temperature decreases to a predetermined tolerance above setpoint, the green INRANGE light is illuminated.

c. When the return air temperature decreases to 0.2C (0.4F) below setpoint, contacts TC, TS and TN are opened to de-energize the compressor, economizer solenoid valve and condenser fan motor. The white COOL light is also de-energized. The EEV will close.

d. The evaporator fan motors continue to run in low speed to circulate air throughout the container. The green IN-RANGE light remains illuminated as long as the return air is within tolerance of setpoint.

e. If return air temperature drops to 10C (18F) or more below setpoint, the evaporator fans switch to high speed.

f. When the return air temperature increases to 0.2C (0.4F) above setpoint and three minutes have elapsed, the EEV opens and contacts TC, TS and TN close to restart the compressor, open the ESV and restart the condenser fan motor. The white COOL is illuminated.

Figure 4.9 Frozen Mode

NOTE The EEV and DUV are independently operated by the microprocessor. Complete schematics and legends are located in Section 8.

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TN

ST F

HPS CH

IP-CM

TC

CF

TEIP-EM1 EFIP-EM2

HTT TH HR

ESVTS

TV EF ES

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4.3.20 Defrost

Defrost is initiated to remove ice buildup from the evaporator coil which can obstruct air flow and reduce the cooling capacity of the unit. The defrost cycle may consist of up to three distinct operations depending upon the reason for the defrost or model number configuration. The first is de-icing of the coil, the second is defrost due to a probe check cycle and the third is a snap freeze process based on the unit model configuration.

De-icing the coil consists of removing power to the cooling components (compressor, evaporator fans, and condenser fan), closing the EEV, and turning on the heaters, which are located below the evaporator coil. During normal operation, de-icing will continue until temperatures indicate that the ice on the coil has been removed, proper air flow has been restored, and the unit is ready to control temperature efficiently.

If defrost was initiated by the probe check logic, then the Probe Check is carried out after the completion of the defrost cycle. A Probe Check is initiated only when there is an inaccuracy between the controller temperature sensors.

Snap Freeze allows the system to cool for a period of time after de-icing, with the evaporator fans turned off and is only carried out if configured by model number. Snap-Freeze allows for the removal of latent de-icing heat from the evaporator coils, and freezes any remaining moisture that might otherwise be blown into the container.

For more information on Probe Check and Probe Diagnostics, see Section 5.11.

4.3.21 Defrost Operation

Initiation of defrost is dependent on the state of the Defrost Temperature Sensor (DTS). When the DTS senses a temperature less than 10C (50F), the defrost options become active and the timer is engaged for the initiation of the defrost cycle. The defrost time accumulates when the compressor is running. In the perishable mode this is the same as real time as the compressor in general runs continuously. In frozen mode the actual time necessary to count down to the next defrost will exceed the defrost interval depending on the compressor duty-cycle.

When the defrost mode is in the active state, defrost can be initiated when any one of the following additional conditions become true:

1. Manually: While in the Defrost screen, when the Manual Defrost soft key is selected, if conditions will allow for a defrost, a manual defrost is initiated. The Defrost Indicator light is lit, and the user is brought back to the Main / Default screen.

While in the Defrost screen, when Manual Defrost soft key is selected, and conditions will NOT allow a defrost, a pop up message screen appears.

2. Timer: The Defrost Interval Timer reaches the user selectable Interval. The user-selected intervals are 3, 6, 9, 12, 24 Hours, Off, AUTO, Pulse, or AUTO2; factory default is AUTO. See Defrost Interval setting on the Trip Settings screen.

a. Automatic defrost starts with an initial defrost at three 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 termination of defrost, the time will not begin counting down until the DTS reading falls below 10C (50F). If the reading of DTS rises above termination setting any time during the timer count down, the interval is reset and the countdown starts over. The Auto defrost time is reset to three hours start time after every PTI initiation or trip start interval.

b. Fan Pulsing Logic is used to help prevent ice formation in the drain gutter and drain cup and ice buildup in supply air channel by using the evaporator fans to blow the warm air onto these areas during unit defrost. When cooling at lower set points, evaporator fan pulsing can be used during Defrost/De-ice when the Pulse option is selected for the Defrost Interval setting on the Trip Settings screen. When enabled, evaporator fan pulsing will occur based on the unit temperature set point and the Evap Fan Pulsing Temp setting on the Trip Settings screen. QUEST II also pulses the evaporator fans during Defrost/De-ice within a narrow perishable set point range. The logic for each evaporator fan pulsing feature is described below.

c. After a new Defrost Interval is selected, the previously selected Interval is used until the next defrost termination, the next time the DTS contacts are OPEN, or the next time power to the control is interrupted. If the previous value or the new value is OFF, the newly selected value will be used immediately.

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3. Probe Check: If defrost is initiated due to Probe Check immediately following the defrost cycle the evaporation fans are started and run for eight minutes to stabilize the temperature throughout the container. A probe check comparison is carried out at the end of the eight minute period if any sensor is found out of calibration. At this time its alarm set is no longer used for control/reorder purposes.

4. Probe Check Logic: The logic determines that a Probe Check is necessary based on temperature values currently reported by the supply and return probes

5. Delta T Logic: If the difference between return and supply air temperature (Delta T) becomes too great indicating possible reduced airflow over the evaporator coil caused by ice buildup requiring a defrost.

a. In Perishable Pull Down - Delta T increases to greater than 12C, and 90 minutes of compressor run time have been recorded.

b. In Perishable Steady State A baseline Delta T is recorded following the first defrost cycle after steady state conditions are reached, (the unit is cooling, and the evaporator fans and heaters must remain in a stable state for a period of five minutes). Defrost will be initiated if Delta T increases to greater than 4C above the baseline, and 90 minutes of compressor run time have been recorded.

c. In Frozen Mode - Defrost will be initiated if Delta T increases to greater than 16C and 90 minutes of compressor run time have been recorded.

When defrost is initiated, the controller closes the EEV, opens contacts TC, TN and TE (or TV) to de-energize the compressor, condenser fan and evaporator fans.

The controller then closes contacts TH to supply power to the heaters. The orange DEFROST light and heat light are illuminated and the COOL light is also de-energized.

Figure 4.10 Defrost

The EEV and DUV are independently operated by the microprocessor. Complete schematics and legends are located in Section 9.

Defrost will terminate when the DTS reading rises above one of two model number configurable options selection, either an upper setting of 25.6C (78F) which is default or lower setting of 18C (64F). When the DTS reading rises to the configured setting, the de-icing operation is terminated.

4.3.22 Defrost Related Settings

DTS Failure

When the return air temperature falls to 7C (45F), the controller ensures that the defrost temperature sensor (DTS) reading has dropped to 10C or below. If it has not, it indicates a failed DTS. A DTS failure alarm is triggered and the defrost mode is operated by the return temperature sensor (RTS). Defrost will terminate after 1 hour.

If the DTS fails to reach is termination setting, the defrost terminate after 2 hours of operation.

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TN

ST F

HPS PB

IP-CM

TC

CF

TEIP-EM1 EFIP-EM2

HTT TH HR

ESVTS

TV EF ES

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Defrost Timer

If CnF23 is configured to SAv (save), 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. If the save option is not selected the defrost timer will re- initiate and begin recounting.

If CnF11 is model number configured to OFF the operator will be allowed to choose OFF as a defrost interval option.

If CnF64 is configured in the operator will be allowed to choose PuLS as a defrost interval option. For units operating with PuLS selected, defrost interval is determined by the unit temperature set point and the Evap Fan Pulsing Temp setting on the Trip Settings screen. When the unit temperature set point is equal to or less than the Evaporator Fan Pulsing Temperature Setting, the defrost interval is set to 6 hours. Otherwise, the defrost interval is determined using the Automatic Defrost Interval Determination logic. In either case, PuLS remains displayed in this function select code.

If any Auto Pretrip sequence is initiated, the Defrost Interval setting will be set to AUTO unless CnF49 (OEM Reset) is set to Custom AND CnF64 (Evaporator Fan Pulsing Logic) configuration variable is set to IN, in which case the Defrost Interval setting on the Trip Settings screen will be set to Pulse.

If defrost does not terminate correctly and temperature reaches the set point of the Heat Termination Thermostat (HTT) 54C (130F), the HTT will open to de-energize the heaters (AL059 & AL060). If the HTT does not open and termination does not occur within two hours, the controller will terminate defrost. AL060 will be activated to inform of a possible DTS failure.

Protection Modes of Operation

4.3.23 Evaporator Fan Operation Opening of an evaporator fan internal protector will shut down the unit.

4.3.24 Failure Action Function code Cd29 may be operator set to select the action the controller will take upon a system failure. The factory default is full system shutdown. See Table 46.

4.3.25 Generator Protection Function codes Cd31 (Stagger Start, Offset Time) and Cd32 (Current Limit) may be operator set to control the start up sequence of multiple units and operating current draw. The factory default allows on demand starting (no delay) of units and normal current draw. See Table 46.

4.3.26 Compressor High Temperature Protection The controller continuously monitors compressor discharge pressure and 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 and on every 3 minutes. Condenser and evaporator fans will continue to operate during the compressor off cycle.

If high compressor dome temperature occurs, as measured by the CPDS, the controller will allow additional refrigerant to be released into the system in order to provide cooling to the evaporator coil and compressor dome. The controller is alerted to high compressor dome temperatures via the CPDS when ambient temperature is greater than 43.3C (110F), return air temperature is less than -17.5C (0.5F) and the compressor discharge temperature is greater than 117.7C (244F).

Dome temperature control logic will disengage when return air temperature and ambient temperature return to allowed limits or when the compressor turns off.

4.3.27 Compressor Low Pressure Protection If the suction pressure low limit is triggered, the DUV will energize to raise the suction pressure.

4.3.28 Perishable Mode - System Pressure Regulation In Perishable mode, system pressures may need to be regulated at ambient temperatures of 20C (68F) 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, -18C (0F), heater cycling may occur within normal system operation based on discharge pressure limits.

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4.3.29 Condenser Fan Override When CnF17 (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 pressure conditions are not maintaining discharge temperature, the logic will energize the condenser fan as follows:

1. If the DUV is less than 80% open when the controller calls for it to be100% open, the condenser fan is energized. When the DUV is 100% open, the fan will de-energize.

2. If DPT reading is invalid or out of range (AL65), the condenser fan is energized and will remain energized until system power is cycled.

3. If the system is running on condenser fan override and the high pressure switch opens, the condenser fan is energized and will remain energized until the system power is cycled.

4.4 QUEST QUEST is a method of temperature control using compressor-cycle during steady-state perishable cooling (also referred to as Compressor-Cycle Perishable Cooling, CCPC) that cycles the compressor on and off according to return air temperature.

To be eligible for steady-state control, the unit must first complete a setpoint pulldown phase and a QUEST pulldown phase:

During setpoint pulldown, supply air temperature is controlled according to the units nominal supply air setpoint.

During QUEST pulldown, supply air temperature is lowered somewhat relative to the nominal setpoint. Evaporator fans are forced to operate at high speed.

Steady-state QUEST mode control maintains the same lowered supply air temperature that was used during QUEST pulldown. The compressor cycles on and off according to return air high and low limits. Depending on the fan mode of operation selected, the evaporator fans may be programmed to run at low speed some or all of the time according to the control logic.

4.5 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 alarms is described in Section 4.10.

The alarm philosophy balances the protection of the refrigeration unit and that of the refrigerated cargo. The action taken when an error is detected always considers the survival of the cargo. Rechecks are made 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: The red alarm light will illuminate for alarm code numbers 15, 17, 20, 21, 22, 23, 24, 25, 26, and 27.

If a detectable problem exists, its alarm code will be alternately displayed with the setpoint on the left display.

The user should scroll through the alarm list to determine what alarms exist or have existed. Alarms must be diagnosed and corrected before the Alarm List can be cleared.

To Display Alarm Codes: 1. While in the Default Display mode, press the ALARM LIST key. This accesses the Alarm List Display mode,

which displays any alarms archived in the alarm queue.

2. The alarm queue stores up to 16 alarms in the sequence in which they occurred. The user may scroll through the list by pressing an Arrow key.

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

4. 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 Section 4.10 for alarm listing.

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

6. CLEAr is displayed if all alarms are inactive. The alarm queue may then be cleared by pressing ENTER. The alarm list will clear and ----- will be displayed.

NOTICE AL26 is active when none of the sensors are responding. Check the connector at the back of the controller, if it is loose or unplugged, reconnect it, then run a pre-trip test (P5) to clear AL26.

4.6 Pre-Trip Diagnostics Pre-Trip Diagnostics is an independent controller function that suspends normal refrigeration controller activities and provides preprogrammed test routines. The test routine can be run in Auto Mode, which automatically performs a pre programmed sequence of tests, or Manual Mode, which allows the operator to select and run any of the individual tests.

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

CAUTION! When the pre-trip key is pressed economy, dehumidification and Bulb Mode will be deactivated. At the completion of the pre-trip test, economy, dehumidification and Bulb Mode must be reactivated.

A pre-trip test may be initiated by use of the keypad 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 ENTER will allow the user to see the results for each of the sub-tests. The results will be displayed as PASS or FAIL for each test run to completion.

A detailed description of the pre-trip tests and test codes is described in Table 47. Detailed operating instructions are described in Section 5.10.

4.7 DataCORDER 4.7.1 Description Carrier Transicold DataCORDER software is integrated into the controller and serves to eliminate the temperature recorder and paper chart. DataCORDER functions may be accessed by keypad selections and viewed on the display module. The unit is also fitted with interrogation connections (see Figure 4.1) which may be used with the Carrier Transicold DataReader to download data. A personal computer with Carrier Transicold DataLINE software installed 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 two years of data (based on one hour interval). b. Records and displays alarms on the display module. c. Records results of pre-trip testing.

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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 (with and without battery pack) Power Up (with and without battery pack) Remote Probe Temperatures in the Container (USDA Cold treatment and Cargo probe recording) Return Air Temperature Setpoint Change Supply Air Temperature Real Time Clock Battery (Internal) Replacement Real Time Clock Modification Trip Start ISO Trip Header (When entered via Interrogation program) Economy Mode Start and End Auto 1 / Auto 2 / Auto 3 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

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

Operational Software The Operational Software reads and interprets inputs for use by the Configuration Software. The inputs are labeled Function Codes. Controller functions (see Table 48) 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 and 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. If a longer display time is desired, press the ENTER key to extend the display time to 30 seconds.

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 using the DataLINE interrogation software.

A list of the configuration variables is provided in Table 43. Descriptions of DataCORDER operation for each variable setting are provided in the following paragraphs.

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4.7.3 Sensor Configuration (dCF02) Two modes of operation may be configured: Standard Mode and Generic Mode.

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 are described in Table 44. 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 4.11).

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).

Generic Mode The Generic Recording Mode allows user selection of the network data points to be recorded. The user may select up to a total of eight data points for recording. Changing the configuration to generic and selecting which data points to record may be done using the Carrier Transicold Data Retrieval Program. A list of the data points available for recording follows.

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. Evaporator electronic expansion valve (EEV) percentage 10. Discrete outputs (Bit mapped - require special handling if used) 11. Discrete inputs (Bit mapped - require special handling if used) 12. Ambient temperature sensor (AMBS) 13. Evaporator temperature sensor (ETS) 14. Compressor discharge sensor (CPDS) 15. Return temperature sensor (RTS) 16. Supply temperature sensor (STS) 17. Defrost temperature sensor (DTS) 18. Discharge pressure transducer (DPT) 19. Suction pressure transducer (SPT) 20. Vent position sensor (VPS)

4.7.4 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).

4.7.5 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 with variable resolutions depending on temperature range. The long records temperature in 0.01C (0.02F) steps for the entire range.

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Figure 4.11 Standard Configuration Download Report

Table 43 DataCORDER Configuration Variables

Config 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

Raw Data Report for ABC1234567 Jan 01, 2015 to Mar 01, 2015

System Configuration at the Time of Interrogation:

Interrogated On Mar 05, 2015 Extracted by DataLINE Rev 1.0.0

Controller Software: 5361 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 ________________________________________________________________________________________

Jan 01, 2015

Setpoint: 1.66, Container : Serial : 04189552

9 Sensors Logged at 15 Minute Interval

Sensor Format Resolution

J a n 0 1 , 2 0 1 5

J a n 0 2 , 2 0 1 5

J a n 0 3 , 2 0 1 5

J a n 0 4 , 2 0 1 5

J a n 0 5 , 2 0 1 5

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4.7.6 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, supply and return temperature readings are averaged and the three USDA probe readings are snapshot.

4.7.7 Alarm Configuration (dCF07 - dCF10)

USDA and cargo probe alarms may be configured to OFF, ON or AUTO.

If a probe alarm is configured to OFF, the alarm for this probe is always disabled.

If a probe alarm is configured to ON, the associated 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 the DataCORDER configured for USDA recording, but do not 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, all of the alarms are enabled and the remaining probes that are not installed will give active alarm indications.

4.7.8 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, the DataCORDER will power up for communication 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 finished 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, the controller will energize and perform a 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.

Table 44 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)

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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, it indicates that the battery pack needs replacement.

4.7.9 Pre-Trip Data Recording

The DataCORDER will record the initiation of a pre-trip test (see Section 4.6) and the results of each test included in pre-trip. The data is time-stamped and may be extracted via the Data Retrieval program. See Table 49 for a description of the data stored in the DataCORDER for each corresponding pre-trip test.

4.7.10 DataCORDER Communications

Data retrieval from the DataCORDER can be accomplished by using the DataLINE, DataBANK Card, or a communications interface module.

NOTE A DataLINE or communications interface module display of Communication 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 mis-assigned.

Configuration identification for the models covered herein may be obtained on the Container Products Group Information Center by authorized Carrier Transicold Service Centers.

DataLINE

The DataLINE software for a personal computer is supplied on CD. This software allows interrogation, configuration variable assignment, screen view of the data, hard copy report generation, cold treatment probe calibration and file management. See Data Retrieval manual 62-10629 for a more detailed explanation of the Data LINE in ter rog at io n so f twa re. The D ataL IN E ma nu al ma y be fo und on th e In tern et a t www.container.carrier.com.

DataBANK Card

The DataBANK card is a PCMCIA card that interfaces with the controller through the programming slot and can download data at a fast rate. Files downloaded to DataBANK card files are accessible through an Omni PC Card Drive. The files can then be viewed using the DataLINE software.

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 communications interface module 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. See the master system technical manual for further information.

4.7.11 USDA Cold Treatment

Sustained cold temperature has been employed as a post-harvest method for the control of fruit flies and other insect genera. The commodity, insect species, treatment temperatures and exposure times are found in sections T107, T108, and T109 of the USDA Treatment Manual.

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 set point and record minute changes in product temperature within the DataCORDER memory, thus meeting USDA criteria. Information on USDA is provided in the following sub-paragraphs.

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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 3-pin receptacles are for the probes. The 5-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 up by a battery so recording can continue if AC power is lost.

USDA / Message Trip Comment

A special feature in DataLINE allows the user to enter a USDA (or other) message in the header of a data report. The maximum message length is 78 characters. Only one message will be recorded per day.

4.7.12 USDA Cold Treatment Procedure The following is a summary of the steps required to initiate a USDA Cold Treatment. If configured for USDA probes, setup can be verified as follows.

NOTE See the DataLine User manual 62-10629 for more details.

1. Ensure the DataCorder is configured as follows from the Configuration Screen (see Figure 4.12):

a. Configuration Option is set for USDA probes.

b. Logging Interval is set for 60 minutes.

c. DataCorder Sample Type is set for 2 Averaged 3-USDA.

d. Resolution is set for Normal.

Figure 4.12 DataCORDER Configuration Screen

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2. Calibrate the three USDA probes by ice bathing the probes and performing the calibration function (see Figure 4.13) with the DataLINE. Refer to the Ice Bath Preparation procedure. This calibration procedure generates the probe offsets which are stored in the controller and applied to the USDA sensors for use in generating sensor type reports.

NOTE See the DataLine User manual 62-10629 for more details.

Figure 4.13 DataCorder Probe Calibration Screen

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

4. Install the DataCORDER module battery pack (if not already installed).

5. Place the three probes. See USDA Treatment Manual for directions on placement of probes in fruit and probe locations in container.

6. To initiate USDA recording, connect the personal computer and Enter ISO header information using the DataLINE software. See Figure 4.14 and DataCorder Alarms Section.

a. Enter ISO header information.

b. Enter a trip comment if desired.

Sensor 1 Place the first sensor, labeled USDA1, in a box at the top of the stack of the fruit near- est to the air return intake.

Sensor 2 Place the second sensor, labeled USDA2, slightly aft of the middle of the container, halfway between the top and bottom of the stack.

Sensor 3 Place the third sensor, labeled USDA3, one pallet stack in from the doors of the con- tainer, halfway between the top and bottom of the stack.

423 T-362

Figure 4.14 DataCorder Probe Calibration Screen

c. Using the System Tools screen (see Figure 4.15) in the DataLine software perform a Trip Start.

Figure 4.15 DataCorder Systems Tool Screen

4.7.13 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 to the DataCORDER, an alarm is generated. The DataCORDER contains a buffer of up to eight alarms. A listing of the DataCORDER alarms is described in Table 410. See Section 4.7.7 for configuration information.

Displaying Alarm Codes:

1. While in the Default Display Mode, press the ALT. MODE and ALARM LIST keys. This brings up the DataCORDER Alarm List Display Mode, which displays any alarms stored in the alarm queue.

2. To scroll to the end of the alarm list, press the Up Arrow key. Pressing the Down Arrow key will scroll the list backward.

3. 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

4. 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.

T-362 424

5. If no alarms are active, the alarm queue may be cleared. The exception to this rule is the DataCORDER alarm queue Full alarm (AL91), which does not have to be inactive in order to clear the alarm list. To clear the alarm list:

a. Press the ALT. MODE and ALARM LIST keys.

b. Press the Up or Down Arrow key until CLEAr is displayed.

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

d. 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.

e. Upon clearing of the alarm queue, the alarm light will be turned off.

4.7.14 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 established with the DataCORDER, 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.

4.8 Controller Configuration Variables

Table 45 Controller Configuration Variables

Config Title Default Option CnF02 Evaporator Fan Speed dS (Dual) SS (Single) CnF03 Control Temperature Sensors FOUr duAL CnF04 Enable Dehumidification On OFF CnF08 Evaporator Motor Type 1Ph 3Ph CnF09 Refrigerant Type r134a r744 CnF11 Defrost Off Selection noOFF OFF CnF15 Enable Discharge Temperature Sensor Out In CnF16 Enable DataCORDER On (Yes) (Not Allowed) CnF17 Enable Discharge Pressure Sensor Out (No) In (Yes) CnF18 Heater Type Old (Low Watt) nEW (High Watt) CnF20 Enable Suction Pressure Transducer Out (No) In (Yes) CnF22 Economy Mode OFF Std, Full CnF23 Enable Defrost Interval Save noSAv SAv CnF24 Enable Long Pre-Trip Test Series Auto Auto2, Auto 3 CnF25 Enable Pre-Trip Data Recording rSLtS dAtA CnF26 Heat Lockout Temperature Set to -10C Set to -5C

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Note: Configuration numbers not listed are not used in this application. These items may appear when loading configuration software to the controller but changes will not be recognized by the controller programming.

CnF27 Enable Suction Temperature Sensor Out In CnF28 Enable Bulb Mode NOr bULb CnF31 Probe Check SPEC Std CnF32 Enable Single Evaporator Operation 2EF0 (Not Allowed) CnF33 Enable Snap Freeze OFF SnAP CnF34 Temperature Unit Display nOth F CnF37 Electronic Chart Probe rEtUR SUPPL, bOth CnF41 Enable Low DTT Setting Out In CnF44 Autoslide Enable Out LO, UP CnF45 Low Humidity Enabled Out In CnF46 Quench / Liquid Injection Valve Type nO=0=no nC=1=nc CnF47 Vent Position OFF UP, LOW, CUStOM CnF49 OEM Reset Option OFF 0-off,1-std, 2-spec,3-cust CnF50 Enhanced Bulb Mode Interface 0-out 1-in CnF51 Timed Defrost Disable 0-out 1-in CnF52 Oil Return Algorithm 0-out 1-in CnF53 Water Cool Oil Return Logic 0-out 1-in CnF55 TXV Boost Relay 0-out 1-in CnF56 TXV Boost Circuit 0-out 1-in CnF57 PWM Compressor Control 0-out 1-in CnF59 Electronic Evaporator Expansion Valve 0-none 1-EC, 2-KE, 3-NA CnF61 ACT ASC Control Enable 0-out 1-in CnF62 Extended Temperature Control Enable 0-out 1-in CnF63 QUEST Pre-Trip / TripWise Default State 0-on 1-off CnF64 Enable Fan Pulsing Logic 0-in 1-out CnF66 High Speed Evaporator Fan Option 0-off 1-on CnF67 Air Heaters 0-out 1-in CnF68 Enable Default Pulsing Temperature 0-out 1-in CnF70 Enable XtendFRESH Logic 0-out 1-in CnF71 XtendFRESH Pre-Trip / TripWise Default State 0-off 1-on CnF74 TripWise Pretrip / TripWise Default State 0-off 1-on CnF78 XtendFRESH Scrubber Output Available 0-out 1-in

Table 45 Controller Configuration Variables (Continued)

Config Title Default Option

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4.9 Controller Function Codes

Table 46 Controller Function Codes

Code Title Description

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

Display Only Functions - Cd01 through Cd26 are display only functions. Cd01 Capacity Modulation

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

Cd03 Compressor Motor Current

The current sensor measures current draw in lines L1 & L2 by all of the high volt- age 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 con- trol 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 deter- mine 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 Frequency The value of the main power frequency is displayed in Hertz. The frequency dis-

played will be halved if either fuse F1 or F2 is bad (alarm code AL21). Cd09 Ambient Temperature The ambient sensor reading is displayed. Cd10 Compressor Suction

Temperature / Evaporator Temperature

Evaporator temperature sensor reading is shown on the right display.

Cd11 Compressor Dome Temperature / Discharge Temperature

Compressor discharge temperature sensor reading, using compressor dome temperature, is displayed.

Cd12 Compressor Suction Port Pressure / Evaporator Pressure

Reading for evaporator pressure transducer (EPT) is shown on the left display; Press ENTER at Cd12 to show reading for compressor suction port pressure on right display.

Cd14 Compressor Discharge Pressure

Compressor discharges pressure transducer reading is displayed.

Cd15 Digital Unloader Valve The status of the valve is displayed (Open - Closed). Cd16 Compressor Motor

Hour Meter / Unit Run Time Hour Meter

This code displays the compressor motor hours. User can view unit run time by pressing the ENTER key while in Cd16. Total hours are recorded in increments of 10 hours (i.e., 3000 hours is displayed as 300). The Compressor Motor Hour Meter display can be reset to 0 by pressing and holding the ENTER key for 5 seconds. The Unit Run Time Hour Meter cannot be reset.

Cd17 Relative Humidity (%) Humidity sensor reading is displayed. This code displays the relative humidity, as a percent value.

427 T-362

Cd18 Software Revision Number

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 bat- tery voltages less than 4.5 volts. After the result is displayed for four seconds, btest will again be displayed, and the user may continue to scroll through the various codes.

Cd20 Config / Model Number This code indicates the dash number of the model for which the Controller is con- figured (i.e., if the unit is a 69NT40-551-100, the display will show 51100). To display controller configuration database information, press ENTER. Values in CFYYMMDD format are displayed if the controller was configured with a con- figuration card or with a valid OEM serial port configuration update; YYMMDD represents the publication date of the model configuration database.

Cd21 Capacity Mode The mode of operation is displayed (Unloaded - Standard - Economized). Cd22 Compressor State The status of the compressor is displayed (OFF, On). Cd23 Evaporator Fan State Displays the current evaporator fan state (OFF, LOW, HIGH). Cd25 Compressor Run Time

Remaining Until 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 - 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) This is the desired period of time between defrost cycles. Factory default is AU- TO. See Section NO TAG for information on Defrost Interval. CnF11 determines whether the operator will be allowed to chose OFF as a de- frost interval option. CnF64 determines whether the operator will be allowed to choose PuLS as a defrost interval option. For units operating with PuLS selected, defrost interval is determined by the unit temperature setpoint and the Evaporator Fan Pulsing Temperature Setting (Cd60). When the unit temperature setpoint is equal to or less than the Evaporator Fan Pulsing Temperature Setting, the defrost interval is set to 6 hours. Otherwise, the defrost interval is determined using the Automatic Defrost Interval Determination logic. In either case, PuLS remains displayed in this function select code. After a new Defrost Interval is selected, the previously selected Interval is used until the next defrost termination, the next time the DTT contacts are OPEN, or the next time power to the control is interrupted. If the previous value or the new value is OFF, the newly selected value will be used immediately. If any Auto Pre-trip sequence is initiated, Cd27 will be set to AUTO unless CnF49 (OEM Reset) is set to Custom AND CnF64 (Evaporator Fan Pulsing Logic) configuration variable is set to IN, in which case Cd27 will be set to PuLS.

Cd28 Temperature Units (Degrees C or Degrees F)

This code determines the temperature units (C or F) that will be used for all tem- perature displays. The user selects C or F by selecting function code Cd28 and pushing the ENTER key. The factory default value is Celsius units. This function code will display ----- if CnF34 is set to F.

Table 46 Controller Function Codes (Continued)

Code Title Description

T-362 428

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.) b - Partial Cooling (Compressor is on, standard operation.) C - Evaporator Fan Only (Evaporator fans on high speed, not applicable with fro- zen setpoints.) d - Full System Shutdown - Factory Default (Shut down every component in the unit.)

Cd30 In-Range Tolerance The in-range tolerance will determine the temperature band around the setpoint which will be designated as in-range. For normal temperature control, control temperature is considered in range if it is within setpoint in-range Tolerance. There are four possible values: 1 = +/- 0.5C (+/-0.9F) 2 = +/- 1.0C (+/-1.8F) 3 = +/- 1.5C (+/-2.7F) 4 = +/- 2.0C (+/-3.6F) - Factory Default If the control temperature is in-range, the green IN-RANGE light will be illuminated. In-range tolerance shall be set to +/- 2.0C upon activation of dehumidification or Bulb Mode (Cd33, Cd35, Cd48). When CCPC is actively controlling, in-range tolerance is not considered. ----- will be displayed whenever Dehumidification or Bulb Mode is enabled or when CCPC with six hour re-activation is actively controlling. ----- will be displayed whenever Frozen Economy Mode is operating.

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.

Cd32 System 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. When de- sirable, the limit can be lowered. Note, however, that capacity is also reduced. The five values for 460 VAC operation are: 15, 17, 19, 21, or 23 amperes. The factory default setting is 21 amperes.

Cd33 Humidity Setpoint This is the value in percent to which the system will dehumidify or humidify. There are configuration variables that determine whether dehumidification/hu- midification capabilities are installed. In the Test Mode, the setpoint will be tem- porarily set to 1%, allowing the test of dehumidification. After 5minutes, the normal setpoint is restored. If unit is configured for HUMIDIFICATIONMODE then selection of a setpoint greater than 75% will activate humidification, and a setpoint less than or equal to 75% will activate dehumidification. If the unit is con- figured for dehumidification only, then the entire setpoint range will apply to de- humidification. If Pre-trip is initiated, this value will be set to OFF automatically. (Replaced by Cd48 interface if CnF50 Enhanced Bulb Mode Interface is active.)

Cd34 Economy Mode (On- Off)

The current state of the Economy Mode option, -----, On, or Off. CnF22 deter- mines whether Economy Mode offered. Economy Mode is a user selectable mode of operation provided for power saving purposes.

Table 46 Controller Function Codes (Continued)

Code Title Description

429 T-362

Cd35 Bulb Mode The current state of the Bulb Mode option, -----, nOr, or bULb. (Replaced by Cd48 if CnF50, Enhanced Bulb Mode, is active.) Bulb Mode is an extension of dehumidification control (Cd33). If dehumidification (CnF04) is set to Off, Cd35 will display Nor and the user will be unable to change it. CnF28 determines whether the Bulb Mode selection is offered. After a dehumidification setpoint has been selected and entered for code Cd33, the user may then change Cd35 to bulb. After Bulb Mode has been selected and entered, the user may then utilize function codes Cd36 and Cd37 to make the desired changes.

Cd36 Evaporator Fan Speed This is the desired evaporator fan speed for use during the bulb Dehumidification and Humidification Mode option. (Replaced by Cd48 if CnF50, Enhanced Bulb Mode, is active.) This code is enabled only if in the Dehumidification Mode (Cd33) and Bulb Mode (Cd35) has been set to bulb. If these conditions are not met, alt will be dis- played (indicating that the evaporator fans will alternate their speed) and the dis- play cannot be changed. If a dehumidification setpoint 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 Variable DTT Setting (Bulb Mode)

This is the variable defrost termination thermostat setting to be used with the op- tional Bulb Mode functionality. This item is only displayed if the Bulb Mode option is configured on. (Replaced by Cd48 interface if CnF50 Enhanced Bulb Mode Interface is active.)

Display Only Functions - Cd38 through Cd40 are display only functions. Cd38 Secondary Supply

Temperature Sensor Cd38 will display the current supply recorder sensor (SRS) reading for units con- figured 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

Cd39 will display the current return recorder sensor (RRS) reading for units con- figured 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 Identification Number

If a valid container id exists, the default display for Cd40 will be cd40_XXXXX where XXXXX is the 5th character through the 9th character of the container id. Pressing the ENTER key on Cd40 will display id_YYYYYYY where YYYYYYY is the 5th character to the 11th character of the container id. If no valid container id exists or the container id is blank, the default display will have Cd40 on the left display and the right display will alternate between _nEEd and ___id. Pressing the ENTER key while on Cd40 in the state will prompt the Set Id Interface. On start up if the container id is not valid, Cd40 will be brought up on the display for the first minute of power up. This can be left by either entering a container id or leaving the code select normally. Cd40 is configured at commissioning to read a valid container identification num- ber. The reading will not display alpha characters; only the numeric portion of the number will display.

Table 46 Controller Function Codes (Continued)

Code Title Description

T-362 430

Cd41 Valve Override SERVICE FUNCTION: This code is used for troubleshooting, and allows manual positioning of the economizer solenoid valve, electronic expansion valve, and digital unloader valve. Provides readings such as: Percent Capacity, EEV, Ca- pacity Mode, LIV and DUV. See Section 7.25 for operating instructions.

Configurable Functions - Cd43 is a user-selectable function. The operator can change the value of this function to meet the operational needs of the container. Cd43 eAutoFresh Mode Cd43 is a user selectable mode of operation that allows the opening and closing

of a mechanical air vent door via a stepper motor. These selection modes are as follows: OFF - Air makeup vent will remain closed. USER - Allows for manual selection of the setting. DELAY -The opening of the door is based on selected time, return temperature and flow rate (percent opened). gASLM - The opening is based percent open and CO2 and O2 selectable limits (LM). This selection is only active if the unit has a CO2 sensor. TEST / CAL (CO2 sensor option units only) - The door will fully open and close to allow the user to inspect its operation. If CAL is selected, the controller will zero calibrate the CO2 sensor input.

Cd43 XtendFRESH Mode Cd43 has three selectable modes of operation: FRESH - All XtendFRESH operations are enabled and setpoints for CO2 and O2 can be edited. OFF - All XtendFRESH operations are disabled. TEST - the operator has the ability to test operation of mechanical components, test and calibrate the CO2 sensors and verify the validity of the O2 sensor.

Display Only Function - Cd44 is a display only function. Cd44 eAutoFresh Values /

CO2 Sensor Status Cd44 displays the eAutoFresh CO2 and O2 values (CO2 and O2) and CO2 and O2 limits (CO2 LIM and O2 LIM), respectively. This function code will be dashed if CO2 sensor is not detected, and a sensor is not expected (didnt have one previously). This function code will display ChECK if a CO2 sensor has not been auto-de- tected at the most recent power-up and was detected at a previous power-up. If ChECK is displayed and the ENTER key is pressed, SEnSr is displayed with the choices of YES and no: YES sensor should be remembered as detected (present) no sensor should not be remembered as being detected (not present)

Cd44 XtendFRESH Values Cd44 allows the user to view the following XtendFRESH values: CO2 setpoint, CO2 percentage, O2 setpoint, O2 percentage, and O2 voltage. For the CO2 setpoint, the range is from 0 to 19% in 1% increments with a default setting of 5%. For the O2 setpoint, the range is from 3% to 21% in 1% increments with a default setting of 10%.

Configurable Functions - Cd45 through Cd48 are user-selectable functions. The operator can change the value of these functions to meet the operational needs of the container.

Table 46 Controller Function Codes (Continued)

Code Title Description

431 T-362

Cd45 Vent Position Sensor (VPS) Position

Values: 0 to 240 for UPPER / 0 to 225 for LOWER This function code will be dashed out if not configured for VPS. When configured for VPS, Cd45 displays the current vent position in units of 5 CMH (units displayed as CM) or CFM (units displayed as CF) depending on the selection of Cd46 (Airflow display units), Cd28 (Metric/Imperial) or the press- ing of the deg C/F key. Cd45 will display whenever the control detects movement via the sensor unless AL50 is active. Cd45 will display for 30 seconds, then time out and return to the normal display mode.

Cd46 Airflow Display Units Selects the airflow units to be displayed by Cd45 if configured for Vent Position Sensor or displayed by USER/FLO under Cd43 if configured for Autoslide. CF = Cubic Feet per Minute CM = Cubic Meters per Hour bOth = Displays CF or CM depending on the setting of Cd28 (Metric/Imperial) or the pressing of the degree C/F key.

Cd47 Variable Economy Temperature Setting

Used when Economy Mode (CnF22) is set to 3-cust. Display will show ---- when the unit is not configured for Economy Mode. When the unit has a perishable setpoint and Economy Mode is active, at the start of each cooling or heating cycle, high speed evaporator fans will run for 3 min- utes. After three minutes, the evaporator fans will be switched to low speed any time that the supply temperature is within +/- 0.25C of the setpoint and the return temperature is less than or equal to the supply temperature + the user selected Cd47 (values are 0.5C - 4.0C, default is 3.0C).

Table 46 Controller Function Codes (Continued)

Code Title Description

T-362 432

Cd48 Dehumidification / Bulb Cargo Mode Parameter Selection

Initially Cd48 will display current dehumidification-mode; bUlb - bulb cargo mode, dEhUM - normal dehumidification, or OFF - off. This display is steady. Pressing ENTER key will take the interface down into a hierarchy of parameter selection menus (mode, setpoint, evaporator speed, DTT setting). Pressing EN- TER key in any parameter selection menu commits to selection of the currently displayed parameter and causes the interface to descend into the next parame- ter selection menu. All parameter selection menus alternate between a blank dis- play and the current selection in the right hand display. Pressing CODE SELECT key in a selection menu cancels the current selection activity and ascends back up to the next higher selection menu (or to Cd48 dis- play mode if that is the next higher). If the operator does not press any key for five seconds the interface reverts to normal system display and the current selection menu is cancelled, but any pre- viously committed changes are retained. Available parameters and parameter ranges are a function of configuration op- tions and previously selected parameters as indicated above. Whenever any pre-trip test is initiated, dehumidification-mode goes to OFF. Whenever dehumidification-mode goes to OFF:

Dehumidification control setpoint goes to0%RHinternally but will then initialize to 95% RH when dehumidification-mode leaves OFF.

Evaporator speed select goes to Alt for units without PWM Compressor Control (Cnf57 = Out), Evaporator speed select goes to Hi for units with PWM Compressor Control (Cnf57 = In).

DTT setting goes to 25.6_C or 18.0_C, depending on Cnf41. Whenever dehumidification-mode is set to bUlb, DTT setting goes to 18.0C if it had been set higher. Whenever dehumidification-mode is set to dEhUM, DTT setting goes to 25.6C or 18.0C, depending on Cnf41. For units without PWM Compressor Control (Cnf57 = Out):

Whenever dehumidification control setpoint is set below 65% RH evaporator speed select goes to LO if it had been set to Hi.

Whenever dehumidification control setpoint is set above 64% RH evaporator speed select goes to Alt if it had been set to LO.

For units with PWM Compressor Control (Cnf57 = In): Whenever dehumidification control setpoint is set below 60% RH, the evaporator

fan speed is set to LO, the user has the ability to set the evaporator fan speed to Hi via the keypad.

Whenever dehumidification control setpoint is set equal to or above 60% RH, the evaporator fan speed is set to Hi, the user has the ability to set the evaporator fan speed to LO via the keypad.

Display Only Function - Cd49 is a display only function. Cd49 Days Since Last

Successful Pre-Trip Displays the number of days since last successful pre-trip sequence. Press ENTER to view the number of days since the last successful pre-trip for Auto1, Auto2, and Auto2 in sequence. Press CODE SELECT to step back through the list and ultimately to exit the Cd49 display.

Configurable Functions - Cd50 through Cd53 are user-selectable functions. The operator can change the value of these functions to meet the operational needs of the container.Cd50

Table 46 Controller Function Codes (Continued)

Code Title Description

433 T-362

Cd50 Quest Enable / Disable OFF = disabled. On = enabled. SEtPt = suspended by setpoint too low. CAHUM = suspended by CA or humidity control. ACt = suspended by ACT active. FAIL = all return temperature probe failure for CCPC. PrtrP = pre-trip active. C LIM = suspended by cool limit logic. PULL = pulldown active. ALArM = suspended by shutdown alarm Press ENTER, Arrow keys, and then enter to select OFF or On. If On is selected, CCPC operation may be suspended as indicated by one of the suspension codes listed above. If CCPC is not OFF and is not suspended, On will be displayed.

Cd51 Automatic Cold Treatment (ACT) Mode Parameter Selection

Automatic Cold Treatment (ACT) mode: Cd51 increments of (1 day)_(1hr), Display: default 0_0 done mm-dd this will be display is ACT has completed ACt value On OFF or ----Display /Select: default OFF trEAt value C / F on 0.1 degree increments Display/Select: default 0.0C DAyS value 0 99 increments of 1 Display/Select: default 0 ProbE value Probe positions ex 1 2 _ 4 1 _ 3 _ Display: default ---- SPnEW value C / F on 0.1 increments Display/Select: default 10.0C Initially Cd51 will display current countdown timer increments of (1 day)_(1hr), default 0_0. See Section 5.14 for procedure to set ACT using Cd51. Pressing ENTER key will take the interface down into a hierarchy of parameter selection menus (act, treat, days, probe and spnew setting). Pressing ENTER key in any of the parameter selection menus commits to selec- tion of the currently displayed parameter and causes the interface to descend into the next parameter selection menu. All parameter selection menus alternate between a blank display and the current selection in the right hand display. Pressing CODE SELECT key in a selection menu cancels the current selection activity and ascends back up to the next higher selection menu (or to Cd51 dis- play mode if that is the next higher). If the operator does not press any key for five seconds the interface reverts to normal system display and the current selection menu is cancelled, but any pre- viously committed changes are retained. Parameter with the exception of Act may not be altered if Cd51 is re-entered if Act is On. When ACT has completed including reaching the new setpoint do- ne on the left display and the MONTH DAY of completion on the right display will be displayed as the second entry in the menu. Turning ACT off clears this entry. This action also resets Cd51 to initial time remaining. ACT must then be turned on to view or modify the additional parameters. Whenever any auto pre-trip test or Trip Start is initiated, ACT mode goes to OFF.

Table 46 Controller Function Codes (Continued)

Code Title Description

T-362 434

Cd53 Automatic Setpoint Change (ASC) Mode Parameter Selection

Automatic Setpoint Change (ASC) Mode: Cd53 increments of (1 day)_(1hr), Display: default 0_0 done mm-dd this will be display is ASC has completed ASC value On OFF Display /Select: default OFF nSC value 1 - 6 (This is the value n for the subsequent entries). SP (n-1) value C / F on 0.1 degree increments Display/Select: default 10.0C DAY (n-1) value 1 99 increments of 1 Display/Select: default 1 SP (n) value C / F on 0.1 degree increments Display/Select: default 10.0C Initially Cd53 will display current count down timer increments of (1 day)_(1hr), default 0_0 Pressing ENTER key will take the interface down into a hierarchy of parameter selection menus, (mode, act, treat, days, probe and spnew setting). Pressing ENTER key in any of the parameter selection menus selects the currently dis- played parameter and causes the interface to descend into the next parameter selection menu. All parameter selection menus alternate between a blank dis- play and the current selection in the right hand display. Pressing CODE SELECT key in a selection menu cancels the current selection activity and ascends back up to the next higher selection menu (or to Cd53 dis- play mode if that is the next higher). If the operator does not press any key for five seconds the interface reverts to normal system display and the current selection menu is cancelled, but any pre- viously committed changes are retained. Available parameters and parameter ranges are a function of configuration op- tions and previously selected parameters as indicated above. Parameter with the exception of ASC may not be altered if Cd53 is re-entered if ASC is On. When ASC has completed including reaching the last setpoint done on the left display and the MONTH DAY of completion on the right display will be displayed as the second entry in the menu. Turning ASC off clears this entry. This action also resets Cd53 to initial time remaining. ASC must then be turned on to view or modify the additional parameters. Whenever any auto pre-trip test or Trip Start is initiated, ASC mode goes to OFF.

Display Only Functions - Cd54 through Cd58 are display only functions. Cd54 Suction Port Superheat

/ Electronic Expansion Valve Status

Reading for evaporator superheat (suction temperature minus suction saturation temperature as calculated from suction pressure) is shown on the right display. Press ENTER at Cd54 to show reading for EEV position (in %) on left display.

Cd55 Discharge Superheat Cd55 will display discharge superheat (discharge temperature minus discharge saturation temperature as calculated from discharge pressure) values in C /F as calculated by the discharge temperature minus the discharge saturation tem- perature as calculated from discharge pressure. ----- will be displayed if selec- tion is not valid.

Table 46 Controller Function Codes (Continued)

Code Title Description

435 T-362

Cd58 Water Pressure Switch / Condenser Fan Switch State or Override Logic State

Cd58 will display CLOSE if the WPS or CFS switch contacts are closed or if these options are not installed. OPEn is displayed when the WPS or CFS switch contacts are open. When the WPS/CFS Override Logic is TRUE, the right display will flash on all units. NOTE: 1. This CLOSE/OPEn state displayed in this Code Select function only applies to units that have the ability to detect the state of a WPS/CFS. This function should not be relied upon to display the condition of the switch on units that dont have a WPS/CFS switch connected to ECG2 exclusively. 2. The right display will flash if the WPS/CFS Override Logic is TRUE on all units. This is always the case, whether the unit has a WPS or CFS installed or not. 3. The ability of the WPS/CFS Override Logic to control the condenser fan is lim- ited. It is not possible for this logic to control the fan on units that have the WPS or CFS wired in series with the fan contactor. Units wired in this configuration can indicate that the WPS/CFS Override Logic is active by flashing the right display, however, the wiring will not allow for control of the condenser fan.

Configurable Functions - Cd59 through Cd61 are user-selectable functions. The operator can change the value of these functions to meet the operational needs of the container. Cd59 Pump Down Logic Cd59 allows operation of the pump down logic control. The display will flash be-

tween STArT PdN and PrESS EnTEr. Upon entering Cd59 the operator will be required to acknowledge that they want to initiate the pump down control. The display will flash between STArT PdN and PrESS EnTEr. Once the decision to continue is confirmed pump down logic will begin, and will take complete control of the unit until pump down either suc- ceeds or fails. This operation can not be halted once it begins without power cy- cling the unit. After pump down logic has been initiated, the operator will be notified to close the Liquid Line Valve, the display will flash between CLOSE LLV and PrESS En- TEr. Once complete the display will read P dN to the left, and the current suc- tion pressure to the right. If the automatic pump down logic succeeds within 20 minutes, the unit will turn itself off, and the display will notify the operator that pump down is complete by flashing between P dN DOnE and SHUT OFF. The operator must then shut off the unit. If the automatic pump down logic does not complete within 20 minutes, the unit will drop out of Cd59 and return to its previous control condition.

Cd60 Evaporator Fan Pulsing Temperature Setting

Cd60 contains a selectable temperature range used to determine the engage- ment point of the Evaporator Fan Pulsing logic. Default setting is -18.1C. The user may change the temperature by pressing ENTER, then scrolling to the de- sired temperature using either Arrow key. Press Enter to accept the change. The temperature setting will be retained until either a pre-trip or Trip Start is initiated at which time the temperature will set to the default setting. ----- will be displayed if CnF68 is configured OUT.

Cd62 High Speed Evaporator Fan Setting

Cd62 is used to force evaporator fan speed to high while temperature control is being performed in the perishable setpoint range. When set to On, evaporator fans operate in high speed regardless of any other active option that can control evaporator fan speed. Following a power cycle, the state of the function select code is retained at its state prior to the power cycle. If On, this function select code will be set to OFF when any trip start occurs or any pre-trip test is initiated. ----- will be displayed if setpoint is in frozen range or if CnF66 is configured OFF.

Table 46 Controller Function Codes (Continued)

Code Title Description

T-362 436

Cd63 FuelWise Cd63 is used to enable FuelWise. Following a power cycle, the state of the function select code is retained at its state prior to the power cycle if CNF72 = Default ON else if Default OFF this will be set to OFF. If On, this function select code will be set to OFF when any trip start occurs or any pretrip test is initiated. Event 120 shall be logged when ever CD63 is Turned ON OR if CD63 state is ON at Midnight. ----- will be displayed if Cnf72 is configured OFF.

Cd65 TripWise Setting If the function is off, display "OFF". If the function is on, display "ON". ----- will be displayed if the TripWise option is not active for the current config- uration. Press the ENTER key. The existing entry will flash. Use the Arrow keys to alter- nate between OFF and ON. Press ENTER again to set the Expiration Interval. Left display: dAyS Right display: Expiration Interval 2 through 365 in one day increments. Default value is 30.

Cd66 Instantaneous Power (kW)

Real power in kW currently being used by the system. Value is -----, nnn.n Display ----- if not configured else nnn.n

Cd67 Total Power (kW-hr) Energy used by the system, in kW-hrs, since last Trip Start. Value is -----, nnnnn Display ----- if not configured else nnnnn

Cd70 Temp Setpoint Lock Cd70 locks out setpoint selection, requiring the user to manually turn the lock off, prior to making a setpoint change. If the setpoint lock is ON, and the user at- tempts to enter a new setpoint, a message SPLK (Setpoint Lock) is in the left display and ON in the right display for five seconds. Press the ENTER key. SPLK will display along with the current setting of ON or OFF. Use the Arrow keys to change the selection - the new selection will then flash for five seconds. Press the ENTER key to confirm the new selection. An event will be recorded in the DataCorder each time the action of turning it ON or OFF is taken. Default setting is OFF. Unit will default to OFF with the selection of PTI or a TripWise on the unit.

Table 46 Controller Function Codes (Continued)

Code Title Description

437 T-362

Figure 4.16 Alarm Troubleshooting Sequence

Start Troubleshooting

Unit configured correctly?

Pass Pre-trip

inspection?

Active Alarms?

Correct software version?

Did Evaporator fans start?

Operating pressures normal?

Check Power Supply

Install Latest Software Revision

Load correct unit

configuration

See alarm details &

repair

Correct all faults

Yes

Yes

Yes

Yes

No

Yes

No

Yes

No

No

No

No

Correct Refrigerant

issue

Unit OK

Yes

No

Refer to CONNECT POWER

Refer to CONNECT POWER

Refer to CONTROLLER SOFTWARE

Refer to Configuration Software (Variables)

Refer to Controller Alarm Indications

Refer to Pre-trip Diagnostics

Refer to REFRIGERATION SERVICE

Check Power Supply

Unit does self test? Section 5.2

Section 5.2

Section 4.2

Section 4.2.1

Section 4.5

Section 4.6

Section 7.3

T-362 438

4.10 Controller Alarm Indications

AL03 Loss of Superheat Control Cause: Superheat has remained below 1.66C (3F) degrees for five minutes continuously while compres-

sor running. Compressor drawing more than 2.0 amps, compressor pressure ratio is greater than 1.8, and Electronic Expansion Valve (EEV) is at 0% open.

Component Electronic Expansion Valve (EEV) Troubleshooting Check the operation of the EEV using Cd41.

Corrective Action Replace EEV if defective. Component Evaporator Temperature Sensor(s) ETS & ETS1.

Troubleshooting Verify accuracy of temperature sensors. See Sensor Checkout Proce- dure Section 7.28.2.

Corrective Action Replace ETS or ETS1 if defective. Component Evaporator Fans

Troubleshooting Confirm fans operating properly Corrective Action Replace fan(s) if defective. See Evaporator Fan Motor Assembly Sec-

tion 7.17.

AL05 Manual Defrost Switch Failure Cause: Controller has detected continuous Manual Defrost Switch activity for five minutes or more.

Component Keypad Troubleshooting Power cycle the unit.

Corrective Action Resetting the unit may correct problem, monitor the unit. If the alarm reappears after 5 minutes, replace the keypad.

AL06 Keypad or Keypad Harness Fail Cause: Controller has detected one of the keypad keys is continuously activity.

Component Keypad or Harness Troubleshooting Power cycle the unit.

Corrective Action Resetting the unit may correct problem, monitor the unit. If the alarm reappears, replace the keypad and harness.

AL07 Fresh Air Vent Open Cause: For units equipped with XtendFRESH and a Vent Position Sensor, the controller will monitor the

manual fresh air opening at a pre-determined time. If during this time the fresh air vent is open and XtendFRESH is active, an alarm will be generated. If alarm is active, the controller monitors the man- ual fresh air once per hour. Upon clearing the alarm, the controller goes back to monitoring at the pre-determined time.

Component Vent Position Sensor (VPS) Troubleshooting Manually reposition vent to 0% and confirm using Cd45. If Cd45 is not

reading 0%, perform a calibration of the panel. See Vent Position Sensor Service Section 7.29.

Corrective Action If unable to obtain a zero reading, replace the defective VPS. If unit is loaded, ensure vent is closed. Note and replace VPS on next PTI. The alarm will not affect the XtendFRESH system from operating.

439 T-362

AL08 High Compressor Pressure Ratio Cause: Controller detects discharge pressure to suction pressure ratio is too high.

The controller will attempt to correct the situation by restarting the compressor. Component Discharge Pressure Transducer (DPT)

Troubleshooting Confirm accurate DPT pressure readings. See Manifold Gauge Set Sec- tion 7.2.

Corrective Action Replace DPT if defective.

AL09 O2 Sensor Failure Cause: Triggered anytime the O2 sensor reading is outside of the normal operation range, after an initial sig-

nal was detected. Component O2 Sensor, O2 Amplifier, Sensor Switch Module (if equipped)

Troubleshooting Check Cd44 and scroll down to 02V. The O2 sensor output will be dis- played in millivolts (130mV to 4100mV). Switch equipped: If voltage is not present at Cd44 and a sensor switch module is installed, check for O2 voltage on the black wire connected to the sensor switch module, connecting ground of meter to TP9. If the volt- age is in the 130mV to 4.1V range, directly wire the black wire to KD04. This may cause an AL07 depending on O2 reading but XtendFRESH will operate normally. If no voltage on the black wire, proceed to next step. Check wiring (see schematic), and correct if found mis-wired. If O2 sensor is available, remove the upper fresh air panel and evapora- tor motor and replace the sensor. If after replacing sensor AL09 contin- ues, replace amplifier. If parts are not available, turn XtendFRESH option off (Cd43) and open the Manual Fresh Air Vent.

AL10 CO2 Sensor Failure Cause: Triggered anytime the CO2 sensor reading is outside of the normal operation range, after an initial

signal was detected. Component CO2 Sensor

Troubleshooting Check the voltage at MC5 to the ground pin on TP9 (1 - 4.7 vdc). Check wiring (see schematic), and correct if found mis-wired. If part is available, remove upper fresh air panel and evaporator motor; replace sensor. If no part is available, take no action and service at next PTI. XtendFRESH will continuously run the scrubber. O2 level will be controlled with the opening and closing of the fresh air vents as required.

Corrective Action The alarm is triggered off when voltage is within operating range.

T-362 440

AL14 Phase Sequence Detect Fault Cause: Controller is unable to determine the correct phase relationship.

Component N/A Troubleshooting Power cycle the unit.

Corrective Action Resetting the unit may correct problem, monitor the unit. Component Wiring

Troubleshooting Check unit wiring. Confirm pressure readings during start-up; suction pressure should de- crease and discharge pressure should increase.

Corrective Action Correct wiring. Component Current Sensor

Troubleshooting Check Cd41, right most digit: If display is 3 or 4, check compressor / sensor wiring. If display is 5, the current sensor is defective.

Corrective Action Replace current sensor if defective.

AL16 Compressor Current High Cause: Compressor current draw is over the calculated maximum for 10 minutes.

Component Current Sensor Troubleshooting Compare Cd3 to actual measured current at wire T1-T2 or T3 going to

the compressor contactor. If there is a difference, determine whether this is caused by current sensor or amp clamp tool.

Corrective Action Replace current sensor if defective. Component Amperage is indeed too high.

Troubleshooting Confirm supply voltage / frequency is within specification and balanced according to Electrical Data Section 3.3.

Corrective Action Correct power supply. Component Operating Conditions

Troubleshooting Make sure system pressures are relevant to operating conditions. Corrective Action Check air flow of condenser.

Check Refrigerant charge. See Refrigeration System Service Section 7.3.

Component Monitor Unit Troubleshooting Alarm is display only the alarm may clear itself during operation.

Corrective Action If alarm remains active or is repetitive replace compressor at next avail- able opportunity. See Compressor Service Section 7.9.

441 T-362

AL17 Compressor Pressure Delta Fault Cause: Compressor has attempted to start in both directions and fails to generate sufficient pressure differ-

ential between SPT and DPT. Component N/A

Troubleshooting Controller will attempt to restart every 20 minutes and deactivate the alarm if successful.

Corrective Action Resume normal operation. Component Discharge Pressure Transducer (DPT)

Troubleshooting Confirm accurate DPT pressure readings. See Manifold Gauge Set Sec- tion 7.2.

Corrective Action Replace DPT if defective. Component Suction Pressure Transducer (SPT)

Troubleshooting Confirm accurate SPT pressure readings. See Manifold Gauge Set Sec- tion 7.2.

Corrective Action Replace SPT if defective. Component Monitor Unit

Troubleshooting Alarm is display only; the alarm may clear itself during operation. Corrective Action If alarm remains active or is repetitive, replace compressor at next avail-

able opportunity.

AL18 Discharge Pressure High Cause: Discharge pressure is over the maximum for 10 minutes within the last hour.

Component Restrictions in the refrigeration system. Troubleshooting Ensure Liquid Line Service Valve is fully open.

Corrective Action Open Liquid Line Service Valve as needed. Component Filter Drier

Troubleshooting Check the filter drier. If it is iced up or very cold, it indicates that the filter drier needs replacement.

Corrective Action Replace the filter drier if needed. See Filter Drier Service Section 7.14. Component Condenser Fan

Troubleshooting Check Condenser Fan for proper operation. Corrective Action Correct as required.

Component Discharge Pressure Transducer (DPT) Troubleshooting Confirm accurate DPT pressure readings. See Manifold Gauge Set Sec-

tion 7.2. Corrective Action Replace DPT if defective.

Component Non-condensables in the refrigeration system. Troubleshooting With the unit off, allow system to stabilize to ambient temperature.

Check system pressure against Pressure Temperature Chart. See Ta- ble 75, Table 76.

Corrective Action Correct as required. See Refrigerant Charge Section 7.7.1. Component Refrigerant

Troubleshooting Check refrigerant level. Corrective Action Correct as required. See Refrigerant Charge Section 7.7.1.

T-362 442

AL19 Discharge Temperature High Cause: Discharge temperature exceeds 135C (275F) for 10 minutes within the last hour.

Component Restrictions in the refrigeration system. Troubleshooting Ensure the Discharge Service Valve is fully open.

Corrective Action Open the Discharge Service Valve as needed. Troubleshooting Check the unit for air flow restrictions.

Corrective Action Clean or remove any debris from coils. Component Non-condensables in the refrigeration system.

Troubleshooting With the unit off allow system to stabilize to ambient temperature. Check system pressure against Pressure Temperature Chart. See Ta- ble 75, Table 76.

Corrective Action Correct as required. See Refrigerant Charge Section 7.7.1. Component Additional Alarms such as AL16, AL24.

Troubleshooting Check compressor operation. Corrective Action If the alarm persists, it may indicate a failing compressor, replace the

compressor. See Compressor Service Section 7.9.

AL20 Control Contactor Fuse (F3) Cause: Control power fuse (F3A or F3B) is open.

Component Check F3A fuse. Troubleshooting If fuse is open, check PA, PB, CH coils for short to ground.

Corrective Action If short is found, replace the defective coil. Replace the fuse.

Component Check F3B fuse. Troubleshooting If fuse is open, check ESV coil resistance at TP7 to TP9. If short to

ground, or if resistance is less than 4 ohms, coil is defective. Check CF, ES, EF, HR coils for short to ground. If short is found, coil is defective.

Corrective Action Replace the defective coil. Replace the fuse.

Component Check Voltage at QC1. Troubleshooting If voltage is present, it indicates a defective microprocessor.

Corrective Action See Controller Service Section 7.27.

443 T-362

AL21 Control Circuit Fuse (F1 / F2) Cause: One of the 18 VAC controller fuses (F1 / F2) is open. See Cd08.

Component System Sensors Troubleshooting Check system sensors for short to ground.

Corrective Action Replace defective sensor(s). Component Wiring

Troubleshooting Check wiring for short to ground. Corrective Action Repair as needed.

Component Controller Troubleshooting Controller may have an internal short.

Corrective Action Replace controller. See Controller Service Section 7.27.

AL22 Evaporator IP Cause: Evaporator motor internal protector (IP) is open.

Component Evaporator Motor Troubleshooting Shut down unit, disconnect power and check Evaporator Motor IP at

plug connection pins 4 & 6. Corrective Action Replace defective evaporator fan motor. See Evaporator Fan Motor Ser-

vice Section 7.17.

AL23 Loss of Phase B Cause: Controller fails to detect current draw.

Component Incoming Power Troubleshooting Check incoming power source.

Corrective Action Correct power source as required.

AL24 Compressor IP Cause: Compressor internal protector (IP) is open.

Component Compressor Troubleshooting Shut down unit disconnect power and check resistance of compressor

windings at contactor T1-T2, T2-T3. Corrective Action Monitor unit, if alarm remains active or is repetitive replace the compressor

at the next available opportunity. See Compressor Service Section 7.9.

AL25 Condenser IP Cause: Condenser fan motor internal protector (IP) is open.

Component Insufficient Air Flow Troubleshooting Shut down unit and check condenser fan for obstructions.

Corrective Action Remove obstructions. Component Condenser Fan Motor

Troubleshooting Shut down unit, disconnect power and check Condenser Fan Motor IP at plug connection pins 4 & 6.

Corrective Action Replace defective condenser fan motor. See Condenser Fan Motor As- sembly Service Section 7.12.

T-362 444

AL26 All Sensors Failure: Supply / Return Probes Cause: Sensors out of range.

Component All sensors detected as out of range. Troubleshooting Perform pre-trip P5.

Corrective Action If P5 passes, no further action is required. Corrective Action If P5 fails, replace the defective sensor as determined by P5. See Tem-

perature Sensor Service Section 7.28.

AL27 Analog to Digital Accuracy Failure Cause: Controller AD converter faulty.

Component Controller Troubleshooting Power cycle the unit. If the alarm persists, it indicates a defective micro-

processor. Corrective Action Replace defective microprocessor. See Controller Service Section

7.27.

AL28 Low Suction Pressure Cause: Suction pressure too low for normal operation.

Component N/A Troubleshooting Power cycle the unit.

Corrective Action Resetting the unit may correct problem, monitor the unit. Component Suction Pressure Transducer (SPT)

Troubleshooting Confirm accurate SPT pressure readings. See Manifold Gauge Set Sec- tion 7.2.

Corrective Action Replace SPT if defective. Component Discharge Pressure Transducer (DPT)

Troubleshooting Confirm accurate DPT pressure readings. See Manifold Gauge Set Sec- tion 7.2.

Corrective Action Replace DPT if defective.

AL29 AutoFresh Failure (eAutoFresh) Cause: Alarm 29 is triggered if CO2 or O2 level is outside of the limit range and the vent position is at 100%

for longer than 90 minutes. Component Alarm LED will be activated and user intervention is required.

Troubleshooting See eAutoFresh manual. Corrective Action The alarm is triggered off when atmospheric conditions are within limit

settings.

445 T-362

AL29 Loss of Atmospheric Control (XtendFRESH) Cause: Triggered whenever the CO2 level is above its upper limit by 1% for 60 minutes. Or, when the O2

level is greater than 1% below its setpoint for longer than 30 minutes after the unit has been in range. The alarm is triggered off when the levels return to within the normal range.

Setup Run Cd43 test mode for troubleshooting the below components. At the end of test mode, a sensor calibration will be attempted. Under loaded box conditions, the sensor values may post No Cal or CAL FAIL. Results from original calibration will be retained. If test mode times out, then hold the code select key for 3 seconds to exit test mode.

Troubleshooting If components do not energize, check FX1 and FX2 for power (460 VAC). If fuse is open, check heater continuity (XHT1 to ground). Must be greater than 1 mega ohm. If less than 1, disconnect the heater at XHT1 and XHT2. Replace fuse. Unit will control on fresh air solenoids.

Component Solenoid Air Vents. Troubleshooting Visually inspect to see if the Solenoid Valves are opening air vents. If

vents open, troubleshoot the next component. If vents do not open, con- tinue with troubleshooting below. Check FX4 fuse for power (~20 volts dc). If fuse is open, check wiring and or replace solenoid if part is available. If no part is available, open manual fresh air vent.

Component XtendFRESH Fan(s) / XtendFRESH Scrubber Motor Troubleshooting Visually inspect to see if the XtendFRESH Fan(s) are running (air blow-

ing on left, intake on right), check current draw of motor at the XST1 (~40 to 200 milliamps / contactor load side). Troubleshoot the non-operating component. If both are running, proceed to next component. Verify XS contactor is pulling in. If not, check FX6 fuse for power (24 VAC). If not, check power at controller KB4. Check FX3 fuse for power (~20 vdc). If no power, replace fuse. If fuse opens a second time, take no further action. O2 level will be controlled with the opening and closing of the fresh air vents. If part is available, replace either fan or scrubber motor. Fan is replace- able from the front on a loaded unit; Scrubber motor is not. If no part is available or accessible, take no action and service at next PTI. O2 level will be controlled with the opening and closing of the fresh air vents.

Component Heater Troubleshooting Verify XH contactor is pulling in. If not, check FX6 for power (24 VAC). If

open ohm contactors XHA1 and XSA1 to ground. Replace (12 Amp) contactor. If contactor is pulling, power unit off and check heater resis- tance from XH1 to XH2 (450 to 500 ohms). If heater is outside of the range, disconnect heater at XHT1 and XHT2 and replace at next PTI. Unit will control on fresh air solenoids.

AL50 Air Vent Position Sensor (VPS) Cause: Vent Position Sensor (VPS) Sensor out of range.

Component Vent Position Sensor (VPS) Troubleshooting Make sure VPS is secure.

Corrective Action Manually tighten panel. Troubleshooting If the alarm persists, replace the sensor or the assembly.

Corrective Action Replace VPS.

T-362 446

AL51 EEPROM Failure Cause: Controller Memory Failure

Component Controller Troubleshooting Pressing the ENTER key when CLEAr is displayed will result in an at-

tempt to clear the alarm. Corrective Action If action is successful (all alarms are inactive), alarm 51 will be reset. Troubleshooting Power cycle the unit. If the alarm persists, it indicates defective controller

memory. Corrective Action Replace defective controller. See Controller Service Section 7.27.

AL52 EEPROM Alarm List Full Cause: Alarm list queue is full

Component Active Alarms Troubleshooting Repair any alarms in the queue that are active. Indicated by AA.

Corrective Action Clear alarms. See Controller Alarms Section 4.5.

AL53 Battery Pack Failure Cause: Battery voltage low

Component Battery Troubleshooting If this alarm occurs on start up, allow a unit fitted with rechargeable bat-

teries to operate for up to 24 hours to charge rechargeable batteries suf- ficiently. Once fully charged, the alarm will deactivate.

Corrective Action To clear the alarm press ENTER and ALT simultaneously at the startup of Cd19 (Battery Check). If alarm persists, replace the battery pack. See Section 7.27.5 Battery Replacement.

AL54 Primary Supply Sensor (STS) Cause: Invalid Supply Temperature Sensor (STS) reading.

Component Supply Temperature Sensor (STS) Troubleshooting Perform pre-trip P5.

Corrective Action If P5 passes, no further action is required. If P5 fails, replace the defective sensor as determined by P5. See Tem- perature Sensor Service Section 7.28.

AL56 Primary Return Sensor (RTS) Cause: Invalid Return Temperature Sensor (RTS) reading.

Component Return Temperature Sensor (RTS) Troubleshooting Perform pre-trip P5.

Corrective Action If P5 passes, no further action is required. If P5 fails, replace the defective sensor as determined by P5. See Tem- perature Sensor Service Section 7.28.

447 T-362

AL57 Ambient Sensor (AMBS) Cause: Invalid Ambient Temperature Sensor (AMBS) reading.

Component Ambient Temperature Sensor (AMBS) Troubleshooting Test the AMBS. See Sensor Checkout Procedure Section 7.28.2.

Corrective Action Replace AMBS if defective. See Temperature Sensor Service Section 7.28.

AL58 Compressor High Pressure Safety (HPS) Cause: High pressure safety switch remains open for at least one minute.

Component High Pressure Switch (HPS) Troubleshooting Test the HPS. See Checking High Pressure Switch, Section 7.10.1.

Corrective Action Replace HPS if defective. See Sensor Replacement, Section 7.28. Component Refrigeration System

Troubleshooting Check unit for air flow restrictions. Corrective Action Clean or remove any debris from coils.

AL59 Heater Termination Thermostat (HTT) Cause: Heat Termination Thermostat (HTT) is open.

Component Heat Termination Thermostat (HTT) Troubleshooting Check for 24 volts at test point TP10. If no voltage at TP10 after unit has

reached setpoint, HTT is open. Corrective Action Replace HTT if defective. See Sensor Replacement Section 7.28.

AL60 Defrost Temperature Sensor (DTS) Cause: Failure of the Defrost Temperature Sensor (DTS) to open.

Component Defrost Temperature Sensor (DTS) Troubleshooting Test the DTS; see Sensor Checkout Procedure Section 7.28.2.

Corrective Action Replace the DTS if defective. See Sensor Replacement Section 7.28.

AL61 Heater Current Draw Fault Cause: Improper current draw during heat or defrost mode.

Component Heater(s) Troubleshooting While in heat or defrost mode, check for proper current draw at heater

contactors. See Electrical Data Section 3.3. Corrective Action Replace heater(s) if defective. See Evaporator Heater Removal and Re-

placement Section 7.16. Component Contactor

Troubleshooting Check voltage at heater contactor on the heater side. Corrective Action If no voltage present, replace heater contactor if defective.

T-362 448

AL62 O2 Out of Range Cause: This is a notification alarm and does not pose a risk to fresh produce. It is triggered when there is an

indication that O2 level is rising after reaching its setpoint (+ 1%). If O2 level exceeds 4% above setpoint, the alarm is activated. The alarm does not activate if the unit was pre-tripped or trip started between last reaching its O2 setpoint and exceeding the plus 4%, or if power has been turned off for eight hours. The alarm is deactivated if O2 drops below setpoint (+ 1%) or if a pre-trip or trip start is performed.

Component Scrubber Failure Troubleshooting See the troubleshooting of the Scrubber Motor in the AL29 alarm.

Component XtendFRESH Solenoid Valves Troubleshooting See the troubleshooting of the Solenoid Air Vent in the AL29 alarm.

Component Container Air Tightness Troubleshooting Seal container where possible (access panels, rear doors, mounting

hardware, etc).

AL63 Current Limit Cause: Unit operating above current limit.

Component Refrigeration System Troubleshooting Check unit for air flow restrictions.

Corrective Action Clean or remove any debris from coils. Troubleshooting Check unit for proper operation.

Corrective Action Repair as needed. Component Power supply

Troubleshooting Confirm supply voltage/frequency is within specification and balanced according to Electrical Data Section 3.3.

Corrective Action Correct power supply. Component Current limit set too low

Troubleshooting Check current limit setting Code Cd32. Corrective Action The current limit can be raised (maximum of 23 amps) using Cd32.

AL64 Discharge Temperature Sensor (CPDS) Cause: Compressor Discharge Temperature Sensor (CPDS) out of range.

Component Compressor Discharge Temperature Sensor (CPDS). Troubleshooting Test the CPDS. See Sensor Checkout Procedure, Section 7.28.2.

Corrective Action Replace the CPDS if defective. See Sensor Replacement Section 7.28.

AL65 Discharge Pressure Transducer (DPT) Cause: Compressor Discharge Pressure Transducer (DPT) is out of range.

Component Compressor Discharge Pressure Transducer (DPT) Troubleshooting Confirm accurate DPT pressure readings. See Manifold Gauge Set Sec-

tion 7.2. Corrective Action Replace DPT if defective.

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AL66 Suction Pressure Transducer (SPT), Evaporator Pressure Transducer (EPT) Cause: Suction Pressure Transducer (SPT) out of range.

Component Suction Pressure Transducer (SPT) Troubleshooting Confirm accurate EPT and SPT pressure readings. See Manifold Gauge

Set Section 7.2. Performing a pre-trip 5-9 test will also check the transducers.

Corrective Action Replace EPT/SPT if defective. Troubleshooting Monitor

Corrective Action If the alarm persists, it may indicate a failing compressor. See Compres- sor Service Section 7.9.

AL67 Humidity Sensor Cause: Humidity Sensor (HS) reading out of range.

Component Humidity Sensor (HS) Troubleshooting Make sure the humidity sensor is properly connected in the socket.

Make sure the humidity sensor wires have not been damaged. See Section 7.20 to test operation of Humidity Sensor.

Corrective Action Monitor, replace HS if alarm persists.

AL69 Evaporator Temp Sensor (ETS1) Cause: Evaporator Temperature Sensor (ETS1) out of range.

Component Evaporator Temperature Sensor (ETS1) Troubleshooting Test the ETS1. See Sensor Checkout Procedure Section 7.28.2.

Corrective Action Replace Evaporator Temperature Sensor (ETS1) if defective.

AL70 Secondary Supply Sensor (SRS) Cause: Secondary Supply Sensor (SRS) is out of range.

Component Secondary Supply Sensor (SRS) Troubleshooting Perform pre-trip P5.

Corrective Action If P5 passes, no further action is required. Corrective Action If P5 fails, replace the defective sensor as determined by P5. See Tem-

perature Sensor Service Section 7.28.

AL71 Secondary Return Sensor (RRS) Cause: Secondary Return Sensor (RRS) is out of range.

Component Secondary Return Sensor (RRS) Troubleshooting Perform pre-trip P5.

Corrective Action If P5 passes, no further action is required. Corrective Action If P5 fails, replace the defective sensor as determined by P5. See Tem-

perature Sensor Service Section 7.28.

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NOTICE If the controller is configured for four probes without a DataCORDER, the DataCORDER alarms AL70 and AL71 will be processed as Controller alarms AL70 and AL71. See Table 410.

AL72 Control Temp Out of Range Cause: After the unit goes in-range for 30 minutes then out of range for a continuous 120 minutes.

Component Refrigeration System Troubleshooting Ensure unit is operating correctly.

Corrective Action Power cycle unit. Control Temperature is in In-range. Any pre-trip mode, resets the timers.

AL96 Scrubber Rotational Feature - optional feature Cause: Feedback from the Scrubber Motor to the controller is not sensed when the motor is turning.

Component Scrubber Fuse Troubleshooting Check to see if Scrubber Fuse is blown. Replace Fuse if necessary.

Component Scrubber Motor Troubleshooting Run Test Mode and verify scrubber bed is turning. If back panel cannot

be removed to check, verify the scrubber amperage consumption, read at XS contactor wire XSL1. If between 40 and 200mA, motor is rotating properly. If no current detected, check and replace FX3. If current spik- ing to 350mA for 2 seconds then dropping to 90mA, the scrubber motor is located. If scrubber motor is locked, further inspection of the scrubber bed is required. Unit will control CO2 with the fresh air solenoid when this alarm occurs if scrubber inaccessible. If Scrubber Motor not operating, follow the troubleshooting flowchart in XtendFresh manual and take appropriate action.

Component Ground Interface Module (GIM) Troubleshooting Once it has been verified that the scrubber motor is rotating, check the

wiring connections to the GIM module. If all wires secured properly, re- place the GIM module if one is available. If not, the unit will control CO2 using the fresh air solenoids.

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ERR# Internal Microprocessor Failure Cause: 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 whereby 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 fail-

ure 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 indi-

cate 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 Set point (Press Arrow & Enter)

Cause: The controller is prompting the operator to enter a setpoint.

LO Low Main Voltage (Function Codes Cd27-38 disabled and NO alarm stored.) Cause: This message will be alternately displayed with the setpoint whenever the supply voltage is less than

75% of its proper value.

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4.11 Controller Pre-Trip Test Codes The pre-trip selection menu provides the user the option of selecting one of two automatic tests (short sequence or long sequence). 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. The short pre-trip test sequence will appear as either AUtO or AUtO1 in the display. This runs tests P0 through P6, which includes most functions, sensors and system components. The long pre-trip test sequence is selected by either AUtO2 or AUtO3 in the display. AUtO2 runs tests P0 through P10 and AUtO3 runs tests P0 through P8. The long test sequence includes all of the short sequence tests and also tests for the high pressure switch, heater performance and cooling performance.

Table 47 Controller Pre-Trip Test Codes

Code Description Detail P0-0 Pre-Trip Initiated:

Configuration Display, Indicator Lamps, LEDs, and Displays

Container identifier code, Cd18 Software Revision Number, Cd20 Container Unit Model Number, & configuration database identifier CFMMYYDD are dis- played in sequence. Next the unit will indicate the presence or non-presence of an RMU according to whether any RMU inquiry messages have been received since the unit was booted. Units equipped with Autoslide Enabled (Cnf44) will cause the vent to seek to its closed position, followed by two sequences of opening to 100% and returning to the closed position. No other autoslide mode of operation will be available un- til the two cycles of opening and closing have completed. Since the system cannot recognize lights and display failures, there are no test codes or results associated with this phase of pre-trip. To know if the test passes the operator must observe that the LCD display elements and the indicator lights behave as described below.

P1 Tests - Heaters Current Draw: Heater is turned on, then off. Current draw must fall within specified range. No other system components will change state during this test.

P1-0 Heaters Turned On Heater starts in the off condition, current draw is measured, and then the heater is turned on. After 15 seconds, the current draw is measured again. The change in current draw is then recorded. Test passes if the change in current draw test is in the range specified.

P1-1 Heaters Turned Off Heater is then turned off. After 10 seconds, the current draw is measured. The change in current draw is then recorded. Test passes if change in current draw test is in the range specified.

P2 Tests - Condenser Fan Current Draw: Condenser fan is turned on, then off. Current draw must fall within specified range. No other system components will change state during this test. If the Water Pres- sure Switch is open this test will be skipped.

P2-0 Condenser Fan On Condenser fan starts in the off condition, current draw is measured, and con- denser fan is then turned on. After 15 seconds the current draw is measured again. The change in current draw is then recorded. Test passes if change in current draw test is in the specified range.

P2-1 Condenser Fan Off Condenser fan is then turned off. After 10 seconds the current draw is mea- sured. The change in current draw is then recorded. Test passes if change in current draw test is in the specified range.

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P3 Tests - Low Speed Evaporator Fan Current Draw: The system must be equipped with a low speed evaporator fan, as determined by CnF02, the Evaporator Fan Speed Select configuration variable. Low speed evaporator fan is turned on, then off. Current draw must fall within specified range. No other sys- tem components will change state during this test.

NOTE If unit configured for single evaporator fan operation and either AL11 or AL12 is active at the start of either test, then the test will fail immediately. If AL11 or AL12 become active during the test, then the test will fail upon conclusion of the test.

P3-0 Low Speed Evaporator Fan Motors On

High speed evaporator fans will be turned on for 20 seconds, the fans will be turned off for 4 seconds, current draw is measured, and then the low speed evaporator fans are turned on. After 60 seconds the current draw is measured again. The change in current draw is then recorded. Test passes if change in current draw test is in the specified range.

P3-1 Low Speed Evaporator Fan Motors Off

Low speed evaporator fans are then turned off. After 10 seconds the current draw is measured. The change in current draw is then recorded. Test passes if change in current draw test is in the specified range.

P4 Tests - High Speed Evaporator Fans Current Draw: High speed evaporator fans are turned on, then off. Current draw must fall within specified range and measured current changes must exceed spec- ified ratios. No other system components will change state during this test.

NOTE If unit configured for single evaporator fan operation and either AL11 or AL12 is active at the start of either test, then the test will fail immediately. If AL11 or AL12 become active during the test, then the test will fail upon conclusion of the test.

P4-0 High Speed Evaporator Fan Motors On

Evaporator fans start in the off condition, current draw is measured, then high speed evaporator fans will be turned on. After 60 seconds the current draw is measured again. The change in current draw is then recorded. Test passes if change in current draw in the specified range AND measured cur- rent changes exceed specified ratios. If the three phase motors are configured IN, the change ratio test is skipped.

P4-1 High Speed Evaporator Fan Motors Off

High speed evaporator fans are then turned off. After 10 seconds the current draw is measured. The change in current draw is then recorded. Test passes if change in current draw test is in the specified range.

P5 Tests - Air Stream Temperature Sensor Tests: Tests the validity of the Air Stream Temperature Sensors.

P5-0 Supply / Return Probe Test

The High Speed Evaporator Fan is turned on and run for eight minutes, with all other outputs de-energized. A temperature comparison is made between the re- turn and supply probes. Test passes if temperature comparison falls within the specified range.

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

P5-1 Supply Probe Test This test if for units equipped with secondary supply probe only. The temperature difference between primary supply probe and secondary sup- ply probe is compared. Test passes if temperature comparison falls within the specified range.

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 the multiple tests, the display will read P5 PASS.

Table 47 Controller Pre-Trip Test Codes (Continued)

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P5-2 Return Probe Test For units equipped with secondary return probe only. The temperature difference between return temperature sensor (RTS) and re- turn temperature sensor (RRS) probe is compared. Test passes if temperature comparison falls within the specified range.

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 multi- ple 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.

P5-3 Evaporator Fan Direction Test

With evaporator fan running on high speed, measure the temperature difference between the primary supply and primary return probes. Turn the heaters on for 60 seconds then measure the temperature difference between the primary sup- ply and primary return probes for up to 120 additional seconds. This is a Pass/Fail test. The test passes if differential of STS is 0.25C higher than RTS. Test P5-0 must pass before this test is run.

P5-7 Primary vs. Secondary Evaporator Temperature Sensor Test

This is a Pass / Fail test of the primary Evaporator Temperature Sensor (ETS1) and secondary Evaporator Temperature Sensor (ETS2). Test passes if secondary Evaporator Temperature Sensor (ETS2) is within +/- 0.5C of the primary Evaporator Temperature Sensor (ETS1).

P5-8 Future Expansion This is no longer active and will be displayed as ----- at this time. P5-9 Primary vs. Secondary

Evaporator Pressure Transducer Test

This is a Pass / Fail test of the primary Evaporator Pressure Transducer and secondary Evaporator Pressure Transducer. Test passes if secondary Evaporator pressure is within +/- 1.5 psi of the primary Evaporator pressure.

P5-10 Humidity Sensor Controller Configuration Verification Test

This is a Pass / Fail / Skip test of the humidity sensor configuration. Test passes if the controller configuration has humidity sensor in. Test fails if the controller configuration has humidity sensor out and Vout is greater than 0.20 Volts for the humidity sensor. Test is skipped if the controller configuration has the humidity sensor out and Vout is less than 0.20 Volts. Test P5-9 must pass before this test is run.

P5-11 Humidity Sensor Installation Verification Test

This is a Pass / Fail test of humidity sensor installation (sensor is present). Test passes if Vout is greater than 0.20 Volts for the humidity sensor. Test fails if Vout is less than 0.20 Volts for the humidity sensor. Test P5-10 must pass before this test is run.

P5-12 Humidity Sensor Range Check Test

This is a Pass / Fail test of the Humidity Sensor Range. Test passes if Vout for the humidity sensor is between 0.33 Volts and 4 Volts. Test fails if Vout is outside of this range. Test P5-11 must pass before this test is run.

P6 Tests - Refrigerant Probes, Compressor and Refrigerant Valves: Pass / Fail testing is performed for the compressor, EEV, DUV, LIV (if equipped), ESV, and the refrigerant pressure and temperature sen- sors.

P6-0 Discharge Thermistor Test

If Alarm 64 is active the test fails. Otherwise, the test passes.

P6-1 Suction Thermistor Test

If the Suction Temperature Sensor (CPSS) both is configured ON and is invalid, the test fails. Otherwise the test passes.

Table 47 Controller Pre-Trip Test Codes (Continued)

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P6-2 Discharge Pressure Transducer Test

If Alarm 65 is active any time during the first 45 second period, the test fails. Oth- erwise, the test passes.

P6-3 Suction Pressure Transducer Test

If Alarm 66 is active the test fails. Otherwise the test passes.

P6-4 Compressor Current Draw Test

Compressor current is tested before and 10 seconds after start up. If current does not increase, the test fails. P6-7 is run at the end of P6-4. If this test fails, P6-6 is skipped.

P6-5 Compressor Leak Test Pre-trip P6-5 ensures that the compressor holds pressure. After compressor pump up and pump down, the compressor is turned off for 62 seconds. When suction side pressure holds (less than 8 psi rise) for 10 seconds, P6-5 passes, otherwise the Compressor Leak Test fails. See the July 2017 issue of TechLine for a procedure to assist the technician in troubleshooting a P6-5 occurrence.

NOTE P6-6 through P6-10 are conducted by changing status of each valve and comparing suction pressure change and/or compressor current change with predetermined values. Tests will cause compressor and condenser fans to cycle on and off as needed to generate the pressure required for individual pre-trip sub tests. The compressor will start in order to build discharge pressure, followed by compressor pump down sequence. At the conclusion of compressor pump down sequence, the compressor will shut down and the valve test will start.

P6-6 Economizer Valve Test Passes if suction pressure increases a minimum of 4 psia when the valve opens for 15 seconds.

P6-7 Digital Unloader Valve Test

Passes if pressure and current changes are within 3 seconds of DUV switch sig- nal and either the pressure change or the current draw change is above 5 psi or above 1.5A, respectively.

P6-9 Liquid Injection Valve Test

(If equipped) Test passes if change of suction pressure is greater than 4 psia when the valve opens for 10 seconds. Otherwise, it fails.

P6-10 Electronic Expansion Valve Test

The test records the suction pressure during the open valve position and passes if the suction pressure increase is above 3 psi when the valve opens for 10 sec- onds.

NOTE P7-0 & P8 are included with Auto 2 & Auto 3 only. P9-0 through P10 are included with Auto2 only. P7 Tests - High Pressure Tests: Unit is run at full capacity without condenser fan running to make sure that the HPS opens and closes properly.

Table 47 Controller Pre-Trip Test Codes (Continued)

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P7-0 High Pressure Switch (HPS) Opening Test

Test is skipped if sensed ambient temperature is less than 7.2C (45F), return air temperature is less than -17.8C (0F), or the water pressure switch is open. With the unit running, the condenser fan is turned off and a 900 second (15 min- ute) timer is started. The right display shows Discharge Pressure if the sensor is configured and valid, else Discharge Temperature. The unit needs to disable Discharge Pressure limit and enable Current Limit checks. The test fails immediately if:

- Ambient Temperature Sensor invalid - Composite Return Temperature Sensor invalid - HPS is open

The test fails if: - HPS fails to open before 900 seconds total test time. - Evaporator or Compressor IP Alarm. - Calculated Dome Temperature exceeds 137.78C (280F). - Discharge pressure exceeds 370 psig. - Compressor Current exceeds limits

The test passes if HPS opens within the 15 minute time limit. P7-1 High Pressure Switch

(HPS) Closing Test If return temperature greater than -2.4C, set setpoint to -5.0C, else set set- point to -30C. Restart unit according to normal startup logic. Run unit normally for 120 seconds. The test passes if the high pressure switch closes within 75 seconds after end of Test 7-0, else the test fails. Test P7-0 must pass for this test to execute.

P8 Tests - Perishable Mode Tests: Pre-trip tests P7-0 and P7-1 must have passed or have been skipped for these tests to execute.

P8-0 Perishable Mode Test If the control temperature is below 15.6C, the setpoint is changed to 15.6C, and a 180 Minute timer is started. The control will then be placed in the equiva- lent of normal heating. If the control temperature is above 15.6C. at the start of the test, then the test proceeds immediately to test 8-1. While in test 8-0 the right display will show the value of the control temperature. The test fails if the 180 Minute timer expires before the control temperature reaches setpoint - 0.3C. If the test fails, it will not auto-repeat. There is no pass display for this test. Once the control temperature reaches setpoint, the test pro- ceeds to test 8-1.

P8-1 Perishable Mode Pull Down Test / eAutoFresh CO2 Sensor Calibration

Control temperature must be at least 15.6C (60F). The setpoint is changed to 0C (32F), and a 180-minute timer is started. The left display will read P8-1, the right display will show the supply air tempera- ture. The unit will then start to pull down the temperature to the 0C setpoint. The test passes if the container temperature reaches setpoint before the 180- minute timer expires. On units where the CO2 Sensor Status indicates that a CO2 sensor is present, calibration of the CO2 sensor will be attempted during P8-1. Once P8-1 begins, calibration will be attempted when the supply temperature goes below 5C. If the CO2 sensor voltage reads within the 0.95 <>1.15Vdc range before the end of P8-1, the sensor will be calibrated by holding the CO2 zero line low for 4 sec- onds. Once calibration is performed, the sensor voltage will be verified to make sure it is in the 0.95 to 1.05 Vdc range. If the voltage is not within this range, CO2 sensor calibration fails.

Table 47 Controller Pre-Trip Test Codes (Continued)

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P8-2 Perishable Mode Maintain Temperature Test

Test P8-1 must pass for P8-2 to execute. A fifteen minute timer is started, and the system will attempt to minimize control temperature error (supply temperature minus setpoint) until the timer expires. The control temperature will be sampled each minute starting at the beginning of P8-2. During P8-2, the left display will read P8-2, and the right display will show the supply air temperature. When the test is completed, the average control temperature error will be com- pared to the pass/fail criteria. Test passes if the average temperature error is within +/- 1.0C. Test fails if the average temperature error is greater than +/- 1.0C, or if the DataCORDER supply temperature probe is invalid. If the test fails, the control probe temperature will be recorded as -50.0C.

P9 Test - DTT Close and Open Test: The DTT in this control is not a physical device, with actual metal- lic contacts, it is a software function that acts similar to a thermostat. Using various temperature inputs, the DTT function determines whether a thermostat mounted on the Evaporator Coil would have OPEN or CLOSED contacts. Primarily, the DTT function operates based on the temperature reading from the Defrost Termination Sensor.

P9-0 DTT Closed and Open Test

During P9-0 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 consid- ered closed. This step may not have to be executed. Once the DTT is consid- ered closed, the unit simulates defrost by running the heaters for up to two hours, or until the DTT is considered open. Test fails if The DTT is not considered closed after the 30 minutes of full cooling. Or, if the HTT opens when DTT is considered closed or if return air temperature rises above 48C (120F). Test passes if the DTT is considered open within the 2 hour heat cycle time limit.

P10 Tests - Frozen Mode Tests: P10-0 Frozen Mode Heat

Test If the container temperature is below 7.2C, the setpoint is changed to 7.2C, and a 180 Minute timer is started. The control will then be placed in the equiva- lent of normal heating. If the container temperature is above 7.2C. at the start of the test, then the test proceeds immediately to test 10-1. During this test, the control temperature will be shown on the right display. The test fails if the 180 Minute timer expires before the control temperature reaches setpoint - 0.3C. If the test fails, it will not auto-repeat. There is no pass display for this test. Once the control temperature reaches setpoint, the test pro- ceeds to test 10-1.

P10-1 Frozen Mode Pulldown Test

Control temperature must be at least 7.2C (45F) The setpoint is changed to -17.8C. The system will then attempt to pull down the control temperature to setpoint using normal frozen mode cooling. During this test, the control temperature will be shown on the right display. The test passes if the control temperature reaches setpoint minus 0.3C before the 180 minute timer expires. Otherwise, the test fails. Upon failure and when initiated by an automatic pre-trip sequence, P10-1 will auto-repeat once by start- ing P10-0 over again.

P10-2 Frozen Mode Maintain Temperature Test

Test P10-1 must pass for this test to execute. Same as for test 8-2 except control temperature is the return probe temperature. The average error must be +/-1.6C. If the DataCORDER supply temperature probe is invalid, the test fails and the control probe temperature will be recorded as -50C. Upon failure and when initiated by an automatic pre-trip sequence, P10-2 will auto-repeat by starting P10-0 over again.

Table 47 Controller Pre-Trip Test Codes (Continued)

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Table 48 DataCORDER Function Code Assignments

NOTE Inapplicable Functions Display -----

To Access: Press ALT. MODE key then CODE SELECT key

Code 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 Temperatures 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 controller once every minute.

dC14 Cargo Probe 4 Temperature 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 Sensors 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 in- terrogation program.

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

dC26,27 Future Expansion These codes are for future expansion, and are not in use at this time.

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

dC29 Days Stored Number of days of data that are currently stored in the DataCORD- ER.

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 ENTER key for five seconds to initiate a Trip Start.

dC31 Battery Test Results 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.

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Table 49 DataCORDER Pre-Trip Result Records

Test Title Data

1-0 Heater On Pass / Fail / Skip Result, Change in current for Phase A, B & C

1-1 Heater Off Pass / Fail / Skip Result, Change in currents for Phase A, B & 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 & C

3-0 Low Speed Evaporator Fan On Pass / Fail / Skip Result, Change in currents for Phase A, B & C

3-1 Low Speed Evaporator Fan Off Pass / Fail / Skip Result, Change in currents for Phase A, B & C

4-0 High Speed Evaporator Fan On Pass / Fail / Skip Result, Change in currents for Phase A, B & C

4-1 High Speed Evaporator Fan Off Pass / Fail / Skip Result, Change in currents for Phase A, B & C

5-0 Supply / Return Probe Test Pass / Fail / Skip Result, STS, RTS, SRS and RRS

5-1 Secondary Supply Probe (SRS) Test

Pass / Fail / Skip

5-2 Secondary Return Probe (RRS) Test

Pass / Fail / Skip

5-3 Evaporator Fan Direction Test Pass / Fail / Skip

5-7 Primary vs. Secondary Evaporator Temperature Sensor Test

Pass / Fail / Skip

5-8 Future Expansion Not Run

5-9 Primary vs. Secondary Evaporator Pressure Transducer Test

Pass / Fail / Skip

5-10 Humidity Sensor Controller Configuration Verification Test

Pass / Fail / Skip

5-11 Humidity Sensor Installation Verification Test

Pass / Fail / Skip

5-12 Humidity Sensor Range Check Test

Pass / Fail / Skip

6-0 Discharge Thermistor Test Pass / Fail / Skip

6-1 Suction Thermistor Test Pass / Fail / Skip

6-2 Discharge Pressure Transducer Test

Pass / Fail / Skip

6-3 Suction Pressure Transducer Test Pass / Fail / Skip

6-4 Compressor Current Draw Test Pass / Fail / Skip

6-5 Compressor Leak Test Pass / Fail / Skip

6-6 Economizer Valve Test Pass / Fail / Skip

6-7 Digital Unloader Valve Test Pass / Fail / Skip

6-9 Liquid Injection Valve Test (If equipped)

Pass / Fail / Skip

6-10 Electronic Expansion 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 16C (60F)

8-1 Perishable Mode Pulldown Test Pass / Fail / Skip Result, STS, time it takes to pull down to 0C (32F)

8-2 Perishable Mode Maintain Test Pass / Fail / Skip Result, Averaged DataCORDER supply tempera- ture (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 Pulldown Test Pass / Fail / Skip Result, STS, time to pull down unit to -17.8C (0F).

10-2 Frozen Mode Maintain Test Pass / Fail / Skip Result, Averaged DataCORDER return temperature (RRS) over last recording interval.

Table 410 DataCORDER Alarm Indications

To Access: Press ALT. MODE key then ALARM LIST key

Code Title Description

dAL70 Recorder Supply Temperature Out of Range

The supply recorder sensor reading is outside of the range of -50C to 70C (-58F to +158F), 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 Temperature Out of Range

The return recorder sensor reading is outside of the range of -50C to 70C (-58F to +158F), 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 outside of -50C to 70C (- 58F to +158F) range.

dAL75 Cargo Probe 4 Out of Range The cargo probe temperature reading is outside of -50C to 70C (- 58F 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 Data- CORDER is configured by default to record the supply and return re- corder sensors. The DataCORDER may be configured to record up to eight 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 as- signed. When a humidity sensor is installed, it is usually assigned to AL78.

Table 49 DataCORDER Pre-Trip Result Records (Continued)

Test Title Data

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dAL86 RTC Battery Low The real time clock (RTC) backup battery is too low to adequately maintain the RTC reading. A real time clock failure is critical to the operation of the unit. If this alarm occurs, replace the RTC battery at the next available opportu- nity. After replacing the battery the following actions are required:

- Update the RTC setting - Update the units software configuration - Update the operational software - Update all user selectable function code settings (defrost, setpoint, etc)

dAL87 RTC Failure An invalid time has been detected. Either the DataCORDER run time hour and minute have not changed at the start of the hour, or the real time clock (RTC) time has gained or lost more than 2 minutes in the hour. This situation may be corrected by cycling the power, setting the clock or meeting the above criteria for an hour.

dAL88 DataCORDER EEPROM Fail- ure

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).

Table 410 DataCORDER Alarm Indications (Continued)

To Access: Press ALT. MODE key then ALARM LIST key

Code Title Description

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SECTION 5 OPERATION

5.1 Inspection

WARNING! Beware of unannounced starting of the evaporator and condenser fans. The unit may cycle the fans and compress or unexpectedly as control requirements dictate.

1. Check inside the unit for the following conditions:

Check channels or T bar floor for cleanliness. Channels must be free of debris for proper air circulation.

Check container panels, insulation and door seals for damage. Perform permanent or temporary repairs.

Check visually that the evaporator fan motor mounting bolts are properly secured (see Section 7.17).

Check for visible corrosion on the evaporator stator and fan deck (see Section 7.18).

Check for dirt or grease on evaporator fans or fan deck and clean if necessary (see Section 7.18).

Check evaporator coil for cleanliness or obstructions. Wash with fresh water (see Section 7.18).

Check defrost drain pans and drain lines for obstructions and clear if necessary. Wash with fresh water.

Check panels on refrigeration unit for loose bolts and condition of panels. Make sure T.I.R. devices are in place on access panels.

2. Check condenser coil for cleanliness. Wash with fresh water (see Section 7.11).

3. Open the control box door. Check for loose electrical connections or hardware.

4. Check color of moisture-liquid indicator.

5.2 Connect Power

WARNING! Do not attempt to remove power plug(s) before turning OFF the Start-Stop switch (ST), unit cir- cuit breaker(s) and external power source.

WARNING! Make sure the power plugs are clean and dry before connecting to power receptacle.

5.2.1 Connecting to 380/460 VAC Power 1. Make sure the Start-Stop switch (ST), located on the control panel, is in 0 position (Off).

2. Make sure circuit breaker CB-1, located in the control box, is in 0 position (Off).

3. Plug the 460 VAC (yellow) cable into a de-energized 380/460 VAC, 3-phase power source and energize the power source.

4. Place circuit breaker CB-1 in I position (On).

5. Close and secure the control box door.

5.2.2 Connecting to 190/230 VAC Power To allow unit operation on nominal 230 volt power, an autotransformer (see Figure 5.1) is required. The autotrans- former 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 provides 380/460 VAC, 3-phase, 50/60 Hz power to the unit when the 230 VAC power cable is connected to a 190/230 VAC, 3-phase power source.

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PROCEDURE:

1. Make sure the Start-Stop switch (ST), located on the control panel, is in 0 position (Off).

2. Make sure circuit breaker CB-1, located in the control box, and CB-2, located on the transformer, are both in 0 position (Off).

3. Plug in and lock the 460 VAC power plug at the receptacle on the transformer.

4. Plug the 230 VAC (black) cable into a de-energized 190/230 VAC, 3-phase power source and energize the power source.

5. Set circuit breakers CB-1 and CB-2 to I position (On).

6. Close and secure the control box door.

Figure 5.1 Autotransformer

1) Circuit Breaker (CB-2) 230-Volt 2) 460 VAC Power Receptacle

3) Dual Voltage Module Autotransformer

- - - - -

5.3 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 vent must be closed when transporting frozen foods.

Air exchange depends on static pressure differential, which will vary depending on the container and how the con- tainer is loaded.

Units may be equipped with a vent position sensor (VPS). The VPS determines the position of the fresh air vent (upper or lower, as equipped) and sends data to the controller display.

5.3.1 Upper Fresh Air Makeup Vent

Two slots and a stop are designed into the Upper Fresh Air disc for air flow adjustments. The first slot allows for a 0 to 30% air flow; 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 the gap between the slots, loosen the wing nut until the disc clears the stop.

See Figure 5.2 for air exchange values for an empty container. Higher values can be expected for a fully loaded container.

1

3

2

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Figure 5.2 Upper Fresh Air Make Up Flow Chart

5.3.2 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 (100%) posi- tion. 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 Lower Fresh Air Makeup

NOTE In order to prevent inaccurate display readings on units equipped with a VPS, ensure that the rack and pinion drive of the VPS is not disrupted when adjusting the air makeup vent.

NOTE Do not loosen the hex nut beyond its stop. Doing so may cause inaccurate display readings and errors in DataCORDER reports.

Similar to the Upper Fresh Air Makeup vent, two slots and a stop are designed into the Lower Fresh Air slide for air flow adjustments. The first slot allows for a 0 to 25% air flow; the second slot allows for a 25 to 100% air flow. To adjust the percentage of air flow, loosen the hex nut and rotate the disc until the desired percentage of air flow matches with the arrow. Tighten the hex nut. To clear the gap between the slots, loosen the hex nut until the disc clears the stop.

On some models the air slide is supplied with two adjustable air control discs. The fresh air makeup can be adjusted for 15, 35, 50 or 75 cubic meters per hour (CMH). The air flow has been established at 60 Hz power and 2-1/2 inch T bar and with 15 mm (0.6 inch) H2O external static above free blow.

Loosen the hex nut, adjust each disc to the required air flow, then tighten the hex nut.

NOTE The main air slide is in the fully closed position during reduced air flow operation when equipped with air control discs.

c. Air Sampling for Carbon Dioxide (CO2) Level

Loosen the hex nuts and move the cover until the arrow on the cover is aligned with the atmosphere sampling port label. Tighten the hex nuts and attach a 3/8 in. hose to the sampling port.

If the internal atmosphere content has reached an unacceptable level, the operator may adjust the disc opening to meet the required air flow volume to ventilate the container.

0

50

100

150

200

250

0 10 20 30 40 50 60 70 80 90 100

TBAR 1 1/2

TBAR 2 5/8 TBAR 3

AIR FLOW (CMH) 50HZ

PERCENT OPEN

0

50

100

150

200

250

300

0 10 20 30 40 50 60 70 80 90 100

TBAR 1 1/2

TBAR 2 5/8 TBAR 3

AIR FLOW (CMH) 60HZ

PERCENT OPEN

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5.3.3 Vent Position Sensor The vent position sensor (VPS) allows the user to determine the position of the fresh air vent via Cd45. This func- tion 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 Cd45 will display the Fresh Air Vent Position.

The position of the vent will be recorded in the DataCORDER whenever the unit is running under AC power and during any of the following conditions:

Trip start Every power cycle Midnight Manual changes greater than 5 CMH (3 CFM) remaining in the new position for at least four minutes

NOTE The user has four minutes to make necessary adjustments to the vent setting. This time calculation begins on the initial movement of the sensor. The vent can be moved to any position within the four minutes. On completion of the first four minutes, the vent is required to remain stable for the next four minutes. If vent position changes are detected during the four-minute stability period, AL50 will be generated. This provides the user with the ability to change the vent setting without generating multi- ple events in the DataCORDER.

5.4 eAutoFresh Operation The optional eAutoFresh venting system is controlled through two function codes, Code 43 and Code 44. Code 43 contains specific parameters for operation and Code 44 provides a visible display of component conditions.

Procedures and technical information related to the eAutoFresh venting system can be found in the T-342 eAut- oFresh Manual, located in the Literature section of the Container Refrigeration website. To find the manual from the Literature section, click on Options > eAutoFresh.

5.5 XtendFRESH Operation The optional XtendFRESH controlled atmosphere system is controlled through two function codes, Code 43 and Code 44. Code 43 contains specific parameters for operation and Code 44 provides a visible display of component conditions.

Procedures and technical information related to the XtendFRESH controlled atmosphere system can be found in the T-366 XtendFRESH Manual, located in the Literature section of the Container Refrigeration website. To find the manual from the Literature section, click on Options > XtendFRESH.

5.6 Connect Water-Cooled Condenser The water-cooled condenser is used when cooling water is available and heating the surrounding air is objection- able, such as in a ships hold. If water-cooled operation is desired, connect in accordance with the following sub- paragraphs.

5.6.1 Water-Cooled Condenser with Water Pressure Switch

1. Connect the water supply line to the inlet side of the condenser and the discharge line to the outlet side of the condenser (see Figure 3.7, Figure 3.8).

2. 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 fan motor will stop and will remain stopped until the water pressure switch closes.

3. To shift to air-cooled condenser operation, disconnect the water supply and the discharge line to the water- cooled condenser. The refrigeration unit will shift to air-cooled condenser operation when the water pressure switch closes.

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5.6.2 Water-Cooled Condenser with Condenser Fan Switch

1. Connect the water supply line to the inlet side of condenser and the discharge line to the outlet side of the condenser (see Figure 3.7, Figure 3.8).

2. Maintain a flow rate of 11 to 26 lpm (3 to 7 gpm).

3. 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 condenser water 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.

4. 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

5.7 Connect Remote Monitoring Receptacle If remote monitoring is required, connect the remote monitor plug at the unit receptacle (see Figure 3.9).

When the remote monitor plug is connected to the remote monitoring receptacle, the following remote circuits are energized:

5.8 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.

NOTE The electronic phase detection system will check for proper compressor rotation within the first 30 sec- onds. If rotation is not correct, the compressor will be stopped and restarted in the opposite direction. If the compressor is producing unusually loud and continuous noise after the first 30 seconds of oper- ation, stop the unit and investigate.

5.8.1 Starting the Unit 1. Verify that power is properly applied, the fresh air vent is in proper position, and (if required) the water-

cooled condenser is connected.

2. Place the Start-Stop switch (ST) to position I (ON) (see Figure 3.9). The controller function codes for the container ID (Cd40), software version (Cd18) and unit model number (Cd20) will be displayed in sequence.

3. Continue with the Start Up Inspection. See Section 5.9.

5.8.2 Stopping the Unit 1. To stop the unit, place the Start-Stop switch (ST) in position 0 (OFF).

5.9 Start-Up Inspection

5.9.1 Physical Inspection Check rotation of condenser and evaporator fans.

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

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5.9.2 Check Controller Function Codes Check, and if required, reset controller Function Codes (Cd27 through Cd39) in accordance with desired operating parameters. See Table 46.

5.9.3 Start Temperature Recorder 1. Check and, if required, set the DataCORDER Configuration in accordance with desired recording parame-

ter. See Section 4.7.3.

2. Enter a Trip Start with the following instructions:

a. Press the ALT MODE key. When the left display shows dC, press the ENTER key.

b. Scroll to Code dC30.

c. Press and hold the ENTER key for five seconds.

d. The Trip Start event will be entered in the DataCORDER.

5.9.4 Complete Inspection Allow the unit to run for five minutes to stabilize conditions, and then perform a pre-trip diagnosis in accordance with Section 5.10.

5.10 Pre-Trip Diagnosis

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

CAUTION! When PRE-TRIP key is pressed, economy, dehumidification and bulb mode will be deactivated. At the completion of pre-trip activity, economy, dehumidification and bulb mode must be reac- tivated.

Pre-trip diagnosis provides automatic testing of the unit 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 47. If no selection is made, the pre-trip menu selection process will terminate automatically. However, dehumidification and bulb mode must be reactivated man- ually 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 pow- ered up, - - - - will be displayed.

NOTE Pre-trip may also be initiated via communications. The operation is the same as for the keypad initia- tion described below except that should a test fail, the pre-trip mode will automatically terminate. When initiated via communications, a pre-trip test may not be interrupted with an Arrow key, but the pre-trip test can be terminated with the PRE-TRIP key.

57 T-362

5.10.1 Prior to Starting a Pre-Trip

Verify the following conditions prior to starting a pre-trip. Unit voltage (Cd07) is within tolerance.

Unit amperage draw (Cd04, Cd05, Cd06) are within expected limits.

All alarms are cleared and rectified.

5.10.2 Starting a Pre-Trip

1. Press the PRE-TRIP key to access the pre-trip test selection menu.

2. To Run an Automatic Test: Scroll through the selections by pressing the Up or Down Arrow keys to display AUTO, AUTO 1, AUTO 2 or AUTO 3 as desired, then press the ENTER key.

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.

While tests are running, P#-# will appear on the left display; the #s indicate the test number and sub- test. The right display will show a countdown time in minutes and seconds, indicating the amount of time remaining in the test.

When a Pre-trip Auto 1 test runs to completion without a failure, the unit will exit pre-trip mode and return to normal control operation. However, dehumidification and bulb mode must be reactivated manually if required.

CAUTION! When a Pre-trip Auto 2 test runs to completion without being interrupted, the unit will terminate Pre-trip and display Auto 2 end. The unit will suspend operation until the user depresses the ENTER key!

3. When an automatic 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 number to the left. Press the Down Arrow key to repeat the test, the Up Arrow key to skip to the next test, or the PRE-TRIP key to terminate testing. The unit will wait indefinitely or until a command is entered.

CAUTION! When a failure occurs during automatic testing, the unit will suspend operation awaiting oper- ator intervention.

4. To Run an Individual Test: Scroll through the selections by pressing the Up or Down Arrow keys to display an individual test code. Press the ENTER key when the desired test code is displayed.

Individually selected tests, other than the LED / Display test, will perform the operations necessary to verify the operation of the component. At the conclusion, PASS or FAIL will be displayed. This mes- sage 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 terminate Pre-trip and return to control mode operation.

While the tests are being executed, the user may terminate the Pre-trip diagnostics by pressing and holding the PRE-TRIP key. The unit will then resume normal operation. If the user decides to terminate a test but remain at the test selection menu, the user may press the Up Arrow key. When this is done, all test outputs will be de-energized and the test selection menu will be displayed.

Throughout the duration of any Pre-trip test (except during P-7 high pressure switch tests), the current lim- iting and pressure limiting processes are both active. The current limiting process is only active for P-7.

T-362 58

5.10.3 Displaying Pre-Trip Test Results

1. Press the PRE-TRIP key to access the Pre-trip test selection menu. SELCt Prtrp will be displayed.

2. Press the Arrow keys until the message P, rSLts (Pre-trip results) is displayed.

3. Press the ENTER key. The results for all Pre-trip sub tests are available from this menu (i.e., 1-0, 1-1, etc).

The results will 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.

5.11 Probe Diagnostics A complete temperature probe check is performed during the P5 pre-trip test. A probe check is also run at the end of a defrost cycle; the defrost light will remain on during this period. If supply probes are within limits and return probes are within limits, the unit will return to normal operation. During normal operation, the controller continu- ously monitors and compares adjacent temperature probe readings.

The probe check procedure consists of running the evaporator fans for up to eight minutes in order to compare the readings from the adjacent temperature probes. If a significant difference in temperature readings is detected between probes, a defrost cycle, followed by another probe check may be initiated. Any continued disagreement between probes will prompt the controller to invalidate the failed temperature probe, and the backup probe will be used for temperature control.

In Perishable Mode, both pairs of supply and return probes are monitored for probe disagreement. Probe disagree- ment is considered a difference of 0.5C (0.9F) or greater between the supply air sensors and/ or a difference of 2.0C (3.6F) between the return air sensors. Probe disagreement found in either pair can trigger a defrost probe check.

In Frozen Mode, only the controlling probes are considered. Disagreement of the controlling probes can trigger a defrost probe check, which will occur when the difference between the sensors is greater than 2.0C (3.6F). Nor- mally, the controlling probes are the return probes but if both return probes are invalidated, the supply probes are used for control purposes. Probe disagreement of the non-controlling probe pair will not trigger a defrost probe check.

If after the defrost probe check the supply probes agree and return probes agree, all supply and return sensors are considered valid and the unit returns to normal control.

In the Case of Probe Disagreement: If the supply probes disagree and the return probes agree, the controller will invalidate the worst supply probe. If the probe check is run as part of pre-trip P-5, an alarm will be triggered for the invalidated probe. If it is a run time defrost probe check, the invalidated probe will be passed over and no alarm will be triggered. However, if the best supply probe is greater than 1.2C (2.2F) difference with respect to its return probes, the best supply probe is also invali- dated. If unit is in Perishable Mode, a probe alarm will be triggered for both supply probes.

If the supply probes agree and the return probes disagree, invalidate the worst return probe. If the probe check is being run as part of pre-trip P-5, an alarm will be triggered for the invalidated probe. If it is a run time defrost probe check, the invalidated probe will be passed over and no alarm will be necessary. If the best return probe is greater than 1.2C (2.2F) difference with respect to its supply probes, then the best return probe is also invalidated. If the unit is in perishable mode, a probe alarm will be triggered for both return probes.

5.12 Emergency Bypass Operation (Option) Emergency Bypass operation is used to override the controller, in the case of a controller malfunction, to keep the unit cooling. When Emergency Bypass is installed and turned on, the unit will remain in a continuous state of full cool until the Emergency Bypass switch is turned off.

To place the unit in the Emergency Bypass Operation:

1. Locate the connection diagram and connectors for the emergency bypass (EB) sensors behind the top left side of the compressor.

2. Disconnect the emergency bypass connector from the controller connector and attach it to the emergency bypass module connector (See Figure 5.3).

59 T-362

3. Locate the wire tire located at the EB switch in the control box.

4. Cut the wire tie, then place the EB switch in the On position.

5. Place the Mode Switch (MS) in the Full Cool position to enable the system for cooling.

6. Manually control container air temperature by cycling the Mode switch between Full Cool and evaporator Fans Only.

To operate the fans only, the MODE switch must be in the Fans Only position and the EMERGENCY BYPASS switch must be in the Bypass position.

The EBS module uses the systems safety devices (high pressure switch, motor internal protectors, and heat termi- nation thermostat) to protect the system while in Emergency Bypass Mode.

CAUTION! The unit will remain in the full cooling mode as long as the EB switch is in the On position and the Mode Switch is in the Full Cool position. If the cargo can be damaged by low temperatures, the operator must monitor container temperature and manually cycle operation as required to maintain temperature within required limits.

When the Emergency Bypass switch is in the Bypass position, the EBS will be enabled.

With the Mode switch in Full Cool mode, the following will occur simultaneously:

a. The EBS switch will enable EBS input.

b. The phase detection circuit will detect the phase rotation and close to provide power to the compressor con- tactor.

c. The condenser fan contact will close to energize the condenser contactor and provide power to the con- denser fan motor.

d. The evaporator fan contact will close to energize the high speed evaporator contactor and provide power to the evaporator fan motor.

e. The EBS electronic module will operate the EEV to control superheat.

To return the unit to normal operation:

1. Locate the connectors behind the compressor.

2. Disconnect the Emergency Bypass connector from the EBS module connector and reconnect it to the con- troller connector (see Figure 5.3).

3. Inside the control box, place the EB switch in the Off position.

4. Re-install the wire tie at the switch mounting.

Figure 5.3 Diagram of Emergency Bypass Connections

TO BYPASS MODULE

TO CONTROLLERTO SENSORS

EMERGENCY BYPASS CONNECTOR

Diagram Shows Connection for Emergency Bypass Operation

T-362 510

5.13 TripWise (Option) TripWiseTM is a new premium option available for PrimeLINE and PrimeLINE with Edge units. TripWise is software logic that runs during every voyage as often as possible to indicate whether a standard Pre-trip Inspection (PTI) is needed and skip unless necessary. The tests run in the background and are similar to those completed as part of the standard PTI selection, which includes the following:

Alarm Presence Evaporator Motor Current Heater Current Condenser Motor Current Compressor Current Humidity Sensor Supply / Return Sensors Evaporator Temperature and Pressure Sensors

Defrost Temperature Sensor Electronic Expansion Valve RMU Presence Compressor Test Digital Loader / Unloader Valves Economizer Valve Temperature Control Suction / Discharge Temperature and Pressure

5.13.1 Checking TripWise Status

To check the status of the container, press the PRE-TRIP key on the keypad. The message SELCt | PrtrP will appear on the display module, alternating with one of the following TripWise status messages:

trIPW | OFF. The TripWise option is turned off.

trIPW | EX (Expired). It is recommended to pre-trip the unit prior to the unit's next trip following customer- specific guidelines.

trIPW | PASS. The container should be ready for use after the operator has conducted a visual inspection. Standard PTI is not required.

trIPW | CHECK. If any TripWise test(s) execute and do not meet the pass / fail requirements, It is recom- mended to pre-trip the unit following customer-specific guidelines prior to the unit's next trip.

Pressing the ENTER key while SELCt | PrtrP is displayed will enter into the Pre-trip test menu. Pressing the Arrow keys will navigate through the standard PTI test selections menu.

5.13.2 Enabling or Disabling TripWise Option

1. Press the CODE SELECT key on the keypad.

2. Use the Arrow keys to bring up code Cd65 in the display.

3. Press the ENTER key. The display will show either -----, OFF or ON.

NOTE If ----- is displayed, the TripWise function option is not active on the unit. To add this option to the unit, the equipment owner would need to contact their Regional Carrier Sales Manager.

4. Use the Arrow keys to toggle between ON and OFF and then press the ENTER key to select the desired option.

5. If ON is selected, the display will show dAYS. This is the expiration time (2 through 365 in 1 day incre- ments). Use the Arrow keys to change the parameter and then press the ENTER key to confirm.

NOTE The expiration interval is the total maximum days allowed between the running of each test. For exam- ple, if days are set to 30 and the low speed evaporator fan test has not run within those 30 days, the

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

511 T-362

TripWise expired message will be displayed. If the TripWise expired message is displayed, it is recom- mended to Pre-trip the unit following customer specific guidelines prior to the next trip.

5.13.3 TripWise Status Event

A TripWise status event will be recorded in the DataCorder recorder when the PTI is selected. In the current DataLINE software release, the event will show the status of the unit.

Figure 5.4 TripWise Status in DataCorder

In DataLINE version 3.2, perform an all data download by selecting from the drop down menu TripWise Summary and then select a date in User Logged Events as shown in the Figure below.

Figure 5.5 Generating TripWise Summary Report

This will generate the status / results in a DataLINE TripWise Summary Report as shown in the Figure below.

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Figure 5.6 TripWise Summary Report

Status Results

513 T-362

5.14 Automatic Cold Treatment (Option) Cold Treatment has been employed as an effective post-harvest method for the control of Mediterranean and certain other tropical fruit flies. Exposing infested fruit to temperatures of 2.2C (3.6F) or below for specific time periods results in the mortality of various life stages for this group of insects. Automated Cold Treatment (ACT) in the Carrier Transicold unit is a method to simplify the task of completing cold treatment by automating the process of changing the setpoints. ACT is set up through function code Cd51. Refer to Function Code table in this manual for Cd51 menu processing and displays.

NOTE ACT, setup with Cd51, and Automatic Setpoint Change (ASC), setup with Cd53, will not work simulta- neously. Setting one will deactivate the other.

Procedure to Set ACT: 1. Enter the required cargo setpoint. It must be lower than the treatment temperature discussed in step 5.

2. Press the CODE SELECT key.

3. Use the Arrow keys to scroll to Cd51, and then press the ENTER key.

4. "ACt" is now displayed in the left display and the right will display "Off". Use the Arrow keys to bring up "On" in the right display and press the ENTER key.

5. trEAt" is now displayed in the left display and the right will be flashing the last setting (shown as XX.XC). Use the Arrow keys to select the desired cold treatment setpoint and press the ENTER key.

NOTE "trEAt" is the maximum value that the USDA probes need to remain below, to pass the Cold Treatment protocol. For instance, if the treat value is set at 35.0F (1.7C) then the USDA probe temperatures must remain below 35.0F (1.7C) to pass.

6. "dAyS" is now displayed in the left display and the right will be flashing. Use the Arrow keys to select the desired days for cold treatment and press the ENTER key.

7. "ProbE" is now displayed in the left display and the right will display the probe numbers that are connected. Press the ENTER key. For instance, if "1234" is displayed, then all four of the probes are connected.

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

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8. "SPnEW" is now displayed in the left display and the right will be flashing. Use the Arrow keys to select the desired setpoint after the cold treatment process has successfully completed and press the ENTER key. This would be the final temperature prior to the delivery of the cargo.

9. Cd51 is now displayed in the left display and the right will display days / hours remaining in cold treatment.

10. The unit will start to countdown once all detected USDA probes have reached the specified cold treatment temperature. The cold treatment process will continue until the specified number of days is reached. During operation, Cd51 will show the number of days and hours remaining in the cold treatment.

NOTE Once the cold treatment process has been initiated, setpoint change via the keypad is disabled.

11. While the unit is operating in ACT mode, the left hand display will alternate between "COLd" and setpoint. The right hand display will alternate between "trEAt" and the cargo temperature. Once the treatment time has been completed, the setpoint temperature will increase to the "SPnEW" setting chosen in step 8.

12. When the cold treatment process is complete, the "SPnEW" setpoint will be displayed in the left hand dis- play and cargo temperature in the right hand display, alternating with "COLd" "Done". "COLd" "Done" will continue to alternate with the setpoint and cargo temperature until ACT is turned off.

Procedure to Turn ACT OFF:

ACT will be automatically turned off with a TripStart, or if a Pretrip is initiated.

1. To manually turn ACT Off, press the CODE SELECT key.

2. Use the Arrow keys to scroll to Cd51, and then press the ENTER key.

3. Use the Arrow keys to bring up "Off" in the right display and press the ENTER key.

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

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5.15 Automatic Setpoint Change (ASC) Cd53 Automatic Setpoint Change (ASC) allows up to 6 setpoint changes to be pre-programmed over defined periods of time using Cd53.

1. Press the CODE SELECT key.

2. Use the Arrow keys to scroll to Cd53, then press the ENTER key.

3. Use the Arrow keys to scroll to ON, then press the ENTER key. If ASC is already ON, selecting OFF will ter- minate ASC.

4. Select the desired number of setpoint changes (nSC) by scrolling through the available flashing options (1 6) in the right display, then press the ENTER key.

5. Select the initial setpoint: With (SP 0) in the left display, select by scrolling to the desired flashing setpoint in the right display and press ENTER.

6. Select the days desired for initial setpoint (SP 0): With (DAY 0) in the left display, select by scrolling to the desired flashing days (1 to 99) in the right display and press ENTER.

7. Select the next setpoint (SP 1): With (SP 1) in the left display, select by scrolling to the desired flashing set- point in the right display and press ENTER.

8. Continue to select each additional setpoint.

9. Select a final setpoint (SP x): With (SP x) in the left display, select by scrolling to the desired flashing set- point in the right display and press ENTER.

While the unit is operating in ASC mode, the left hand display will alternate between current unit setpoint and ASC. The right hand display will alternate between current control temperature and ACtvE. The user can deter- mine the amount of time left at the current setpoint by selecting Cd53. The amount of time left will be displayed in the right display (XX (days) / XX (hours). By sequentially pressing ENTER, set parameters can be viewed.

At completion of ASC mode, the left hand display will alternate between current unit setpoint ASC. The right hand display will alternate between current control temperature and Done.

The display will remain this way until ASC is turned off. The user can determine the date of completion by selecting Cd53. With (done) in the left display, the date of completion will be displayed in the right display (Month / Day).

ASC can be manually turned off by selecting Cd53, scrolling to Off and pressing the ENTER key.

ACS will be automatically turned off after three days without power, or if a Pre-trip is initiated.

ACS (Cd53) will work independently of Automatic Cold Treatment (ACT) (Cd51). Setting one deactivates the other.

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SECTION 6 TROUBLESHOOTING

Condition Possible Cause Remedy / Reference 6.1 Unit will not Start or Starts then Stops

No power to unit

External power source OFF Turn on Start-Stop switch (ST) OFF or defective Check Circuit breaker tripped or OFF Check Autotransformer not connected Section 5.2.2

Loss of control power

Circuit breaker OFF or defective Check Control transformer defective Replace Fuse (F3A/F3B) blown Check Start-Stop switch (ST) OFF or defective Check

Component(s) not operating

Evaporator fan motor internal protector open Section 7.17 Condenser fan motor internal protector open Section 7.9 Compressor internal protector open Section 7.9 High pressure switch open Section 6.7 Heat termination thermostat open Replace Malfunction of current sensor Replace

Compressor hums, but does not start

Low line voltage Check Single phasing Check Shorted or grounded motor windings Section 7.9 Compressor seized Section 7.9

6.2 Unit Operates Long or Continuously in Cooling

Container Hot load Normal Defective box insulation or air leak Repair

Refrigeration system

Shortage of refrigerant Section 7.3 Evaporator coil covered with ice Section 6.6 Evaporator coil plugged with debris Section 7.15 Evaporator fan(s) rotating backwards Section 7.15/Section 7.17 Air bypass around evaporator coil Check Controller set too low Reset Compressor service valves or liquid line shutoff valve partially closed

Open valves completely

Dirty condenser Section 7.11.2 Compressor worn Section 7.9 Current limit (function code Cd32) set to wrong value Section 4.3.25 Economizer solenoid valve malfunction Section 7.25 Digital unloader valve stuck open Replace Electronic expansion valve Replace

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6.3 Unit Runs but has Insufficient Cooling

Refrigeration system

Abnormal pressures Section 6.7 Abnormal temperatures Section 6.16 Abnormal currents Section 6.17 Controller malfunction Section 6.9 Evaporator fan or motor defective Section 7.17 Compressor service valves or liquid line shutoff valve partially closed

Open valves completely

Frost on coil Section 6.10 Digital unloader valve stuck open Replace Electronic expansion valve Replace

6.4 Unit will not Heat or has Insufficient Heating

No operation of any kind Start-Stop switch (ST) 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 Section 7.17 Heat relay defective Check Heater termination thermostat open Section 7.15

Unit will not heat or has insufficient heat

Heater(s) defective Section 7.15 Heater contactor or coil defective Replace Evaporator fan motor(s) defective or rotating back- wards

Section 7.15/Section 7.17

Evaporator fan motor contactor defective Replace Controller malfunction Section 6.9 Defective wiring Replace Loose terminal connections Tighten Low line voltage Section 3.3

6.5 Unit will not Terminate Heating

Unit fails to stop heating

Controller improperly set Reset Controller malfunction Section 6.9 Heater termination thermostat remains closed along with the heat relay

Section 7.15

6.6 Unit will not Defrost Properly

Will not initiate defrost automatically

Defrost timer malfunction (Cd27) Table 45 Loose terminal connections Tighten Defective wiring Replace Defrost temperature sensor defective or heat termina- tion thermostat open

Replace

Heater contactor or coil defective Replace

Condition Possible Cause Remedy / Reference

63 T-362

Will not initiate defrost manually

Manual defrost switch defective Replace Keypad is defective Replace Defrost temperature sensor open Replace

Initiates but relay (DR) drops out

Low line voltage Section 3.3

Initiates but does not defrost Heater contactor or coil defective Replace Heater(s) burned out Section 7.15

Frequent defrost Wet load Normal

6.7 Abnormal Pressures

High discharge pressure

Condenser coil dirty Section 7.11.2 Condenser fan rotating backwards Section 7.11 Condenser fan inoperative Section 7.12 Refrigerant overcharge or non-condensibles Section 7.3 Discharge service valve partially closed Open Electronic expansion valve (EEV) control malfunction Replace

Low suction pressure

Incorrect software and/or controller configuration Check Failed suction pressure transducer (SPT) or evapora- tor pressure transducer (EPT)

Replace

Suction service valve partially closed\ Open Filter drier partially plugged Section 7.14 Low refrigerant charge Section 7.3 No evaporator air flow or restricted air flow Section 7.15 Excessive frost on evaporator coil Section 6.6 Evaporator fan(s) rotating backwards Section 7.17.3 EEV control malfunction Replace Failed digital unloader valve (DUV) Replace

Suction and discharge pressures tend to equalize when unit is operating

Compressor operating in reverse Section 6.15 Compressor cycling/stopped Check Failed digital unloader valve (DUV) Replace

6.8 Abnormal Noise or Vibrations

Compressor

Compressor start up after an extended shutdown Normal Brief chattering when manually shut down Compressor operating in reverse Section 6.15 Loose mounting bolts or worn resilient mounts Tighten/Replace Loose upper mounting Section 7.9.1 Loose slugging Section 7.15

Condenser or Evaporator Fan

Bent, loose or striking venturi Check Worn motor bearings Section 7.12/Section 7.17 Bent motor shaft Section 7.12/Section 7.17

Condition Possible Cause Remedy / Reference

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6.9 Microprocessor Malfunction

Will not control

Incorrect software and/or controller configuration Check Defective sensor Section 7.28 Defective wiring Check Low refrigerant charge Section 7.3

6.10 No Evaporator Air Flow or Restricted Air Flow

Evaporator coil blocked Frost on coil Section 6.6 Dirty coil Section 7.15

No or partial evaporator air flow

Evaporator fan motor internal protector open Section 7.17 Evaporator fan motor(s) defective Section 7.17 Evaporator fan(s) loose or defective Section 7.17 Evaporator fan contactor defective Replace

6.11 EAUTOFRESH not Operating

Vent not opening

Unit not Configured for eAutoFresh Operation No action Cd43 in Off mode Section 5.4 Wiring disconnected Check wiring Stepper drive defective Section 7.30 Stepper motor defective Section 7.30 Unit operating in frozen mode Section 5.4

Gas Limit mode unavailable Check CO2 sensor Section 5.4 Wiring disconnected Check wiring Unit operating in frozen mode Section 5.4

Unable to calibrate CO2 sensor

Enter Key not held for sufficient length of time Section 5.4 CO2 outside of acceptable levels Check Check CO2 sensor Section 5.4

Code 44 displays - - - - - Unit not Configured for eAutoFresh Operation No action Check CO2 sensor Section 5.4

6.12 Electronic Expansion Valve Malfunction

Low suction pressure

Incorrect software and/or controller configuration Check Failed suction pressure transducer (SPT) or evapora- tor pressure transducer (EPT)

Replace

Suction service valve partially closed Open Filter drier partially plugged Section 7.14 Low refrigerant charge Section 7.3 No evaporator air flow or restricted air flow Section 7.15 Excessive frost on evaporator coil Section 6.6 Evaporator fan(s) rotating backwards Section 7.17.3 EEV control malfunction Section 7.19 Failed digital unloader valve (DUV) Replace Loose or insufficiently clamped sensor Replace

Condition Possible Cause Remedy / Reference

65 T-362

High suction pressure with low superheat

Foreign material in valve Section 7.19 Failed suction pressure transducer (SPT) or evapora- tor pressure transducer (EPT)

Replace

EEV control malfunction Replace Improperly seated powerhead Ensure powerhead is

locked and in place

Liquid slugging in compressor

Failed suction pressure transducer (SPT) or evapora- tor pressure transducer (EPT)

Replace

Failed EEV Replace

6.13 Autotransformer Malfunction

Unit will not start

Circuit breaker (CB-1 or CB-2) tripped Check Autotransformer defective Section 7.26 Power source not turned ON Check 460 VAC power plug is not inserted into the receptacle Section 5.2.2

6.14 Water-Cooled Condenser or Water Pressure Switch

High discharge pressure Dirty coil

Section 7.13 Non-condensibles

Condenser fan starts and stops

Water pressure switch malfunction Check Water supply interruption Check

6.15 Compressor Operating in Reverse

NOTE The compressor may start in reverse for up to 10 seconds to determine correct phase rotation if required for phase detection.

CAUTION! Allowing the scroll compressor to operate in reverse for more than two minutes will 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

Condition Possible Cause Remedy / Reference

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6.16 Abnormal Temperatures

High discharge temperature

Condenser coil dirty Section 7.11.2 Condenser fan rotating backwards Section 7.12 Condenser fan inoperative Section 7.12.1 Refrigerant overcharge or non-condensibles Section 7.3 Discharge service valve partially closed Open Electronic expansion valve (EEV) control malfunction Replace Failed suction pressure transducer (SPT) or evapora- tor pressure transducer (EPT)

Replace

Discharge temperature sensor drifting high Replace Failed economizer expansion valve, economizer coil, or economizer solenoid valve

Replace

Plugged economizer expansion valve, economizer coil, or economizer solenoid valve

Replace

Loose or insufficiently clamped sensor Replace

6.17 Abnormal Currents Unit reads abnormal currents Current sensor wiring Check

Condition Possible Cause Remedy / Reference

71 T-362

SECTION 7 SERVICE

NOTE Use a refrigerant recovery system whenever removing refrigerant. When working with refrigerants you must comply with all local government environmental laws. In the U.S.A., refer to EPA section 608.

WARNING! EXPLOSION HAZARD Failure to follow this WARNING can result in death, serious personal injury and / or property damage. Never use air or gas mixtures containing oxygen (O2) for leak testing or operating the product. Charge only with refrigerants R-134a or R-513A as specified for the unit model number: Refrigerant must conform to AHRI Standard 700 specification.

NOTE Annual maintenance procedures for PrimeLINE units 69NT40-561 can be found in the 62-10327 Annual Maintenance Manual, located in the Literature section of the Container Refrigeration website. To find the manual from the Literature section, click on Container Units > All Container Units > Operation.

7.1 Section Layout Service procedures are provided in this section beginning with refrigeration system service, then refrigeration system component service, electrical system service, temperature recorder service and general service. See the Table of Contents to locate specific topics.

7.2 Manifold Gauge Set The manifold gauge set (see Figure 7.1) is used to determine system operating pressure, add refrigerant charge, and to equalize or evacuate the system.

Figure 7.1 Manifold Gauge Set

1) Suction Pressure Valve (shown backseated)

2) Suction Pressure Gauge 3) Discharge Pressure Gauge 4) Discharge Pressure Valve

(shown frontseated)

5) High Side Connection 6) Utility Connection to:

a. Refrigerant Cylinder b. Vacuum Pump c. Oil Container

7) Low Side Connection - - - - -

When the Suction Pressure Valve is frontseated (turned all the way in), the suction (low) pressure can be checked at the Suction Pressure Gauge. When the Discharge Pressure Valve is frontseated, the discharge (high) pressure can be checked at the Discharge Pressure Gauge. When both valves are backseated (all the way out), high pressure vapor will flow into the low side.

1

2 3

4 567

T-362 72

When the Suction Pressure Valve is open and the Discharge Pressure Valve is shut, the system can be charged through the Utility Connection. Oil can also be added to the system.

A manifold gauge / hose set with self-sealing hoses (see Figure 7.2) is required for service of the models covered within this manual. The manifold gauge/hose set is available from Carrier Transicold. (P/N 07-00294-00, which includes items 1 through 6, Figure 7.2.)

NOTE It is recommended that the manifold gauge set be dedicated to a specified refrigerant (R-134a or R-513A).

7.2.1 Evacuating the Manifold Gauge Set If the manifold gauge / hose set is new or was exposed to the atmosphere, it will need to be evacuated to remove contaminants and air as follows:

1. Backseat (turn counterclockwise) both field service couplings (see Figure 7.2) and midseat both hand valves.

2. Connect the yellow hose to a vacuum pump and refrigerant cylinder.

3. Evacuate to 10 inches of vacuum and then charge with refrigerant to a slightly positive pressure of 0.1 kg / cm2 (1.0 psig).

4. Frontseat both manifold gauge set valves and disconnect from cylinder. The gauge set is now ready for use.

Figure 7.2 Manifold Gauge / Hose Set

1) RED Refrigeration and / or Evacuation Hose (SAE J2196 / R- 134a)

2) Hose Fitting (0.5-16 Acme) 3) YELLOW Refrigeration and/or

Evacuation Hose (SAE J2196 / R-134a)

4) Hose Fitting with O-ring (M14 x 1.5) 5) High Side Field Service Coupling (Red

Knob) 6) BLUE Refrigeration and/or Evacuation

Hose (SAE J2196/R-134a) 7) Low Side Field Service Coupling (Blue

Knob) - - - - -

7.3 Service Connections The compressor suction, compressor discharge, and the liquid line service valves (see Figure 7.3) are provided with a double seat and an access valve which enables 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.

To Low Side Access Valve

To High Side Access Valve

1

2

3

2

6

4 7 4 5

73 T-362

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.

Figure 7.3 Service Valve

1) Access Valve 2) Step Cap 3) Valve Stem

4) Compressor or Filter Drier Inlet Connection

5) Line Connection - - - - -

Connection of the manifold gauge / hose set (see Figure 7.4) is dependent on the component being serviced. If only the compressor is being serviced, the high side coupling is connected to the discharge service valve.

For service of the low side (after pump down), the high side coupling is connected to the liquid line service valve. The center hose connection is brought to the tool being used (vacuum, tank, etc.).

7.3.1 Connecting the Manifold Gauge Set 1. Remove the service valve stem cap and make sure the valve is backseated.

2. Remove the access valve cap (see Figure 7.3).

3. Connect the field service coupling (see Figure 7.2) to the access valve.

4. Turn the field service coupling knob clockwise to open the system to the gauge set.

5. Slightly midseat the service valve to read system pressures.

6. Repeat the procedure to connect the other side of the gauge set.

CAUTION! To prevent trapping liquid refrigerant in the manifold gauge set, make sure set is brought to suction pressure before disconnecting.

7.3.2 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.

4. Backseat both field service couplings and frontseat both manifold hand valves.

5. Remove couplings from the access valves.

6. Install both service valve stem caps and service port caps (finger-tight only).

7.4 Pump Down the Unit To service the filter drier, economizer, expansion valves, economizer solenoid valve, digital unloader valve or evaporator coil, pump the refrigerant into the high side of the unit:

5

1

2

3 4

Valve (Frontseated) Valve (Backseated)

T-362 74

CAUTION! The scroll compressor achieves low suction pressure very quickly. Do not use the compressor to evacuate the system below 0 psig. Never operate the compressor with the suction or discharge service valves closed (frontseated). Internal damage will result from operating the compressor in a deep vacuum.

7.4.1 Automatic Pump Down 1. To perform an Automatic Pump Down, use function code Cd59 Pump Down Logic. See Cd59 description in

Table 46 Controller Function Codes.

7.4.2 Manual Pump Down: 1. Attach manifold gauge set to the compressor suction and discharge service valves. See Section 7.2.

2. Start the unit and run in the frozen mode, with controller set below -10C (14F), for 10 to 15 minutes.

3. Check function code Cd21 (See Section 4.2.2). The economizer solenoid valve should be open. If not, continue to run until the valve opens.

4. Frontseat the liquid line service valve. When the suction reaches a positive pressure of 0.1 bar (1.4 psig), place the Start-Stop switch (ST) to 0 to turn the unit Off.

5. Frontseat the suction service valve and discharge service valve. The refrigerant will be trapped between the discharge service valve and the liquid line valve.

6. Before opening up any part of the system, a slight positive pressure should be indicated on the pressure gauge. Remove power from the unit before opening any part of the system. If a vacuum is indicated, emit refrigerant by cracking the liquid line valve momentarily to build up a slight positive pressure.

7. 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.

8. After repairs have been made, make sure to perform a refrigerant leak check (See Section 7.5), and evacuate and dehydrate the low side (see Section 7.6).

9. Check refrigerant charge. See Section 7.7.1.

7.5 Refrigerant Leak Checking

WARNING! EXPLOSION HAZARD Failure to follow this WARNING can result in death, serious personal injury and / or property damage. Never use air or gas mixtures containing oxygen (O2) for leak testing or operating the product. Charge only with refrigerants R-134a or R-513A as specified for the unit model number: Refrigerant must conform to AHRI Standard 700 specification.

1. The recommended procedure for finding leaks in a system is with an appropriate electronic leak detector. Testing joints with soapsuds is satisfactory only for locating large leaks.

2. If the system is without refrigerant, charge the system with refrigerant to build up pressure between 2.1 to 3.5 bar (30.5 to 50.8 psig). To ensure complete pressurization of the system, refrigerant should be charged at the compressor suction valve and the liquid line service valve. Remove refrigerant cylinder and leak- check all connections.

NOTE Only refrigerant R-134a or R-513A, as specified for the unit model number, should be used to pressurize the system. Any other gas or vapor will contaminate the system, which will require additional purging and evacuation of the system.

3. If required, remove refrigerant using a refrigerant recovery system and repair any leaks. Check for leaks.

4. Evacuate and dehydrate the unit. See Section 7.6.

5. Charge unit. See Section 7.7.

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7.6 Evacuation and Dehydration 7.6.1 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.

7.6.2 Preparation 1. Evacuate and dehydrate only after completing a pressure leak test. See Section 7.5.

2. Essential tools to properly evacuate and dehydrate any system include a vacuum pump (8m3/hr = 5 cfm volume displacement) and an electronic vacuum gauge. The pump is available from Carrier Transicold, P/N 07-00176-11. The micron gauge is P/N 07-00414-00.

3. If possible, keep the ambient temperature above 15.6C (60F) to speed evaporation of moisture. If the ambient temperature is lower than 15.6C (60F), ice might form before moisture removal is complete. Heat lamps or alternate sources of heat may be used to raise the system temperature.

4. Additional time may be saved during a complete system pump down by replacing the filter drier with a section of copper tubing and the appropriate fittings. Installation of a new drier may be performed during the charging procedure.

Figure 7.4 Refrigeration System Service Connections

1) Economizer Solenoid Valve 2) Receiver or Water Cooled Condenser 3) Compressor 4) Discharge Service Connection 5) Suction Service Connection 6) Vacuum Pump

7) Electronic Vacuum Gauge 8) Refrigerant Cylinder 9) Reclaimer 10) Manifold Gauge Set 11) Liquid Service Connection

- - - - -

7.6.3 Evacuate and Dehydrate - Complete System

NOTE See Partial System procedure for information pertaining to partial system evacuation and dehydration.

1. Remove all refrigerant using a refrigerant recovery system.

DS

11

1

2

4

5

6

7

10

9

8

3

T-362 76

2. The recommended method to evacuate and dehydrate the system is to connect evacuation hoses at the compressor suction and liquid line service valve (see Figure 7.4). Make sure the service hoses are suited for evacuation purposes.

NOTE To prevent the area between the Economizer Solenoid Valve (ESV) and the compressor from being isolated during evacuation, it is necessary to open the ESV using a magnet tool (Carrier Transicold P/ N 07-00512-00).

3. Remove the ESV coil from the valve body. Place the magnet tool over the valve stem. An audible click will be heard when the ESV opens.

NOTE Make sure to replace the valve coil before restating the unit. Starting the unit with the coil removed from the valve will burn out the coil.

4. 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.

5. Midseat the refrigerant system service valves.

6. Open the vacuum pump and electronic vacuum gauge valves, if they are not already open. Start the vacuum pump. Evacuate the unit until the electronic vacuum gauge indicates 2000 microns. Close the electronic vacuum gauge and vacuum pump valves. Shut off the vacuum pump. Wait a few minutes to be sure the vacuum holds.

7. Break the vacuum with either clean refrigerant (R-134a or R-513A as specified for the unit model number) or dry nitrogen. Raise system pressure to roughly 0.14 bar (2 psig), monitoring it with the compound gauge.

8. If refrigerant was used, remove using a refrigerant recovery system. If nitrogen was used, relieve the pressure.

9. Repeat steps 6 and 7 one time.

10. Remove the copper tubing and change the filter drier. Evacuate unit to 500 microns. Close the electronic vacuum gauge and vacuum pump valves. Shut off the vacuum pump. Wait five minutes to see if vacuum holds. This procedure checks for residual moisture and/or leaks.

11. With a vacuum still in the unit, the refrigerant charge may be drawn into the system from a refrigerant container on weight scales.

7.6.4 Evacuate and Dehydrate - Partial System 1. If refrigerant charge has been removed from the low side only, evacuate the low side by connecting the

evacuation set-up at the compressor suction valve and the liquid service valve but leave the service valves frontseated until evacuation is completed.

2. 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.

7.7 Refrigerant Charge

WARNING! EXPLOSION HAZARD Failure to follow this WARNING can result in death, serious personal injury and / or property damage. Never use air or gases containing oxygen (O2) for leak testing or operating the product. Charge only with refrigerants R-134a or R-513A as specified for the unit model number: Refrigerant must conform to AHRI Standard 700 specification.

7.7.1 Checking the Refrigerant Charge

NOTE Use a refrigerant recovery system whenever removing refrigerant. When working with refrigerants you must comply with all local government environmental laws. In the U.S.A., see EPA Section 608.

77 T-362

1. Connect the gauge manifold to the compressor discharge and suction service valves. For units operating on a water-cooled condenser, change over to air-cooled operation.

2. Bring the container temperature to approximately 0C (32F) or below. Then set the controller setpoint to - 25C (-13F).

3. Partially block the condenser coil inlet air. If covering the lower portion of the coil is not sufficient, remove the left hand infill panel and cover the left side of the coil. Increase the area blocked until the compressor discharge pressure is raised to approximately 12.8 bar (185 psig).

4. On units equipped with a receiver, the level should be between the glasses. On units equipped with a watercooled condenser, the level should be at the center of the glass. If the refrigerant level is not correct, See Section 7.7.2 and Section 7.7.3 to add or remove refrigerant as required.

7.7.2 Adding Refrigerant to System - Full Charge 1. Evacuate unit and leave in deep vacuum. See Section 7.6.1.

2. Place refrigerant cylinder on scale and connect charging line from cylinder to liquid line valve. Purge charging line at liquid line valve and then note weight of cylinder and refrigerant.

3. Open liquid valve on cylinder. Open liquid line valve halfway and allow liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added as indicated by scales. See Section 3.2

4. It may be necessary to finish charging unit through suction service valve in gas form, due to pressure rise in high side of the system.

5. Backseat the manual liquid line valve to close off the gauge port. Close liquid valve on cylinder.

6. Start the unit in cooling mode. Run for approximately 10 minutes and check the refrigerant charge.

7.7.3 Adding Refrigerant to System - Partial Charge 1. Examine the refrigerant system for any evidence of leaks, repair as necessary. See Section 7.5.

2. Maintain the conditions outlined in Section 7.7.1.

3. Fully backseat the suction service valve and remove the service port cap.

4. Connect the charging line between suction service valve port and refrigerant cylinder. Open the VAPOR valve.

5. Partially frontseat (turn clockwise) the suction service valve and slowly add charge until the refrigerant appears at the proper level. Be careful not to frontseat the suction valve fully. If the compressor is operated in a vacuum, internal damage may result.

7.8 Converting to R-513A Refrigerant This procedure only applies to R-513A-ready units for 69NT40-561-500 models. This conversion is only by approval of the equipment owner.

1. The compressor will have a green dot on the DUV fitting to note that it can accept R-513A.

2. Recover all R-134a refrigerant from the unit, by following procedure in Section 7.6.

3. Change the filter drier.

4. Evacuate to 500 microns by placing the vacuum pump on the liquid line and suction service valve.

5. Charge the unit with a full charge of R-513A refrigerant, by following procedure in Section 7.7.2. Charge amounts are found in Section 3.2 Refrigeration System Data.

CAUTION! When charging the unit with R-513A refrigerant, charge as a liquid only. R-513A is an azeotrope blend containing R-1234yf and R-134a. Charging or topping off as a vapor will result in an incorrect mixture of blend in the system.

6. Upon completion, change the refrigerant label (Carrier P/N 76-50235-00) on the front of the unit indicating the change in refrigerant.

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7.9 Compressor

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

WARNING! Before disassembly of the compressor, be sure to relieve the internal pressure very carefully by slightly loosening the couplings to break the seal.

CAUTION! The scroll compressor achieves low suction pressure very quickly. Do not use the compressor to evacuate the system below 0 psig. Never operate the compressor with the suction or discharge service valves closed (frontseated). Internal damage will result from operating the compressor in a deep vacuum.

CAUTION! The PrimeLINE unit has a hermetically sealed compressor that should not be opened and/or repaired. Doing so can cause a loss in performance and premature system failure due to the precision machinery and assembly required within the compressor. To repair the unit, remove the faulty compressor and replace with an approved Carrier compressor. If the return of the compressor is not required, follow local waste collection & recycling regulations in discarding the compressor.

NOTICE Replacement compressors are supplied without oil.

7.9.1 Removing and Replacing the Compressor 1. Turn the unit ON and run it in full cool mode for 10 minutes.

NOTE If the compressor is not operational, frontseat the suction and discharge service valves and go to step 5.

2. Frontseat the manual liquid line valve and allow the unit to pull-down to 0.1 kg/cm2 (1 psig).

3. Place the Start-Stop switch (ST) to 0, turn the unit circuit breaker (CB-1) OFF, and disconnect power to the unit.

4. Frontseat the discharge and suction service valves.

5. Remove all remaining refrigerant from the compressor using a refrigerant recovery system.

6. Remove the compressor terminal cover, disconnect the ground wire and pull the cable plug from the compressor terminals. Install the terminal cover back after removing the power cable.

NOTE Inspect the power cable (plug) terminals to ensure they are not deformed or have any signs of heat or arcing. If any damage is noted, replace the power cable.

7. Remove the Rotalock fittings from the suction and discharge service connections, and uncouple the unloader and economizer lines from the compressor.

8. Cut the dome temperature sensor (CPDS) wires. The replacement compressor comes with a CPDS already assembled.

9. Remove and save the compressor base mounting bolts. Discard the four top resilient mounts and washers.

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10. Remove (slide out) the old compressor from the unit.

11. Inspect compressor base plate for wear. Replace, if necessary.

12. Wire tie the compressor base plate to the compressor, and slide the new compressor into the unit. See Figure 7.5.

Figure 7.5 Compressor Kit

1) Compressor Discharge Temperature Sensor (CPDS)

2) O-Ring, Economizer Connection 3) Teflon Seal for Valve Connection (2) 4) Base Mounting Bolts 5) SST Washers 6) Resilient Mount

7) SST Washers 8) Mylar Washers 9) Wire Ties 10) Power Cable Gasket, Ground

Connection Screw 11) Teflon Seal for Valve Connection (2) 12) O-Ring, Unloader Connection

- - - - -

13. Cut and discard the wire ties used to hold the base plate to the compressor.

14. Place the new SST washers on each side of the resilient mounts, and the new Mylar washer on the bottom of it as shown in Figure 7.5. Install the four base mounting bolts loosely.

15. Place the new Teflon seals at the compressor suction and discharge ports as well as the O-rings at the unloader and economizer line connection ports. Hand tighten all four connections.

16. Torque the four base-mounting screws to 6.2 mkg (45 ft-lbs).

17. Torque the compressor ports / connections.

18. Connect (butt-splice and heat shrink) the new compressor dome temperature sensor with the old sensor wires removed in step 8. Wire-tie any loose wiring as appropriate.

19. Evacuate the compressor to 1000 microns if the unit was pumped down before the replaced compressor was removed. Otherwise, evacuate the complete unit and charge it with refrigerant (see Section 7.6.1 and Section 7.7.1).

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12 1

2

4

5

6 7

8 9

10

3

Power Cable Lubricant: Krytox (Not Shown)

Service Valve / Connection Torque Value Suction and Discharge Rotalocks 108.5 to 135.5 Nm (80 to 100 ft-lbs.)

Unloader connection 24.5 to 27 Nm (18 to 20 ft-lbs.) Economized connection 32.5 to 35 Nm (24 to 26 ft-lbs.)

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20. Open the compressor terminal cover and connect the compressor power cable following the steps below:

a. Liberally coat the orange gasket surfaces with the Krytox lubricant.

b. Install the orange gasket part onto the compressor fusite with the grooved or threaded side out. Ensure that the gasket is seated onto the fusite base.

c. Coat the inside of the power plug (female) connector pins with the Krytox lubricant, and insert the plug onto the compressor terminal connections. Make sure, the orange gasket has bottomed out onto the fusite and it fits securely onto the terminal pins while fully inserted into the orange plug.

d. Connect the green ground wire to the grounding tab located inside the terminal box of the compressor using the self-tapping grounding screw. Close the compressor terminal box using the terminal cover removed in step 20.

21. Backseat all service valves, connect the power to the unit and run it for at least 20 minutes.

22. Perform a leak check of the system.

7.10 High Pressure Switch 7.10.1 Checking High Pressure Switch

WARNING! Do not use a nitrogen cylinder without a pressure regulator.

NOTE The high pressure switch is non-adjustable.

1. Remove switch as outlined in Section 7.10.2. 2. 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. 3. Connect hose to a cylinder of dry nitrogen (see Figure 7.6).

Figure 7.6 High Pressure Switch Testing

1) Cylinder Valve and Gauge 2) Pressure Gauge (0 to 36 kg/

cm2 = 0 to 400 psig) 3) Bleed-Off Valve

4) 1/4 inch Connection 5) Nitrogen Cylinder 6) Pressure Regulator

- - - - - 4. Set nitrogen pressure regulator at 26.4 kg/cm2 (375 psig) with bleed-off valve closed. 5. Close valve on cylinder and open bleed-off valve. 6. 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/cm2 (350 psig). If a light is used, the light will go out. If an ohmmeter is used, the meter will indicate open circuit.

7. Slowly open bleed-off valve to decrease the pressure. The switch should close at 18 kg/cm2 (250 psig).

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7.10.2 Replacing High Pressure Switch 1. Remove the refrigerant charge.

2. Disconnect wiring from defective switch. The high pressure switch is located on the discharge connection or line and is removed by turning counterclockwise.

3. Install a new high pressure switch after verifying switch settings.

4. Evacuate, dehydrate and recharge the system.

5. Start the unit, verify refrigeration charge and oil level.

7.11 Condenser Coil 7.11.1 Condenser Coil Cleaning To ensure optimal efficiency of the unit the condenser coil must be clean. The condenser coil should be cleaned at least once a year, but more frequent cleaning may be required depending on operating conditions. The coil is cleaned with fresh water sprayed in the reverse direction of the air flow to remove any debris from the coil. A high pressure washer is not required, mains water pressure is sufficient.

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

1. Make sure the unit is powered off and the plug is disconnected. 2. Remove the condenser fan grille. 3. Starting from the top of the coil, use a water hose with a nozzle to wash the coil from the inside out. 4. Systematically wash across the inside top face of the coil until the water runs clean. 5. Wash down the center section, and then through the bottom of the coil, continue washing until the water

runs clear. 6. After the coil is clean, rinse the condenser fan to remove any dirt build up from the blades. 7. Replace the condenser fan grille ensuring that it is centered around the fan.

7.11.2 Condenser Coil Removal 1. Using a refrigerant reclaim system remove the refrigerant charge.

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

2. Remove the condenser fan grille, retain all bolts and washers for reuse. 3. Remove the condenser fan. 4. Remove the infill panels to the left and right of the condenser fan shroud. 5. Remove the condenser fan shroud. 6. Unplug the condenser fan motor. 7. Remove and retain sufficient putty from around the motor wire harness to allow the harness to be slid back

through the side support bracket. 8. Cut the top and bottom drain lines midway between the side support bracket and the first cable tie, approx

150mm (6) from the side support bracket. 9. Remove and retain sufficient putty from around the drain lines to allow the tubes to be slid back through the

side support bracket. 10. Remove filter drier. 11. Unbraze the inlet connection to coil.

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12. Remove the cushion clamps securing the liquid line to the top and bottom receiver brackets, retain all clamps and securing hardware.

13. Place a support under the condenser coil before releasing the coil from the frame. 14. Remove the lower mounting bracket bolts from the inside of the coil. 15. Remove the top mounting bracket bolts and grille extension mount from inside the coil. 16. Remove the side support bracket mounting bolts. 17. Slide the condenser assembly with receiver out of the unit.

7.11.3 Condenser Coil Preparation Before installing the new condenser coil, the receiver assembly and mounting hardware must be removed from the old coil assembly:

1. From the old coil, unbolt the receiver assembly from side support bracket.

2. Unbraze the receiver assembly from the coil outlet line and remove from the coil assembly.

3. Unbolt the side support bracket from the top and bottom coil supports and remove from old coil.

4. Refit the side support bracket to the new coil ensuring that the top and bottom are flush mounted with the coil support.

7.11.4 Condenser Coil Installation Once the side support bracket has been secured to the new condenser coil, the entire assembly is ready to be installed into the unit:

1. Slide the new condenser coil into place ensuring the coil inlet connection is mated to the pipework and that the coil is fully supported.

2. Secure the condenser coil into the unit using the retained hardware; refit the mylar and fender washers:

a. Refit the side support bracket bolts.

b. Refit the top support bracket bolts as well as the top grille extension support.

c. Refit the bottom support bracket bolts.

3. Braze the condenser coil inlet connection.

4. Insert the receiver pipe work onto the coil outlet and loosely secure the receiver assembly to the side support bracket with the retained hardware.

5. Braze the outlet connection to the receiver assembly.

6. Install a new filter drier.

7. Replace the liquid line cushion clamps.

8. Secure the receiver assembly to the side support bracket.

9. Pressure / leak test the coil and filter drier connections. See Section 7.5.

10. Evacuate the entire unit. See Section 7.6.

11. Slide the top and bottom drain lines back into place through the side support bracket.

12. Using the two supplied straight connectors and contact adhesive reconnect the drain lines.

13. Slide the condenser fan motor wiring harness back through the side support bracket and refit to condenser motor.

14. Replace all wire ties that were removed to properly secure the drain line and wiring.

15. Reseal the wire harness and drain line penetrations with the putty.

16. Slide the condenser fan onto the motor shaft reversed but do not secure.

17. Refit the condenser fan shroud to the unit. Use the condenser fan as a guide to ensure the shroud is properly centered around the fan.

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18. Remove the condenser fan, and place it on the shaft facing the correct direction. Adjust the fan to the correct position, 37mm (1.5) from the fan shroud, see Figure 7.7.

Figure 7.7 Condenser Fan Position

19. Use Loctite H on the fan set screws, and tighten.

20. Refit left and right infill panels.

21. Refit the condenser fan grille, ensuring the grille is properly centered around the condenser fan.

22. Evacuate the entire unit. See Section 7.6.

23. Recharge the unit with the charge shown on the unit serial plate. See Section 7.7. It is important for proper unit operation that the charge is weighed into the unit.

7.11.5 Micro Channel Heat Exchanger (MCHE) Repair Instructions

WARNING! Before proceeding with the installation, make sure power to the unit is OFF and the power plug is disconnected.

WARNING! Follow proper lockout / tagout procedures to ensure that the power cannot be inadvertently energized.

WARNING! Dress with personal protective equipment (PPE) gear before attempting any field repairs. Aluminum fin is extremely sharp. Wear gloves and protective eye wear.

37mm (1.5)

Fan

Shroud

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Tools Required: Screw driver set Standard hand tools Needle nose pliers (long nose) 35 degree bent long nose pliers Duckbill pliers Tube brush (soft bristle) Emery cloth Disposable gloves Utility knife Protective goggles Vacuum pump Gauge manifold Alcohol Water

Parts Required:

Procedure:

NOTE This repair is only a limp home repair. The coil should be replaced at the earliest convenience.

1. Locate the suspect leak using an electronic leak detector or liquid soap (looking for bubbles). If required, pressurize the unit with Nitrogen confirming the leak location.

NOTE When refrigerant escapes, oil that also escapes will typically result in a wet looking area and or heavy concentrations of dirt sticking to oil. These are usually good indicators of where to begin a check.

2. Remove the refrigerant and or any nitrogen used for leak checking from the system.

Item Part Number Description Quantity 76-00893-00 MCHE Repair Kit 1

1 02-00312-00 3M SCOTCH-WELD DP100 Epoxy B/A Gray 1 2 58-05127-00 Dispensing Gun For 1.69 oz Cartridges 1 3 58-05127-01 Plunger, 1:1 Mix Ratio 1 4 58-05127-02 Mixer Nozzles, 1.69 oz Cartridges 3 5 68-18212-00 Plate, Aluminum 3 6 58-05127-03 Emery Cloth Block-Shaped 180 Grit, 1 x 7 2 7 58-05127-04 Zip-Press Polyethylene Bag 2 Mil Thick, 2 x 2 1 8 58-05127-05 Documents Holder, Press to Close, 10 x 8-1/2 1 9 58-05127-06 Nonmarring Picks, Wood, Flat Tip/Point Tip, 7" Length 1

10 98-02667-00 Instruction Sheet 1

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3. Using a utility knife, carefully section off the area around the leak (approximately 0.5 inches)

4. Using needle nose pliers, carefully remove the fins from the damaged area above and below the tube needing repair. The fins to be removed should be approximately 1/2 of fin material from each side of the repair location.

5. Remove dirt from the surface around the leak point with a soft bristle brush and water. Then wash off any residual oil with alcohol. Allow the surfaces to fully air dry.

6. Open up the leak point to at least 1 mm width by using the tip of a knife carefully. Remove all aluminum fragments. Shape the cut to make it easy for epoxy resin to enter the microchannel.

7. Clean the area around the leak point with alcohol.

8. Connect the gauge manifold to the HI and LO service valves and evacuate the unit using a vacuum pump.

9. Remove the coil coating from the repair area by brushing the upper and lower portion of the tube with the round tube brush.

10. Prepare the precut aluminum wrapper by folding it in half along the short (0.75) length.

11. Using the emery cloth, remove any rough edges on the upper and lower portion of the tube and also scuff the inside of the aluminum wrapper.

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12. Prepare the required amount of epoxy resin per instructions on the package and place on the cardboard and replace the cap onto the epoxy container after use.

NOTE When the temperature is below 10C (50F), warm up the affected area prior to the repair using a heat gun. Do not use an open flame.

13. Place mixed epoxy onto the leak point using wooden picks (while the unit is under vacuum).

14. The vacuum pump should be able to pull the epoxy through the cut area to form a shape that works as a plug.

15. Apply additional mixed epoxy with the application tool to the leak area and along the cleared fin section. Make sure that resin is sucked into the opening.

16. Place mixed epoxy on the aluminum wrapper and place the aluminum wrapper over the leak area.

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17. Lightly crimp the aluminum wrapper with needle nose pliers.

18. Allow an additional one to two hours for epoxy to cure before leak checking the system.

NOTE Keep the unit under vacuum until the epoxy is fully cured.

19. Repeat the original leak check of the system in step 4 to verify that the leak has been plugged.

20. Evacuate and recharge the unit with refrigerant following procedures identified in the unit model Operations & Service Manual.

7.12 Condenser Fan and Fan Motor The condenser fan rotates counter-clockwise (viewed from front of unit). The fan pulls air through the condenser coil, and discharges the air horizontally through the front of the unit.

7.12.1 Condenser Fan Motor Remove/Replace

WARNING! Before removing the condenser fan grille, make sure power to the unit is OFF and the power plug is disconnected

1. Remove the condenser fan grille, retain all bolts and washers for reuse.

2. Remove the condenser fan by loosening the two set screws.

3. Disconnect the condenser fan motor wiring.

CAUTION! Take necessary steps (place plywood over coil or use sling on motor) to prevent motor from falling into condenser coil.

4. Note the number of shims on each side of the motor as the same configuration will be required to refit the new motor.

5. Remove the fan motor mounting hardware and remove motor.

6. Loosely mount the new motor using new lock nuts.

7. Connect the fan motor wiring to the new fan motor.

8. Replace the shims in the same configuration as they were removed.

9. Tighten the fan motor mounting bolts to properly secure the motor.

10. To make sure that the motor is aligned properly, slide the condenser fan onto the motor shaft reversed but do not secure.

11. Rotate the fan to make sure the fan blades do not contact the shroud:

a. If the fan motor is misaligned vertically, add or remove shims to align.

b. If the fan motor is not properly centered, loosen the mounting bolts, and adjust the motor position on the bracket, and then secure the motor.

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12. Remove the condenser fan, and connect the fan motor wiring to the fan motor.

13. Place the condenser fan on the shaft facing the correct direction. Adjust the fan to the correct position, 37mm (1.5) from the fan shroud, see Figure 7.7.

14. Use Loctite H on the fan set screws, and tighten.

15. Refit the left and right infill panels.

16. Refit the condenser fan grille, ensuring the grille is properly centered around condenser fan.

7.13 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 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.

If the water-cooled condenser is dirty, it may be cleaned and de-scaled.

7.13.1 Cleaning Supplies Needed Oakite Aluminum Cleaner 164, available as a powder in 20 kg (44 lb) pails and 205 kg (450 lb) drums.

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.

Fresh clean water.

Acid proof pump and containers or bottles with rubber hose.

NOTE When Oakite Compound No. 32 is used for the first time, the local Oakite technical service representative should be called in for suggestions in planning the procedure. The representative will advise the reader on how to do the work with 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. The representatives knowledge of metals, types of scale, water conditions and de-scaling techniques will be highly useful.

7.13.2 Cleaning Procedure Summary 1. Turn the unit off and disconnect main power.

2. Disconnect the water pressure switch tubing by loosening the two flare nuts. Install a 1/4 inch flare cap on the water-cooled condenser inlet tube (replaces tubing flare nut). De-scale tubing if necessary.

3. Drain water from the condenser tubing circuit.

4. Clean the water tubes with Oakite Aluminum Cleaner 164 to remove mud and slime.

5. Flush.

6. De-scale the water tubes with Oakite No. 32 to remove scale.

7. Flush.

8. Neutralize.

9. Flush.

10. Put the unit back in service under normal load and check head (discharge) pressure.

7.13.3 Cleaning Procedure Detailed 1. Drain and flush the water circuit of the condenser coil. If scale on the tube inner surfaces is accompanied by

slime, a thorough cleaning is necessary before de-scaling process can be accomplished.

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2. To remove slime or mud, use Aluminum Cleaner 164. Mix 170 grams (6 ounces) per 3.785 liters (1 U.S. gallon) of water. Mix cleaner in one half the volume of water, while stirring, and then add remaining water. Warm this solution and circulate through the tubes until all slime and mud has been removed.

3. After cleaning, flush the 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 accomplished by slowly adding 0.47 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 contact occurs. Do not allow the solution to splash onto concrete.

5. Fill the tubes with this solution by filling from the bottom. See Figure 7.8.

Figure 7.8 Water-Cooled Condenser Cleaning - Forced Circulation

1) Pump 2) Priming Connection (Centrifugal pump

50 gpm at 35 head) 3) Globe valves 4) Vent 5) Close vent pipe valve when pump is

running

6) Condenser 7) Remove water regulating valve 8) Return 9) Fine mesh screen 10) Pump support 11) Tank 12) Suction

- - - - -

NOTE It is important to provide a vent at the top for escaping gas.

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 7.9) filled with the solution and attached to the coils by a hose can serve the same purpose by 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 regularly opening the vent to release gas. Keep flames away from the vent gases.

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7. The time required for de-scaling will vary, depending upon the extent of the deposits. One way to determine when de-scaling has been completed is to titrate the solution periodically, using titrating equipment 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.

Figure 7.9 Water-Cooled Condenser Cleaning - Gravity Circulation

8. When de-scaling is complete, drain the solution and flush thoroughly with water.

NOTE If condenser cooling water is not being used as drinking water or is not re-circulated in a closed or tower system, neutralizing is not necessary.

9. Following the water flush, circulate a 56.7 gram (2 ounce) per 3.785 liter (1 U.S. gallon) solution of Oakite Aluminum Cleaner 164 through the tubes to neutralize. Drain this solution.

10. Flush the tubes thoroughly with fresh water.

11. Put the unit back in service and operate under normal load. Check the head pressure. If normal, a thorough de-scaling has been achieved.

What You Can Do For Further Help: Contact the Engineering and Service Department of OAKITE PRODUCTS CO., 675 Central Avenue, New Providence, NJ 07974 U.S.A. (or visit www.oakite.com)

7.14 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, the unit may have a low refrigerant charge or the filter drier could be partially plugged.

7.14.1 Checking the Filter Drier: 1. Test for a restricted or plugged filter drier by feeling the liquid line inlet and outlet connections. If the outlet

side feels cooler than the inlet side, then the filter drier should be changed.

2. Check the moisture-liquid indicator. If it shows a high level of moisture, the filter drier should be replaced.

7.14.2 Replacing the Filter Drier: 1. Pump down the unit (see Section 7.4). If the unit is not equipped with service values, evacuate the unit.

Then replace filter drier.

3 to 4

Fill condenser with cleaning solution. Do not add solution more rapidly than vent can exhaust gases caused by chemical reaction.

1 pipe Approximately 5

Condenser

Vent pipe

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2. Evacuate the low side in accordance with Section 7.6.

3. After unit is in operation, inspect for moisture in the system and check charge.

7.15 Evaporator Coil The evaporator section, including the evaporator 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.

7.15.1 Evaporator Coil Replacement 1. Pump unit down. See Section 7.4.

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

2. With power OFF and power plug removed, remove the screws securing the panel covering the evaporator section (upper panel).

3. Disconnect the defrost heater wiring.

4. Remove the mounting hardware from the coil.

5. Unsolder the two coil connections, one at the distributor and the other at the coil header.

6. Disconnect the defrost temperature sensor (see Section 7.28) from the coil.

7. Remove middle coil support.

8. After defective coil is removed from unit, remove defrost heaters and install on replacement coil.

9. Install coil assembly by reversing above steps.

10. Leak check connections. Evacuate and add refrigerant charge.

7.16 Evaporator Heaters Figure 7.10 Heater Arrangement

1) Heater Element 2) Bracket

3) Retainer

- - - - -

The heaters are wired directly back to the contactor and if a heater failure occurs during a trip, the heater set containing that heater may be disconnected at the contactor.

The next pre-trip (P1) will detect that a heater set has been disconnected and indicate that the failed heater should be replaced.

1

2

3

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7.16.1 Megger Testing the Heaters

WARNING! Always turn OFF the unit circuit breakers, disconnect the main power supply, and perform Lock Out / Tag Out before working on moving parts.

All of the checks performed during this procedure should be carried out using a 500v Meg-ohm tester.

1. Connect the ground wire from the insulation tester to a fixed ground point, preferably the ground plate in the control box.

2. At the load side of the heater contactor, check the insulation resistance to ground.

If readings are > 2 Mohm, then the heaters are operating properly and no action is needed.

If readings are < 1 Mohm, then the faulty heater needs to be identified. Proceed to step 3 for units with a heater access panel or step 4 for units without a heater access panel.

If readings are between 1 and 2 Mohm, then the heaters need to be re-tested with the following steps:

a. Reconnect the unit to power and power the unit on.

b. Set the unit set point to a minimum of 10C higher than the current temperature of the container. Allow the unit to go into heat mode, reach the temperature set point and maintain for 10-15 minutes.

c. Power the unit off. Allow the unit to cool to ambient temperature.

d. Connect the ground wire from the insulation tester to a fixed ground point, preferably the ground plate in the control box.

e. At the load side of the heater contactor, check the insulation resistance to ground.

If readings are > 1 Mohm, then the heaters are operating properly and no action is needed.

If readings are < 1 Mohm, then the faulty heater needs to be identified. Proceed to step 3 for units with a heater access panel or step 4 for units without a heater access panel.

3. Identify the faulty heater(s) for units with a heater access panel:

a. Open the access panel and cut out all wire splices to isolate all heaters inside of the unit.

b. Repeat the Megger test on each individual heater. Connect the ground clip to the outer metal sheath of the heater and the test clip to one of the wires from the same heater.

c. Replace any heater where the readings are < 1 Mohm.

4. Identify the faulty heater(s) for units without a heater access panel:

a. Remove all six connections from the Heater (HR) contactor load side, which splits the six heaters into three separate pairs.

b. Identify the following three wires: DHTL, DHML, DHBL. There is one from each load connection.

c. Repeat the Megger test on each pair of heaters to identify the faulty heater pair. Connect the ground clip from the insulation tester to a fixed ground point on the unit, preferably the ground plate in the control box. Connect the test clip to one of the wires stated above.

d. Test all three wires and replace any heater pair that has readings < 1 Mohm.

5. If the unit is loaded, and the heater can not be immediately replaced, perform the following steps:

a. Identify the wire at the opposite end of the faulty heater pair: DHTL - DHTR, DHML - DHMR, DHBL - DHBR.

b. Isolate the two wires.

c. Reconnect the remaining good wiring pairs to their original connections.

d. The unit will fail the PTI test P1-0 at the next pre-trip inspection. Repair action can be taken at that time.

6. If the unit is empty, replace the faulty heater:

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WARNING! Always turn OFF the unit circuit breakers, disconnect the main power supply, and perform Lock Out / Tag Out before working on moving parts.

a. With the heater pair identified, remove the upper back panel inside the container.

b. Identify the center point connection for the heater pair (black wiring from heaters) either against the unit back wall or in the wiring loom.

c. Cut the splice to separate the two heaters.

d. Carry out a Megger check on the two heaters in the same way as for units with heater panel. Replace any heater where the Megger readings are < 1 Mohms.

NOTE If all heaters are above the acceptable limit with the wiring disconnected, then this indicates that the fault was in one or more of the wire splices that were removed.

e. Remove the hold-down clamp securing the heater(s) to the coil.

f. Verify that the heaters are not hot before handling them.

g. Lift the bent end of the heater (with the opposite end down and away from the coil). Move the heater to the side enough to clear the heater end support and remove.

h. To install heater, reverse steps.

i. Reconnect all wiring using new splices and heat shrink where needed. The heat shrink MUST have a 'melt-able' liner to ensure that the connections are properly sealed when shrunk. This can be seen as a 'Ring' of melt liner pushed from under the heat shrink at each end of the shrink tube.

NOTE Failure to use melt liner heat shrink allows moisture to 'wick' up under the heat shrink and cause a leakage path.

7.17 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.

7.17.1 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.

1. Remove the access panel by removing the mounting bolts and TIR locking device. Reach inside of the unit and remove the Ty-Rap securing the wire harness loop. Disconnect the connector by twisting to unlock and pulling to separate.

2. Loosen four 1/4-20 clamp bolts that are located on the underside of the fan deck at the sides of the fan assembly. Slide the loosened clamps back from the fan assembly.

3. Slide the fan assembly out from the unit and place on a sturdy work surface.

7.17.2 Disassemble the Evaporator Fan Assembly 1. 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 7.11).

2. Remove the spanner wrench. Use a universal wheel puller and remove the fan from the shaft. Remove the washers and key.

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3. Remove the four 1/4-20 x 3/4 long bolts that are located under the fan that support the motor and stator housing. Remove the motor and plastic spacer.

7.17.3 Assemble the Evaporator Fan Assembly 1. Assemble the motor and plastic spacer onto the stator.

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 common practice to insert a screwdriver between the fan blades to keep it from turning. This practice can no longer be used, as the blade is made up of a material that will be damaged. It is recommended that an impact wrench be used when removing the blade. Do not use the impact wrench when reinstalling, as galling of the stainless steel shaft can occur.

2. Apply Loctite to the 1/4-20 x 3/4 long bolts and torque to 0.81 mkg (70 inch-pounds).

3. 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).

4. Install the fan onto the motor shaft. Place one 5/8 flat washer with a 5/8-18 locknut onto the motor shaft and torque to 40 foot-pounds.

Figure 7.11 Evaporator Fan Assembly

1) Fan 2) Washer 3) Nut 4) Screws / Washers

5) Protector 6) Motor 7) Stator

- - - - -

5. Install the evaporator fan assembly in reverse order of removal. Torque the four 1/4-20 clamp bolts to 0.81 mkg (70 inch-pounds). Connect the wiring connector.

6. Replace the access panel making sure that the panel does not leak. Make sure that the TIR locking device is lockwired. Torque the access panel hardware to 69 kg-cm (60 in/lbs.) using a crossing pattern as shown in Figure 7.12. Repeat the pattern twice for a proper seal.

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Figure 7.12 Access Panel Torque Pattern

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7.18 Evaporator Section Cleaning Containers and Container units that are exposed to certain fumigants may develop visible surface corrosion. This corrosion will show up as a white powder found on the inside of the container and on the reefer unit evaporator stator and fan deck.

Analysis by Carrier Transicold environmental specialists have identified the white powder as consisting predominantly of aluminum oxide. Aluminum oxide is a coarse crystalline deposit most likely the result of surface corrosion on the aluminum parts within the container. If left untreated over time, it may build up in thickness and eventually flake as a light-weight white powder.

The surface corrosion of aluminum is brought about by exposure to chemicals such as sulfur dioxide and possibly other fumigants that are commonly used for fumigation and protection of some perishable cargo such as grapes, for example. Fumigation is the process by which a chemical is released into an enclosed area to eliminate infestations of insects, termites, rodents, weeds and soil-born disease.

Typically any aluminum oxide that becomes detached from evaporator fan stators will be blown into the wet evaporator coil where it will be caught and then flushed out of the unit during routine defrost cycles.

However, it is still highly recommended that after carrying cargo subject to fumigation procedures, that the inside of the unit be thoroughly cleansed prior to reuse.

Carrier Transicold has identified a fully biodegradable and environmentally safe alkaline cleaning agent (Tri-Powr HD) for the unit. This will assist in helping to remove the corrosive fumigation chemicals and dislodging of the corrosive elements.

This cleaner is available from the Carrier Transicold Performance Parts Group (PPG) and can be ordered through any of the PPG locations; Part Number NU4371-88.

As a general safety precaution, before using this product, see and retain the Material Safety Data (MSDS) sheet.

7.18.1 Cleaning Preparation Always wear goggles, gloves and work boots.

Avoid contact with skin and clothing, and avoid breathing mists.

When mixing, add water to the sprayer first, then the cleaner.

ALWAYS provide for proper ventilation when cleaning indoor evaporator coils (rear doors must be open).

Be aware of surroundings - food, plants, etc., and the potential for human exposure.

Always read directions and follow recommended dilution ratios. More is not always better. Using non-diluted cleaner is not recommended.

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7.18.2 Cleaning Procedure 1. Remove the upper evaporator access panel inside of the unit.

2. Spray the surface with water before applying the cleaning solution. This helps the cleaner work better.

3. Liberally apply the prepared cleaner solution (5 parts water and 1 part cleaner).

4. Allow the cleaner to soak in for five to seven minutes.

5. Assess area for rinsing. Follow all local regulations regarding disposal of waste water.

6. Thoroughly rinse the cleaner and surrounding area, floor, etc. When rinsing where heavy foaming solution is present, it is very important to take the time to thoroughly rinse the equipment and surroundings.

7. Always rinse the empty coil cleaner bottle, cap tightly and dispose of properly.

7.19 Electronic Expansion Valve (EEV) The electronic expansion valve (EEV) is an automatic device which maintains required superheat of the refrigerant gas leaving the evaporator. The valve functions are: (a) automatic response of refrigerant flow to match the evaporator load and (b) prevention of liquid refrigerant entering the compressor. Unless the valve is defective, it seldom requires any maintenance.

Figure 7.13 Electronic Expansion Valve (EEV)

1) Electronic Expansion Valve 2) Coil Boot

3) Coil 4) Strainer

- - - - -

7.19.1 Removing an EEV

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

1. Pump down the compressor (see Section 7.4) and frontseat both suction and discharge valves.

2. Turn unit power off and remove power from the unit.

3. Remove the coil.

4. Remove the valve. The preferred method of removing the valve is to cut the connection between the brazed section and the valve, using a small tube cutter. Remove the valve.

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Alternatively, use a wet rag to keep the valve cool. Heat inlet and outlet connections to valve body and remove valve.

5. Clean the valve stem with mild cleaner, if necessary.

7.19.2 Installing an EEV 1. Install the valve and a new strainer with the cone of the strainer / screen pointing into the liquid line at the

inlet to the valve.

2. During installation, make sure the EEV coil is snapped down fully, and the coil retention tab is properly seated in one of the valve body dimples. Also, ensure that coil boot is properly fitted over valve body. See Figure 7.13.

3. Replace the filter drier.

4. Evacuate to 500 microns by placing the vacuum pump on the liquid line and suction service valve.

5. Open the liquid line service valve and check refrigerant level.

6. Check superheat. See Section 3.2.

7. Check unit operation by running a pre-trip. See Section 4.7.

7.20 Humidity Sensor (HS) The humidity sensor is an optional component that allows setting of a humidity set point in the controller. In dehumidification mode, the controller will operate to reduce internal container moisture level.

7.20.1 Checking the Operation of the Humidity Sensor (HS)

This procedure is to be performed in an effort to ease the troubleshooting of the humidity sensor. When performing this procedure and while working on the unit, always follow the proper lockout/tagout procedures.

Items Required:

One 7/16 socket wrench or nut driver.

One 1/4 socket wrench or nut driver.

One clean, clear water bottle with a minimum 6 cm (2.5 in) opening and capacity to hold 500 ml (16.9 oz).

100 ml (3.4 oz) of fresh water - distilled if available.

50 gm of Salt (NaCl).

Procedure:

1. Remove the left Upper Fresh Air Makeup Vent panel. 2. Remove the humidity sensor from the mounting hardware and bring to the front of the access panel. 3. Disconnect the humidity sensor from the harness. 4. Drill a 3 cm (1.25 in) hole in the cap of a bottle. 5. Pour approximately 100 ml (3.4 oz) of water into the empty clean bottle. 6. Add salt to the water until it is present at the bottom of the bottle. 7. Cap the bottle and tape over the drilled hole. 8. Shake the bottle until the salt dissolves and water is saturated.

NOTE To ensure saturation, add additional salt until it settles at the bottom without dissolving while shaking.

9. Remove the cap and insert the humidity sensor into the bottle through the bottle opening and pull the connector back through the drilled hole in the cap. Then, secure the cap and seal the wire going through the cap.

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NOTE Make sure that the sensor is not at all in contact with the salt water.

10. Allow the saturated salt mixture to settle for approximately ten minutes.

11. Reconnect the humidity sensor to the harness and power the reefer unit on.

12. Press the CODE SELECT key on the keypad.

13. Use the Arrow keys until Cd17 is displayed then press the ENTER key.

14. This displays the humidity sensor reading. Verify the reading is between 60% and 85% relative humidity.

15. If the humidity sensor display is outside of this range, reconfirm the salt mixture and retest. If not in range, replace the sensor at the next opportunity.

16. Wipe clean and reinstall the humidity sensor and access panel. Torque the access panel hardware to 69 kg- cm (60 in.-lbs.) using a crossing pattern similar to the numbering below.

17. If the panel gasket is damaged and needs to be replaced, use the following part numbers:

42-00296-01: Standard Panel Gasket 42-00823-00: XtendFRESH Panel Gasket

Cap opening (6 cm) Cap hole (3 cm)

Salt water solution

Humidity Sensor

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

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7.21 Economizer Solenoid Valve (ESV)

Figure 7.14 Coil View of Economizer Solenoid Valve (ESV)

1) Slotted Screw 2) Top Coil (small) O-ring 3) Solenoid Coil, Enclosing Tube

and Body

4) Bottom Coil (large) O-ring 5) Brass Spacer

- - - - -

7.21.1 Removing a Solenoid Valve Coil

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

1. Turn unit power off and remove power from the unit. Disconnect leads.

2. Remove the top screw and o-ring. Remove the coil and save mounting hardware, seals and spacer for reuse (see Figure 7.14). See Valve Coil Installation Procedure.

7.21.2 Removing the Solenoid Valve 1. Pump down the compressor (see Section 7.4) and frontseat both suction and discharge valves.

2. Remove the valve. The preferred method of removing the solenoid valve is to cut the connection between the brazed section and the valve, using a small tube cutter. Remove valve. Alternatively, heat inlet and outlet connections to valve body and remove valve.

3. Clean the valve stem with mild cleaner, if necessary.

7.21.3 Installing the Solenoid Valve 1. Fit the new solenoid valve into position and braze. Use a wet rag to keep valve cool whenever brazing.

7.21.4 Installing the Solenoid Valve Coil 1. Install the brass spacer on the valve stem.

2. Lubricate both o-rings with silicone provided in the kit.

3. Install bottom coil o-ring on the valve stem.

4. Install the solenoid coil on the valve stem.

5. Place the top coil o-ring on the coil mounting screw and secure the coil to the valve using a torque wrench. Torque the screw to 25 in-lbs.

6. Connect coil wires using butt-splices and heat shrink tubing.

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7.22 Economizer Expansion Valve (EXV) The economizer expansion valve (See Figure 7.15) is an automatic device that maintains constant superheat of the refrigerant gas leaving at the point of bulb attachment, regardless of suction pressure.

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.

NOTE The economizer expansion valve is a hermetic valve, it does not have adjustable superheat.

Figure 7.15 Economizer Expansion Valve

7.22.1 Removing the Economizer Expansion Valve 1. Pump down the compressor (see Section 7.4) and frontseat both suction and discharge valves. If unit is not

equipped with service valves, evacuate unit. See Section 7.6.1.

2. Turn unit power off and remove power from the unit.

3. Remove cushion clamps located on the inlet and outlet lines.

4. Remove insulation (Presstite) from the expansion valve bulb.

5. Unstrap the bulb, located on the economizer line.

6. Remove the valve. The preferred method of removing the valve is to cut the connection between the brazed section and the valve, using a small tube cutter. Remove valve. Alternatively, use a wet rag to keep valve cool. Heat inlet and outlet connections to valve body and remove valve.

7. Clean the valve stem with a mild cleaner, if necessary.

7.22.2 Installing the Economizer Expansion Valve 1. The economizer expansion valve should be wrapped in a soaked cloth for brazing.

2. Braze the inlet connection to the inlet line.

3. Braze the outlet connection to the outlet line.

4. Reinstall the cushion clamps on the inlet and outlet lines.

5. Replace the filter drier. See Section 7.14.

6. Evacuate to 500 microns by placing vacuum pump on liquid line and suction service valve.

7. Check economizer expansion valve superheat. See Section 3.2.

7.23 Troubleshooting P6-7 (DUV) A failed digital unloader valve (DUV), which is normally closed, or an internal seal failure of the compressor can result in the unit running continually in the fully loaded mode causing it to undershoot its setpoint temperature.

Both of these conditions can be evaluated by running pre-trip test P6-7. When running P6-7, the controller is looking for the differences in pressure and current draw between loaded mode and unloaded mode to make a judgment. If there are no differences, then it will show fail.

Inlet

Outlet

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To confirm what caused the test to fail, perform the following additional test.

1. Connect the manifold gauge set to discharge service valve (DSV) and suction service valve (SSV).

2. Front seat the SSV and pump down the compressor.

3. Front seat the DSV valve to isolate the compressor.

4. Disconnect the DUV from the top of compressor and install a 1/2 to 1/4 flared adapter / O-ring (P/N 40- 50076-00sv).

Figure 7.16 Adapter and O-Ring

5. Using refrigerant (R-134a or R-513A as specified for the unit model number) or Nitrogen, pressurize the line to 50 psi (3.5 bar) at the adapter connection and close supply at the tank. Pressure should hold as the valve is normally closed. If pressure drops, check for leaks at the installed fitting (part number 40-50076-00sv); repair and retest. If pressure increases at the suction service valve and decreases at the pressure supply; the valve is leaking and should be replaced. If no leak proceed to step 6.

6. Energize the DUV by removing the coil and placing a magnet on the valve stem opening the valve. If the pressure does not increase at the SSV and decrease at the supply, replace the valve as it did not open.

If a magnet is not available, a jumper procedure can be used as follows:

1. Remove all four controller fuses (F1, F2, F3a, F3b).

2. Remove the KA6 wire from the KA controller connector on the front of the controller.

3. Disconnect the X1 wire from the 24VAC side of the transformer (black wire) and locate it away from the transformer.

4. Jumper between the black transformer wires to the KA6 wire removed from the connector.

5. Connect power to the unit and turn the circuit breaker on. The DUV coil is now energized.

6. Pressure should drop.

7. Power the circuit breaker off, reconnect wires and reinstall fuses.

8. If the valve opens and closes properly, the failure mode is with the compressor and it should be changed at the earliest opportunity.

7.24 Digital Unloader Valve (DUV)

7.24.1 Removing the DUV 1. Pump down the compressor (see Section 7.4) and frontseat both suction and discharge valves. In the event

the DUV is stuck open and compressor cannot pump down, remove charge.

CAUTION! The scroll compressor achieves low suction pressure very quickly. Do not use the compressor to evacuate the system below 0 psig. Never operate the compressor with the suction or discharge service valves closed (frontseated). Internal damage will result from operating the compressor in a deep vacuum.

2. Turn unit power off and remove power from the unit.

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O-Ring

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3. Loosen the bolt on top of the DUV and remove the coil assembly.

NOTE There is a small spacer tube between the top of the valve and the 12 VDC coil that needs to be reinstalled into the solenoid valve coil. When removing the coil, it may fall out when lifted from the valve body. Take care that the spacer is not lost; the valve will not function correctly without it.

4. Remove the clamps holding the DUV to the discharge line. 5. Loosen the nuts attaching the DUV to the top of the compressor. 6. Remove the valve. The preferred method of removing the solenoid valve is to cut the connection between

the brazed section and the valve, using a small tube cutter. Remove valve. (See Figure 7.17). Alternatively, use a wet rag to keep valve cool. Heat outlet connection to valve body and remove valve.

Figure 7.17 View of Digital Unloader Valve (DUV) Assembly

1) Screen Valve Strainer 2) Tube 3) Solenoid Valve Body

4) Hex Nut, 1/2 OD 5) Sleeve 6) O-ring (hidden)

- - - - - 7. Examine the compressor and service valves. Ensure that the o-ring is not stuck in the gland of the valve. 8. Discard the o-ring on the o-ring face seal connection.

7.24.2 Installing the DUV 1. Lubricate the gland shoulder area and o-ring with refrigerant oil. 2. Fit the new valve in position and hand-tighten the o-ring nut. 3. Use a wet rag to keep the valve cool while brazing. Braze the DUV to service valve connection. 4. Reinstall and tighten the brackets that secure the valve body to the discharge line. 5. Torque the o-ring face seal connections to 18 to 20 ft-lbs. 6. Install the coil onto the valve body and tighten the attachment bolt.

NOTE Confirm that the small spacer tube is inserted into the coil prior to attaching it to the valve body. The valve will not function correctly without it.

7. Leak check and evacuate the low side of unit as applicable. See Section 7.6.1. 8. Open the service valves.

7.25 Valve Override Controls Controller function code Cd41 is a configurable code that allows timed operation of the automatic valves for troubleshooting. Test sequences are provided in Table 71. Capacity mode (CAP) allows alignment of the economizer solenoid valve in the standard and economized operating configurations. DUV Capacity Modulation% Setting (PCnt) and Electronic Expansion Valve (EEV) allows opening of the digital unloader valve and electronic expansion valve, respectively, to various percentages. If the unit is equipped with an LIV, the Liquid Valve Setting allows the LIV to be automatically controlled, or manually opened and closed.

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The Override Timer (tIM) selection is also provided to enter a time period of up to five minutes, during which the override(s) are active. If the timer is active, valve override selections will take place immediately. If the timer is not active, changes will not take place for a few seconds after the timer is started. When the timer times out, the override function is automatically terminated and the valves return to normal machinery control. To operate the override:

1. Press the CODE SELECT key then press an Arrow key until Cd41 is displayed in the left window. The right window will display a controller communications code.

2. Press the ENTER key. The left display will show a test name alternating with the test setting or time remaining. Use an Arrow key to scroll to the desired test. Press the ENTER key, SELCt will appear in the left display.

3. 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 Table 71.

4. If the timer is not operating, follow the above procedure to display the timer. Use an Arrow key to scroll to the desired time interval and press ENTER to start the timer.

5. The above described sequence may be repeated during the timer cycle to change to another override.

7.26 Autotransformer If the unit does not start, check the following:

1. Verify the 460 VAC (yellow) power cable is plugged into the receptacle (see Figure 7.18) and locked in place.

2. Verify that circuit breakers CB-1 and CB-2 are in the ON position. If the circuit breakers do not hold in, check voltage supply.

3. 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.

Table 71 Valve Override Control Displays

Left Display Controller Communication Codes (Right Display)

Setting Codes (Right Display)

Cd 41/SELCt

tIM (Override Timer)

0 00 (0 minutes/0 Seconds) In 30 second increments to 5 00 (5 minutes/ 0 seconds)

PCnt (% Setting - DUV Capacity Modulation)

AUtO (Normal Machinery Control)

0 3 6 10 25 50 100

EEV (% Setting - Electronic Expansion Valve)

AUtO (Normal Machinery Control)

CLOSE (Closed) 0 3 6 10 25 50 100

CAP (Capacity Mode)

AUtO (Normal Control)

Std UnLd

(Economizer = Closed)

ECOn (Economizer = Open)

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Figure 7.18 Autotransformer

1) Circuit Breaker (CB-2) 230-Volt 2) 460 VAC Power Receptacle 3) Dual Voltage Modular Autotransformer

- - - - -

7.27 Controller

7.27.1 Controller Module Handling

CAUTION! Do not remove wire harnesses from circuit boards unless you are grounded to the unit frame with a static safe wrist strap or equivalent static drain device.

CAUTION! Remove the controller module and unplug all connectors before performing any arc welding on any part of the container.

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.

1. Obtain a grounding wrist strap (Carrier Transicold P/N 07-00304-00) and a static dissipation mat (Carrier Transicold P/N 07-00277-00). The wrist strap, when properly grounded, will dissipate any potential static buildup on the body. The dissipation mat will provide a static-free work surface on which to place and/or service the modules.

2. Disconnect and secure power to the unit.

3. Place strap on wrist and attach the ground end to any exposed unpainted metal area on the refrigeration unit frame (bolts, screws, etc.).

4. Carefully remove the module. Do not touch any of the electrical connections if possible. Place the module on the static mat.

NOTE The strap should be worn during any service work on a module, even when it is placed on the mat.

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7.27.2 Controller Troubleshooting A group of test points (TP, see Figure 7.19) are provided on the controller for troubleshooting electrical circuits (see schematic diagram sections). A description of the test points is provided in Table 72.

NOTE Use a digital voltmeter to measure AC voltage between TPs and ground (TP9), except for TP8.

Figure 7.19 Controller

1) Micro-Link 3 Controller / DataCORDER Module

2) Mounting Screw 3) Connectors 4) Test Points

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

- - - - -

Table 72 Test Point Descriptions

Test Point Description TP1 Not used in this application. TP2 Check if the high pressure switch (HPS) is open or closed. TP3 Check if the water pressure switch (WP) contact is open or closed. TP4 Check if the internal protector for the condenser fan motor (IP-CM) is open or closed.

TP5 Check if the internal protectors for the evaporator fan motors (IP-EM1 or IP-EM2) are open or closed.

TP6 (if equipped) - Check if the controller liquid injection valve relay (TQ) is open or closed. TP7 Check if the controller economizer solenoid valve relay (TS) is open or closed. TP8 Not used in this application. TP9 Chassis (unit frame) ground connection.

TP10 Check if the heat termination thermostat (HTT) contact is open or closed.

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F3A (7.5A)

F3B (7.5A)

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12-00579-00 59980 KB

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7.27.3 Controller Programming Procedures

CAUTION! The unit must be OFF whenever a programming card is inserted or removed from the controller programming port.

NOTE Units must be loaded with software version 5354 or higher. See the label in the control box door for factory installed software version.

Loading Operational Software

1. Place the Start-Stop switch (ST) to 0 to turn unit power off.

2. Insert the software / programming PCMCIA card into the programming slot on the controller. (See Figure 7.19) The PCMCIA card will contain the following (example) files:

menuDDMM.ml3: file to allow the user to select a file/program to upload into the controller. cfYYMMDD.ml3: multi-configuration file.

3. Place the Start-Stop switch (ST) to I to turn unit power on.

4. The display will show the message SEt UP.

5. Press the Up or Down Arrow keys on the keypad until the display reads LOAd 53XX. The XX represents the software revision.

6. Press the ENTER key.

7. The display will alternate between the messages PrESS EntR and rEV 53XX.

8. Press the ENTER key.

9. The display will show the message Pro SoFt. This message will last for up to one minute as new software is loading. When software loading complete, the display will show the message Pro donE.

If a problem occurs while loading the software, the display will blink the message Pro FAIL or bad 12V. Place the Start-Stop switch (ST) to 0 and remove the card.

10. Place the Start-Stop switch (ST) to 0 to turn unit power off.

11. Remove the PCMCIA card from the programming slot.

12. Place the Start-Stop switch (ST) to I to return the unit to normal operation.

13. On power up, the status LED will flash quickly and the display will remain blank as the controller loads the new software. This takes about 15 seconds. When complete, the controller will reset and power up normally.

14. Wait for the default display to appear: setpoint on the left, and control temperature on the right.

15. To confirm the correct software revision is loaded, use the keypad to bring up function code Cd18.

Changing Controller Configuration

1. Place the Start-Stop switch (ST) to 0 to turn unit power off.

2. Insert the software / programming PCMCIA card into the programming slot on the controller. (See Figure 7.19) The PCMCIA card will contain the following (example) files:

menuDDMM.ml3, this file allows the user to select a file/program to upload into the controller. cfYYMMDD.ml3, multi-configuration file.

3. Place the Start-Stop switch (ST) to I to turn unit power on.

4. The display will show the message SEt UP.

5. Press the ENTER key on the keypad.

6. The display will show the message ruN ConFG.

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If the display has blinking message bAd CArd, then the card is defective. Place the Start-Stop switch (ST) to 0 to turn unit power off and remove the card.

7. Press the ENTER key.

8. The display module will go blank briefly and then display 5XX XXX, based on the operational software installed.

9. Press the Up or Down Arrow key until the display reads the desired model number.

If the display has blinking message bAd CArd, then the card is defective. Place the Start-Stop switch (ST) to 0 to turn unit power off and remove the card.

10. Press the ENTER key.

11. When software loading has successfully completed, the display will show the message COnFG donE.

If the display has blinking message Pro FAIL or bad 12V, then a problem has occurred while loading the software. Place the Start-Stop switch (ST) to 0 to turn unit power off and remove the card.

12. Place the Start-Stop switch (ST) to 0 to turn unit power off.

13. Remove the PCMCIA card from the programming slot.

14. Place the Start-Stop switch (ST) to I to return the unit to normal operation.

15. To confirm the correct model configuration was loaded, use the keypad to bring up function code Cd20. The model displayed should match the last five digits of the model number listed on the unit nameplate.

Setting the Date and Time

1. Place the Start-Stop switch (ST) to 0 to turn unit power off.

2. Insert the software / programming PCMCIA card into the programming slot on the controller. (See Figure 7.19) The PCMCIA card will contain the following (example) files:

menuDDMM.ml3, this file allows the user to select a file/program to upload into the controller. cfYYMMDD.ml3, multi-configuration file.

3. Place the Start-Stop switch (ST) to I to turn unit power on.

4. The display will show the message SEt UP.

5. Press the ENTER key on the keypad.

6. The display will show the message ruN ConFG.

7. Press the Up or Down Arrow key until the display reads SEt tIM.

8. Press the ENTER key on the keypad.

9. The display will show the date in YYYY MM-DD format. The day value will be blinking.

10. The date values are modified from right to left. Press the Up or Down Arrow key to increase or decrease the values. Press the ENTER key to confirm the value for the current field and move to the next value. Press the CODE SELECT key to modify the previous value.

11. After pressing ENTER to confirm the year value, the time will be displayed in HH MM format with the hours being in a 24 hour format. The minutes will be blinking.

12. The time values are modified from right to left. Press the Up or Down Arrow key to change the values. Press the ENTER key to confirm the value for the current field and move to the next value. Press the CODE SELECT key to modify the previous value.

13. After pressing ENTER to confirm the hour value, the display will return to SEt tIM.

14. Place the Start-Stop switch (ST) to 0 to turn unit power off.

15. Remove the PCMCIA card from the programming slot.

16. Place the Start-Stop switch (ST) to I to return the unit to normal operation.

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Setting the Container ID

NOTE The characters will be preset to the container ID already on the controller. If none exist, the default will be AAAA0000000.

1. Place the Start-Stop switch (ST) to 0 to turn unit power off.

2. Insert the software / programming PCMCIA card into the programming slot on the controller. (See Figure 7.19) The PCMCIA card will contain the following (example) files:

menuDDMM.ml3, this file allows the user to select a file/program to upload into the controller. cfYYMMDD.ml3, multi-configuration file.

3. Place the Start-Stop switch (ST) to I to turn unit power on.

4. The display will show the message SEt UP.

5. Press the ENTER key on the keypad.

6. The display will show the message ruN ConFG.

7. Press the Up or Down Arrow key until display reads SEt Id.

8. Press the ENTER key on the keypad.

9. The display will show the first letter of the container ID.

10. Press the Up or Down Arrow key to increase or decrease the values. Press ENTER to confirm a value for the current field and move to the next value. Press CODE SELECT to modify a previous value.

11. When the last value is entered, press the ENTER key to enter the information to the controller. The display will return to SEt Id.

12. Place the Start-Stop switch (ST) to 0 to turn unit power off.

13. Remove the PCMCIA card from the programming slot.

14. Place the Start-Stop switch (ST) to I to return the unit to normal operation.

15. To confirm that the correct container ID was loaded, use the keypad to bring up function code Cd40.

7.27.4 Removing and Installing a Controller

Removal:

1. Disconnect all front wire harness connectors and move wiring out of the way.

2. The lower controller mounting is slotted. Loosen the top mounting screw (see Figure 7.19) and lift up and out.

3. Disconnect the back connectors and remove the module.

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 packaging has been designed to protect the module from both physical and electrostatic discharge damage during storage and transit.

Installation:

1. Install the module by reversing the removal steps.

2. Torque values for mounting screws (item 2, see Figure 7.19) are 0.23 mkg (20 inch-pounds). Torque value for the connectors is 0.12 mkg (10 inch-pounds).

7.27.5 Battery Replacement Standard Battery Location (Standard Cells):

1. Turn unit power Off and disconnect the power supply.

2. Slide the bracket out and remove the old batteries. (See Figure 4.4, Item 8.)

3. Install new batteries and slide the bracket into the control box slot.

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CAUTION! Use care when cutting wire ties to avoid nicking or cutting wires.

Standard Battery Location (Rechargeable Cells): 1. Turn unit power Off and disconnect the power supply.

2. Disconnect the battery wire connector from the control box.

3. Slide out and remove the old battery and bracket. (See Figure 4.4, Item 8.)

4. Slide the new battery pack and bracket into the control box slot.

5. Reconnect the battery wire connector to the control box and replace wire ties that were removed.

Secure Battery Option (Rechargeable Cells Only): 1. Turn unit power Off and disconnect the power supply.

2. Open the control box door and remove both the high voltage shield and clear plastic rain shield (if installed).

3. Disconnect the battery wires from the KA plug positions 14, 13, 11.

4. Using Driver Bit, Carrier Transicold part number 07-00418-00, remove the four screws securing the display module to the control box. Disconnect the ribbon cable and set the display module aside.

NOTE The battery wires must face toward the right.

5. 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.

6. Reconnect the ribbon cable to display and re-install the display.

7. Route the battery wires from the battery along the display 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.

8. Replace wire ties that were removed.

7.28 Temperature Sensor Service Service procedures for the return recorder (RRS), return temperature (RTS), supply recorder (SRS), supply temperature (STS), ambient temperature (AMBS), defrost temperature (DTS), evaporator temperature (ETS), and compressor discharge temperature (CPDS) sensors are provided here.

7.28.1 Ice Bath Preparation The ice-water bath is a method for testing the accuracy of sensors by submerging the sensors in an insulated container with ice cubes or chipped ice, then filling voids between ice with water and agitating until mixture reaches 0C (32F) measured on a laboratory thermometer.

Notes: Wherever possible, use a thermometer that is regularly calibrated by an accredited test lab. Contact your

instrument representative if the reference thermometer is not showing correct readings. Always use a temperature measurement reference instrument which is of higher accuracy than the device

checked for e.g., a thermometer with a rated accuracy of +/- 0.2 C should be used to check a device with a rated accuracy +/- 0.3 C.

A thermally insulated container, tub open to atmosphere and large enough to contain crushed ice and water should be used. The tub should be large enough to contain the units sensor and the reference thermometer.

Enough distilled water should be available to make ice cubes and to set up a proper and stable ice-water tri- ple-point mixture. Prepare ice using distilled water.

Pre-cool distilled water for testing.

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Procedure:

1. Prepare a mixture of clean ice using distilled water in a clean insulated container. If possible, the person handling should be wearing latex gloves.

a. Crush or chip the ice to completely fill the container. The finer the ice particles, the more accurate the mixture.

b. Add enough pre-cooled distilled water to fill the container.

c. Stir the mixture for a minimum of 2 minutes to ensure water is completely cooled and good mixing has occurred.

d. The mixture should generally contain about 85% ice with the distilled water occupying the rest of the space.

e. Add more ice as the ice melts.

2. Stir the ice water slurry mixture to maintain a temperature 0C (32F).

3. Constantly monitor the temperature of the ice water slurry with your reference thermometer. Ensure that the temperature of the bath has stabilized. The criterion for stability generally is to take two readings at 1 minute intervals, and the two readings should give you 0C (32F).

7.28.2 Sensor Checkout Procedure This procedure is performed to verify the accuracy of a temperature sensor.

1. Remove the sensor and place in a 0C (32F) ice-water bath. Refer to Ice Bath Preparation Procedure.

2. Start the unit and check sensor reading on the control panel. The reading should be 0C (32F). If the reading is correct, reinstall sensor; if it is not, continue with the next step.

3. Place the Start-Stop switch (ST) to 0 to turn the unit Off. Disconnect the power supply.

4. See Section 7.27 to remove the controller to gain access to the sensor plugs.

5. Using the plug connector marked EC that is connected to the back of the controller, locate the sensor wires (RRS, RTS, SRS, STS, AMBS, DTS, or CPDS as required). Follow those wires to the connector and using the pins of the plug, measure the resistance. Values are provided in Table 73 and Table 74.

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- ing will usually be much higher or lower than the resistance values given.

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Table 73 Sensor Resistance - AMBS, DTS, ETS, RRS, RTS, SRS, STS C F OHMS C F OHMS -40 -40 336,500 6 42.8 24,173 -39 -38.2 314,773 7 44.6 23,017 -38 -36.4 294,600 8 46.4 21,922 -37 -34.6 275,836 9 48.2 20,886 -36 -32.8 258,336 10 50 19,900 -35 -31 242,850 11 51.8 18,975 -34 -29.2 228,382 12 53.6 18,093 -33 -27.4 214,164 13 55.4 17,258 -32 -25.6 200,909 14 57.2 16,466 -31 -23.8 188,545 15 59 15,715 -30 -22.0 177,000 16 60.8 15,002 -29 -20.2 166,360 17 62.6 14,325 -28 -18.4 156,426 18 64.4 13,683 -27 -16.6 147,148 19 66.2 13,073 -26 -14.8 138,478 20 68 12,494 -25 -13 130,374 21 69.8 11,944 -24 -11.2 122,794 22 71.6 11,420 -23 -9.4 115,702 23 73.4 10,923 -22 -7.6 109,063 24 75.2 10,450 -21 -5.8 102,846 25 77 10,000 -20 -4 97,022 26 78.8 9,572 -19 -2.2 91,563 27 80.6 9,164 -18 -0.4 86,445 28 82.4 8,777 -17 1.4 81,644 29 84.2 8,407 -16 3.2 77,139 30 86 8,055 -15 5 72,910 31 87.8 7,720 -14 6.8 68,938 32 89.6 7,401 -13 8.6 65,206 33 91.4 7,096 -12 10.4 61,699 34 93.2 6,806 -11 12.2 58,401 35 95 6,529 -10 14 55,330 36 96.8 6,265 -9 15.8 52,381 37 98.6 6,013 -8 17.6 49,634 38 100.4 5,772 -7 19.4 47,047 39 102.2 5,543 -6 21.2 44,610 40 104.0 5,323 -5 23 42,314 41 105.8 5,114 -4 24.8 40,149 42 107.6 4,914 -3 26.6 38,108 43 109.4 4,723 -2 28.4 36,182 44 111.2 4,540 -1 30.2 34,365 45 113 4,365 0 32 32,650 46 114.8 4,198 1 33.8 31,030 47 116.6 4,038 2 35.6 29,500 48 118.4 3,885 3 37.4 28,054 49 120.2 3,739 4 39.2 26,688 50 122 3,599 5 41 25,396

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7.28.3 GDP Supply and Return Sensor Calibration European Commission GDP (Good Distribution Practices) guidelines, which are used worldwide, call for the equipment used to control or monitor environments where medicinal products are stored or transported be calibrated in accordance with pharmaceutical shipper specifications, typically every six months or annually.

This procedure explains how to perform a GDP calibration of the supply (STS/SRS) and return (RTS/RRS) sensors using DataLINE software version 3.1 or higher. The calibration procedure should be conducted in pairs (STS/SRS, or RTS/RRS) and it is recommended to calibrate before the full pre-trip inspection.

Table 74 Sensor Resistance - PrimeLINE CPDS

C F OHMS C F OHMS -40 -40 2,889,600 18 64.4 117,656 -38 -36.4 2,532,872 20 68.0 107,439 -36 -32.8 2,225,078 22 71.6 98,194 -34 -29.2 1,957,446 24 75.2 89,916 -32 -25.6 1,724,386 25 77 86,113 -30 -22.0 1,522,200 26 78.8 82,310 -28 -18.4 1,345,074 28 82.4 75,473 -26 -14.8 1,190,945 30 83.0 69,281 -24 -11.2 1,056,140 32 89.6 63,648 -22 -7.6 938,045 34 93.2 58,531 -20 -4.0 834,716 36 96.8 53,887 -18 -0.4 743,581 38 100.4 49,656 -16 3.2 663,593 40 104.0 45,812 -14 6.8 593,030 42 107.6 42,294 -12 10.4 530,714 44 111.2 39,078 -10 14.0 475,743 46 114.8 36,145 -8 17.6 426,904 48 118.4 33,445 -6 21.2 383,706 50 122.0 30,985 -4 24.8 345,315 52 125.6 28,724 -2 28.4 311,165 54 129.2 26,651 0 32.0 280,824 56 132.8 27,750 2 35.6 253,682 58 136.4 23,005 4 39.2 229,499 60 140.0 21,396 6 42.8 207,870 62 143.6 19,909 8 46.4 188,494 64 147.2 18,550 10 50.0 171,165 66 150.8 17,294 12 53.6 155,574 68 154.4 16,133 14 57.2 141,590 70 158.0 15,067 16 60.8 129,000 72 161.6 14,078

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WARNING! Before removing the Supply or Return air sensors from the unit, turn the ON/OFF switch and circuit breaker to the OFF position. Disconnect the power plug from the unit. Follow proper lockout/tagout procedures to ensure the power cannot inadvertently be energized. It is important that all dismantling work is done and tools and personnel are away from the unit before powering on the unit for calibration.

WARNING! When performing the Return Air Sensor calibration, disconnect both evaporator motors.

Before proceeding with the calibration procedure, ensure that controller software version is 5368 or higher and DataLINE version 3.1 or higher is installed onto the download device. Only the latest DataLINE and controller software will allow users to carry out Good Distribution Practice (GDP) calibration. Do not downgrade the software after installing the latest software.

Before proceeding with the calibration procedure, it is recommended to check the sensors by running pre-trip P5-0. This test checks the sensor values. If the test fails, identify and correct the faulty sensor and rerun the test.

Tools Required: Socket screwdrivers set Phillips screwdriver Standard hand tools Interrogator cable Laptop with DataLINE 3.1 or above installed Clean insulated container for distilled water and ice A regularly calibrated reference thermometer, recommended to be of accuracy up to 2 decimal places.

GDP Calibration, Removing Supply Sensors (STS/SRS) from Unit:

1. Locate the supply sensors cover assembly on the suction side of the compressor. Remove the two fasteners securing the cover of the sensors (see Figure 7.20).

2. Remove the cover and rotate the supply air sensors, STS/SRS, in a clockwise direction and remove the sensors from the sensor housing (see Figure 7.20).

Figure 7.20 Supply Sensors - Cover Assembly and Sensors

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GDP Calibration, Removing Return Sensors (RTS/RRS) from Unit:

1. Remove both front access panels from the unit by removing 8 fasteners from each panel (see Figure 7.21). Save all hardware for re-installation.

Figure 7.21 Removing Front Access Panels

2. On the right side, disconnect the fan motor wiring, loosen the fastener and remove (slide) the evaporator motor from the unit (see Figure 7.22).

Figure 7.22 Removing Evaporator Motor

3. Loosen the fastener on the sensor bracket (see Figure 7.23).

Figure 7.23 Return Sensors - Bracket

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4. Cut all the wire ties (see Figure 7.24) that are securing the sensors to the harness and remove sensor.

Figure 7.24 Return Sensors - Cutting Wire Ties

GDP Calibration, Perform Calibration:

1. Connect the interrogator cable to the interrogator port. Then, power on the unit.

WARNING! Before powering on the unit, it is important to ensure that all dismantling work is done and tools are away and service personnel are not working on the unit at the time of power on.

2. Open DataLINE version 3.1 or above. From the DataLINE launch pad, click on the Probe Calibration button (see Figure 7.25) to go to the Probe Calibration screen. A pop-up window will appear reminding the user to ensure proper ice bath temperature. Click OK to acknowledge.

Figure 7.25 DataLINE - Probe Calibration

3. On the Probe Calibration screen, click on the Calibrate Supply sensors or Calibrate Return sensors button (see Figure 7.26).

Figure 7.26 DataLINE - Calibrate Sensors Button

4. A Location of Service pop-up window will appear (see Figure 7.27). In the appropriate fields, enter the Service Center Name and Service Center Location where the calibration is being performed. Then, click the Save button. A pop-up window will appear reminding the user to ensure proper ice bath temperature. Click OK to acknowledge and remember to maintain the Ice bath at 0C (32F).

Figure 7.27 DataLINE - Enter Service Center Information

5. Prepare the ice bath. Refer to the Ice Bath Preparation procedure.

Ensure that the set-up (i.e. ice bath, sensors, reference thermometer) has reached a stable state before beginning the calibration process. Ensure that the set-up is clean and the reference thermometer is reg- ularly maintained and calibrated.

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6. Place the ice bath in a location near sensors (see Figure 7.28). For Return Sensors, place the ice bath on an elevated platform (ladder) of appropriate height.

Figure 7.28 Ice Bath

7. Once temperature stability is ensured, submerge the sensors in the ice water slurry. Make certain that the sensors do not contact the container sides or bottom, or each other. Continuously stir the slurry mixture during calibration.

8. Ensure that the Ice bath is at 0C (32F) using the calibrated reference thermometer. Confirm that the sensor readings have stabilized and the sensors are within +/- 0.3C (0.5F). The readings can be taken from the Uncal column in the Current Probe Offset Temperatures table.

9. Then, after confirming the sensor readings have stabilized, click on the Start Cal button (see Figure 7.29). After clicking Start Cal, the process begins automatically and will complete in less than 5 minutes. Continue to stir the ice bath during testing. Calibration will fail if the stability cannot be achieved or the sensor offset is greater than 0.3C (0.5F).

Figure 7.29 DataLINE - Start Cal Button

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10. Once the calibration has completed, a pop-up will appear with the message Calibrate Complete. Click OK to acknowledge and the results will then be displayed on the screen in the Results column (see Figure 7.30).

Calibration will fail if the stability cannot be achieved or the sensor offset is greater than 0.3C (0.5F). The validity of a sensor can be checked by hand warming the sensors to see if there are changes in the readings on the DataLINE screen. If calibration will not complete, replace and recalibrate the sensors. Refer to the Sensor Replacement procedure.

Figure 7.30 DataLINE - Calibration Results

11. After completing the calibration event, download a DCX file and check that all of the following information is captured: service center name, location, the results of the calibration and the offset applied. Ensure that all the information is captured and the event is considered a success when all the intended sensors in calibration have passed.

NOTE If there is uncal in the download, it means that the calibration process was not completed.

12. After the completion of the calibration, restore the unit to its original state.

7.28.4 Sensor Replacement

WARNING! Always turn OFF the unit circuit breaker (CB-1) and disconnect main power supply before removing electrical parts.

1. Place the Start-Stop switch (ST) to 0 to turn the unit Off. Disconnect the power supply.

NOTE Include white date code label when cutting out and removing defective sensors. The label could be required for warranty returns.

2. Cut the cable. Slide the cap and grommet off the bulb type sensor and save for reuse. Do not cut the grommet.

3. Cut one wire of existing cable 40 mm (1-1/2 inches) shorter than the other wire.

4. Cut the replacement sensor wires (opposite colors) back 40 mm (1-1/2 inches). See Figure 7.31.

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Figure 7.31 Sensor Types

5. Strip back insulation on all wiring 6.3 mm (1/4 inch).

6. 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 fittings as shown in Figure 7.32.

Figure 7.32 Sensor and Cable Splice

1) Sensor (typical) 2) Heat Shrink Tubing (2 or 3 as

required)

3) Cable 4) Large Heat Shrink Tubing (1)

- - - - -

7. If required, slide the cap and grommet assembly onto the replacement sensor.

8. 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 crimping tool.

9. Solder spliced wires with a 60% tin and 40% lead Rosincore solder.

10. Slide heat shrink tubing over each splice so that ends of tubing cover both ends of crimp as shown in Figure 7.32.

11. Heat tubing to shrink over splice. Make sure all seams are sealed tightly against the wiring to prevent moisture seepage.

CAUTION! Do not allow moisture to enter wire splice area as this may affect sensor resistance.

12. Slide large heat shrink tubing over both splices and shrink.

13. Position sensor in unit as shown in Figure 7.32 and re-check sensor resistance. See following sections:

See Figure 7.33 for Supply Sensor Positioning See Figure 7.34 for Return Sensor Positioning See Figure 7.35 for ETS Sensor Positioning

40 mm (1 1/2 in) 2 or 3 wires as required

6.3 mm (1/4 in)

40 mm (1 1/2 in) 2 or 3 wires as required

6.3 mm (1/4 in)

3

4

2

1

14. Reinstall sensor. See following sections: See Section 7.28.5 for STS and SRS Reinstallation See Section 7.28.6 for RRS and RTS Reinstallation See Section 7.28.7 for DTS Reinstallation See Section 7.28.8 for ETS1 and ETS2 Reinstallation

NOTE The P5 Pre-Trip test must be run to deactivate probe alarms (see Section 5.10).

7.28.5 Supply Sensor (STS/SRS) Reinstallation To properly reinstall a unit Supply Temperature Sensor (STS) or Supply Recorder Sensor (SRS), 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 back panel. The design minimum clearance of 6 mm (1/4 inch) should be maintained (see Figure 7.33).

Figure 7.33 STS/SRS Positioning

1) Sensor Wire 2) Cap & Grommet Assembly 3) Probe Holder

4) Evaporator Back Panel 5) Supply Sensor

- - - - -

7.28.6 Return Sensor (RRS/RTS) Reinstallation To properly reinstall a Return Temperature Sensor (RTS) or Return Recorder Sensor (RRS), be sure to position the enlarged positioning section of the sensor against the side of the mounting clamp (see Figure 7.34).

Figure 7.34 RRS/RTS Positioning

1) Mounting Clamp 2) Return Sensor - - - - -

1 2

4

Supply Air Stream

5 6mm (1/4)

3

1 1.5 in (38.1 cm)2

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7.28.7 Defrost Temperature Sensor (DTS) Reinstallation To properly reinstall a Defrost Temperature Sensor (DTS), insulating material must be placed completely over the sensor to ensure the coil metal temperature is sensed.

7.28.8 Evaporator Temperature Sensor (ETS1/ETS2) Reinstallation The Evaporator Temperature Sensors (ETS1/ETS2) are located in a tube holder under insulation (see Figure 7.35). To properly reinstall this combo sensor, it must be placed in a tube holder by applying thermal grease. Insulating material must completely cover the sensor to ensure the correct temperature is sensed.

Figure 7.35 ETS1/ETS2 Positioning

1) Insulation 2) Wire Tie

3) ETS Tube Holder 4) ETS1 and ETS2

- - - - -

7.28.9 Compressor Discharge Temperature Sensor (CPDS) Reinstallation

1. Ensure the unit is disconnected from the power source. 2. Verify that the Start-Stop switch (ST) is in the 0 position. 3. Remove the existing sensor. 4. Clean all silicone sealer and dielectric compound from the sensor well. Make sure that the well is clean and

dry. The top of the compressor, where the sensor seals, must also be clean and dry (see Figure 7.36).

Figure 7.36 Compressor Discharge Temperature Sensor

1) Sensor 2) Silicon Bead

3) Sensor Well

- - - - - 5. Using the syringe supplied with the replacement sensor, squeeze all of the dielectric compound into the

sensor well.

1

3

4

2

1 .0 25.4cm

1

2

3

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6. Place a bead of the silicone sealer supplied with the replacement sensor around the sensor sealing ring. Insert sensor into the well with the leads parallel to the suction fitting.

7. Reconnect the sensor (see Figure 7.32) and run pre-trip P5.

7.29 Vent Position Sensor (VPS) The vent position sensor (VPS) determines fresh air vent position in near real-time via function code Cd45.

The fresh air vent position sensor alarm (AL50) will occur if the sensor reading is not stable for four minutes or if 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 four 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.

Upper VPS: In order to replace the Upper VPS, the panel must be removed and replaced with another upper fresh air panel equipped with VPS. Upon installation, a new VPS assembly requires calibration.

1. Rotate the vent to the 0 CMH / CFM position.Cd45 will automatically display.

2. Press and hold the ENTER key for five seconds.

3. After the ENTER key has been pressed the display will read CAL (for calibration).

4. Press and hold the ALT MODE key for five seconds.

5. After the calibration has been completed, Cd45 will display 0 CMH / CFM.

7.30 eAutoFresh Service Procedures and technical information related to the eAutoFresh venting system can be found in the T-342 eAutoFresh Manual, located in the Literature section of the Container Refrigeration website. To find the manual from the Literature section, click on Options > eAutoFresh.

7.31 XtendFRESH Service Procedures and technical information related to the XtendFRESH controlled atmosphere system can be found in the T-366 XtendFRESH Manual, located in the Literature section of the Container Refrigeration website. To find the manual from the Literature section, click on Options > XtendFRESH.

7.32 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 the area to bare metal using a wire brush, emery paper or equivalent cleaning method. Immediately following cleaning, apply paint to the area, and allow to dry. See the Parts List for proper paint selection.

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7.33 Communications Interface Module Installation

Figure 7.37 Communications Interface Installation

1) Circuit Breaker 460V (CB1) 2) Communications Interface Module - - - - -

Units that have been factory provisioned for installation of a Communication Interface Module (CIM) have the required wiring installed. If the unit is not factory provisioned, a provision wiring kit (Carrier Transicold part number 76-00685-00) must be installed. Installation instructions are packaged with the kit.

7.33.1 Installing the Module

WARNING! Installation requires wiring to the main unit circuit breaker, CB1. Make sure the power to the unit is off and power plug disconnected before beginning installation.

1. CB1 is connected to the power system, see wiring schematic.

2. Open control box, (see Figure 7.37) and remove low voltage shield.

3. Open high voltage shield.

4. If using factory provisioned wiring, remove the circuit breaker panel, with circuit breaker, from the control box. 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.

5. Refit the circuit breaker panel.

6. Fit the new CIM into the unit.

7. Attach three wires CB21/CIA3, CB22/CIA5 and CB23/CIA7 to the CIM at connection CIA.

8. Locate connectors CIA and CIB, remove plugs if required, and attach to the module.

9. Replace the low voltage shield.

1 2

T-362 754

Table 75 R-134a Refrigerant Pressure Temperature Chart

Note: Underline figures are inches of mercury vacuum

F C PSIG C F BAR -40 -40.0 14.8 -40 -40.0 -0.49 -38 -38.9 13.9 -39 -38.2 -0.46 -36 -37.8 13.0 -38 -36.4 -0.43 -34 -36.7 12.0 -37 -34.6 -0.40 -32 -35.6 10.9 -36 -32.8 -0.37 -30 -34.4 9.8 -35 -31.0 -0.34 -28 -33.3 8.7 -34 -29.2 -0.30 -26 -32.2 7.5 -33 -27.4 -0.27 -24 -31.1 6.3 -32 -25.6 -0.23 -22 -30.0 5.0 -31 -23.8 -0.20 -20 -28.9 3.7 -30 -22.0 -0.16 -18 -27.8 2.3 -29 -20.2 -0.12 -16 -26.7 0.8 -28 -18.4 -0.07 -14 -25.6 0.3 -27 -16.6 -0.03 -12 -24.4 1.1 -26 -14.8 0.02 -10 -23.3 1.9 -25 -13.0 0.06 -8 -22.2 2.8 -24 -11.2 0.11 -6 -21.1 3.6 -23 -9.4 0.16 -4 -20.0 4.6 -22 -7.6 0.22 -2 -18.9 5.5 -21 -5.8 0.27 0 -17.8 6.5 -20 -4.0 0.33 2 -16.7 7.5 -19 -2.2 0.39 4 -15.6 8.5 -18 -0.4 0.45 6 -14.4 9.6 -17 1.4 0.51 8 -13.3 10.8 -16 3.2 0.57 10 -12.2 11.9 -15 5.0 0.64 12 -11.1 13.1 -14 6.8 0.71 14 -10.0 14.4 -13 8.6 0.78 16 -8.9 15.7 -12 10.4 0.85 18 -7.8 17.0 -11 12.2 0.93 20 -6.7 18.4 -10 14.0 1.01 22 -5.6 19.9 -9 15.8 1.09 24 -4.4 21.3 -8 17.6 1.17 26 -3.3 22.9 -7 19.4 1.25 28 -2.2 24.5 -6 21.2 1.34 30 -1.1 26.1 -5 23.0 1.43 32 0.0 27.8 -4 24.8 1.53 34 1.1 29.5 -3 26.6 1.62 36 2.2 31.3 -2 28.4 1.72 38 3.3 33.1 -1 30.2 1.82 40 4.4 35.0 0 32.0 1.93

42 5.6 37.0 1 33.8 2.04 44 6.7 39.0 2 35.6 2.15 46 7.8 41.1 3 37.4 2.26 48 8.9 43.2 4 39.2 2.38 50 10.0 45.4 5 41.0 2.50 52 11.1 47.7 6 42.8 2.62 54 12.2 50.0 7 44.6 2.75 56 13.3 52.4 8 46.4 2.88 58 14.4 54.9 9 48.2 3.01 60 15.6 57.4 10 50.0 3.15 62 16.7 60.0 11 51.8 3.29 64 17.8 62.7 12 53.6 3.43 66 18.9 65.4 13 55.4 3.58 68 20.0 68.2 14 57.2 3.73 70 21.1 71.1 15 59.0 3.88 72 22.2 74.1 16 60.8 4.04 74 23.3 77.1 17 62.6 4.21 76 24.4 80.2 18 64.4 4.37 78 25.6 83.4 19 66.2 4.54 80 26.7 86.7 20 68.0 4.72 82 27.8 90.0 21 69.8 4.90 84 28.9 93.5 22 71.6 5.08 86 30.0 97.0 23 73.4 5.27 88 31.1 100.6 24 75.2 5.46 90 32.2 104.3 25 77.0 5.65 92 33.3 108.1 26 78.8 5.85 94 34.4 112.0 27 80.6 6.06 96 35.6 115.9 28 82.4 6.27 98 36.7 120.0 29 84.2 6.48 100 37.8 124.2 30 86.0 6.70 102 38.9 128.4 31 87.8 6.93 104 40.0 132.7 32 89.6 7.15 106 41.1 137.2 33 91.4 7.39 108 42.2 141.7 34 93.2 7.63 110 43.3 146.4 35 95.0 7.87 112 44.4 151.1 36 96.8 8.12 114 45.6 156.0 37 98.6 8.37 116 46.7 160.9 38 100.4 8.63 118 47.8 166.0 39 102.2 8.90 120 48.9 171.2 40 104.0 9.17 122 50.0 176.5 41 105.8 9.44 124 51.1 181.8 42 107.6 9.72

Table 75 R-134a Refrigerant Pressure Temperature Chart

Note: Underline figures are inches of mercury vacuum

F C PSIG C F BAR

T-362 756

126 52.2 187.4 43 109.4 10.01 128 53.3 193.0 44 111.2 10.30 130 54.4 198.7 45 113.0 10.60 132 55.6 204.6 46 114.8 10.90 134 56.7 210.6 47 116.6 11.21 136 57.8 216.7 48 118.4 11.53 138 58.9 222.9 49 120.2 11.85 140 60.0 229.2 50 122.0 12.18 142 61.1 235.7 51 123.8 12.51 144 62.2 242.3 52 125.6 12.85 146 63.3 249.0 53 127.4 13.20 148 64.4 255.9 54 129.2 13.56 150 65.6 262.9 55 131.0 13.92

56 132.8 14.28 57 134.6 14.66 58 136.4 15.04 59 138.2 15.42 60 140.0 15.82 61 141.8 16.22 62 143.6 16.63 63 145.4 17.04 64 147.2 17.47 65 149.0 17.90

Table 75 R-134a Refrigerant Pressure Temperature Chart

Note: Underline figures are inches of mercury vacuum

F C PSIG C F BAR

757 T-362

Table 76 R-513A Refrigerant Pressure Temperature Chart

Note: Underline figures are inches of mercury vacuum

F C PSIG C F BAR -40 -40.0 9.8 -40 -40.0 -0.32 -38 -38.9 8.6 -39 -38.2 -0.28 -36 -37.8 7.4 -38 -36.4 -0.25 -34 -36.7 6.2 -37 -34.6 -0.21 -32 -35.6 4.9 -36 -32.8 -0.17 -30 -34.4 3.6 -35 -31.0 -0.13 -28 -33.3 2.2 -34 -29.2 -0.09 -26 -32.2 0.7 -33 -27.4 -0.05 -24 -31.1 0.4 -32 -25.6 0.00 -22 -30.0 1.1 -31 -23.8 0.04 -20 -28.9 1.9 -30 -22.0 0.09 -18 -27.8 2.8 -29 -20.2 0.14 -16 -26.7 3.7 -28 -18.4 0.19 -14 -25.6 4.6 -27 -16.6 0.25 -12 -24.4 5.5 -26 -14.8 0.30 -10 -23.3 6.5 -25 -13.0 0.36 -8 -22.2 7.5 -24 -11.2 0.42 -6 -21.1 8.5 -23 -9.4 0.48 -4 -20.0 9.6 -22 -7.6 0.54 -2 -18.9 10.7 -21 -5.8 0.61 0 -17.8 11.9 -20 -4.0 0.67 2 -16.7 13.1 -19 -2.2 0.74 4 -15.6 14.3 -18 -0.4 0.81 6 -14.4 15.6 -17 1.4 0.89 8 -13.3 16.9 -16 3.2 0.96 10 -12.2 18.3 -15 5.0 1.04 12 -11.1 19.7 -14 6.8 1.12 14 -10.0 21.1 -13 8.6 1.21 16 -8.9 22.6 -12 10.4 1.29 18 -7.8 24.2 -11 12.2 1.38 20 -6.7 25.8 -10 14.0 1.47 22 -5.6 27.5 -9 15.8 1.56 24 -4.4 29.2 -8 17.6 1.66 26 -3.3 30.9 -7 19.4 1.76 28 -2.2 32.7 -6 21.2 1.86 30 -1.1 34.6 -5 23.0 1.97 32 0.0 36.5 -4 24.8 2.07 34 1.1 38.5 -3 26.6 2.18 36 2.2 40.5 -2 28.4 2.30 38 3.3 42.6 -1 30.2 2.41 40 4.4 44.8 0 32.0 2.53

T-362 758

42 5.6 47.0 1 33.8 2.65 44 6.7 49.3 2 35.6 2.78 46 7.8 51.6 3 37.4 2.91 48 8.9 54.0 4 39.2 3.04 50 10.0 56.5 5 41.0 3.18 52 11.1 59.0 6 42.8 3.32 54 12.2 61.6 7 44.6 3.46 56 13.3 64.3 8 46.4 3.60 58 14.4 67.0 9 48.2 3.75 60 15.6 69.8 10 50.0 3.91 62 16.7 72.7 11 51.8 4.06 64 17.8 75.7 12 53.6 4.22 66 18.9 78.7 13 55.4 4.39 68 20.0 81.8 14 57.2 4.56 70 21.1 85.0 15 59.0 4.73 72 22.2 88.2 16 60.8 4.91 74 23.3 91.6 17 62.6 5.09 76 24.4 95.0 18 64.4 5.27 78 25.6 98.5 19 66.2 5.46 80 26.7 102.1 20 68.0 5.65 82 27.8 105.7 21 69.8 5.85 84 28.9 109.5 22 71.6 6.05 86 30.0 113.3 23 73.4 6.26 88 31.1 117.3 24 75.2 6.47 90 32.2 121.3 25 77.0 6.68 92 33.3 125.4 26 78.8 6.90 94 34.4 129.6 27 80.6 7.13 96 35.6 133.9 28 82.4 7.36 98 36.7 138.3 29 84.2 7.59 100 37.8 142.8 30 86.0 7.83 102 38.9 147.4 31 87.8 8.07 104 40.0 152.0 32 89.6 8.32 106 41.1 156.8 33 91.4 8.57 108 42.2 161.7 34 93.2 8.83 110 43.3 166.7 35 95.0 9.10 112 44.4 171.8 36 96.8 9.37 114 45.6 177.0 37 98.6 9.64 116 46.7 182.3 38 100.4 9.92 118 47.8 187.7 39 102.2 10.21 120 48.9 193.3 40 104.0 10.50 122 50.0 198.9 41 105.8 10.79 124 51.1 204.7 42 107.6 11.10

Table 76 R-513A Refrigerant Pressure Temperature Chart

Note: Underline figures are inches of mercury vacuum

F C PSIG C F BAR

759 T-362

126 52.2 210.5 43 109.4 11.40 128 53.3 216.5 44 111.2 11.72 130 54.4 222.7 45 113.0 12.04 132 55.6 228.9 46 114.8 12.36 134 56.7 235.2 47 116.6 12.70 136 57.8 241.7 48 118.4 13.03 138 58.9 248.3 49 120.2 13.38 140 60.0 255.1 50 122.0 13.73 142 61.1 261.9 51 123.8 14.09 144 62.2 268.9 52 125.6 14.45 146 63.3 276.1 53 127.4 14.82 148 64.4 283.3 54 129.2 15.20 150 65.6 290.8 55 131.0 15.58

56 132.8 15.97 57 134.6 16.37 58 136.4 16.77 59 138.2 17.18 60 140.0 17.60 61 141.8 18.03 62 143.6 18.46 63 145.4 18.90 64 147.2 19.35 65 149.0 19.80

Table 76 R-513A Refrigerant Pressure Temperature Chart

Note: Underline figures are inches of mercury vacuum

F C PSIG C F BAR

T-362 760

Table 77 Recommended Bolt Torque Values (Dry, Non-Lubricated for 18-8 Stainless Steel)

Bolt Diameter Threads In-Lb Ft-Lb Nm Free Spinning

#4 40 5.2 0.4 0.6 #6 32 9.6 0.8 1.1 #8 32 20 1.7 2.3

#10 24 23 1.9 2.6 1/4 20 75 6.3 8.5 5/16 18 132 11 14.9 3/8 16 240 20 27.1 7/16 14 372 31 42 1/2 13 516 43 58.3

9/16 12 684 57 77.3 5/8 11 1104 92 124.7 3/4 10 1488 124 168.1

Non Free Spinning (Locknuts etc.) 1/4 20 82.5 6.9 9.3 5/16 18 145.2 12.1 16.4 3/8 16 264 22.0 29.8 7/16 14 409.2 34.1 46.2 1/2 13 567.6 47.3 64.1 9/16 12 752.4 62.7 85 5/8 11 1214.4 101.2 137.2 3/4 10 1636.8 136.4 184.9

81 T-362

SECTION 8 ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS

Figure 8.1 LEGEND - Standard Unit Configuration

SYMBOL DESCRIPTION

AMBS AMBIENT SENSOR (C- 23)

C CONTROLLER (L- 21)

CB1 CIRCUIT BREAKER - 460 VOLT (J- 1)

CB2 OPTIONAL CIRCUIT BREAKER - DVM (OPTION) (D- 1) TERMINAL BLOCK WHEN CB2 NOT PRESENT

CF CONDENSER FAN CONTACTOR (N- 8, L- 11)

CH COMPRESSOR CONTACTOR (L- 10, P- 1)

CI COMMUNICATIONS INTERFACE MODULE (OPTION) (A- 4)

CL COOL LIGHT (OPTION) (L- 12)

CM CONDENSER FAN MOTOR (E- 11, G- 11, R- 9)

CP COMPRESSOR MOTOR (T- 4)

CPDS DISCHARGE TEMPERATURE SENSOR (A- 23)

CS CURRENT SENSOR (M- 2)

DHBL DEFROST HEATER - BOTTOM LEFT (R- 8)

DHBR DEFROST HEATER - BOTTOM RIGHT (T- 7)

DHML DEFROST HEATER - MIDDLE LEFT (R- 7)

DHMR DEFROST HEATER - MIDDLE RIGHT (T- 7)

DHTL DEFROST HEATER - TOP LEFT (R- 7)

DHTR DEFROST HEATER - TOP RIGHT (T- 8)

DL DEFROST LIGHT (OPTION) (L- 7)

DPT DISCHARGE PRESSURE TRANSDUCER (K- 23)

DTS DEFROST TEMPERATURE SENSOR (C- 23)

DUV DIGITAL UNLOADER VALVE (F- 24)

DVM DUAL VOLTAGE MODULE (OPTIONAL) (D- 1)

DVR DUAL VOLTAGE RECEPTACLE (OPTIONAL) (F- 3)

EEV ELECTRONIC EXPANSION VALVE (R- 16)

EF EVAPORATOR FAN CONTACTOR- HIGH SPEED (N- 11, K- 13)

EM EVAPORATOR FAN MOTOR (T- 11, T- 13, E- 14, F- 14, G- 14)

EPT EVAPORATOR PRESSURE TRANSDUCER (H- 23)

ES EVAPORATOR FAN CONTACTOR- LOW SPEED (P- 10, L- 13)

ETS EVAPORATOR TEMPERATURE SENSOR (SUCTION) (D- 23)

ESV ECONOMIZER SOLENOID VALVE (J- 11)

F FUSE (C- 7, D- 7, F- 21, G- 21)

FLA FULL LOAD AMPS

HPS HIGH PRESSURE SWITCH (G- 9)

HR HEATER CONTACTOR (N- 7, L- 15)

SYMBOL DESCRIPTION

HS HUMIDITY SENSOR (OPTIONAL) (F- 23)

HTT HEAT TERMINATION THERMOSTAT (E- 15)

ICF INTERROGATOR CONNECTOR FRONT (T- 23)

ICR INTERROGATOR CONNECTOR REAR (T- 24)

IP INTERNAL PROTECTOR (E- 14, F- 11, G- 14)

IRL IN RANGE LIGHT (OPTION) (K- 15)

PA UNIT PHASE CONTACTOR (K- 9, L- 8, N- 1)

PB UNIT PHASE CONTACTOR (K- 8, L- 9, N- 3)

PR USDA PROBE RECEPTACLE (M- 24, N- 24, P- 24)

PTC PTC FOR VENT POSITIONING SENSOR (N- 17)

RM REMOTE MONITORING RECEPTACLE (OPTION) (K- 7, L- 7, K- 12, L- 12, K- 15, L- 15)

RRS RETURN RECORDER SENSOR (C- 23)

RTS RETURN TEMPERATURE SENSOR (B- 23)

SPT SUCTION PRESSURE TRANSDUCER (H- 23)

SRS SUPPLY RECORDER SENSOR (L- 23)

ST START - STOP SWITCH (K- 5)

STS SUPPLY TEMPERATURE SENSOR (A- 23)

TC CONTROLLER RELAY- COOLING (J- 9)

TCC TRANSFRESH COMMUNICATIONS CONNECTOR (OPTION) (D- 6)

TCP CONTROLLER RELAY - PHASE SEQUENCING

(J- 8, J- 9)

TE CONTROLLER RELAY - HIGH SPEED EVAPORATOR FANS (J- 14)

TH CONTROLLER RELAY - HEATING (J- 15)

TF CONTROLLER RELAY - DEFROST (E- 7)

TI IN- RANGE RELAY (J- 15)

TL CONTROLLER RELAY - COOL LIGHT (J- 12)

TN CONTROLLER RELAY - CONDENSER FAN (J- 11)

TP TEST POINT (H- 9, F- 10, H- 11, G- 12, H- 13, G- 15, L- 17)

TR TRANSFORMER (M- 3)

TRANS AUTO TRANSFORMER 230/460 (OPTION) (D- 3)

TRC TRANSFRESH REAR CONNECTOR (OPTION) (E- 7)

TS CONTROLLER RELAY - ECONOMIZER SOLENOID VALVE (E- 10)

TV CONTROLLER RELAY - LOW SPEED EVAPORATOR FANS (J- 13)

VPS VENT POSITION SENSOR (UPPER) (N- 17)

WCR WETTING CURRENT RESISTOR (OPTION) (J- 12)

WP WATER PRESSURE SWITCH (OPTION) (E- 12)

T-362 82

ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS

Figure 8.2 Schematic Diagram

Based on Drawing 62- 11737

83 T-362

ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS

Figure 8.3 Unit Wiring Diagram (Sheet 1 of 2)

Based on Drawing 62- 11737

T-362 84

ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS

Figure 8.4 Unit Wiring Diagram (Sheet 2 of 2)

Based on Drawing 62- 11737

85 T-362

ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS

Figure 8.5 Legend - Unit With Transformer

SYMBOL DESCRIPTION

AMBS AMBIENT SENSOR (C- 23)

C CONTROLLER (L- 21)

CB1 CIRCUIT BREAKER - 460 VOLT (J- 1)

CB2 OPTIONAL CIRCUIT BREAKER - DVM (OPTION) (D- 1) TERMINAL BLOCK WHEN CB2 NOT PRESENT

CF CONDENSER FAN CONTACTOR (N- 8, L- 11)

CH COMPRESSOR CONTACTOR (L- 10, P- 1)

CI COMMUNICATIONS INTERFACE MODULE (OPTION) (A- 4)

CL COOL LIGHT (OPTION) (L- 12)

CM CONDENSER FAN MOTOR (E- 11, G- 11, R- 9)

CP COMPRESSOR MOTOR (T- 4)

CPDS DISCHARGE TEMPERATURE SENSOR (A- 23)

CS CURRENT SENSOR (M- 2)

DHBL DEFROST HEATER - BOTTOM LEFT (R- 8)

DHBR DEFROST HEATER - BOTTOM RIGHT (T- 7)

DHML DEFROST HEATER - MIDDLE LEFT (R- 7)

DHMR DEFROST HEATER - MIDDLE RIGHT (T- 7)

DHTL DEFROST HEATER - TOP LEFT (R- 7)

DHTR DEFROST HEATER - TOP RIGHT (T- 8)

DL DEFROST LIGHT (OPTION) (L- 7)

DPT DISCHARGE PRESSURE TRANSDUCER (K- 23)

DTS DEFROST TEMPERATURE SENSOR (C- 23)

DUV DIGITAL UNLOADER VALVE (F- 24)

DVM DUAL VOLTAGE MODULE (OPTIONAL) (D- 1)

DVR DUAL VOLTAGE RECEPTACLE (OPTIONAL) (F- 3)

EEV ELECTRONIC EXPANSION VALVE (R- 16)

EF EVAPORATOR FAN CONTACTOR- HIGH SPEED (N- 11, K- 13)

EM EVAPORATOR FAN MOTOR (T- 11, T- 13, E- 14, F- 14, G- 14)

EPT EVAPORATOR PRESSURE TRANSDUCER (H- 23)

ES EVAPORATOR FAN CONTACTOR- LOW SPEED (P- 10, L- 13)

ETS EVAPORATOR TEMPERATURE SENSOR (SUCTION) (D- 23)

ESV ECONOMIZER SOLENOID VALVE (J- 11)

F FUSE (C- 7, D- 7, F- 21, G- 21)

FLA FULL LOAD AMPS

HPS HIGH PRESSURE SWITCH (G- 9)

HR HEATER CONTACTOR (N- 7, L- 15)

LEGEND

SYMBOL DESCRIPTION

HS HUMIDITY SENSOR (OPTIONAL) (F- 23)

HTT HEAT TERMINATION THERMOSTAT (E- 15)

ICF INTERROGATOR CONNECTOR FRONT (T- 23)

ICR INTERROGATOR CONNECTOR REAR (T- 24)

IP INTERNAL PROTECTOR (E- 14, F- 11, G- 14)

IRL IN RANGE LIGHT (OPTION) (K- 15)

PA UNIT PHASE CONTACTOR (K- 9, L- 8, N- 1)

PB UNIT PHASE CONTACTOR (K- 8, L- 9, N- 3)

PR USDA PROBE RECEPTACLE (M- 24, N- 24, P- 24)

PTC PTC FOR VENT POSITIONING SENSOR (N- 17)

RM REMOTE MONITORING RECEPTACLE (OPTION) (K- 7, L- 7, K- 12, L- 12, K- 15, L- 15)

RRS RETURN RECORDER SENSOR (C- 23)

RTS RETURN TEMPERATURE SENSOR (B- 23)

SPT SUCTION PRESSURE TRANSDUCER (H- 23)

SRS SUPPLY RECORDER SENSOR (L- 23)

ST START - STOP SWITCH (K- 5)

STS SUPPLY TEMPERATURE SENSOR (A- 23)

TBU TRANSFORMER BRIDGING UNIT (D- 1, D- 2)

TC CONTROLLER RELAY- COOLING (J- 9)

TCC TRANSFRESH COMMUNICATIONS CONNECTOR (OPTION) (D- 6)

TCP CONTROLLER RELAY - PHASE SEQUENCING

(J- 8, J- 9)

TE CONTROLLER RELAY - HIGH SPEED EVAPORATOR FANS (J- 14)

TH CONTROLLER RELAY - HEATING (J- 15)

TF CONTROLLER RELAY - DEFROST (E- 7)

TI IN- RANGE RELAY (J- 15)

TL CONTROLLER RELAY - COOL LIGHT (J- 12)

TN CONTROLLER RELAY - CONDENSER FAN (J- 11)

TP TEST POINT (H- 9, F- 10, H- 11, G- 12, H- 13, G- 15, L- 17)

TR TRANSFORMER (M- 3)

TRANS AUTO TRANSFORMER 230/460 (OPTION) (D- 3)

TRC TRANSFRESH REAR CONNECTOR (OPTION) (E- 7)

TS CONTROLLER RELAY - ECONOMIZER SOLENOID VALVE (E- 10)

TV CONTROLLER RELAY - LOW SPEED EVAPORATOR FANS (J- 13)

VPS VENT POSITION SENSOR (UPPER) (N- 17)

WCR WETTING CURRENT RESISTOR (OPTION) (J- 12)

WP WATER PRESSURE SWITCH (OPTION) (E- 12)

T-362 86

ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS

Figure 8.6 Schematic Diagram - Unit With Transformer

Based on Drawing 62- 66088

87 T-362

ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS

Figure 8.7 Unit Wiring Diagram - Unit With Autotransformer (Sheet 1 of 2)

Based on Drawing 62- 11737

T-362 88

ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS

Figure 8.8 Unit Wiring Diagram - Unit With Transformer (Sheet 2 of 2)

Based on Drawing 62- 11737

91 T-362

SECTION 9

We, manufacturer: Carrier Transicold Pte Ltd 251 Jalan Ahmad Ibrahim Singapore 629146

Declare, under our sole responsibility, that the PrimeLINE Container Unit:

is in conformity with the provisions of the following European Directives:

Machinery Directive 2006/42/EC following Annex VIII

Electromagnetic Compatibility Directive 2014/30/EU following Annex II

Radio Equipment Directive 2014/53/EU Annex II (with select options)

The assembly was assessed for applicability under the Pressure Equipment Directive, 2014/68/EU, but determined to be outside of the scope based on the exclusion indicated in PED Article 1, Paragraph 2.f. The assembly was determined to be no higher than PED Category I and is covered by the Machinery Directive 2006/42/EC.

The following Harmonized Standards were applied for this equipment:

The following Technical Standards were applied for this equipment: ISO 1496-2:2008

Person established in Europe authorized to compile a copy of the Technical File:

Shaun Bretherton Service Engineering Manager of CTL Rotterdam Pittsburgstraat 21 3047 BL Rotterdam Netherlands

Serial Number: __________-__________

Manufacturing Date: ___________

EU DECLARATION OF CONFORMITY

Model: 69NT40-561

Machinery Directive EMC Directive RED Directive (with select option - TripLINK 12LB (CT4000))

EN ISO 12100:2010 EN 60204-1:2006 EN 13857:2008

EN 61000-6-2:2005 EN 61000-6-4:2007+A1:2011

EN55011:2009+A1:2010/CISPR11:2009+A1:2010 EN61000-4-2:2009

EN 61000-4-3:2006,+A1:2008, +A2:2010 EN 61000-4-4:2012 EN 61000-4-5:2006 EN 61000-4-6:2009 EN 61000-4-8:2010 EN 61000-4-11:2004

EN 61000-4-5:2006, EN 60950-1:2006, EN 62368-1:2014, EN 62311:2008,

EN301 489-1 v2.1.1, EN 301 489-3 v2.1.1, EN 301 489-7 v1.3.1, EN 301 489-17 v3.2.1, EN 301 489-19 v2.1.1, EN 301 489-20 v2.1.1, EN 301 489-52 v1.1.0, EN 301 511 v12.5.1, EN 301 908-1 v11.1.1, EN 301 908-2 v11.1.2, EN 301 908-13 v11.1.2, EN 303 413 v1.1.1,

EN 300 328 v2.2.1, EN 300 220-2 v3.2.1

China RoHS per SJ/T 11364-2014

(Pb)

(Hg)

(Cd)

(Cr (VI))

(PBB)

(PBDE)

O O O O O O O O O O O O X O O O O O O O O O O O O O O O O O X O O O O O O O O O O O O O O O O O X O O O O O O O O O O O X O O O O O / O O O O O O O O X O O O O O O O O O X O O O O O SJ/T 11364 O GB/T 26572 X GB/T 26572

62-66122-00, Rev A

Index1 T-362

INDEX

Numerics 230 Volt Cable 23 460 Volt Cable 23

A Access Panels Location 31 Adjust Fresh Air Makeup Vent 52 Air-Cooled Condenser Section 34 Alarm Configuration (dCF07 - dCF10) 419 Ambient Temperature Sensor (AMBS) Location 31 Automatic Cold Treatment (Option) 513 Autotransformer 23 Autotransformer Location 31 Autotransformer Service 733

B Back Panels 23 Battery 22, 738 Battery Replacement 738

C Cable Restraint 23 Communications Interface Module 22, 39 Communications Interface Module Installation 753 Complete Inspection 56 Compressor 22 Compressor Discharge Temperature Sensor (CPDS) Lo- cation 34 Compressor Discharge Temperature Sensor (CPDS) Service 751 Compressor Location 31, 34 Compressor Section 34 Compressor Terminal Box Location 34 Condenser Coil 22 Condenser Coil Cleaning 711 Condenser Coil Cover Location 34 Condenser Coil Installation 712 Condenser Coil Location 34 Condenser Coil Service 711 Condenser Fan and Fan Motor Service 717 Condenser Fan Location 31, 34 Condenser Fan Motor Location 34 Condenser Fan Motor Remove/Replace 717 Condenser Grille 24 Condenser Grille and Venturi Assembly Location 34 Configuration Identification 21 Configuration Software (CnF Variables) Description 44 Connect Power 51 Connect Remote Monitoring Receptacle 55 Connect Water-Cooled Condenser 54 Connection To 190/230 VAC Power 51 Connection To 380/460 VAC Power 51 Container Unit Description 31

Container Unit Description, Front Section 31 Container Unit Operation 51 Container Unit Service 71 Control Box 21 Control Box Component Location 39 Control Box Section 39 Control Module 43 Control Panel Location 31 Controller 23, 43, 734 Controller Alarm Indications 438 Controller Alarms Description 414 Controller Configuration Variables 424 Controller Function Codes 426 Controller Function Codes Check 56 Controller Module Handling 734 Controller Pre-Trip Test Codes 452 Controller Software Description 43 Controller Troubleshooting 735

D DataCORDER Alarms Description 423 DataCORDER Communications Description 420 DataCORDER Description 415 DataCORDER Power Up Procedure 419 DataCORDER Software Description 416 Defrost Description 411 Defrost Operation 411 Defrost Related Settings 412 Defrost Temperature Sensor (DTS) Location 32 Defrost Temperature Sensor (DTS) Operation 411 Defrost Temperature Sensor (DTS) Service 751 Defrost Timer 413 Dehumidification 22 Digital Unloader Valve (DUV) Location 34 Digital Unloader Valve (DUV) Service 731 Discharge Connection Location 34 Discharge Pressure Transducer (DPT) Location 34 Discharge Service Valve Location 34 Display Module 41

E eAutoFresh 24, 752 eAutoFresh Operation 54 Economized Operation Description 313 Economizer Connection Location 34 Economizer Expansion Valve (EXV) Location 34 Economizer Expansion Valve (EXV) Service 730 Economizer Heat Exchanger Location 31 Economizer Location 34 Economizer Solenoid Valve (ESV) Location 34 Economizer Solenoid Valve (ESV) Service 729 Electrical Data 311 Electronic Expansion Valve (EEV) Description 313

T-362 Index2

Electronic Expansion Valve (EEV) Location 32 Electronic Expansion Valve (EEV) Service 726 Emergency Bypass 24 Emergency Bypass Operation (option) 58 Evacuation and Dehydration 75 Evaporator 22 Evaporator Coil Heaters Location 32 Evaporator Coil Location 32 Evaporator Coil Replacement 721 Evaporator Coil Service 721 Evaporator Fan #1 Location 32 Evaporator Fan #2 Location 32 Evaporator Fan and Motor Assembly Service 723 Evaporator Fan Operation 22 Evaporator Heaters Megger Testing 722 Evaporator Pressure Transducer (EPT) Location 34 Evaporator Section 32 Evaporator Section Cleaning 725 Evaporator Temperature Sensors (ETS1 / ETS2) Loca- tion 32 Evaporator Temperature Sensors (ETS1 / ETS2) Ser- vice 751

F Feature Descriptions 21 Filter Drier Location 34 Filter Drier Service 720 First Aid 11 Fork Lift Pockets Location 31 Fresh Air Make Up 23 Fresh Air Makeup Vent 32 Frozen Heat Mode 410 Frozen Economy Mode 410 Frozen Idle Mode 49 Frozen Mode - Temperature Control 49 Frozen Mode Cooling - Sequence of Operation 410 Frozen Steady State 49 FuelWise Option 24 Fusible Plug Location 34

G Gutters 23

H Handles 23 Heat Termination Thermostat (HTT) Location 32 High Pressure Switch (HPS) Location 34 High Pressure Switch (HPS) Replace 711 High Pressure Switch (HPS) Service 710 Humidity Sensor (HS) Location 32 Humidity Sensor (HS) Service 727 Humidity Sensor (HS) Troubleshooting 727

I Indicator Lights 41 Inspection 51

Interrogator 22 Interrogator Connector Receptacle (ICR) Location 32 Introduction 21, 91 ISO Trip Header 424

K Keypad 41 Keypad Location 31

L Labels 23 Logging Interval (dCF03) 417 Lower Air 23

M Manifold Gauge Set 71 Manual Pump Down 74 Micro-Link 3 Microprocessor 41 Microprocessor 41 ML3 Controller 41 Modes of Operation 44

O Oil Drain Location 34 Operating Precautions 11 Operational Software (Function Codes) Description 44 Options Descriptions 22 Options Label Location 31

P Painted Surfaces 752 Perishable Dehumidification 46 Perishable Dehumidification - Bulb Mode 46 Perishable Economy 47 Perishable Heating 45 Perishable Idle, Air Circulation 45 Perishable Mode - Trim Heat 49 Perishable Mode Cooling - Sequence of Operation 47 Perishable Mode Heating - Sequence of Operation 48 Perishable Mode Temperature Control 44 Perishable Pulldown 45 Perishable Steady State 45 Physical Inspection 55 Plate Set 22 Power Cables and Plug Location 31 Pressure Readout 21 Pre-Trip Data Recording Description 420 Pre-Trip Diagnosis 56 Pre-Trip Diagnostics Description 415 PrimeLINE 21 PrimeLINE models 21 Probe Diagnostics 58 Protection Modes of Operation 413 Pump Down 73 Push Button Switches 41

Index3 T-362

Q QUEST operation 414 QUEST Option 24

R Receiver Liquid Level / Moisture Indicator Location 34 Receiver Location 34 Receiver Sight Glass Location 34 Refrigerant - Adding Full Charge to System 77 Refrigerant - Adding Partial Charge to System 77 Refrigerant - Checking Charge 76 Refrigerant Description 21 Refrigerant Leak Checking 74 Refrigeration Circuit Description 313 Refrigeration System Data 310 Refrigeration Unit 31 Remote Monitoring 22 Remote Monitoring Receptacle Location 31 Replacing the Evaporator Fan Assembly 723 Return Recorder Sensor (RRS) Location 32 Return Recorder Sensor (RRS) Service 750 Return Temperature Sensor (RTS) Location 32 Return Temperature Sensor (RTS) Service 750

S Safety and Protective Devices 312 Safety Notices 11 Safety Summary 11 Sampling Type (dCF05 & dCF06) 419 Sensor 750 Sensor Checkout 740 Sensor Configuration (dCF02) 417 Service Access Valve Location 34 Service Connections 72 Specific Hazard Statements 11 Standard Battery 738 Standard Operation Description 313 Start Temperature Recorder 56 Start Up - Compressor Bump Start 44 Start Up - Compressor Phase Sequence 44 Starting and Stopping Instructions 55 Starting the Unit 55 Start-Stop Switch (ST) Location 31 Start-Up Inspection 55 Stopping the Unit 55 Suction Connection Location 34 Suction Pressure Transducer (SPT) Location 34 Suction Service Valve Location 34 Supply Recorder Sensor (SRS) Location 34 Supply Temperature Sensor (STS) Location 34

T Temperature Control Microprocessor System 41 Temperature Readout 21 Temperature Sensor Service 739

Thermistor Format (dCF04) 417 Thermometer Port 23 TripWise Option 24, 510 Troubleshooting 61 Troubleshooting P6- 7 (DUV) 730

U Unit Display Location 31 Unit Identification Information 21 Unit Nameplate Location 31 Upper Air 23 Upper Fresh Air Makeup Vent 52 USDA 22 USDA Cold Treatment Description 420 USDA Cold Treatment Procedure 421 USDA Probes Location 32

V Valve Override Controls 732 Vent Position Sensor (VPS) Operation 54 Vent Position Sensor (VPS) Service 752

W Water Cooling 23 Water-Cooled Condenser (WCC) Cleaning 718 Water-Cooled Condenser (WCC) Operation 54 Water-Cooled Condenser WCC) Description 37

X XtendFRESH Option 24

Carrier Transicold Division, Carrier Corporation

P.O. Box 4805 Syra