Contents

Carrier Transicold 69NT40-561-019 Operation Manual PDF

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1 of 140

Summary of Content for Carrier Transicold 69NT40-561-019 Operation Manual PDF

Container Refrigeration

OPERATIONS AND SERVICE For

69NT40-561-019 Evergreen Container Refrigeration Units

T-359 Rev C

OPERATIONS AND SERVICE For

69NT40-561-019 Evergreen Container Refrigeration Units

2021 Carrier Corporation Printed in USA January 2021

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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 WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

2.3.1 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3.2 Temperature Readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3.3 Pressure Readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3.4 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3.5 Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3.6 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3.7 Evaporator Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3.8 Plate Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.4 OPTION DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.4.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.4.2 Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.3 USDA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.4 Interrogator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.5 Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.6 Communications Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.7 Temperature Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.8 Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.9 460 Volt Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.10 Cable Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.11 Upper Air (Fresh Air Make Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.12 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.13 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4.14 Condenser Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1.1 Refrigeration Unit - Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.1.2 Fresh Air Makeup Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.1.3 Evaporator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3.1.4 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3.1.5 Air-Cooled Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3.1.6 Control Box Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3.1.7 Communications Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.2 REFRIGERATION SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 3.3 ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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3.4 SAFETY AND PROTECTIVE DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 3.5 REFRIGERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.5.1 Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3.5.2 Economized Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3.5.3 Electronic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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

4.1.1 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 4.1.2 Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 4.1.3 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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

4.3 CONTROLLER SEQUENCE AND MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 4.3.1 Start Up - Compressor Phase Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 4.3.2 Start Up - Compressor Bump Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 4.3.3 Perishable Set Point Temperature - Perishable Pulldown . . . . . . . . . . . . . . . . . . . . . . . . . . 45 4.3.4 Perishable Set Point Temperature - Standard Temperature Control Mode . . . . . . . . . . . . . 45 4.3.5 Perishable Set Point Temperature - Economy Fan Operation Mode . . . . . . . . . . . . . . . . . . 45 4.3.6 Perishable Set Point Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 4.3.7 Perishable Mode Cooling - Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 4.3.8 Perishable Mode Heating - Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 4.3.9 Sequence of Operation - Perishable Mode (Capacity Trim Heat) . . . . . . . . . . . . . . . . . . . . . 47 4.3.10 Perishable Mode - Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 4.3.11 Perishable, Dehumidification - Bulb Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 4.3.12 Frozen Mode - Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.3.13 Frozen Mode - Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.3.14 Frozen Mode - Heat Lockout Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.3.15 Frozen Mode Cooling - Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 4.3.16 Frozen Mode - Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 4.3.17 Defrost Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 4.3.18 Defrost Mode - Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 4.3.19 Defrost Pulsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

4.4 PROTECTION MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.4.1 Evaporator Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.4.2 Failure Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.4.3 Generator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.4.4 Compressor High Temperature, Low Pressure Protection . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.4.5 Perishable Mode - System Pressure Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 4.4.6 Condenser Fan Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413

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

4.7.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415 4.7.2 DataCORDER Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416 4.7.3 Sensor Configuration (dCF02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416 4.7.4 Logging Interval (dCF03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 4.7.5 Thermistor Format (dCF04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 4.7.12 USDA/ Message Trip Comment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 4.7.13 USDA Cold Treatment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 4.7.14 DataCORDER Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422 4.7.15 ISO Trip Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.1 INSPECTION (BEFORE LOADING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.2 CONNECT POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.2.1 Connection To 380/460 VAC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.3 ADJUST FRESH AIR MAKEUP VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.3.1 Upper Fresh Air Makeup Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 5.3.2 Vent Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.4 CONNECT REMOTE MONITORING RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.5 STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.5.1 Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.5.2 Stopping the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.6 START-UP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.6.1 Physical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.6.2 Check Controller Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.6.3 Start Temperature Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.6.4 Complete Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.7 PRE-TRIP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 5.8 OBSERVE UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.8.1 Probe Diagnostic Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 6.6 UNIT WILL NOT DEFROST PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 6.7 ABNORMAL PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 6.8 ABNORMAL NOISE OR VIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 6.9 MICROPROCESSOR MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 6.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . 64 6.11 ELECTRONIC EXPANSION VALVE MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 6.12 COMPRESSOR OPERATING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 6.13 ABNORMAL TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 6.14 ABNORMAL CURRENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 7.1 SECTION LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 7.2 MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 7.3 REFRIGERATION SYSTEM SERVICE - UNITS WITH STANDARD PIPING . . . . . . . . . . . . . . . 72

T-359 iv

7.3.1 Service Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 7.3.2 Pumping Down the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 7.3.3 Refrigerant Leak Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 7.3.4 Evacuation and Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 7.3.5 Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

7.4 COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 7.4.1 Removal and Replacement of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

7.5 HIGH PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 7.5.1 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 7.5.2 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711

7.6 CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 7.7 CONDENSER FAN AND MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 7.8 FILTER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712 7.9 EVAPORATOR COIL AND HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712

7.9.1 Evaporator Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712 7.9.2 Evaporator 5+1 Heater Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712

7.10 EVAPORATOR FAN AND MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713 7.10.1 Replacing the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 7.10.2 Disassemble the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 7.10.3 Assemble the Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714

7.11 EVAPORATOR SECTION CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715 7.12 ELECTRONIC EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716

7.12.1 Replacing Electronic Expansion Valve and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717 7.13 ECONOMIZER EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717

7.13.1 Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718 7.14 ECONOMIZER SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719 7.15 DIGITAL UNLOADER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 7.16 VALVE OVERRIDE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 7.17 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722

7.17.1 Handling Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722 7.17.2 Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722 7.17.3 Controller Programming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 7.17.4 Removing and Installing a Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 7.17.5 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725

7.18 VENT POSITION SENSOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 7.19 TEMPERATURE SENSOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726

7.19.1 Sensor Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727 7.19.2 Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 7.19.3 Sensor Re-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731

7.20 ELECTRONIC PARTLOW TEMPERATURE RECORDER (IF EQUIPPED) . . . . . . . . . . . . . . . 733 7.20.1 Replacing the Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734 7.20.2 Re-zeroing the Recording Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734

7.21 MAINTENANCE OF PAINTED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735 7.22 COMMUNICATIONS INTERFACE MODULE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 735

ELECTRICAL WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 8.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

vii T-359

LIST OF ILLUSTRATIONS FIGURE NUMBER Page

Figure 3.1 Refrigeration Unit - Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Figure 3.2 Evaporator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Figure 3.3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Figure 3.4 Air-Cooled Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Figure 3.5 Control Box Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Figure 3.6 Refrigeration Circuit Schematic - Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Figure 3.7 Refrigeration Circuit Schematic - Economized Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Figure 4.1 Temperature Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Figure 4.2 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Figure 4.3 Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Figure 4.4 Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Figure 4.5 Controller Operation - Perishable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Figure 4.6 Perishable Mode - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Figure 4.7 Perishable Mode Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 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 Data Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 Figure 4.13 Alarm Troubleshooting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431 Figure 5.1 Upper Fresh Air Make Up Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Figure 7.1 Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Figure 7.2 R-134a 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 Heater Arrangement - Omega Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713 Figure 7.8 Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715 Figure 7.9 Electronic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717 Figure 7.10 Economizer Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718 Figure 7.11 Coil View of Economizer Solenoid Valve (ESV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719 Figure 7.12 Digital Unloader Valve (DUV) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 Figure 7.13 Controller Section of the Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 Figure 7.14 Sensor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730 Figure 7.15 Sensor and Cable Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730 Figure 7.16 Supply Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732 Figure 7.17 Return Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732 Figure 7.18 Evaporator Temperature Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732 Figure 7.19 Compressor Discharge Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733 Figure 7.20 Electronic Partlow Temperature Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734 Figure 7.21 Communications Interface Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735 Figure 8.1 LEGEND -- Evergreen Unit Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Figure 8.2 SCHEMATIC DIAGRAM -- Evergreen Unit Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Figure 8.3 UNIT WIRING DIAGRAM -- Evergreen Unit Configuration (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . 84 Figure 8.4 UNIT WIRING DIAGRAM -- Evergreen Unit Configuration (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . 85

T-359 viii

LIST OF TABLES TABLE NUMBER Page

Table 31 Safety and Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Table 41 Keypad Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Table 42 DataCORDER Configuration Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 Table 43 DataCORDER Standard Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 Table 44 Controller Configuration Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 Table 45 Controller Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 Table 46 Controller Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432 Table 47 Controller Pre-trip Test Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 Table 48 DataCORDER Function Code Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446 Table 49 DataCORDER Pre-trip Result Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 Table 410 DataCORDER Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448 Table 71 Valve Override Control Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 Table 72 Sensor Resistance - AMBS, DTS, ETS, RRS, RTS, SRS, STS . . . . . . . . . . . . . . . . . . . . . . . . . . 728 Table 73 Sensor Resistance - PrimeLINE CPDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 Table 74 Recommended Bolt Torque Values (Dry, Non-Lubricated for 18-8 Stainless Steel) . . . . . . . . . . 736 Table 75 R-134a Refrigerant Pressure Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737

11 T-359

SECTION 1 SAFETY SUMMARY

1.1 General Safety Notices 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.

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

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

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

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

T-359 12

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

DANGER! Never use air for leak testing. It has been determined that pressurized, mixtures of refrigerant and air can undergo combustion when exposed to an ignition source.

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

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

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

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 com- pressor.

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. Do not use oxygen in or near a refrigeration system as an explosion may occur.

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

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

13 T-359

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

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.

CAUTION! Charge 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.

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

CAUTION! When Pre-Trip key is pressed, economy, de humidification and bulb mode will be deactivated. At the completion of Pre-Trip activity, economy, dehumidification and bulb mode must be reac- tivated.

CAUTION! When a failure occurs during automatic testing, the unit will suspend operation awaiting oper- ator 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!

T-359 14

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 be sure set is brought to suc- tion 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 (frontseated). Internal damage will result from operating the com- pressor 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.

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

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 per forming arc welding on any part of the container.

CAUTION! The unit must be OFF whenever a program ming card is inserted or removed from the control- ler 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 the sensor resistance.

21 T-359

SECTION 2 INTRODUCTION

2.1 Introduction The Carrier Transicold model 69NT40-561-019 series units are of lightweight aluminum frame construction, designed to fit in the front of a container and serve as the container's front wall. They are one piece, 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 R-134a and compressor lubricating oil, and are ready for operation upon installation. Forklift pockets are provided for unit installation and removal. The base unit operates on nominal 380/460 volt, 3-phase, 50/60 hertz (Hz) power. Power for the control system is provided by a transformer which steps the supply power down to 18 and 24 volts, single phase. The controller is a Carrier Transicold Micro-Link 3 microprocessor. The controller will operate automatically to select cooling, holding or heating as required to maintain the desired set point temperature within very close limits. The unit may also be equipped with an electronic temperature recorder. The controller has a keypad and display for viewing or changing operating parameters. The display is also equipped with lights to indicate various modes of operation.

2.2 Configuration Identification Unit identification information is provided on a plate located to the left of the receiver on the back wall of the con- denser section. The plate provides the unit model number, the unit serial number and the unit parts identification number (PID). The model number identifies the overall unit configuration, while the PID number provides informa- tion on specific optional equipment, factory provisioned to allow for field installation of optional equipment and dif- ferences in detailed parts.

2.3 Feature Descriptions 2.3.1 Control Box Units are equipped with an aluminum control box.

2.3.2 Temperature Readout The unit is fitted with suction and discharge temperature sensors. The sensor readings may be viewed on the con- troller display.

2.3.3 Pressure Readout The unit is fitted with evaporator and discharge transducers. The transducer readings may be viewed on the con- troller display.

2.3.4 Compressor The unit is fitted with a scroll compressor equipped with suction and discharge service connections.

2.3.5 Condenser Coil The unit is fitted with a four-row condenser coil using 7mm tubing.

2.3.6 Evaporator Evaporator section is equipped with an electronic expansion valve (EEV).

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

2.3.8 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.

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

2.4.1 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.

T-359 22

2.4.2 Dehumidification The unit is fitted with a humidity sensor. This sensor allows setting of a humidity set point in the controller. In dehu- midification mode, the controller will operate to reduce internal container moisture level.

2.4.3 USDA The unit is 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.

2.4.4 Interrogator Units use the DataCORDER function, they 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).

2.4.5 Remote Monitoring The unit is 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.

2.4.6 Communications Interface Module The unit is 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.

2.4.7 Temperature Recorder The unit has been provisioned to be fitted with an electronic temperature recording device.

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

2.4.9 460 Volt Cable A power cable and CEE17 plug are available for the main 460 volt supply.

2.4.10 Cable Restraint A bungee cord style cable restraint is available for storage of the power cables.

2.4.11 Upper Air (Fresh Air Make Up) The unit is fitted with an upper fresh air makeup assembly. The fresh air makeup assembly is equipped with a vent positioning sensor (VPS).

2.4.12 Labels Safety Instruction and Function Code listing labels are supplied in English and Traditional Chinese.

2.4.13 Controller Two replacement controllers are available:

1. Remanufactured - Controller is the equivalent of a new OEM controller and is supplied with a 12-month warranty.

2. Repaired - Controller has had previous faults re paired and upgraded with the latest software.

NOTE Repaired controllers are NOT to be used for warranty repairs; only full OEM Remanufactured 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.

2.4.14 Condenser Grille The unit is equipped with direct bolted grilles.

31 T-359

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 serial plate to the left of the receiver on the back wall of the condenser section. 3.1.2 Fresh Air Makeup Vent The function of the upper 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.

Figure 3.1 Refrigeration Unit - Front Section

1. Access Panel (Evap. Fan #1) 2. Fork Lift Pockets 3. Control Box 4. Compressor Cover 5. Compressor 6. Economizer 7. Filter Drier 8. Receiver 9. Unit Serial Number, Model Number and

Parts Identification Number (PID) Plate

10. Power Cables and Plug (Location) 11. Condenser Fan 12. Interrogator Connector (Front left) 13. Temperature Recorder (Provisioned) 14. TIR (Transports Internationaux Routiers)

Sealing Provisions - Typical All Panels 15. Upper Fresh Air Makeup Vent Panel 16. Access Panel (Evap. Fan #2)

- - - - -

1

2

3

4

5

6 78

9 10

11

12

13

14

15

16

T-359 32

3.1.3 Evaporator Section

The evaporator section (Figure 3.2) contains the return temperature sensor, humidity sensor, electronic expansion valve, dual speed evaporator fans (EM1 and EM2), evaporator coil and heaters, defrost temperature sensor, heat termination thermostat and evaporator temperature sensors (ETS1 and ETS2).

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

Most evaporator components are accessible by removing the upper rear panel (as shown in the illustration) or by removing the evaporator fan access panels (see Figure 3.1, Items 1 and 16).

Figure 3.2 Evaporator Section

1. Evaporator Fan Motor #1 (EM1) 2. Return Recorder Sensor/Temperature Sensor

(RRS/RTS) 3. Humidity Sensor (HS) 4. Evaporator Fan Motor #2 (EM2) 5. Evaporator Coil 6. Evaporator Coil Heaters (Underside of Coil) 7. Heater Termination Thermostat (HTT) 8. Defrost Temperature Sensor (DTS)

9. Electronic Expansion Valve (EEV) 10. Evaporator Temperature Sensors (Location)

(ETS1 and ETS2) 11. Interrogator Connector (Rear) (ICR) 12. USDA Probe Receptacle PR2 13. USDA Probe Receptacle PR1 14. USDA Probe Receptacle PR3 15. Cargo Probe Receptacle PR4

- - - - -

1 2

3 4

5

6

7

8

9 10

11

12 13

14 15

33 T-359

3.1.4 Compressor Section

The compressor section (Figure 3.3) 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, supply recorder sensor and ambient sensor are located to the left of the compressor.

Figure 3.3 Compressor Section

1. Compressor 2. Compressor Discharge Temperature Sen-

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

Assembly (STS/SRS)

- - - - -

COMPRESSOR COVER REMOVED FOR CLARITY

1 2 3

4

5

6

7

8 9

10

11

12

13

14

15

T-359 34

3.1.5 Air-Cooled Condenser Section

The air-cooled condenser section (Figure 3.4) consists of the condenser fan, condenser coil, receiver, liquid line service valve, filter drier, fusible plug, economizer, economizer expansion valve, economizer solenoid valve (ESV), and sight glass/moisture indicator.

The condenser fan pulls air through the bottom of the coil and discharges it horizontally through the con denser fan grille.

Figure 3.4 Air-Cooled Condenser Section

1. Grille and Venturi Assembly 2. Condenser Fan 3. Key 4. Condenser Fan Motor 5. Condenser Coil 6. Condenser Coil Cover 7. Receiver 8. Sight Glass

9. Filter Drier 10. Economizer 11. Economizer Solenoid Valve (ESV) 12. Economizer Expansion Valve 13. Service Access Valve 14. Liquid Level/Moisture Indicator 15. Fusible Plug

- - - - -

1

2 3 4

5

6

7

8 9 10

11

12 1314

15

35 T-359

3.1.6 Control Box Section

The control box (Figure 3.5) includes: the manual operation switches, circuit breaker (CB-1), compressor, fan and heater contactors, control power transformer, fuses, key pad, display module, current sensor module, controller module and the communications interface module.

3.1.7 Communications Interface Module

The optional communications interface module is a slave module that 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 master central monitoring station technical manual for additional information.

Figure 3.5 Control Box Section

1. Compressor Contactor - CH 2. Compressor Phase A Contactor - PA 3. Compressor Phase B Contactor - PB 4. Heater Contactor - HR 5. Display Module 6. Communications Interface Module 7. Controller/DataCORDER Module (Controller) 8. Key Pad 9. Remote Monitoring Receptacle

10. Controller Battery Pack (Standard Location) 11. Interrogator Connector (Box Location) 12. Control Transformer 13. Terminal Block - HW 14. High Speed Evaporator Fan Contactor - EF 15. Low Speed Evaporator Fan Contactor - ES 16. Condenser Fan Contactor - CF 17. Circuit Breaker - 460V 18. Current Sensor Module

- - - - -

21 3 4 5 6 7 8

9101112131415161718

T-359 36

3.2 Refrigeration System Data

3.3 Electrical Data

Compressor / Motor Assembly Model Number ZMD26KVE-TFD-274

Weight (With Oil) 42.9 kg (95 lb)

Approved Oil Uniqema Emkarate RL-32-3MAF

Oil Charge 1774 ml (60 ounces)

Electronic Expansion Valve Superheat (Evaporator)

Verify at -18C (0F) container box temperature

4.4 to 6.7C (8 to 12F)

Economizer Expansion Valve Super- heat

Verify at -18C (0F) container box temperature

4.4 to 11.1C (8 to 20F)

Heater Termination Thermostat Opens 54 (+/- 3) C = 130(+/- 5) F

Closes 38 (+/- 4) C = 100 (+/- 7) F

High Pressure Switch Cutout 25 (+/- 1.0) kg/cm2 = 350 (+/- 10) psig

Cut-In 18 (+/- 0.7) kg/cm2 = 250 (+/- 10) psig

CAUTION! Charge receiver according to nameplate specifications to ensure optimal unit performance.

Refrigerant Charge - R-134a Receiver 4.99 kg (11 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.

Circuit Breaker CB-1 Trips at 29 amps

CB-2 (50 amp) Trips at 62.5 amps

CB-2 (70 amp) Trips at 87.5 amps

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

Condenser Fan Motor 380 VAC, Single Phase, 50 Hz

460 VAC, Single Phase, 60 Hz

Full Load Amps 1.3 amps 1.6 amps

Horsepower 0.43 hp 0.75 hp

Rotations Per Minute 1425 rpm 1725 rpm

Voltage and Frequency 360 - 460 VAC +/- 2.5 Hz 400 - 500 VAC +/- 2.5 Hz

Bearing Lubrication Factory lubricated, additional grease not required.

Rotation Counter-clockwise when viewed from shaft end.

37 T-359

Evaporator Coil Heater, Standard

Number of Heaters 4

Rating 750 watts +/- 5% @ 230 VAC

Resistance (cold) 72 ohms +/- 5%

Type Sheath

Evaporator Coil Heater, Straight

Number of Heaters 1

Rating 750 watts +/- 7.5% @ 460 VAC

Resistance (cold) 282 ohms +/-7.5%

Type Sheath

Drain Cup Heater, Omega Number of Heaters 1

Rating 450 watts +5/-7.5% @ 460 VAC

Resistance (cold) 470 ohms +/-7.5%

Type Sheath

Evaporator Fan Motor(s) 380 VAC/3 PH/50 Hz 460 VAC/3 PH/60 Hz

Full Load Amps High Speed

1.0 1.2

Full Load Amps Low Speed

0.6 0.6

Nominal Horsepower High Speed

0.49 0.84

Nominal Horsepower Low Speed

0.06 0.11

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

Fuses Control Circuit 7.5 amps (F3A,F3B)

Controller/ DataCORDER

5 amps (F1 & F2)

Emergency Bypass 10 amps (FEB)

Vent Positioning Sensor Electrical Output 0.5 VDC to 4.5 VDC over 90 degree range

Supply Voltage 5 VDC +/- 10%

Supply Current 5 mA (typical)

Solenoid Valve Coils (ESV) 24 VDC

Nominal Resistance @ 77F (25C)

7.7 ohms +/- 5%

Maximum Current Draw 0.7 amps

DUV Coils 12 VDC Nominal Resistance @ 77F (25C)

14.8 ohms +/- 5%

Maximum Current Draw 929 mA

EEV Nominal Resistance Coil Feed to Ground (Gray Wire)

47 ohms

Coil Feed to Coil Feed 95 ohms

T-359 38

3.4 Safety and Protective Devices Unit components are protected from damage by safety and protective devices listed in Table 31. These de vices 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).

Humidity Sensor Orange wire Power

Red wire Output

Brown wire Ground

Input voltage 5 VDC

Output voltage 0 to 3.3 VDC

Output voltage readings verses relative humidity (RH) percentage:

30% 0.99 V

50% 1.65 V

70% 2.31 V

90% 2.97 V

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

Table 31 Safety and Protective Devices

Unsafe Condition Device Device Setting

Excessive current draw

Circuit Breaker (CB-1) - 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 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/tempera- tures in the high refrigerant side Fusible Plug - Used on the Receiver 99C = (210F)

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

(350 psig)

39 T-359

3.5 Refrigeration Circuit

3.5.1 Standard Operation

Starting at the compressor, (see Figure 3.6) 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 tempera- ture. 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.

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. As the liquid refrigerant passes through the variable orifice of the expansion valve, some of it vaporizes into a gas (flash gas). Heat is absorbed from the return air by the balance of the liquid, causing it to vaporize in the evaporator coil. The vapor then flows through the suction tube back to the compressor.

During the standard mode of operation, the normally closed digital unloader valve (DUV) controls the system refrig- erant 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 sig- nal in order to absorb the excess capacity.

3.5.2 Economized Operation

In the economized mode, (see Figure 3.7) 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 leav- ing 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 liq- uid refrigerant flowing to the electronic expansion valve. The resultant medium temperature/pressure gas enters the compressor at the economizer port fit ting.

When the air temperature falls to 2.0C (3.6F) above set point, the DUV unloads the compressor's 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

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 set point.

T-359 310

Figure 3.6 Refrigeration Circuit Schematic - Standard Operation

Figure 3.7 Refrigeration Circuit Schematic - Economized Operation

CONDENSER

COMBO ETS1 AND 2

EVAPORATOR

DISCHARGE SERVICE VALVE

SUCTION SERVICE VALVE

FILTER DRIER

LIQUID LINE SERVICE VALVE

ECONOMIZER SOLENOID VALVE

ECONOMIZER TXV

ELECTRONIC EXPANSION VALVE

DIGITAL UNLOADER VALVE

ECONOMIZER

RECEIVER

COMPRESSOR

SIGHT GLASS

LIQUID LEVEL/ MOISTURE INDICATOR

STANDARD OPERATION WITH RECEIVER

EVAPORATOR PRESSURE TRANSDUCER

SUCTION PRESSURE TRANSDUCER

DISCHARGE PRESSURE TRANSDUCER

DISCHARGE TEMPERATURE SENSOR

ECON. TXV

SENSING BULB

LIQUID

LIQUID LINE SERVICE VALVE

ECONOMIZER SOLENOID VALVE

ECONOMIZER TXV

ELECTRONIC EXPANSION VALVE

ECONOMIZER

RECEIVER

COMPRESSOR

ECONOMIZER PRESSURE

ECON. TXV

SENSING BULB

41 T-359

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 mod- ule, the control module (controller) and interconnecting wiring. The controller houses the temperature control soft- ware and the DataCORDER software. The temperature control software functions to operate the unit components as required to provide the desired car go temperature and humidity. The DataCORDER soft ware functions to record unit operating parameters and cargo temperature parameters for future retrieval. Cover age of the tempera- ture control software begins with Section 4.2. Coverage of the DataCORDER software is provided in Section 4.7.

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

Figure 4.1 Temperature Control System

T-359 42

4.1.1 Keypad

Figure 4.2 Keypad Table 41 Keypad Function

4.1.2 Display Module

The display module (Figure 4.3) consists of two 5-digit displays and seven indicator lights. The indicator lights include:

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

2. Heat - Orange LED: Energized to indicate heater operation in the heat or defrost mode.

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

4. In-Range - Green LED: Energized when the controlled temperature probe is within specified tolerance of set point.

CODE SELECT

PRE TRIP

ALARM LIST

MANUAL DEFROST/ INTERVAL

ENTER

BATTERY POWER

ALT MODE

RETURN SUPPLY

C F

Key Function CODE

SELECT Accesses function codes.

PRE TRIP Displays Pre-trip selection menu. Discontinues Pre-trip in progress.

ALARM LIST Displays alarm list and clears the alarm queue.

MANUAL DEFROST / INTERVAL

Displays selected defrost mode. Depress and hold the MANUAL DEFROST / INTERVAL key for five (5) seconds to initiate defrost using the same logic as if the optional manual defrost switch was toggled on.

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

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

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

RETURN / SUPPLY

Display non-controlling probe temperature (momentary display).

Celsius / Fahrenheit

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 set point & function code selection if AC power is not connected.

ALT MODE

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

43 T-359

NOTE The controlling probe in the perishable range will be the SUPPLY air probe and the controlling probe in the frozen range will be the RETURN air probe.

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

6. Return - Yellow LED: 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. This LED will flash if dehumidification or humidification is enabled.

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

Figure 4.3 Display Module

4.1.3 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 controller modules. Breaking the seal will void the warranty.

The Micro-Link 3 controller is a dual module microprocessor as shown in Figure 4.4. It is fitted with test points, har- ness connectors and a software card programming port.

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

ataD/ERUTAREPMET RIAedoC/TNIOPTES

T-359 44

Figure 4.4 Control Module

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

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

- - - - -

4.2 Controller Software The controller software is a custom designed program that is subdivided into configuration software and opera- tional software. The controller software performs the fol lowing functions:

a. Control supply or return air temperature to required limits, provide modulated refrigeration operation, econo- mized operation, unloaded operation, electric heat control and defrost. Defrost is performed to clear buildup of frost and ice and ensure proper air flow across the coil.

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

c. Provide ability to read and (if applicable) modify the configuration software variables, operating software Function Codes and Alarm Code indications.

d. 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 limit- ing and current limiting settings.

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

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

4.2.1 Configuration Software (Variables)

The configuration software is a variable listing of the components available for use by the operational soft ware. This software is factory installed in accordance with the equipment fitted and options listed on the original purchase order. Changes to the configuration soft ware are required only when a new controller has been installed or a phys- ical change has been made to the unit such as the addition or removal of an option. A configuration variable list is provided in Table 44. Change to the factory-installed configuration software is achieved via a configuration card or by communications.

4.2.2 Operational Software (Function Codes)

The operational software is the actual operation programming of the controller which activates or deactivates com- ponents in accordance with current unit operating conditions and operator selected modes of operation.

The programming is divided into function codes. Some of the codes are read only while the remaining codes may be user configured. The value of the user configurable codes can be assigned in accordance with user desired mode of operation. A list of the function codes is provided in Table 45.

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 3 3 3 34 5 6 7 8

45 T-359

To access the function codes, perform the following:

a. Press the CODE SELECT key, then press an arrow key until the left window displays the desired code number.

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

c. If a longer time is desired, press the ENTER key to extend the time to five minutes.

4.3 Controller Sequence and Modes of Operation General operation sequences for cooling, heating, and defrost are provided in the following sub-paragraphs. Sche- matic representation of controller action is provided in Figure 4.5.

The operational software responds to various inputs. These inputs come from the temperature and pressure sensors, the temperature set point, the settings of the configuration variables and the function code assignments. The action taken by the operational software will change if any one of the inputs 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 The controller logic will check for proper phase sequencing and compressor rotation. If sequencing is allowing the compressor and three-phase evaporator fan motor to rotate in the wrong direction, the controller will energize or de-energize relay TCP as required (see Figure 8.2). Relay TCP will switch its contacts, energizing or de-energizing relays PA and PB. Relay PA is wired to energize the circuits(s) on L1, L2, and L3. Relay PB is wired to energize the circuit(s) on L3, L2, and L1, thus providing reverse rotation.

4.3.2 Start Up - Compressor Bump Start The controller logic will initiate a compressor bump start procedure to clear refrigerant from the compressor. If suc- tion and discharge pressures have equalized, the compressor will perform three compressor bump starts. A com- pressor bump start may occur after a defrost has been completed.

During the procedure, the EEV will close. Relays TS, TQ, TN, TE, 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 sec- onds. This sequence will be repeated two additional times. After the final bump start the unit will pre-position the EEV to correct starting position pause and startup.

4.3.3 Perishable Set Point Temperature - Perishable Pulldown When cooling from a temperature that is more than 2.5C (4.5F) above set point, the system will be in the perish- able pulldown mode in economized operation. However, pressure and current limit functions may restrict the valve if either exceeds the preset value.

4.3.4 Perishable Set Point Temperature - Standard Temperature Control Mode The unit is capable of maintaining supply air temperature to within +/-0.2C (+/-0.36F) of set point. Supply air tem- perature 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.

Once set point is reached, the unit will transition to the perishable steady state mode. This results in unloaded operation by cycling the DUV to limit capacity and maintain steady temperature control.

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 the perishable idle mode. The compressor is turned off and the evaporator fans continue to run to circulate air throughout the container. If temperature rises above set point +0.2C, the unit will transition back to the perish able steady state mode

If the temperature drops to 0.5C (0.9F) below set point, the unit will transition to the perishable heating mode and the heaters will be energized. The unit will transition back to the perishable idle mode when the temperature rises to 0.2C (0.4F) below the set point and the heaters will de-energize.

4.3.5 Perishable Set Point Temperature - Economy Fan Operation Mode The economy mode is an extension of the standard mode. The mode is activated when the setting of function code Cd34 is ON. Economy mode is provided for power saving purposes. Economy mode could be utilized in the transportation of temperature-tolerant cargo or non-respiration items which do not require high air flow for removing respiration heat. There is no active display indicator that economy mode has been activated. To check for economy mode, perform a manual display of code Cd34.

T-359 46

In order to achieve economy mode, a perishable set point must be selected prior to activation. When economy mode is active, the evaporator fans will be controlled as follows: At the start of each cooling or heating cycle, the evaporator fans will run in high speed for three minutes. They will then be switched to low speed any time the supply air temperature is within +/- 0.2C (0.36F) of the set point and the return air temperature is less than or equal to the supply air temperature +3C (5.4F). The fans will continue to run in low speed for one hour. At the end of the hour, the evaporator fans will switch back to high speed and the cycle will be repeated. If bulb mode is active, the economy fan activity will be overridden. 4.3.6 Perishable Set Point Temperature Control With configuration variable CnF26 (Heat Lockout Temperature) set to -10C the perishable mode of operation is active with set points above -10C (+14F). With the variable set to -5C, the perishable mode is active above -5C (+23F). Refer to Table 44. When in the perishable mode, the controller maintains the supply air temperature at set point, the SUPPLY indica- tor light will be illuminated on the display module and the default reading on the display window will be the supply temperature sensor reading. When the supply air temperature enters the in-range temperature tolerance (as selected at function code Cd30), the in-range light will energize.

Figure 4.5 Controller Operation - Perishable Mode

NOTE 1: TEMPERATURE INDICATIONS ARE ABOVE OR BELOW SET POINT. NOTE 2: ECONOMIZED UNLOADED COOLING OCCURS IF RETURN TEMPERATURE

IS GREATER THAN SET POINT PLUS 1.9_C AND IF CAPACITY MODULATION IS GREATER THAN 70%. IF BOTH CONDITIONS ARE NOT MET, STANDARD UNLOADED COOLING OCCURS.

RISING TEMPERATURE

HEATING

AIR CIRCULATIONSET POINT

+0.20_C

HEATING

+2.5_C (4.5_F)

FALLING TEMPERATURE

MODULATED UNLOADED COOLING

--0.5_C (0.9_F)

AIR CIRCULATION --0.20_C

MODULATED UNLOADED COOLING

47 T-359

4.3.7 Perishable Mode Cooling - Sequence of Operation

NOTE In the Standard Perishable Mode of Operation, the evaporator motors run in high speed. In the Econ- omy Perishable Mode, the fan speed is varied.

With supply air temperature above set point and decreasing, the unit will cool with the condenser fan motor (CF), compressor motor (CH), evaporator fan motors (EF) energized and the COOL light illuminated. (See Figure 4.6). Also, if current or pressure limiting is not active, the controller may close contacts TS to open the economizer sole- noid valve (ESV) and place the unit in economized operation.

When the air temperature decreases to a predetermined tolerance above set point, the in-range light is illuminated.

4.3.8 Perishable Mode Heating - Sequence of Operation

a. If the air temperature decreases 0.5C (0.9F) below set point, 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 termi- nation thermostat (HTT) to energize the heaters (HR). The HEAT light is also illuminated. The evaporator fans continue to run to circulate air throughout the container.

b. When the temperature rises to 0.2C (0.4F) below set point, contacts TH open to de-energize the heaters. The 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.

4.3.9 Sequence of Operation - Perishable Mode (Capacity Trim Heat) If the system capacity has been decreased to the lowest allowable capacity and conditions exist that warrant max- imum temperature stability the controller will pulse the HR relay to energize the evaporator heaters in sequence with the compressor digital signal. Trim heat is enabled only if (12.77C < set point < 15.55C [54.99F < set point < 59.99F]) and (-6.67C < ambient temperature < 1.66C [19.99F < ambient temperature < 34.99F]).

Figure 4.6 Perishable Mode - Cooling 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.

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

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

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-359 48

4.3.10 Perishable Mode - Dehumidification

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

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

2. The unit is in the perishable steady state mode and supply air temperature is less than 0.25C (0.38F) above set point.

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

4. Heater termination thermostat (HTT) is closed.

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

Power is applied to the defrost heaters in the dehumidification mode. This added heat load causes the controller to open the ESV to match the increased heat load while still holding the supply air temperature very close to the set point.

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

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

1. Heater debounce timer (three minutes).

2. Out-of-range timer (five minutes).

The heater debounce timer is started whenever the heater contactor status is changed. The heat contactor remains energized (or de-energized) for at least three minutes even if the set point criteria are satisfied.

The out-of-range timer is started to maintain heater operation during a temporary out-of-range condition. If the sup- ply 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 the temperature exceeds the in-range tolerance value set by function code Cd30.

4.3.11 Perishable, Dehumidification - Bulb Mode Bulb mode is an extension of the dehumidification mode, which allows changes to the evaporator fan speed and/or defrost termination set points.

Bulb mode is active when configuration code Cd35 is set to Bulb. Once the bulb mode is activated, the user may then change the dehumidification mode evaporator fan operation from the default (speed alternates from low to high each hour) to constant low or constant high speed. This is done by toggling function code Cd36 from its default of alt to Lo or Hi as desired. If low speed evaporator fan operation is selected, this gives the user the additional capability of selecting dehumidification set points from 60 to 95% (instead of the normal 65 to 95%).

In addition, if bulb mode is active, function code Cd37 may be set to override the previous defrost termination thermo- stat settings. (Refer to Section 4.3.18) The temperature at which the defrost termination thermostat will be consid- ered 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 defrost termination thermostat is considered closed for interval timer start or demand defrost is 10C for open values from 25.6C (78F) down to a 10C 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 set point to one that is in the frozen range.

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

49 T-359

4.3.12 Frozen Mode - Temperature Control When in the frozen mode, the controller maintains the return air temperature at or below set point, the RETURN indicator light will be illuminated on the display module and the default reading on the display window will be the return air probe reading.

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

Figure 4.8 Controller Operation - Frozen Mode

4.3.13 Frozen Mode - Standard

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

When temperature drops to set point minus 0.2C 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 set point +0.2C, the unit will transition back to the frozen mode cooling.

4.3.14 Frozen Mode - Heat Lockout Temperature With configuration variable CnF26 (Heat Lockout Temperature) set to -10C the frozen mode of operation is active with set points at or below -10C (+14F). With the variable set to -5C, the frozen mode is active at or below -5C (+23F).

If the temperature drops 10C below set point, the unit will transition to the frozen heating mode, in which the evaporator fans are brought to high speed. The unit will transition back to the frozen mode cooling when the tem- perature rises back to the transition point.

SET POINT

FALLING TEMPERATURE

- 0.2 _C

+0.2_C

NOTE: TEMPERATURES INDICATIONS ARE ABOVE OR BELOW SET POINT

AIR CIRCULATION

ECONOMIZED COOLING

SET POINT

RISING TEMPERATURE

T-359 410

4.3.15 Frozen Mode Cooling - Sequence of Operation

a. When the return air temperature is above set point 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 COOL light illuminated. (See Figure 4.9).

b. When the air temperature decreases to a predetermined tolerance above set point, the in-range light is illu- minated.

c. When the return air temperature decreases to 0.2C (0.4F) below set point, contacts TC, TS, and TN are opened to de-energize the compressor, economizer solenoid valve and condenser fan motor. The 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 in- range light remains illuminated as long as the return air is within tolerance of set point.

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

f. When the return air temperature increases to 0.2C (0.4F) above set point 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 cool light is illuminated.

Figure 4.9 Frozen Mode

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

4.3.16 Frozen Mode - Economy In order to activate economy frozen mode operation, a frozen set point temperature must be selected. The economy mode is active when function code Cd34 is set to ON. When economy mode frozen is active, the system will per- form normal frozen mode operations except that the entire refrigeration system, excluding the controller, will be turned off when the control temperature is less than or equal to the set point -2C. After an off-cycle period of 60 min- utes, the unit will turn on high speed evaporator fans for three minutes, and then check the control temperature. If the control temperature is greater than or equal to the set point +0.2C, the unit will restart the refrigeration system and continue to cool until the previously mentioned off-cycle temperature criteria are met. If the control temperature is less than the set point +0.2C, the unit will turn off the evaporator fans and restart another 60 minute off-cycle.

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

411 T-359

4.3.17 Defrost Interval

Controller function code Cd27 sets two modes for defrost initiation, either user-selected timed intervals or auto- matic control. The user-selected values are 3, 6, 9, 12, 24 hours, AUTO, or PuLs. Some units may be configured to allow defrost to be disabled altogether. In this case, a user-selected value of OFF will be available. The factory default for defrost is AUTO. Refer to Table 45.

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

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

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

If defrost does not terminate correctly and temperature reaches set point of the heat termination thermostat (HTT), the thermostat will open to de-energize the heaters. If termination does not occur within two hours, the controller will terminate defrost. An alarm will be activated to inform of a possible DTS failure.

If probe check (controller function code CnF31) is con figured to SPECIAL, the unit will proceed to the next opera- tion (snap freeze or terminate defrost). If the code is configured to STANDARD, the unit will perform a probe check. The purpose of the probe check is to detect malfunctions in the sensed temperature. If probe check fails, the sys- tem will run for eight minutes to validate. At the end of eight minutes, probe alarms will be set or cleared based on the conditions seen.

When the return air falls to 7C (45F), the controller ensures that the defrost temperature sensor (DTS) reading has dropped to 10C or below. If it has not, a DTS failure alarm is given and the defrost mode is operated by the return temperature sensor (RTS).

If controller function code CnF33 is configured to snap freeze, the controller will sequence to this operation. The snap freeze consists of running the compressor without the evaporator fans in operation for a period of 4 minutes at 100% capacity. When the snap freeze is completed, defrost is formally terminated.

4.3.18 Defrost Mode - Sequence of Operation The defrost cycle may consist of up to three distinct operations. The first is de-icing of the coil, the second is a probe check cycle and the third is snap freeze. Defrost may be initiated by any one of the following methods:

1. The manual defrost function (also manual defrost switch function, if equipped) is initiated by the user through the use of the keypad or manual defrost switch. The manual defrost function is ended by use of the DTS.

NOTE The Manual Defrost / Interval key can be used to initiate a manual defrost.

Manual Defrost/Interval key operation: Depressing and holding the Manual Defrost / Interval key for five seconds will initiate defrost. If the Man- ual Defrost / Interval key is released in less than five seconds, defrost interval (code 27) shall be dis- played.

2. The user sends a defrost command by communications.

3. The defrost interval timer (controller function code Cd27) reaches the defrost interval set by the user.

4. The controller probe diagnostic logic determines that a probe check is necessary based on the temperature values currently reported by the supply and return probes.

5. If the controller is programmed with the Demand Defrost option and the option is set to IN the unit will enter defrost if it has been in operation for more than 2.5 hours without reaching set point.

6. The system is actively in a compressor suction pressure or high pressure ratio protection mode and reduced the average system capacity below a predetermined threshold value.

T-359 412

Defrost may be initiated any time the defrost temperature sensor reading falls below the controller defrost termina- mion thermostat set point. Defrost will terminate when the defrost temperature sensor reading rises above the defrost termination thermostat set point. The defrost termination thermostat is not a physical component. It is a controller set- ting that acts as a thermo stat, closing (allowing defrost) when the defrost temperature sensor reading is below the set point and opening (terminating or preventing defrost) when the sensor temperature reading is above set point. When the unit is operating in bulb mode (refer to Section 4.3.11), special settings may be applicable.

If the controller is programmed with the Lower DTT set ting option, the defrost termination thermostat set point may be configured to the default of 25.6C (78F) or lowered to 18C (64F). When a request for defrost is made through the manual defrost switch, communications or probe check the unit will enter defrost if the de frost tem- perature thermostat reading is at or below the defrost termination thermostat setting. Defrost will terminate when the defrost temperature sensor reading rises above the defrost termination thermostat setting. When a request for defrost is made with the defrost interval timer or by demand defrost, the defrost temperature setting must be below 10C (50F).

When the defrost mode 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 COOL light is also de-energized. The controller then closes contacts TH to supply power to the heaters. The defrost light is illuminated. When the defrost tempera- ture sensor reading rises to the defrost termination thermostat setting, the de-icing operation is terminated.

Figure 4.10 Defrost

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

4.3.19 Defrost Pulsing

Pulse defrost logic periodically turns on the evaporator fans to circulate warm air around the drain line system, this prevents water re-freezing during a defrost cycle.

To enable Defrost Pulsing, the user will scroll to Function Code 27, select PuLs and press the Enter key. Once PuLs has been selected the user will then scroll to Function Code 60 and select the Pulse Logic Set Point Engagement Temperature. The selections are from 0.0C (32F) to -18C (0F). At the selected Engagement set point or below, PuLs will be active, and the evaporator fans may turn on. At set points above the selected Engagement set point, AUTO defrost will be active.

NOTE Default setting for PuLs is -18C (0F). The unit will reset to the default setting at the next PTI or Trip Start.

The default defrost interval for PuLs will be every 6 hours. Defrost termination setting for PuLs is set to 20C (68F).

24 VOLT POWER

ENERGIZED DE- ENERGIZED

TN

ST F

HPS PB

IP- CM

TC

CF

TEIP- EM1 EFIP- EM2

HTT TH HR

ESVTS

TV EF ES

413 T-359

During defrost the evaporator fans will cycle ON Low Speed once DTS reaches 0C (32F) and STS is below -5C (23F). Once the evaporator fans cycle ON the controller will monitor STS at 1 second intervals and calculate the difference between the current STS reading and the previous STS reading.

If STS becomes warmer that -5C (23F) or the calculated difference of STS remains below 0.1C (0.18F) for 10 consecutive readings or DTS reaches 20C (68F), the evaporator fans will turn off for 3 minutes. At the end of 3 minutes, the controller will begin checking the conditions for evaporator fans PuLs operation again.

4.4 Protection Modes of Operation

4.4.1 Evaporator Fan Operation

Opening of an evaporator fan internal protector will shut down the unit.

4.4.2 Failure Action

Function code Cd29 may be operator set to select action the controller will take upon system failure. The factory default is full system shutdown. Refer to Table 45.

4.4.3 Generator Protection

Function codes Cd31(Stagger Start, Offset Time) and Cd32 (Current Limit) may be operator set to control start up sequence of multiple units and operating current draw. The factory default allows on demand starting (no delay) of units and normal current draw. Refer to Table 45.

4.4.4 Compressor High Temperature, Low Pressure Protection

The controller monitors compressor discharge pres sure, and temperature and suction pressure. If dis charge pres- sure 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 continue to operate during the compres- sor off cycle.

If high compressor dome temperature occurs, 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 the ambient temperature is greater than 43.3C, the return air temperature is less than -17.5C and if the compressor discharge temperature is greater than 117.7C.

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

If the suction pressure low limit is triggered, the DUV will energize to raise the suction pressure.

4.4.5 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 con denser 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.

4.4.6 Condenser Fan Override

When configuration variable 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 pres- sure conditions are not maintaining dis charge 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 ener- gized. When the DUV is 100% open, the fan will de-energize.

2. If DPT reading is invalid or out of range (AL 65), 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.

T-359 414

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 the alarms is provided in Table 46.

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:

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

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

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

To Display Alarm Codes:

a. 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.

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

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

d. The right display will show the actual alarm code. AA## will display for an active alarm, where ## is the alarm code. Or IA## will display for an inactive alarm, See Table 46.

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

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

NOTE AL26 is active when all of the sensors are not responding. Check the connector at the back of the con- troller; if it is loose or unplugged, reconnect it, then run a pre-trip test (P5) to clear AL26.

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

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

CAUTION! When Pre-trip key is pressed, economy, de humidification and bulb mode will be deactivated. At the completion of Pre-trip activity, economy, dehumidification and bulb mode must be reactivated.

Testing may be initiated by use of the keypad or via communication, but when initiated by communication the con- troller will execute the entire battery of tests (auto mode).

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

A detailed description of the pre-trip tests and test codes is provided in Table 47. Detailed operating instructions are provided in Section 5.7.

4.7 DataCORDER 4.7.1 Description

The Carrier Transicold DataCORDER software is integrated into the controller and serves to eliminate the tem- perature recorder and paper chart. The 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 Data Reader to download data. A personal computer with Carrier Transicold DataLINE software may also be used to download data and configure settings. The DataCORDER consists of:

Configuration Software

Operational Software

Data Storage Memory

Real Time Clock (with internal battery backup)

Six Thermistor Inputs

Interrogation Connections

Power Supply (battery pack)

The DataCORDER performs the following functions:

a. Logs data at 15, 30, 60, or 120 minute intervals and stores 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.

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 Con- tainer (USDA Cold treatment and Cargo probe recording)

Return Air Temperature

Set Point Change

Supply Air Temperature

Real Time Clock Battery (internal battery) Replacement

Real Time Clock Modification

Trip Start

ISO Trip Header (When entered via Interro- gation 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

- - - - -

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

a. Operational Software

The Operational Software reads and interprets inputs for use by the Configuration Software. The inputs are labeled Function Codes. 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 five minutes.

b. Configuration Software

The configuration software controls the recording and alarm functions of the DataCORDER. Reprogramming to the factory-installed configuration is achieved via a configuration card. Changes to the unit DataCORDER configuration may be made using the DataLINE interrogation software. A listing of the configuration variables is provided in Table 42. Descriptions of Data CORDER operation for each variable setting are provided in the following paragraphs.

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

a. Standard Mode

In the standard mode, the user may configure the DataCORDER to record data using one of seven standard con- figurations. The seven standard configuration variables, with their descriptions, are listed in Table 43.

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 tempera- ture control software uses the supply and return temperature sensors (STS, RTS).

b. 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. A list of the data points available for recording follows. Changing the configuration to generic and selecting which data points to record may be done using the Carrier Transicold Data Retrieval Program.

1. Control mode

2. Control temperature

3. Frequency

4. Humidity

5. Phase A current

6. Phase B current

7. Phase C current

8. Main voltage

9. Evaporator expansion valve percentage

10. Discrete outputs (Bit mapped - require special handling if used)

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

12. Ambient sensor

13. Evaporator temperature sensor

14. Compressor discharge sensor

15. Return temperature sensor (RTS)

16. Supply temperature sensor (STS)

17. Defrost temperature sensor

18. Discharge pressure transducer

19. Suction pressure transducer

20. Condenser pressure transducer

21. Vent position sensor (VPS)

- - - - -

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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.

Table 42 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

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Figure 4.11 Standard Configuration Download Report

Raw Data Report for ABC1234567 May 31, 2003 to Jun 04, 2003

System Configuration at the Time of Interrogation:

Interrogated On Sept 05, 2003 Extracted by DataLine Rev 1.0.0

Controller Software: 5120 Controller Serial #: 04163552

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

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

May 31, 2001

25598140:laireS:reniatnoC,66.1:tniopteS

9 Sensors Logged at 15 Minute Interval

Sensor Format Resolution

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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 aver- age of readings taken every minute over the recording period is recorded. When configured to snapshot, the sen- sor reading at the log interval time is recorded. When USDA is configured, the supply and return temperature readings are averaged and the three USDA probe readings are snapshot.

4.7.7 Alarm Configuration (dCF07 - dCF10)

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

If a probe alarm is configured to OFF, 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 their DataCORDER configured for USDA recording, but do not install the probes for every trip. If all the probes are dis- connected, 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 commu- nication when an interrogation cable is plugged into an interrogation receptacle.

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

4. Real Time Clock demand: If the DataCORDER is equipped with a charged battery pack and AC power is not present, the DataCORDER will power up when the real time clock indicates that a data recording should take place. When the DataCORDER is 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 volt- age 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 Data CORDER temperature logging will be prohibited until that time.

Table 43 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, the battery pack needs replacement.

4.7.9 Pre-trip Data Recording The DataCORDER will record the initiation of a pre-trip test (refer to Section 4.6) and the results of each of the tests included in pre-trip. The data is time-stamped and may be extracted via the Data Retrieval program. Refer to Table 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 one of the following: DataReader, DataLINE, or a communications interface module.

NOTE A DataReader, DataLINE or a 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.

3. Chart Recorder Fuse (FCR) blown.

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

a. DataReader

The Carrier Transicold Data Reader (see Figure 4.12) is a simple to operate handheld device designed to extract data from the DataCORDER and upload it to a PC. The Data Reader has the ability to store multiple data files. Refer to Data Retrieval manual 62-10629 for a more detailed explanation of the DataReader.

Figure 4.12 Data Reader

DataReader

1 2

3

4

56

7

8

OFF ON

UP Arrow

RIGHT Arrow

ENTEREscape

DOWN Arrow

LEFT Arrow

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b. DataBANKTM Card

The DataBANKTM card is a PCMCIA card that interfaces with the controller through the programming slot and can download the data at a much faster rate, when compared to the PC or DataReader. Files downloaded to Data- BANK card files are accessible through an Omni PC Card Drive. The files can then be viewed using the DataLINE software.

c. DataLINE

The DataLINE software for a personal computer is supplied on both floppy disks and CD. This software allows interrogation, configuration variable assignment, screen view of the data, hard copy report generation, cold treat- ment probe calibration, and file management. Refer to Data Retrieval manual 62-10629 for a more detailed expla- nation of the DataLINE interrogation soft ware. The DataLINE manual may be found on the Internet at www.container.carrier.com.

d. Communications Interface Module

The communications interface module is a slave module, which allows communication with a master central moni- toring 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. Refer to the master system technical manual for further information.

4.7.11 USDA Cold Treatment

Sustained cold temperature has been employed as an effective post-harvest method for the control of Mediterra- nean and certain other tropical fruit flies. Exposing infested fruit to temperatures of 2.2C (36F) or below for spe- cific periods results in the mortality of the various stages of this group of insects.

In response to the demand to replace fumigation with this environmentally sound process, Carrier has integrated Cold Treatment capability into its microprocessor system. These units have the ability to maintain supply air tem- perature 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.

a. USDA Recording

A special type of recording is used for USDA cold treatment purposes. Cold treatment recording requires three remote temperature probes be placed at prescribed locations in the cargo. Provision is made to connect these probes to the DataCORDER via receptacles located at the rear left-hand side of the unit. Four or five receptacles are provided. The four 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 de vices. 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 dis- plays 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.

4.7.12 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.

4.7.13 USDA Cold Treatment Procedure

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

a. Calibrate the three USDA probes by ice bathing the probes and performing the calibration function with the DataReader or DataLINE. This calibration procedure determines the probe offsets and stores them in the controller for use in generating the cold treatment report. Refer to the Data Retrieval manual 62-10629 for more details.

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

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

T-359 422

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

e. To initiate USDA recording, connect the personal computer and perform the configuration as follows, using the DataLINE software:

1. Enter ISO header information.

2. Enter a trip comment if desired.

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

4. Configure the logging interval for one hour.

5. Set the sensor configuration to USDA.

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

7. Perform a trip start.

4.7.14 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 Data- CORDER contains a buffer of up to eight alarms. A listing of the DataCORDER alarms is provided in Table 410, page. Refer to Section 4.7.7 for configuration information.

To display alarm codes:

a. While in the Default Display mode, press the ALT. MODE & ALARM LIST keys. This accesses the Data- CORDER Alarm List Display Mode, which displays any alarms stored in the alarm queue.

b. To scroll to the end of the alarm list, press the UP ARROW. Depressing the DOWN ARROW key will scroll the list backward.

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

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

e. If no alarms are active, the alarm queue may be cleared. The exception to this rule is the 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:

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

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

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

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

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

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

Sensor 2

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

Sensor 3

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

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4.7.15 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 Func- tions Group Box on the System Tools screen.

F9 function - Provides the user with a shortcut for manually triggering the refresh operation. Before sending modi- fied 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 Data- CORDER 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.

Table 44 Controller Configuration Variables

Config Title Default Option

CnF02 Evaporator Fan Speed dS (Dual) SS (Single)

CnF03 Control Sensors FOUr duAL

CnF04 Dehumidification Mode On OFF

CnF08 Single Phase/3-Phase Evaporator Fan Motor 1Ph 3Ph

CnF09 Refrigerant Selection r134a r744

CnF11 Defrost Off Selection noOFF OFF

CnF15 Discharge Temperature Sensor Out In

CnF16 DataCORDER Present On (Yes) (Not Allowed)

CnF17 Discharge Pressure Sensor Out (No) In (Yes)

CnF18 Heater Old (Low Watt) nEW (High Watt)

CnF20 Suction Pressure Sensor Out (No) In (Yes)

CnF22 Economy Mode Option OFF Std, Full

CnF23 Defrost Interval Timer Save Option noSAv SAv

CnF24 Advanced Pre-trip Enhanced Test Series Option Auto Auto2, Auto 3

CnF25 Pre-trip Test Points/Results Recording Option rSLtS dAtA

CnF26 Heat Lockout Change Option Set to -10C Set to -5C

CnF27 Suction Temperature Display Option Out In

CnF28 Bulb Mode Option NOr bULb

CnF31 Probe Check Option SPEC Std

CnF32 Single Evaporator Fan Option 2EF0 (Not Allowed)

CnF33 Snap Freeze Option OFF SnAP

CnF34 Degree Celsius Lockout Option bOth F

CnF37 Electronic Temperature Recorder rEtUR SUPPL, bOth

CnF41 Lower DTT Setting Out In

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NOTE Configuration numbers not listed are not used in this application. These items may appear when load- ing configuration software to the controller but changes will not be recognized by the controller pro- gramming.

CnF44 eAutoFresh Enabled Out LO, UP

CnF45 Low Humidity Enabled Out In

CnF47 Fresh Air Vent Position Sensor OFF UP, LOW, CUStOM

CnF49 DataCORDER Configuration Restore OFF On

CnF50 Enhanced Bulb Mode Selection OFF Bulb, dEHUM

CnF51 Timed Defrost Disable 0 0-out, 1-in

CnF52 Oil Return Algorithm 1 0-out, 1-in

CnF53 Water Cool Oil Return Logic 0 0-out, 1-in

CnF55 TXV Boost Relay 0 0-out, 1-in

CnF56 TXV Boost Circuit 0 0-out, 1-in

CnF59 Electronic Expansion Valve 0 1-EC, 2-KE, 3- NA

CnF60 Compressor-Cycle Perishable Cooling 0 0-out, 1-in

CnF61 ACT ASC Control Enable 0 0-out, 1-in

CnF62 Extended Temperature Control Enable 0 0-on, 1-in

CnF63 CCPC Pre-trip/Tripstart Default State 0 0-on, 1-off

CnF64 Evaporator Fan Pulsing Logic Enable 0 0-in, 1-out

Table 45 Controller Function Codes

Code Title Description

NOTE If the function is not applicable, the display will read -----

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 voltage components. It also measures current draw in compressor motor leg T3. The compressor leg T3 current is displayed.

Cd04

Cd05

Cd06

Line Current, Phase A

Line Current, Phase B

Line Current, Phase C

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

Cd07 Main Power Voltage The main supply voltage is displayed.

Table 44 Controller Configuration Variables (Continued)

Config Title Default Option

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Cd08 Main Power Frequency

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

Cd09 Ambient Temperature

The ambient sensor reading is displayed.

Cd10 Evaporator Temperature Sensor

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.

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 battery volt ages 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 configured (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 configuration 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 (high, low or off). 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.

Table 45 Controller Function Codes (Continued)

Code Title Description

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Configurable Functions NOTE:

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

Cd27 Defrost Interval (Hours or Automatic)

There are three modes for defrost initiation: user-selected timed intervals, automatic control, and PuLs. The user-selected values are (OFF), 3, 6, 9, 12, 24 hours, AUTO, or PuLs. The factory default is AUTO. Automatic defrost starts with an initial defrost at three hours, then the interval to the next defrost is adjusted based on the accumulation of ice on the evaporator coil. Following a start-up or after termination of a defrost, the time will not begin counting down until the defrost temperature sensor (DTS) reading falls below set point. If the reading of DTS rises above set point any time during the timer count down, the interval is reset and the countdown begins over. If DTS fails, alarm code AL60 is activated and control switches over to the return temperature sensor. The controller will act in the same manner as with the DTS except the return temperature sensor reading will be used. For information on PuLs, refer to Defrost Pulsing Section 4.3.19. Defrost Interval Timer Value (Configuration variable CnF23): If the software is configured to SAv (save) for this option, the value of the defrost interval timer will be saved at power down and restored at power up. This option prevents short power interruptions from resetting an almost expired defrost interval, and possibly delaying a needed defrost cycle.

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

Cd28 Temperature Units (Degrees C or Degrees F)

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

NOTE: This function code will display ----- if CnF34 is set to F.

Cd29 Failure Action (Mode) If all of the control sensors are out of range (alarm code AL26) or there is a probe circuit calibration failure (alarm code AL27), the unit will enter the shutdown state defined by this setting. The user selects one of four possible actions as follows: A - Full Cooling (Compressor is on, economized operation.) B - Partial Cooling (Compressor is on, standard operation.) C - Evaporator Fan Only (Evaporator fans on high speed, not applicable with frozen set points.) D - Full System Shutdown - Factory Default (Shut down every component in unit.)

Cd30 In-Range Tolerance The in-range tolerance will determine the band of temperatures around the set point which will be designated as in-range. If the control temperature is in-range, the in-range light will be illuminated. There are four possible values: 1 = +/- 0.5C (+/- 0.9F) 2 = +/- 1.0C (+/- 1.8F) 3 = +/- 1.5C (+/- 2.7F) 4 = +/- 2.0C (+/- 3.6F) - Factory Default

Cd31 Stagger Start Offset Time (Seconds)

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

Table 45 Controller Function Codes (Continued)

Code Title Description

427 T-359

Cd32 System Current Limit (Amperes)

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

Cd34 Economy Mode (On- Off)

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

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

Cd36 Evaporator Fan Speed This code is enabled only if in the dehumidification mode (code Cd33) and bulb mode (Cd35) has been set to bulb. If these conditions are not met, alt will be displayed (indicating that the evaporator fans will alternate their speed) and the display cannot be changed. If a dehumidification set point has been selected along with bulb mode, 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, the selection reverts back to alt.

Cd37 Variable DTT Setting (Bulb Mode)

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

Cd38 Secondary Supply Temperature Sensor

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

Cd39 Secondary Return Temperature Sensor

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

Cd40 Container Identification Number

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

Cd41 Valve Override SERVICE FUNCTION: This code is used for troubleshooting, and allows manual positioning of the economizer solenoid valve, electronic expansion valve, and digital unloader valve. Provides readings such as: Percent Capacity, EEV, Capacity Mode, LIV, and DUV. Refer to Section 7.16 for operating instructions.

Table 45 Controller Function Codes (Continued)

Code Title Description

T-359 428

Cd43 eAutoFresh Mode Code Cd43 is used to select the mode of operation for the eAutoFresh slides. Associated parameters can also be selected from submenus: OFF, USER, DELAY, TEST and gASLM. If the unit is not configured for eAutoFresh, Cd43 will display -----.

Cd44 eAutoFresh Values / CO2 Sensor Status

Code Cd44 displays the eAutoFresh CO2 and O2 values (CO2 and O2) and CO2 and O2 limits (CO2LIM and O2LIM), respectively. If the unit is not configured for eAutoFresh, Cd44 will display -----.

Cd45 Vent Position Sensor (VPS) Position

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

Cd46 Airflow Display Units This code displays the airflow units to be displayed for Cd 45. Options are CF, CM, or bOth (dependent on the setting of Cd28 or pressing of the C/F key).

Cd47 Variable Economy Temperature Setting

Code Cd47 is used with optional economy mode. Values are 0.5C-4.0C, default is 3.0C. If unit is not configured for economy mode, ---- will be displayed.

Cd48 Dehumidification / Bulb Cargo Mode Parameter Selection

Code Cd48 is used both when dehumidification set point is set above 65% RH and below 64% RH. When dehumidification set point is set above 65% RH, select goes to LO if it had been set to hi. When dehumidification set point is set below 64% RH, select goes to Alt if it had been set to LO.

Cd49 Days Since Last Successful Pre-trip

Code Cd49 will display the time period (days) since the last successful pre-trip completion. Press ENTER repeatedly to display last pre-trip completion in Auto, Auto 1, and Auto 2 modes.

Cd50 Quest Enable / Disable

Code 50 allows selection of CCPC mode. The user can press ENTER, then arrow keys, then ENTER again to enable (On) or suspend (OFF) CCPC mode. If CCPC operation is On, it may be suspended due to one of the following conditions: SEtPt =Set point is too low. CAHUM= CA or humidity control is active ACT=ACT is active. FAIL=Return temperature probe has failed. PrtrP=Pre-trip is active. C LIM= Cool limit logic is active. PULL=Unit is in pulldown mode.

Cd51 Automatic Cold Treatment (ACT) Mode Parameter Selection

Code Cd51 initially displays countdown timer increments of 1 day, 1 hour with the temperature default. Pressing ENTER allows selection of within the current menu and proceeds to the next menu. After five seconds of no activity, the display reverts to normal system display, but retains the parameters previously selected. ACt = On, Off or ----. The default is Off. trEAt=C /F in 0.1 degree increments. The default is 0.0C. DAyS= 0-99 increments of 1. The default is 0. ProbE=probe positions (example 124). The default is ----. SPnEW= C /F in 0.1 degree increments. The default is 10.0C.

Table 45 Controller Function Codes (Continued)

Code Title Description

429 T-359

Cd53 Automatic Setpoint Change (ASC) Mode Parameter Selection

Code Cd53 initially displays countdown timer increments of 1 day, 1 hour with the temperature default. Pressing ENTER allows selection of within the current menu and proceeds to the next menu. After five seconds of no activity, the display reverts to normal system display, but retains the parameters previously selected. ASC=On or Off The default is Off. NSC=1-2 SP 0"=C /F in 0.1 degree increments. The default is 10.0C. DAY 0"= 0-99 increments of 1. The default is 1. SP 1"=C /F in 0.1 degree increments. The default is 10.0C. DAY 1"= 0-99 increments of 1. The default is 1. SP 2"=C /F in 0.1 degree increments. The default is 10.0C.

Cd54 Suction Port Superheat / Electronic Expansion Valve Status

Reading for evaporator superheat is shown on the right display. Press ENTER at Cd54 to show reading for EEV position (in%) on left display.

Cd55 Discharge Superheat

Code Cd55 will display the discharge superheat values in C /F as calculated by the discharge temperature minus the discharge saturation temperature as calculated from discharge pressure. ----- will be displayed if selection is not valid.

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

Code Cd58 will display CLOSE if the WPS or CFS switch contacts are closed or that 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.

Cd59 Pump Down Logic Code Cd59 allows operation of the pump down logic control. The display will flash between STArT PdN and PrESS EnTEr. Once the operator confirms continuation of the sequence, pump down logic begins. If pump down logic is completed within 20 minutes, the unit will turn off and the display will flash P dN DOnE and SHUT OFF. The operator must shut off the unit. If the pump down logic is not completed within 20 minutes, the unit will return to its previous control condition.

Cd60 Evaporator Fan Pulsing Temperature Setting

CD60 contains a selectable temperature range used to determine the engagement 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 desired temperature using either arrow key. Press Enter to accept the change. The temperature setting will be retained until either a Pretrip or Trip Start is initiated at which time the temperature will set to the default setting.

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 45 Controller Function Codes (Continued)

Code Title Description

T-359 430

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 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 configuration. Press the ENTER key. The existing entry will flash. Use the Arrow keys to alternate 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 attempts 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 45 Controller Function Codes (Continued)

Code Title Description

431 T-359

Figure 4.13 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 SYSTEM

Check Power Supply

Unit does self test? Section 5.2

Section 5.2

Section 4.2

Section 4.2.1

Section 4.6

Section 7.3

Table 46

T-359 432

Table 46 Controller Alarm Indications

Code Cause Components Troubleshooting Corrective Actions

AL03 Loss of Superheat Control

Superheat has remained below 1.66C (3F) degrees for five minutes continuously while compressor 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.

Electronic Expansion Valve (EEV)

Check the operation of the EEV using Cd41.

Replace EEV if defective.

Evaporator Temperature Sensor(s) ETS & ETS1.

Verify accuracy of temperature sensors, refer to Sensor Checkout Procedure Section 7.19.1.

Replace ETS or ETS1 if defective.

Evaporator Fans Confirm fans operating properly.

Replace fan(s) if defective, refer to EVAPORATOR FAN MOTOR ASSEMBLY Section 7.10.

AL05 Manual Defrost Switch Failure

Controller has detected continuous Manual Defrost Switch activity for five minutes or more.

Keypad Power cycle the unit.

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

Controller has detected one of the keypad keys is continuously activity.

Keypad or Harness

Power cycle the unit.

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

AL07 Fresh Air Vent Open with Frozen Set Point

The VPS is reading greater than 0 CMH while unit is in frozen mode.

Vent Position Sensor (VPS)

Manually reposition vent and confirm using Cd45. Refer to VENT POSITION SENSOR SERVICE Section.

If unable to obtain zero reading, replace defective VPS.

AL08 High Compressor Pressure Ra- tio

Controller detects discharge pressure to suction pressure ratio is too high. The controller will attempt to correct the situation by restarting the compressor.

Discharge Pressure Transducer (DPT)

Confirm accurate DPT pressure readings, refer to MANIFOLD GAUGE SET Section 7.2.

Replace DPT if defective.

AL10 CO2 Sensor Failure

Alarm 10 is triggered when the CO2 sensor voltage is operating outside of the 0.9 v to 4.7 v range, or if the sensor is out of range.

This is a display alarm and has no associated failure action.

Refer to eAutoFresh manual.

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

433 T-359

AL14 Phase Sequence Detect Fault

Controller is unable to determine the correct phase relationship.

N/A Power cycle the unit. Resetting the unit may correct problem, monitor the unit.

Wiring

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

Correct wiring.

Current Sensor

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

Replace current sensor if defective.

AL16 Compressor Current High

Compressor current draw is over the calculated maximum for 10 minutes.

Current Sensor

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.

Replace current sensor if defective.

Amperage is indeed too high.

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

Correct power supply.

Operating Conditions

Make sure system pressures are relevant to operating conditions.

Check air flow of condenser. Check Refrigerant charge, refer to REFRIGERATION SYSTEM SERVICE Section 7.3.

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

If alarm remains active or is repetitive replace compressor at next available opportunity, refer to COMPRESSOR Service Section 7.4.

Table 46 Controller Alarm Indications

Code Cause Components Troubleshooting Corrective Actions

T-359 434

AL17 Compressor Pressure Delta Fault

Compressor has attempted to start in both directions and fails to generate sufficient pressure differential between SPT and DPT.

N/A

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

Resume normal operation.

Discharge Pressure Transducer (DPT)

Confirm accurate DPT pressure readings, refer to MANIFOLD GAUGE SET Section 7.2

Replace DPT if defective.

Suction Pressure Transducer (SPT)

Confirm accurate SPT pressure readings, refer to MANIFOLD GAUGE SET Section 7.2.

Replace SPT if defective.

Monitor unit Alarm is display only the alarm may clear itself during operation.

If alarm remains active or is repetitive replace compressor at next available opportunity.

AL18 Discharge Pressure High

Discharge pressure is over the maximum for 10 minutes within the last hour.

Restrictions in the refrigeration system.

Ensure Liquid Line Service Valve is fully open.

Open Liquid Line Service Valve as needed.

Filter Drier

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

Replace the filter drier if needed, refer to FILTER DRIER Service Section 7.8.

Condenser Fan Check Condenser Fan for proper operation. Correct as required.

Discharge Pressure Transducer (DPT)

Confirm accurate DPT pressure readings, refer to MANIFOLD GAUGE SET Section 7.2.

Replace DPT if defective.

Non-condensables in the refrigeration system.

With the unit off allow system to stabilize to ambient temperature. Check system pressure against PT Chart for 134a, refer to Table 75.

Correct as required, refer to Refrigerant Charge Section 7.3.5.

Refrigerant Check refrigerant level. Correct as required, refer to Refrigerant Charge Section 7.3.5.

Table 46 Controller Alarm Indications

Code Cause Components Troubleshooting Corrective Actions

435 T-359

AL19 Discharge Tempera- ture High

Discharge temperature exceeds 135C (275F) for 10 minutes within the last hour.

Restrictions in the refrigeration system.

Ensure the Discharge Service Valve is fully open.

Open the Discharge Service Valve as needed.

Check the unit for air flow restrictions.

Clean or remove any debris from coils.

Non-condensables in the refrigeration system.

With the unit off allow system to stabilize to ambient temperature. Check system pressure against PT Chart for 134a, refer to Table 75.

Correct as required, refer to Refrigerant Charge Section 7.3.5.

Additional Alarms such as AL16, AL24.

Check compressor operation.

If the alarm persists, it may indicate a failing compressor, replace the compressor, refer to COMPRESSOR Service Section 7.4.

AL20 Control Con- tactor Fuse (F3)

Control power fuse (F3A or F3B) is open.

Check F3A, if the fuse is open:

Check PA, PB, CH coils for short to ground, if short is found:

Replace the defective coil. Replace the fuse.

Check F3B, if the 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.

Replace the defective coil. Replace the fuse.

Check Voltage at QC1:

If voltage is present, it indicates a defective microprocessor.

Refer to Controller Service Section 7.17.

AL21 Control Cir- cuit Fuse (F1/F2)

One of the 18 VAC controller fuses (F1/ F2) is open. Refer to Cd08.

System Sensors Check system sensors for short to ground.

Replace defective sensor(s)

Wiring Check wiring for short to ground. Repair as needed.

Controller Controller may have an internal short.

Replace controller, refer to Controller Service Section 7.17.

AL22 Evaporator IP

Evaporator motor internal protector (IP) is open.

Evaporator Motor

Shut down unit, disconnect power, & check Evaporator Motor IP at plug connection pins 4 & 6.

Replace defective evaporator fan motor refer to EVAPORATOR FAN MOTOR Service Section 7.10.

AL23 Loss of Phase B

Controller fails to detect current draw.

Incoming Power Check incoming power source.

Correct power source as required.

Table 46 Controller Alarm Indications

Code Cause Components Troubleshooting Corrective Actions

T-359 436

AL24 Compressor IP

Compressor internal protector (IP) is open. Compressor

Shut down unit disconnect power, & check resistance of compressor windings at contactor T1-T2, T2-T3.

Monitor unit, if alarm remains active or is repetitive replace the compressor at the next available opportunity, refer to COMPRESSOR Service Section 7.4.

AL25 Condenser IP

Condenser fan motor internal protector (IP) is open.

Insufficient Air Flow

Shut down unit and check condenser fan for obstructions.

Remove obstructions.

Condenser Fan Motor

Shut down unit, disconnect power, & check Condenser Fan Motor IP at plug connection pins 1 & 2.

Replace defective condenser fan motor, refer to Condenser Fan Motor Assembly Service Section 7.7.

AL26 All Sensors Failure: Sup- ply/Return Probes

Sensors out of range. All sensors. detected as out of range

Perform Pre-trip P5:

If P5 passes, no further action is required.

If P5 fails, replace the defective sensor as determined by P5, refer to TEMPERATURE SENSOR Service Section 7.19.

AL27 Analog to Digital Accu- racy Failure

Controller AD converter faulty.

Controller

Power cycle the unit. If the alarm persists, it indicates a defective microprocessor.

Replace defective microprocessor, refer to Controller Service Section 7.17.

AL28 Low Suction Pressure

Suction pressure too low for normal operation.

N/A Power cycle the unit. Resetting the unit may correct problem, monitor the unit.

Suction Pressure Transducer (SPT)

Confirm accurate SPT pressure readings, refer to MANIFOLD GAUGE SET Section 7.2.

Replace SPT if defective.

Discharge Pressure Transducer (DPT)

Confirm accurate DPT pressure readings, refer to MANIFOLD GAUGE SET Section 7.2.

Replace DPT if defective.

AL50 Air Vent Po- sition Sensor (VPS)

VPS Sensor out of range.

Vent Position Sensor (VPS)

Make sure VPS is secure.

Manually tighten panel.

If the alarm persists, replace the sensor or the assembly.

Replace VPS.

Table 46 Controller Alarm Indications

Code Cause Components Troubleshooting Corrective Actions

437 T-359

AL51 EEPROM Failure

Controller Memory Failure Controller

Pressing the ENTER key when CLEAr is displayed will result in an attempt to clear the alarm.

If action is successful (all alarms are inactive), alarm 51 will be reset.

Power cycle the unit. If the alarm persists, it indicates defective controller memory.

Replace defective controller, refer to Controller Service Section 7.17.

AL52 EEPROM Alarm List Full

Alarm list queue is full. Active Alarms Repair any alarms in the queue that are active. Indicated by AA.

Clear alarms, refer to CONTROLLER ALARMS Section 4.5.

AL53 Battery Pack Failure

Battery voltage low Battery

If this alarm occurs on start up, allow a unit fitted with rechargeable batteries to operate for up to 24 hours to charge rechargeable batteries sufficiently. Once fully charged, the alarm will deactivate.

To clear the alarm press ENTER and ALT simultaneously at the startup of Cd19 (Battery Check). If alarm persists, replace the battery pack, refer to Section 7.17.4 Battery Replacement.

AL54 Primary Supply Sensor (STS)

Invalid Supply Temperature Sensor (STS) reading.

Supply Temperature Sensor (STS)

Perform Pre-trip P5:

If P5 passes, no further action is required.

If P5 fails, replace the defective sensor as determined by P5, refer to TEMPERATURE SENSOR Service Section 7.19.

AL56 Primary Return Sen- sor (RTS)

Invalid Return Temperature Sensor (RTS) reading.

Return Temperature Sensor (RTS)

Perform Pre-trip P5:

If P5 passes, no further action is required.

If P5 fails, replace the defective sensor as determined by P5, refer to TEMPERATURE SENSOR Service Section 7.19

AL57 Ambient Sensor (AMBS)

Invalid Ambient Temperature Sensor (AMBS) reading.

Ambient Temperature Sensor (AMBS)

Test the AMBS, refer to Sensor Checkout Procedure Section 7.19.1.

Replace AMBS if defective, refer to TEMPERATURE SENSOR Service Section 7.19.

AL58 Compressor High Pres- sure Safety (HPS)

High pressure safety switch remains open for at least one minute.

High Pressure Switch (HPS)

Test the HPS; refer to Checking High Pressure Switch, Section 7.5.1.

Replace HPS if defective, refer to Sensor Replacement, Section 7.5.2

Refrigeration System

Check unit for air flow restrictions.

Clean or remove any debris from coils.

Table 46 Controller Alarm Indications

Code Cause Components Troubleshooting Corrective Actions

T-359 438

AL59 Heater Ter- mination Thermostat (HTT)

Heat Termination Thermostat (HTT) is open.

Heat Termination Thermostat (HTT)

Check for 24 volts at test point TP10, if no voltage at TP10 after unit has reached set point HTT is open.

Replace HTT if defective, refer to Sensor Replacement Section 7.19.2.

AL60 Defrost Tem- perature Sensor (DTS)

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

Defrost Temperature Sensor (DTS)

Test the DTS; refer to Sensor Checkout Procedure Section 7.19.1

Replace the DTS if defective, refer to Sensor Replacement Section 7.19.2.

AL61 Heater Cur- rent Draw Fault

Improper current draw during heat or defrost mode.

Heater(s)

While in heat or defrost mode, check for proper current draw at heater contactors, refer to ELECTRICAL DATA Section 3.3.

Replace heater(s) if defective, refer to Section 7.9.2 Evaporator Heater Removal and Replacement.

Contactor

Check voltage at heater contactor on the heater side. If no voltage present:

Replace heater contact or if defective.

AL63 Current Limit

Unit operating above current limit.

Refrigeration System

Check unit for air flow restrictions.

Clean or remove any debris from coils.

Check unit for proper operation.

Repair as needed.

Power supply

Confirm supply voltage/ frequency is within specification and balanced according to ELECTRICAL DATA Section 3.3.

Correct power supply.

Current limit set too low.

Check current limit setting Code Cd32.

The current limit can be raised (maximum of 23 amps) using Cd32.

AL64 Discharge Tempera- ture Sensor (CPDS)

Discharge Temperature sensor out of range.

Discharge temperature sensor (CPDS).

Test the CPDS; refer to Sensor Checkout Procedure, Section 7.19.1

Replace the CPDS if defective, refer to Sensor Replacement Section 7.19.2

AL65 Discharge Pressure Transducer (DPT)

Compressor Discharge Transducer is out of range.

Compressor Discharge Transducer (DPT)

Confirm accurate DPT pressure readings, refer to MANIFOLD GAUGE SET Section 7.2.

Replace DPT if defective.

Table 46 Controller Alarm Indications

Code Cause Components Troubleshooting Corrective Actions

439 T-359

AL66 (SPT) Suc- tion Pressure Transducer, (EPT) Evap- orator Pres- sure Transducer

Suction Pressure Transducer (SPT) out of range.

Suction Pressure Transducer (SPT)

Confirm accurate EPT and SPT pressure readings, refer to MANIFOLD GAUGE SET Section 7.2. - Performing a Pre-trip 5- 9 test will also check the transducers.

Replace EPT/SPT if defective.

Monitor

If the alarm persists, it may indicate a failing compressor, refer to COMPRESSOR Service Section 7.4.

AL67 Humidity Sensor

Humidity Sensor (HS) reading out of range.

Humidity Sensor (HS)

Make sure the humidity sensor is properly connected in the socket. Make sure the humidity sensor wires have not been damaged.

Monitor, replace HS if alarm persists.

AL69 Evaporator Temp Sen- sor (ETS1)

Evaporator Temperature Sensor (ETS1) out of range.

Evaporator Temperature Sensor (ETS1)

Test the ETS1, refer to Sensor Checkout Procedure Section 7.19.1.

Replace Evaporator Temperature Sensor (ETS1) if defective.

AL70 Secondary Supply Sensor (SRS)

Secondary Supply Sensor (SRS) is out of range.

Secondary Supply Sensor (SRS) Perform Pre-trip P5:

If P5 passes, no further action is required.

If P5 fails, replace the defective sensor as determined by P5, refer to TEMPERATURE SENSOR Service Section 7.19.

AL71 Secondary Return Sen- sor (RRS)

Secondary Return Sensor (RRS) is out of range.

Secondary Return Sensor (RRS) Perform Pre-trip P5:

If P5 passes, no further action is required.

If P5 fails, replace the defective sensor as determined by P5, refer to TEMPERATURE SENSOR Service Section 7.19.

AL72 Control Temp Out of Range

After the unit goes in- range for 30 minutes then out of range for a continuous 120 minutes.

Refrigeration System

Ensure unit is operating correctly.

Power cycle unit. Control Temperature is in In-range. Any Pre-Trip mode, resets the timers.

Container doors Check container doors, ensure they are properly closed and sealed

Close the container doors.

Table 46 Controller Alarm Indications

Code Cause Components Troubleshooting Corrective Actions

T-359 440

NOTE 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. Refer to Table 410.

ERR # Internal Microprocessor Failure

The controller performs self-check routines. If an internal failure occurs, an ERRalarm will appear on the display. This is an indication the controller needs to be re placed.

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 controller's Analog to Digital (A-D) converter has failed.

ERR 6-IO Board failure Internal program/update failure.

ERR 7-Controller failure Internal version/firmware incompatible.

ERR 8- DataCORDER failure

Internal DataCORDER memory failure.

ERR 9-Controller failure Internal controller memory failure.

In the event that a failure occurs and the display cannot be updated, the status LED will indicate the appropriate ERR code using Morse code as shown below. E R R 0 to 9 ERR0 = . .-. .-. ----- ERR1 = . .-. .-. . ---- ERR2 = . .-. .-. . . --- ERR3 = . .-. .-. . . . -- ERR4 = . .-. .-. . . . . - ERR5 = . .-. .-. . . . . . ERR6 = . .-. .-. -. . . . ERR7 = . .-. .-. --. . . ERR8 = . .-. .-. ---. . ERR9 = . .-. .-. ---- .

Entr StPt Enter Set point (Press Arrow & Enter) The controller is prompting the operator to enter a set point.

Table 46 Controller Alarm Indications

Code Cause Components Troubleshooting Corrective Actions

441 T-359

LO

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

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

Table 47 Controller Pre-trip Test Codes

Code Title Description

NOTE Auto or Auto1 menu includes the: P0, P1, P2, P3, P4, P5, P6 and rSLts. Auto2 menu includes P0, P1, P2, P3, P4, P5, P6, P7, P8, P9, P10 and rSLts. Auto3 menu includes P0, P1, P2, P3, P4, P5, P6, P7 and P8.

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

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

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

P2-0 Condenser Fan On Requirements: Water pressure switch or condenser fan switch input must be closed. Setup: Condenser fan is turned ON, a current draw test is done after 15 seconds. Pass/Fail Criteria: Passes if current draw change is within the range specified.

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

P3 Low Speed Evaporator Fans

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

P3-0 Low Speed Evaporator Fan Motors On

Setup: The High Speed Evaporator fans will be turned on for 10 seconds, then off for two seconds, then the low speed evaporator fans are turned on. A current draw test is done after 60 seconds. Pass/Fail Criteria: Passes if change in current draw is within the range specified.

P3-1 Low Speed Evaporator Fan Motors Off

Setup: The Low Speed Evaporator fan is turned off, a current draw test is done after 10 seconds. Pass/Fail Criteria: Passes if change in current draw is within the range specified.

P4-0 High Speed Evaporator Fan Motors On

Setup: The high speed evaporator fan is turned on, a current draw test is done after 60 seconds. Pass/Fail Criteria: Passes if change in current draw is within the range specified.

Table 46 Controller Alarm Indications

Code Cause Components Troubleshooting Corrective Actions

T-359 442

P4-1 High Speed Evaporator Fan Motors Off

Setup: The high speed evaporator fan is turned off, a current draw test is done after 10 seconds. Pass/Fail Criteria: Passes if change in current draw is within the range specified.

P5-0 Supply / Return Probe Test

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

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

P5-1 Supply Probe Test Requirements: For units equipped with secondary supply probe only. Pass/Fail Criteria: The temperature difference between supply temperature sensor (STS) and supply recorder sensor (SRS) probe is compared. 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 P 5" PASS.

P5-2 Return Probe Test Requirements: For units equipped with secondary return probe only. Pass/Fail Criteria: The temperature difference between return temperature sensor (RTS) and return temperature sensor (RRS) probe is compared.

NOTES 1. If this test fails, P5-2 and FAIL will be displayed. If both Probe tests

(this test and the SUPPLY/RETURN) pass, because of the multiple tests, the display will read P 5, PASS.

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

P5-3 Evaporator Fan Direction Test

Requirements: Test P5-0 must pass before this test is run. Setup: While the evaporator is running on high speed, the temperature differential between supply temperature sensor (STS) and return temperature sensor (RTS) probes is measured, with and without heaters energized. Pass/Fail Criteria: Passes if differential of STS is 0.25 degree C higher than RTS.

P5-7 Primary vs Secondary Evaporator Temperature Sensor Test

Pass/Fail Criteria: Passes if secondary evaporator temperature sensor (ETS2) is within +/- 0.5 degree C of the primary evaporator temperature sensor (ETS1).

P5-8 Suction Pressure Transducer Test

Requirements: Test P5-7 must pass before this test is run. Pass/Fail Criteria: Passes if suction pressure transducer (SPT) is within +/- 0 psi of saturation pressure at current evaporator temperature. Also passes if suction pressure transducer (SPT) is within +/- 1 psi of discharge pressure 6 hours after a power interruption.

P5-9 Suction (Evaporator) Pressure Transducer Test

Pass/Fail Criteria: Passes if suction pressure transducer (SPT) is within +/- 1.5 psi of the evaporator pressure transducer (EPT).

Table 47 Controller Pre-trip Test Codes (Continued)

Code Title Description

443 T-359

P5-10 Humidity Sensor Controller Configuration Verification Test

Requirements: Test P5-9 must pass before this test is run. Test is skipped if controller is not configured for the humidity sensor and the voltage is less than 0.20 volts. Pass/Fail Criteria: Passes if controller configuration has the humidity sensor in stalled. Fails if controller is not configured for humidity sensor and the voltage is greater than 0.20 volts.

P5-11 Humidity Sensor Installation Verification Test

Requirements: Test P5-10 must pass before this test is run. Pass/Fail Criteria: Passes if voltage is greater than 0.20 volts for the humidity sensor. Fails if voltage is less than 0.20 volts for the humidity sensor.

P5-12 Humidity Sensor Range Check Test

Requirements: Test P5-11 must pass before this test is run. Pass/Fail Criteria: Passes if the voltage for the humidity sensor is between 0.66 volts and 4 volts. Fails if voltage is outside of the 0.66 volt to 4 volt range.

P6-0 Discharge Thermistor Test

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

P6-1 Suction Thermistor Test

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

P6-2 Discharge Pressure Sensor Test

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

P6-3 Suction Pressure Sensor Test

If alarm 66 is activated, the test fails.

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.

NOTE P6-6 through P6-10 tests are conducted by changing the status of each individual valve and compar- ing suction pressure change and/or compressor current change with predetermined values. The tests will cause the compressor and condenser fans to cycle on and off as needed to generate the pressure required for the individual pre-trip sub tests. The compressor will start in order to build discharge pres- sure, followed by a compressor pump down sequence. At the conclusion of the 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 psi 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 signal and either the pressure change or the current draw change is above 5 psi or above 1.5A, respectively.

P6-10 Electronic Expansion Valve Test

Pass/Fail Criteria: 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 seconds.

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

Table 47 Controller Pre-trip Test Codes (Continued)

Code Title Description

T-359 444

P7-0 High Pressure Switch Open

This test is skipped if the sensed ambient temperature is less than 7C (45F), the return air temperature is less than -17.8C (0F), the water pressure switch is open or the condenser fan switch is open. Setup: With the unit running, the condenser fan is turned off and a 900 second (15 minute) timer is started. The right display shows the value of the initial sensor configured and valid out of the discharge pressure, CPC pressure, discharge temperature. Pass/Fail Criteria: The test fails immediately if:

all three sensors are not configured or are invalid. the ambient temperature or return air temperature sensors are invalid

at the start of the test. The test fails if:

the high pressure switch if open at the start of the test. the high pressure switch fails to open within 15 minutes. a valid discharge temperature exceeds 137.78C (280F). a valid discharge pressure or valid condensing pressure exceeds 390

psig. The test passes if the high pressure switch opens within the 15 minute time limit and before any of the valid and configured sensors exceed their limits.

P7-1 High Pressure Switch Closed

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

P8-0 Perishable Mode Heat Test

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

P8-1 Perishable Mode Pulldown Test

Requirements: Control temperature must be at least 15.6C (60F). Setup: The set point 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 temperature. The unit will then start to pull down the temperature to the 0C set point. Pass/Fail Criteria: The test passes if the container temperature reaches set point before the 180 minute timer expires.

P8-2 Perishable Mode Maintain Temperature Test

Requirements: Test P8-1 must pass for this test to execute. This test is skipped if the DataCORDER is not configured or not available. Setup: A 15-minute timer is started. The unit will be required to minimize control temperature error (supply temperature minus set point) until the timer expires. The control temperature will be sampled at least once each minute starting at the beginning of P8-2. Pass/Fail Criteria: If the average recorded temperature is within +/- 1.0C (1.8F) of set point, the test passes. If the average temperature is outside of the tolerance range or if the DataCORDER supply temperature probe is invalid, the test fails and the control probe temperature will be recorded as - 50.0C. P8-2 will auto-repeat by starting P8-0 over.

Table 47 Controller Pre-trip Test Codes (Continued)

Code Title Description

445 T-359

P9-0 Defrost Test Setup: The defrost temperature sensor (DTS) reading will be displayed on the left display. The right display will show the supply air temperature. The unit will run FULL COOL for 30 minutes maximum until the DTT is considered closed. Once the DTT is considered closed, the unit simulates defrost by running the heaters for up to two hours, or until the DTT is considered open. Pass/Fail Criteria: The test fails if: the DTT is not considered closed after the 30 minutes of full cooling, HTT opens when DTT is considered closed or if return air temperature rises above 49C (120F).

P10-0 Frozen Mode Heat Test

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

P10-1 Frozen Mode Pulldown Test

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

P10-2 Frozen Mode Maintain Temperature Test

Requirements: Test P10-1 must pass for this test to execute. This test is skipped if the DataCORDER is not configured or not available. Setup: A 15-minute timer is started. The unit will be required to minimize return probe temperature error (supply temperature minus set point) until the timer expires. The return probe temperature will be sampled at least once each minute starting at the beginning of P10-2. Pass/Fail Criteria: If the average recorded temperature is within +/- 1.6C (+/ - 2.9) of set point, the test passes. If the average temperature is outside of the tolerance range or if the DataCORDER return temperature probe is invalid, the test fails and the control probe temperature will be recorded as -50.0C. P10- 2 will auto-repeat by starting P10-0 over.

Table 47 Controller Pre-trip Test Codes (Continued)

Code Title Description

T-359 446

Table 48 DataCORDER Function Code Assignments

NOTE Inapplicable Functions Display -----

To Access: Press ALT. MODE 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 interrogation program.

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

dC26,27 S/N, Left 4, Right 4 The DataCORDER serial number consists of eight characters. Function code dC26 contains the first four characters. Function code dC27 contains the last four characters. (This serial number is the same as the controller serial number.)

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

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

dC30 Date of Last Trip start The date when a Trip Start was initiated by the user. In addition, if the system goes without power for seven continuous days or longer, a trip start will automatically be generated on the next AC power up. Press and hold ENTER key for five seconds to initiate a Trip Start.

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

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

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

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

dC35 Cargo Probe 4 Calibration

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

447 T-359

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 and C

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

2-0 Condenser Fan On Pass/Fail/Skip Result, Water pressure switch (WPS) - Open/ Closed, Change in currents for Phase A, B and C

2-1 Condenser Fan Off Pass/Fail/Skip Result, Change in currents for Phase A, B and C

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

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

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

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

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

5-1 Secondary Supply Probe (SRS) Test Pass/Fail/Skip

5-2 Secondary Return Probe (RRS) Test Pass/Fail/Skip

6-0 Discharge Thermistor Test Pass/Fail/Skip

6-1 Suction Thermistor Test Pass/Fail/Skip

6-2 Discharge Pressure Sensor Test Pass/Fail/Skip

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

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

6-5 Compressor Leak Test Pass/Fail/Skip

6-6 Economizer Valve Test Pass/Fail/Skip

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

7-0 High Pressure Switch Closed Pass/Fail/Skip Result, AMBS, DPT or CPT (if equipped) Input values that component opens

7-1 High Pressure Switch Open Pass/Fail/Skip Result, STS, DPT or CPT (if equipped) Input values that component closes

8-0 Perishable Mode Heat Test Pass/Fail/Skip Result, STS, time it takes to heat to 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 temperature (SRS) over last recording interval.

9-0 Defrost Test Pass/Fail/Skip Result, DTS reading at end of test, line voltage, line frequency, time in defrost.

10-0 Frozen Mode Heat Test Pass/Fail/Skip Result, STS, time unit is in heat.

10-1 Frozen Mode 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.

T-359 448

Table 410 DataCORDER Alarm Indications

To Access: Press ALT. MODE 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 DataCORDER is configured by default to record the supply and return recorder 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 assigned. When a humidity sensor is installed, it is usually assigned to AL78.

dAL86 RTC Battery Low The real time clock (RTC) backup battery is too low to adequately maintain the RTC reading.

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 Failure

A write of critical DataCORDER information to the EEPROM has failed.

dAL89 Flash Memory Error An error has been detected in the process of writing daily data to the non- volatile FLASH memory.

dAL90 Future Expansion This alarm is for future expansion, and is not in use at this time.

dAL91 Alarm List Full The DataCORDER alarm queue is determined to be full (eight alarms).

51 T-359

SECTION 5 OPERATION

5.1 Inspection (Before Loading)

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

1. Check inside for the following:

a. Check channels or T bar floor for cleanliness. Channels must be free of debris for proper air circulation. b. Check container panels, insulation and door seals for damage. Effect permanent or temporary repairs. c. Visually check evaporator fan motor mounting bolts for proper securement (refer to Section 7.10). d. Check for visible corrosion on the evaporator stator and fan deck (refer to Section 7.11). e. Check for dirt or grease on evaporator fans or fan deck and clean if necessary. f. Check evaporator coil for cleanliness or obstructions. Wash with fresh water. g. Check defrost drain pans and drain lines for obstructions and clear if necessary. Wash with fresh water. h. Check panels on refrigeration unit for loose bolts and condition of panels. Make sure TIR devices are in

place on access panels. 2. Check condenser coil for cleanliness. Wash with fresh water.

3. Open 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) be fore turning OFF start-stop switch (ST), unit circuit breaker(s) and external power source.

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

5.2.1 Connection To 380/460 VAC Power

1. Make sure start-stop switch (ST, on control panel) and circuit breaker (CB-1, in the control box) are in posi- tion 0 (OFF).

2. Plug the 460 VAC (yellow) cable into a de-energized 380/460 VAC, 3-phase power source. Energize the power source. Place circuit breaker (CB-1) in position I (ON). Close and secure control box door.

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 and sends data to the controller display.

T-359 52

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.

Figure 5.1 gives air exchange values for an empty container. Higher values can be expected for a fully loaded con- tainer.

Figure 5.1 Upper Fresh Air Make Up Flow Chart

5.3.2 Vent Position Sensor

The VPS allows the user to determine the position of the fresh air vent via Function Code 45. This function code is accessible via the Code Select key.

The vent position will display for 30 seconds whenever motion corresponding to 5 CMH (3 CFM) or greater is detected. It will scroll in intervals of 5 CMH (3 CFM). Scrolling to Function Code 45 will display the Fresh Air Vent Position.

The position of the vent will be recorded in the DataCORDER whenever the unit is running under AC power and any of the following:

Trip start

On every power cycle

Midnight

Manual changes greater than 5 CMH (3 CFM)

Remaining in the new position for at least 4 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, an alarm will be generated. This provides the user with the ability to change the vent setting without generating multi- ple events in the DataCORDER.

0

50

100

150

200

250

0 10 20 30 40 50 60 70 80 90 100

TBAR 11/2

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 11/2

TBAR 2 5/8 TBAR 3

AIR FLOW (CMH) 60HZ

PERCENT OPEN

53 T-359

5.4 Connect Remote Monitoring Receptacle If remote monitoring is required, connect remote monitor plug at unit receptacle. When the remote monitor plug is connected to the remote monitoring receptacle, the following remote circuits are energized:

5.5 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 be fore connecting to any electrical power source.

5.5.1 Starting the Unit

1. With power properly applied and the fresh air vent position set, place the START-STOP switch to I (ON).

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.

2. 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 Start Up Inspection, Section 5.6.

5.5.2 Stopping the Unit

To stop the unit, place the START-STOP switch in position 0 (OFF).

5.6 Start-Up Inspection

5.6.1 Physical Inspection

Check rotation of condenser and evaporator fans.

5.6.2 Check Controller Function Codes

Check, and if required, reset controller Function Codes (Cd27 through Cd39) in accordance with desired operating parameters. Refer to Table 45.

5.6.3 Start Temperature Recorder

Partlow Recorders (If Equipped)

1. Open recorder door and check battery of electronic recorder. Be sure key is returned to storage clip of mechanical recorder.

2. Lift stylus (pen) by pulling the marking tip outward until the stylus arm snaps into it's retracted position.

3. Install new chart, making sure chart is under the four corner tabs. Lower the stylus until it has made contact with the chart. Close and secure door.

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

T-359 54

DataCORDER

1. Check and, if required, set the DataCORDER Configuration in accordance with desired recording parame- ter. Refer to Section 4.7.3.

2. Enter a Trip Start. To enter a Trip Start, do the fol lowing:

a. Depress the ALT MODE key. When the left display shows, dC, depress the ENTER key. b. Scroll to Code dC30. c. Depress and hold the ENTER key for five seconds. d. The Trip Start event will be entered in the DataCORDER.

5.6.4 Complete Inspection Allow unit to run for five minutes to stabilize conditions and perform a pre-trip diagnosis in accordance with the fol- lowing paragraph.

5.7 Pre-Trip Diagnosis

CAUTION! Pre-trip inspection should not be per formed 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 compari- son 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.

To start a pre-trip test, do the following:

NOTE

1. Prior to starting tests, verify that unit voltage (Function Code Cd07) is within tolerance and unit amper- age draw (Function Codes Cd04, Cd05, Cd06) are within expected limits. Otherwise, tests may fail incorrectly.

2. All alarms must be rectified and cleared before starting tests.

3. Pre-trip may also be initiated via communications. The operation is the same as for the keypad initiation described below except that should a test fail, the pre-trip mode will automatically terminate. When initi- ated via communications, a test may not be interrupted with an arrow key, but the pre-trip mode can be terminated with the PRE-TRIP key.

1. Press the PRE-TRIP key. This accesses a test selection menu.

55 T-359

2. TO RUN AN AUTOMATIC TEST: Scroll through the selections by pressing the UP ARROW or DOWN ARROW keys to display AUTO, AUTO 1, AUTO 2, or AUTO 3 as desired, then press the ENTER key.

a. 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.

b. 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.

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

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. The user may then press the DOWN ARROW to repeat the test, the UP ARROW to skip to the next test or the PRE-TRIP key to terminate testing. The unit will wait indefi- nitely or until the user manually enters a command.

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!

When an Auto 1 runs to completion without a failure, the unit will exit the pre-trip mode and return to normal control operation. However, dehumidification and bulb mode must be reactivated manually if required.

3. TO RUN AN INDIVIDUAL TEST: Scroll through the selections by pressing the UP ARROW or DOWN ARROW keys to display an individual test code. Pressing ENTER when the desired test code is displayed.

a. Individually selected tests, other than the LED/Display test, will perform the operations necessary to ver- ify the operation of the component. At the conclusion, PASS or FAIL will be displayed. This message will remain displayed for up to three minutes, during which time a user may select another test. If the three minute time period expires, the unit will terminate pre-trip and return to control mode operation.

b. 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.

c. Throughout the duration of any pre-trip test (except the P-7 high pressure switch tests), the current and pressure limiting processes are active. The current limiting process only is active for P-7.

d. Pre-Trip Test Results

At the end of the pre-trip test selection menu, the message P, rSLts (pre-trip results) will be displayed. Pressing the ENTER key will allow the user to see the results for all sub-tests (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, dehumidifica- tion and bulb mode must be reactivated manually if required.

5.8 Observe Unit Operation

5.8.1 Probe Diagnostic Logic For units configured with four temperature probes, which include the supply and return temperature probes and the supply and return DataCORDER probes, the controller continuously performs probe diagnosis testing that com- pares the four probes. If the diagnosis result indicates a problem exists, the controller will perform a probe check to identify which probe or probes are in error.

T-359 56

a. Probe Diagnostic Logic

In the perishable mode of operation, both pairs of supply and return probes are monitored for probe disagreement. Probe disagreement 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 the frozen mode of operation, 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 are greater than 2.0C (3.6F). Normally, 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 the supply probes agree and return probes agree, all supply and return sensors are valid and the unit returns to normal control.

If supply probes disagree and the return probes agree, then 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 invalidated. If the unit is in perishable operation, a probe alarm will be triggered for both supply probes.

If the supply probes agree and 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 unit is in perishable operation, a probe alarm will be triggered for both return probes.

b. Probe Check Procedure

A probe check diagnostic procedure is executed during Pre-trip P-5. A defrost cycle probe check may be accom- plished at the end of defrost by energizing the evaporator motors for eight minutes at the end of the normal defrost. The defrost light will remain on during this period. If supply probes are within limits and return probes are within lim- its, the unit will return to normal control.

61 T-359

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 OFF or defective Check

Circuit breaker tripped or OFF Check

Loss of control power

Circuit breaker OFF or defective Check

Control transformer defective Replace

Fuse (F3A/F3B) blown Check

Start-Stop switch OFF or defective Check

Component(s) not operating

Evaporator fan motor internal protector open 7.10

Condenser fan motor internal protector open 7.7

Compressor internal protector open 7.4

High pressure switch open 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 7.4

Compressor seized 7.4

6.2 Unit Operates Long or Continuously in Cooling

Container Hot load Normal

Defective box insulation or air leak Repair

T-359 62

Refrigeration system

Shortage of refrigerant 7.3

Evaporator coil covered with ice 6.6

Evaporator coil plugged with debris 7.9

Evaporator fan(s) rotating backwards 7.9 / 7.10

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 7.6

Compressor worn 7.4

Current limit (function code Cd32) set to wrong value 4.4.3

Economizer solenoid valve malfunction 7.16

Digital unloader valve stuck open Replace

Electronic expansion valve Replace

6.3 Unit Runs but has Insufficient Cooling

Refrigeration system

Abnormal pressures 6.7

Abnormal temperatures 6.13

Abnormal currents 6.14

Controller malfunction 6.9

Evaporator fan or motor defective 7.10

Compressor service valves or liquid line shutoff valve partially closed

Open valves completely

Frost on coil 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 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 7.10

Heat relay defective Check

Heater termination thermostat open 7.9

Condition Possible Cause Remedy / Reference

63 T-359

Unit will not heat or has insufficient heat

Heater(s) defective 7.9

Heater contactor or coil defective Replace

Evaporator fan motor(s) defective or rotating backwards 7.9 / 7.10

Evaporator fan motor contactor defective Replace

Controller malfunction 6.9

Defective wiring Replace

Loose terminal connections Tighten

Low line voltage 3.3

6.5 Unit will not Terminate Heating

Unit fails to stop heating

Controller improperly set Reset

Controller malfunction 6.9

Heater termination thermostat remains closed along with the heat relay 7.9

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 termination thermostat open Replace

Heater contactor or coil defective Replace

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 3.3

Initiates but does not defrost Heater contactor or coil defective Replace

Heater(s) burned out 7.9

Frequent defrost Wet load Normal

6.7 Abnormal Pressures

High discharge pressure

Condenser coil dirty 7.6

Condenser fan rotating backwards 7.7

Condenser fan inoperative 7.7

Refrigerant overcharge or non-condensibles 7.3

Discharge service valve partially closed Open

Electronic expansion valve (EEV) control malfunction Replace

Condition Possible Cause Remedy / Reference

T-359 64

Low suction pressure

Incorrect software and/or controller configuration Check

Failed suction pressure transducer (SPT) or evaporator pressure transducer (EPT) Replace

Suction service valve partially closed Open

Filter drier partially plugged 7.8

Low refrigerant charge 7.3

No evaporator air flow or restricted air flow 7.9

Excessive frost on evaporator coil 6.6

Evaporator fan(s) rotating backwards 7.10.3

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 6.12

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 6.12

Loose mounting bolts or worn resilient mounts Tighten/ Replace

Loose upper mounting 7.4.1

Liquid slugging 7.12

Condenser or Evaporator Fan

Bent, loose or striking venturi Check

Worn motor bearings 7.7 / 7.10

Bent motor shaft 7.7 / 7.10

6.9 Microprocessor Malfunction

Will not control

Incorrect software and/or controller configuration Check

Defective sensor 7.19

Defective wiring Check

Low refrigerant charge 7.3

6.10 No Evaporator Air Flow or Restricted Air Flow

Evaporator coil blocked Frost on coil 6.6

Dirty coil 7.9

No or partial evaporator air flow

Evaporator fan motor internal protector open 7.10

Evaporator fan motor(s) defective 7.10

Evaporator fan(s) loose or defective 7.10

Evaporator fan contactor defective Replace

Condition Possible Cause Remedy / Reference

65 T-359

6.11 Electronic Expansion Valve Malfunction

Low suction pressure

Incorrect software and/or controller configuration Check

Failed suction pressure transducer (SPT), or evaporator pressure transducer (EPT) Replace

Suction service valve partially closed Open

Filter drier partially plugged 7.8

Low refrigerant charge 7.3

No evaporator air flow or restricted air flow 7.9

Excessive frost on evaporator coil 6.6

Evaporator fan(s) rotating backwards 7.10.3

EEV control malfunction 6.11

Failed digital unloader valve (DUV) Replace

Loose or insufficiently clamped sensor Replace

High suction pressure with low superheat

Foreign material in valve 6.11

Failed suction pressure transducer (SPT), or evaporator pressure transducer (EPT) Replace

EEV control malfunction Replace

Improperly seated powerhead Ensure power head is locked and in place

Liquid slugging in compressor

Failed suction pressure transducer (SPT), or evaporator pressure transducer (EPT) Replace

Failed EEV Replace

6.12 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

T-359 66

6.13 Abnormal Temperatures

High discharge temperature

Condenser coil dirty 7.6

Condenser fan rotating backwards 7.7

Condenser fan inoperative 7.7

Refrigerant overcharge or non-condensibles 7.3

Discharge service valve partially closed Open

Electronic expansion valve (EEV) control malfunction Replace

Failed suction pressure transducer (SPT), or evaporator 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

6.14 Abnormal Currents Unit reads abnormal currents Current sensor wiring Check

Condition Possible Cause Remedy / Reference

71 T-359

SECTION 7 SERVICE

7.1 Section Layout

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.

CAUTION! Never use air for leak testing. It has been determined that pressurized, mixtures of refrigerant and air can undergo combustion when exposed to an ignition source.

Service procedures are provided herein beginning with refrigeration system service, then refrigeration system com- ponent service, electrical system service, temperature recorder service and general service. Refer to the Table of Contents to locate specific topics.

7.2 Manifold Gauge Set The manifold gauge set (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. Opened (Backseated) Hand Valve 2. Suction Pressure Gauge 3. Discharge Pressure Gauge 4. Closed (Frontseated) Hand Valve

5. Connection to high side of system 6. Connection to either:

a. Refrigerant cylinder OR b. Oil Container

7. Connection to low side of system - - - - -

When the suction pressure hand valve is frontseated (turned all the way in), the suction (low) pressure can be checked. When the discharge pressure hand valve is frontseated, the discharge (high) pressure can be checked. When both valves are open (all the way out), high pressure vapor will flow into the low side. When the suction pres- sure valve is open and the discharge pressure valve shut, the system can be charged. Oil can also be added to the system.

A R-134a manifold gauge/hose set with self-sealing hoses (Figure 7.2) is required for service of the models cov- ered within this manual. The manifold gauge/ hose set is available from Carrier Transicold. (Carrier Transicold part number 07-00294-00, which includes items 1 through 6, Figure 7.2.) To perform service using the manifold gage/ hose set, do the following:

1

2 3

4567

T-359 72

Preparing Manifold Gauge/Hose Set For Use:

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. Back seat (turn counterclockwise) both field service couplings (Figure 7.2) and midseat both hand valves.

2. Connect the yellow hose to a vacuum pump and refrigerant 134a cylinder.

Figure 7.2 R-134a Manifold Gauge/Hose Set

1. Manifold Gauge Set 2. RED Refrigeration and/or Evacuation Hose (SAE J2196/R-134a) 3. Hose Fitting (0.5-16 Acme) 4. YELLOW Refrigeration and/or Evacuation Hose (SAE J2196/R-134a) 5. Hose Fitting with O-ring (M14 x 1.5) 6. High Side Field Service Coupling (Red Knob) 7. BLUE Refrigeration and/or Evacuation Hose (SAE J2196/R-134a) 8. Low Side Field Service Coupling (Blue Knob)

- - - - -

1. Evacuate to 10 inches of vacuum and then charge with R-134a to a slightly positive pressure of 0.1 kg/ cm2

(1.0 psig).

2. Front seat both manifold gauge set valves and dis connect from cylinder. The gauge set is now ready for use.

7.3 Refrigeration System Service - Units With Standard Piping

7.3.1 Service Connections

The compressor suction, compressor discharge, and the liquid line service valves (see Figure 6-3) are provided with a double seat and an access valve which en ables servicing of the compressor and refrigerant lines. Turning the valve stem clockwise (all the way forward) will frontseat the valve to close off the line connection and open a path to the access valve. Turning the stem counterclockwise (all the way out) will backseat the valve to open the line connection and close off the path to the access valve.

With the valve stem midway between frontseat and backseat, both of the service valve connections are open to the access valve path.

For example, the valve stem is first fully backseated when connecting a manifold gauge to measure pressure. Then, the valve is opened 1/4 to 1/2 turn to measure the pressure.

To High Side Access Valve

To Low Side Access Valve

2

1

3

3

4

55 6

7

8

73 T-359

Figure 7.3 Service Valve

1. Line Connection 2. Access Valve 3. Stem Cap 4. Valve stem

5. Compressor Or Filter Drier Inlet Connection

6. Valve (Frontseated) 7. Valve (Backseated)

- - - - -

To connect the manifold gauge/hose set for reading pressures, do the following:

a. Remove service valve stem cap and check to make sure it is backseated. Remove access valve cap. (Figure 7.3).

b. Connect the field service coupling (see Figure 7.2) to the access valve.

c. Turn the field service coupling knob clockwise, which will open the system to the gauge set.

d. To read system pressures, slightly midseat the service valve.

e. Repeat the procedure to connect the other side of the gauge set.

CAUTION! To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suc- tion pressure before disconnecting.

Removing the Manifold Gauge Set:

a. While the compressor is still ON, backseat the high side service valve.

b. 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.

c. Backseat the low side service valve. Backseat both field service couplings and frontseat both manifold hand valves. Remove the couplings from the access valves.

d. Install both service valve stem caps and service port caps (finger-tight only).

2

1 3

4 5

6 7

T-359 74

7.3.2 Pumping Down the Unit

To service the filter drier, economizer, expansion valves, economizer solenoid valve, digital unloader valve or evap- orator coil, pump the refrigerant into the high side as follows:

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 (frontseated). Internal damage will result from operating the com- pressor in a deep vacuum.

a. Attach manifold gauge set to the compressor suction and discharge service valves. Refer to Section 7.2.

b. Start the unit and run in the frozen mode (controller set below -10C (14F)) for 10 to 15 minutes.

c. Check function code Cd21 (refer to Section 4.2.2). The economizer solenoid valve should be open. If not, continue to run until the valve opens.

d. Frontseat the liquid line service valve. Place start-stop switch in the OFF position when the suction reaches a positive pressure of 0.1 bar (1.4 psig).

e. Frontseat the suction and discharge service valves. The refrigerant will be trapped between the compressor discharge service valves and the liquid line valve.

f. Before opening up any part of the system, a slight positive pressure should be 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.

g. When opening up the refrigerant system, certain parts may frost. Allow the part to warm to ambient tempera- ture before dismantling. This avoids internal condensation which puts moisture in the system.

h. After repairs have been made, be sure to perform a refrigerant leak check (refer to Section 7.3.3), and evacuate and dehydrate the low side (refer to Section 7.3.4).

i. Check refrigerant charge (refer to Section 7.3.5).

7.3.3 Refrigerant Leak Checking

CAUTION! Never use air for leak testing. It has been determined that pressurized, mixtures of refrigerant and air can undergo combustion when exposed to an ignition source.

a. The recommended procedure for finding leaks in a system is with a R-134a electronic leak detector. Testing joints with soapsuds is satisfactory only for locating large leaks.

b. If the system is without refrigerant, charge the system with refrigerant 134a 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 134a should be used to pressurize the system. Any other gas or vapor will contami- nate the system, which will require additional purging and evacuation of the system.

c. If required, remove refrigerant using a refrigerant recovery system and repair any leaks. Check for leaks.

d. Evacuate and dehydrate the unit. (Refer to Section 7.3.4.)

e. Charge unit per Section 7.3.5.

75 T-359

7.3.4 Evacuation and Dehydration

General

Moisture is detrimental to refrigeration systems. The presence of moisture in a refrigeration system can have many undesirable effects. The most common are cop per plating, acid sludge formation, freezing-up of metering devices by free water, and formation of acids, resulting in metal corrosion.

Preparation

a. Evacuate and dehydrate only after pressure leak test.

b. Essential tools to properly evacuate and dehydrate any system include a vacuum pump (8 m3/hr = 5 cfm volume displacement) and an electronic vacuum gauge. (The pump is available from Carrier Transicold, part number 07-00176-11.)

c. 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.

d. Additional time may be saved during a complete system pump down by replacing the filter drier with a sec- tion 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. Liquid Service Connection 2. Receiver 3. Compressor 4. Discharge Service Connection 5. Suction Service Connection

6. Vacuum Pump 7. Electronic Vacuum Gauge 8. Manifold Gauge Set 9. Refrigerant Cylinder 10. Reclaimer

- - - - -

DS

21 3

4

5

6

7

8

9

10

T-359 76

Procedure - Complete System

NOTE Refer to Partial System procedure for information pertaining to partial system evacuation and dehydration.

a. Remove all refrigerant using a refrigerant recovery system.

b. 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). Be sure the service hoses are suited for evacuation purposes.

c. 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.

d. Midseat the refrigerant system service valves.

e. Open the vacuum pump and electronic vacuum gauge valves, if they are not already open. Start the vacuum pump. Evacuate unit until the electronic vacuum gauge indicates 2000 microns. Close the electronic vac- uum gauge and vacuum pump valves. Shut off the vacuum pump. Wait a few minutes to be sure the vac- uum holds.

f. Break the vacuum with clean dry refrigerant 134a gas. Raise system pressure to roughly 0.14 bar (2 psig), monitoring it with the compound gauge.

g. Remove refrigerant using a refrigerant recovery system.

h. Repeat steps e. and f. one time.

i. 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.

j. With a vacuum still in the unit, the refrigerant charge may be drawn into the system from a refrigerant con- tainer on weight scales.

Procedure - Partial System

a. If refrigerant charge has been removed from the low side only, evacuate the low side by connecting the evacuation set-up at the compressor suction valve and the liquid service valve but leave the service valves frontseated until evacuation is completed.

b. Once evacuation has been completed and the pump has been isolated, fully backseat the service valves to isolate the service connections and then continue with checking and, if required, adding refrigerant in accor- dance with normal procedures.

7.3.5 Refrigerant Charge

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., refer to EPA Section 608.

a. Connect the gauge manifold to the compressor discharge and suction service valves.

b. Bring the container temperature to approximately 0C (32F) or below. Then set the controller set point to -25C (-13F).

c. Partially block the condenser coil inlet air. Increase the area blocked until the compressor discharge pres- sure is raised to approximately 12.8 bar (185 psig).

d. On units equipped with a receiver, the level should be between the glasses. If the refrigerant level is not cor- rect, continue with the following paragraphs to add or remove refrigerant as required.

77 T-359

Adding Refrigerant to System (Full Charge)

a. Evacuate unit and leave in deep vacuum. (Refer to Section 7.3.4.)

b. Place cylinder of R-134a 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.

c. Open liquid valve on cylinder. Open liquid line valve half-way and allow the liquid refrigerant to flow into the unit until the correct weight of refrigerant (refer to Section 3.2) has been added as indicated by scales.

NOTE 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.

d. Backseat manual liquid line valve (to close off gauge port). Close liquid valve on cylinder.

e. Start unit in cooling mode. Run for approximately 10 minutes and check the refrigerant charge.

Adding Refrigerant to System (Partial Charge)

a. Examine the unit refrigerant system for any evidence of leaks. Repair as necessary. (Refer to Section 7.3.3).

b. Maintain the conditions outlined in paragraph Section 7.3.5.

c. Fully backseat the suction service valve and remove the service port cap.

d. Connect charging line between suction service valve port and cylinder of refrigerant R-134a. Open VAPOR valve.

e. 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.

7.4 Compressor

CAUTION! Make sure power to the unit is OFF and power plug disconnected before replacing the com- pressor.

CAUTION! 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 dis- charge service valves closed (frontseated). Internal damage will result from operating the com- pressor 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.

T-359 78

7.4.1 Removal and Replacement of Compressor

a. Turn the unit ON and run it in full cool mode for 10 minutes.

NOTE If the compressor is not operational, front-seat the suction and discharge service valves and go to step g. below.

b. Frontseat the manual liquid line valve and allow the unit to pull-down to 0.1 kg/cm2 (1 psig).

c. Turn the unit start-stop switch (ST) and unit circuit breaker (CB-1) OFF, and disconnect power to the unit.

d. Remove the compressor cover.

e. Frontseat the discharge and suction service valves.

f. Remove all remaining refrigerant from the compressor using a refrigerant recovery system.

g. 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 en sure they are not deformed or have any signs of heat or arcing. If any damage is noted, replace the power cable.

h. Remove the Rotalock fittings from the suction and discharge service connections, and uncouple the unloader and economizer lines from the compressor.

i. Cut the dome temperature sensor wires. The replacement compressor comes with a dome temperature sensor already assembled.

j. Remove and save the compressor base mounting bolts. Discard the 4 top resilient mounts and washers.

k. Remove (slide out) the old compressor from the unit.

l. Inspect compressor base plate for wear. Replace, if necessary.

m. Wire tie the compressor base plate to the compressor, and slide the new compressor into the unit. Refer to Figure 7.5.

NOTE DO NOT add any oil to the replacement compressor. Replacement compressor is shipped with full oil charge of 60 oz.

n. Cut and discard the wire ties used to hold the base plate to the compressor.

o. 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.

p. 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.

q. Torque the four base-mounting screws to 6.2 mkg (45 ft-lbs).

79 T-359

Figure 7.5 Compressor Kit

1. Compressor 2. Teflon Seal for Valve Connection (2) 3. O-ring (Unloader Connection) 4. Compressor Dis-charge Temperature Sensor 5. O-ring (Economizer Connection) 6. Base Mounting Bolts 7. SST Washers

8. Resilient Mount 9. Mylar Washers 10. Wire Ties 11. Power Cable Gasket 12. Ground Connection Screw 13. Power Cable Lubricant - Krytox (Not Shown)

- - - - - r. Torque the compressor ports / connections to:

s. Connect (butt-splice and heat shrink) the new compressor dome temperature sensor with the old sensor wires removed in step i. Wire-tie any loose wiring as appropriate.

t. 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 R-134a refrigerant (see Section 7.3.4 and Section 7.3.5).

u. Open the compressor terminal cover and connect the compressor power cable following the steps below:

v. Liberally coat the orange gasket surfaces with the Krytox lubricant.

w. 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.

x. 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.

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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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y. 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 above.

z. Backseat all service valves.

aa. Replace the compressor cover.

ab. Connect the power to the unit and run it for at least 20 minutes.

ac. Perform a leak check of the system.

7.5 High Pressure Switch

7.5.1 Checking High Pressure Switch

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

NOTE The high pressure switch is non-adjustable.

a. Remove switch as outlined in Section 7.5.2.

b. Connect ohmmeter or continuity light across switch terminals. Ohmmeter will indicate no resistance or con- tinuity light will be illuminated if the switch closed after relieving compressor pressure.

c. Connect hose to a cylinder of dry nitrogen. (Figure 7.6)

Figure 7.6 High Pressure Switch Testing

d. Set nitrogen pressure regulator at 26.4 kg/cm2 (375 psig) with bleed-off valve closed.

e. Close valve on cylinder and open bleed-off valve.

f. Open cylinder valve. Slowly close bleed-off valve to increase pressure on switch. The switch should open at a static pressure up to 25 kg/cm2 (350 psig). If a light is used, light will go out. If an ohmmeter is used, the meter will indicate open circuit.

g. Slowly open bleed-off valve to decrease the pressure. The switch should close at 18 kg/cm2 (250 psig).

1. Cylinder Valve and Gauge

2. Pressure Regulator 3. Nitrogen Cylinder 4. Pressure Gauge

(0 to 36 kg/cm2 = 0 to 400 psig)

5. Bleed-Off Valve 6. 1/4 inch Connection

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7.5.2 Replacing High Pressure Switch

a. Remove the refrigerant charge.

b. Disconnect wiring from defective switch. The high pressure switch is located on the discharge connection or line and is removed by turning counterclockwise.

c. Install a new high pressure switch after verifying switch settings.

d. Evacuate, dehydrate and recharge system.

e. Start unit, verify refrigeration charge and oil level.

7.6 Condenser Coil The condenser consists of a series of parallel copper tubes expanded into copper fins. The condenser coil must be cleaned with fresh water or steam so the air flow is not restricted. To replace the coil, do the following:

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

a. Using a refrigerant reclaim system, remove the refrigerant charge.

b. Remove the condenser coil guard.

c. Unsolder discharge line and remove the line to the receiver.

d. Remove coil mounting hardware and remove the coil.

e. Install replacement coil and solder connections.

f. Leak-check the coil connections per Section 7.3.3. Evacuate the unit then charge the unit with refrigerant.

7.7 Condenser Fan and Motor Assembly

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

The condenser fan rotates counter-clockwise (viewed from front of unit), pulls air through the condenser coil, and discharges horizontally through the front of the unit. To replace motor assembly:

a. Open condenser fan screen guard.

b. Loosen two square head set screws on fan. (Thread sealer has been applied to set screws at installation.)

c. Disconnect wiring connector.

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

d. Remove motor mounting hardware and replace the motor. It is recommended that new locknuts be used when replacing motor.

e. Connect the wiring connector. f. Install fan loosely on motor shaft (hub side in). DO NOT USE FORCE. If necessary, tap the hub only, not the

hub nuts or bolts. Install venturi. Apply Loctite H to fan set screws. Adjust fan within venturi so that the outer edge of the fan is within 2.0 +/- 0.07 mm (0.08" +/- 0.03") from the outside of the orifice opening. Spin fan by hand to check clearance.

g. Close and secure condenser fan screen guard.

T-359 712

7.8 Filter Drier If the liquid line 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.

a. To check filter drier:

1. Test for a restricted or plugged filter drier by feeling the liquid line inlet and outlet connections of the drier cartridge. If the outlet side feels cooler than the inlet side, then the filter drier should be changed.

2. Check the moisture-liquid indicator if the indicator shows a high level of moisture, the filter drier should be replaced.

b. To replace filter drier:

1. Pump down the unit (refer to Section 7.3.2). Evacuate if unit is not equipped with service valves. Then replace filter drier.

2. Evacuate the low side in accordance with Section 7.3.4.

3. After unit is in operation, inspect for moisture in system and check charge.

7.9 Evaporator Coil and Heater Assembly The evaporator section, including the coil, should be cleaned regularly. The preferred cleaning fluid is fresh water or steam. Refer to Section 7.11 for additional Evaporator Coil cleaning instructions.

The drain pan hose is routed behind the condenser fan motor and compressor. The drain pan line must be open to ensure adequate drainage.

7.9.1 Evaporator Coil Replacement

a. Pump unit down. (Refer to Section 7.3.2) Evacuate if unit is not equipped with service valves. Refer to Section 7.3.4.

b. With power OFF and power plug removed, remove the screws securing the panel covering the evaporator section (upper panel).

c. Disconnect the defrost heater wiring.

d. Remove the mounting hardware from the coil.

e. Unsolder the two coil connections, one at the distributor and the other at the coil header.

f. Disconnect the defrost temperature sensor (see Figure 3.2) from the coil.

g. Remove middle coil support.

h. After defective coil is removed from unit, remove defrost heaters and install on replacement coil.

i. Install coil assembly by reversing above steps.

j. Leak check connections. Evacuate and add refrigerant charge.

7.9.2 Evaporator 5+1 Heater Removal and Replacement

The heaters are wired to the contactor and to the terminal block. If a heater failure occurs during a trip, the heater set containing that heater may be disconnected at the contactor or at the terminal block. Refer to the schematic diagram to individually isolate and troubleshoot the heaters.

The next pre-trip will detect that a heater set has been disconnected and indicate that the failed heater should be replaced. To remove a heater, do the following:

a. Before servicing unit, make sure the unit circuit breakers (CB-1 and CB-2) and the start-stop switch (ST) are in the OFF position, and that the power plug is disconnected.

b. Remove the upper back panel.

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c. Determine which heater(s) need replacing by checking resistance of each heater set. Refer to Section 3.3 for heater resistance values. Once the set containing the failed heater is determined, cut the splice connec- tion and retest to determine the actual failed heater(s).

To remove U-shaped heater:

1. Remove hold-down clamp securing heater(s) to coil.

2. Lift the bent end of the heater (with the opposite end down and away from coil). Move heater to the side enough to clear the heater end support and remove.

3. To replace a heater, do steps 1 through 2 in reverse.

To remove straight heater:

1. Locate holding clips positioned at the ends of the heater element.

2. Rotate clips toward the center of the container unit.

3. Lift heater slightly up and out to remove.

4. To replace a heater, do steps 1 through 3 in reverse.

To remove Omega heater (see Figure 7.7):

1. Remove the two tube clamps located near the top of the heater element.

2. Locate holding clips positioned at the bottom of the heater element and rotate slightly toward the center of the container unit.

3. Carefully pull heater out to remove.

4. To replace a heater, do steps 1 through 3 in reverse.

Figure 7.7 Heater Arrangement - Omega Heater

7.10 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 refrigera- tion unit into the container. The fan motor bearings are factory lubricated and do not require additional grease.

1. 2.

3.

Omega Heater Tube Clamps (2)

Holding Clips (2)

T-359 714

7.10.1 Replacing the Evaporator Fan Assembly

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

a. Remove upper access panel (see Figure 3.2) by removing mounting bolts and TIR locking device. Reach inside of unit and remove the Ty-Rap securing the wire harness loop. Disconnect the connector by twisting to unlock and pulling to separate.

b. 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.

c. Slide the fan assembly out from the unit and place on a sturdy work surface.

7.10.2 Disassemble the Evaporator Fan Assembly

a. Attach a spanner wrench to the two 1/4-20 holes located in the fan hub. Loosen the 5/8-18 shaft nut by holding the spanner wrench stationary and turning the 5/8-18 nut counter-clockwise (see Figure 7.8).

b. Remove the spanner wrench. Use a universal wheel puller and remove the fan from the shaft. Remove the washers and key.

c. Remove the four 1/4-20 x 3/4 long bolts that are located under the fan that support the motor and stator housing. Remove the motor and plastic spacer.

7.10.3 Assemble the Evaporator Fan Assembly

a. 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.

b. Apply Loctite to the 1/4-20 x 3/4 long bolts and torque to 0.81 mkg (70 inch-pounds).

c. Place one 5/8 flat washer on the shoulder of the fan motor shaft. Insert the key in the keyway and lubricate the fan motor shaft and threads with a graphite-oil solution (such as Never-seez).

d. Install the fan onto the motor shaft. Place one 5/8 flat washer with a 5/8-18 locknut onto the motor shaft and torque to 40 foot-pounds.

715 T-359

Figure 7.8 Evaporator Fan Assembly

1. Stator 2. Flat washer, 5/8 3. Locknut, 5/8-18 4. Impeller Fan

5. Screw, 1/4 6. Flat washer, 1/4 7. Mylar Protector 8. Evaporator Motor

- - - - -

e. 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.

f. Replace access panel making sure that panel does not leak. Make sure that the TIR locking device is lockwired.

7.11 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 sta- tor and fan deck.

Analyses by Carrier Transicold environmental specialists have identified the white powder as consisting predomi- nantly 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 infesta- tions 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 evapo- rator 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.

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T-359 716

Carrier Transicold has identified a fully biodegradable and environmentally safe alkaline cleaning agent (Tri-Pow'r HD) for the unit. This will assist in helping to remove the corrosive fumigation chemicals and dislodging of the cor- rosive 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, refer to and retain the Material Safety Data (MSDS) sheet. This document can be found at: http://www.nucalgon.com/products/coil-cleaners/condensers/tri-powr-hd

Prior to Cleaning: 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.

Cleaning Procedure:

a. Remove the upper evaporator access panel inside of the unit.

b. Spray the surface with water before applying the cleaning solution. This helps the cleaner work better.

c. Liberally apply the prepared cleaner solution (5 parts water and 1 part cleaner).

d. Allow the cleaner to soak in for 5 to 7 minutes.

e. Assess area for rinsing. Follow all local regulations regarding disposal of waste water.

f. 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.

g. Always rinse the empty coil cleaner bottle, cap tightly and dispose of properly.

7.12 Electronic Expansion Valve 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 evapo- rator load and (b) prevention of liquid refrigerant entering the compressor. Unless the valve is defective, it seldom requires any maintenance. See Figure 7.9.

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Figure 7.9 Electronic Expansion Valve

7.12.1 Replacing Electronic Expansion Valve and Strainer

a. Removing an EEV:

1. Pump down compressor (refer to Section 7.3.2) and frontseat both suction and discharge valves.

2. Turn unit power off and remove power from the unit.

3. Remove coil.

4. VALVE REMOVAL: 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 and the strainer.

5. Alternately, use a wet rag to keep valve cool. Heat inlet and outlet connections to valve body and remove valve.

6. Clean the valve stem with mild cleaner, if necessary.

b. Installing an EEV, reverse steps 1 through 4 above to install a new valve:

1. Install the valve and a new strainer with the cone of strainer / screen pointing into 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 7.9.

3. Replace filter drier.

4. Evacuate to 500 microns by placing vacuum pump on liquid line and suction service valve.

5. Open liquid line service valve and check refrigerant level.

6. Check superheat. (Refer to Section 3.2).

7. Check unit operation by running Pre-trip (Refer to Section 4.6).

7.13 Economizer Expansion Valve The economizer expansion valve can be found in Figure 3.4 (Item12). The economizer expansion valve is an auto- matic 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 ther- mal bulb is tightly secured to the suction line and wrapped with insulating compound.

FLOW DIRECTION

1. Coil Boot

2. Coil

3. Electronic Expansion Valve

4. Strainer

T-359 718

7.13.1 Valve Replacement

a. Removing an Expansion Valve:

NOTE The EEV is a hermetic valve and does not have adjustable superheat (See Figure 7.10).

Figure 7.10 Economizer Expansion Valve

1. Pump down the compressor (refer to Section 7.3.2) and frontseat both suction and discharge valves. Evacuate if unit is not equipped with service valves. Refer to Section 7.3.4.

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 expansion valve bulb.

5. Unstrap the bulb, located on the economizer line.

6. VALVE REMOVAL: 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.

Alternately, 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 mild cleaner, if necessary.

b. Installing an Expansion Valve:

1. The economizer valve should be wrapped in a soaked cloth for brazing. Braze inlet connection to inlet line.

2. Braze inlet connection to inlet line.

3. Braze outlet connection to outlet line.

4. Reinstall cushion clamps on inlet and outlet lines.

c. Replace filter drier.

d. Evacuate to 500 microns by placing vacuum pump on liquid line and suction service valve.

e. Check superheat (see Section 3.2).

Inlet

Outlet

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7.14 Economizer Solenoid Valve a. Removing a Solenoid Valve Coil:

1. Turn unit power off and remove power from the unit. Disconnect leads.

2. Remove top screw and O-ring. Remove coil and save mounting hardware, seals and spacer for reuse. (See Figure 7.11). Refer to step d. for valve coil replacement.

Figure 7.11 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

- - - - -

b. Removing the Solenoid Valve:

1. Pump down the compressor (refer to Figure 7.3.2) and frontseat both suction and discharge valves.

2. VALVE REMOVAL: The preferred method of re moving the solenoid valve is to cut the connection between the brazed section and the valve, using a small tube cutter. Remove valve.

Alternately, heat inlet and outlet connections to valve body and remove valve.

3. Clean the valve stem with mild cleaner, if necessary.

c. Installing the Solenoid Valve:

1. Fit the new solenoid valve into position and braze. Use a wet rag to keep valve cool whenever brazing.

d. 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 lb-in.

6. Connect coil wires using butt-splices and heat-shrink tubing.

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7.15 Digital Unloader Valve a. Removing the DUV:

1. Pump down the compressor (refer to Section 7.3.2) and frontseat both suction and discharge valves. In the event the DUV is stuck open and compressor cannot pump down, remove charge.

2. Turn unit power off and remove power from the unit.

3. Loosen bolt on top of the DUV and remove coil assembly.

NOTE There is a loose steel 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 clamps holding the DUV to the discharge line.

5. Loosen the nuts attaching the DUV to the top of the compressor.

6. VALVE REMOVAL: 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 7.12).

Alternately, use a wet rag to keep valve cool. Heat outlet connection to valve body and remove valve.

Figure 7.12 Digital Unloader Valve (DUV) Assembly

1. Sleeve 2. O-ring (hidden) 3. Screen Valve Strainer

4. Tube 5. Solenoid Valve Body 6. Hex Nut, 1/2 OD

- - - - - 7. Examine 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.

b. Installing the Valve:

1. Lubricate the gland shoulder area and O-ring with refrigerant oil.

2. Fit new valve in position and hand-tighten the O-ring nut.

3. Use a wet rag to keep valve cool while brazing. Braze DUV to service valve connection.

4. Reinstall and tighten the brackets that secure the valve body to the discharge line.

5. Torque 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.

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7. Leak check and evacuate low side of unit as applicable. Refer to Section 7.3.4.

8. Open service valves.

7.16 Valve Override Controls Controller function code Cd41 is a configurable code that allows timed operation of the automatic valves for trou- bleshooting. 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.

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, override function is automatically terminated and the valves return to normal machinery control. To operate the override, do the following:

a. Press the CODE SELECT key then press an ARROW key until Cd41 is displayed in the left window. The right window will display a controller communications code.

b. Press the ENTER key. The left display will show a test name alternating with the test setting or time remain- ing. Use an ARROW key to scroll to the desired test. Press the ENTER key and SELCt will appear in the left display.

c. Use an ARROW key to scroll to the desired setting, and then press the ENTER key. Selections available for each of the tests are provided in Table 71.

d. 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.

e. The above described sequence may be repeated during the timer cycle to change to another override.

Table 71 Valve Override Control Displays

Left Display Controller Communications 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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7.17 Controller

7.17.1 Handling Modules

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.

a. Obtain a grounding wrist strap (Carrier Transicold part number 07-00304-00) and a static dissipation mat (Carrier Transicold part number 07-00277-00). The wrist strap, when properly grounded, will dissipate any potential buildup on the body. The dissipation mat will provide a static-free work surface on which to place and/or service the modules.

b. Disconnect and secure power to the unit.

c. Place strap on wrist and attach the ground end to any exposed unpainted metal area on the refrigeration unit frame (bolts, screws, etc.).

d. Carefully remove the module. Do not touch any of the electrical connections if possible. Place the module on the static mat.

e. The strap should be worn during any service work on a module, even when it is placed on the mat.

7.17.2 Controller Troubleshooting

A group of test points (TP, see Figure 7.13) are provided on the controller for troubleshooting electrical circuits (see schematic diagram, Figure 8.2). A description of the test points follows:

NOTE Use a digital voltmeter to measure AC voltage between TP's and ground (TP9), except for TP8.

TP1 This test point is not used in this application.

TP2 This test point enables the user to check if the high pres sure switch (HPS) is open or closed.

TP3 This test point enables the user to check if the water pressure switch (WP) contact is open or closed.

TP 4 This test point enables the user to check if the internal protector for the condenser fan motor (IP-CM) is open or closed.

TP 5 This test point enables the user to check if the internal protectors for the evaporator fan motors (IP-EM1 or IP-EM2) are open or closed.

TP 6 (IF EQUIPPED) This test point enables the user to check if the controller liquid injection valve relay (TQ) is open or closed.

TP 7 This test point enables the user to check if the controller economizer solenoid valve relay (TS) is open or closed.

TP 8 This test point is not used in this application.

TP 9 This test point is the chassis (unit frame) ground connection.

TP 10 This test point enables the user to check if the heat ter- mination thermostat (HTT) contact is open or closed.

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Figure 7.13 Controller Section of the Control Box

7.17.3 Controller Programming Procedure To load new software into the module, the programming card is inserted into the programming/software port.

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

1. Turn unit OFF, via start-stop switch (ST).

2. Insert software/programming PCMCIA card containing the following (example) files into the programming/ software port. (See Figure 7.13):

menuDDMM.ml3, this file allows the user to select a file/program to upload into the controller.

cfYYMMDD.ml3, multi-configuration file.

3. Turn unit ON, via start-stop switch (ST).

7.17.3.1Programming Procedure for Software Versions 5328 and Greater AND With Updated Menu Option (menu0111.ml)

The updated menu option allows the operational soft ware to be loaded, and time and container identification to be set.

a. Procedure for loading operational software:

1. The display module will display the message Set UP.

2. Press the UP or DOWN arrow key until display reads, LOAd 53XX for Scroll.

3. Press the ENTER key on the keypad.

4. The display will alternate to between PrESS EntR and rEV XXXX.

5. Press the ENTER key on the keypad.

6. The display will show the message Pro SoFt. This message will last for up to one minute.

Test Points

Controller Mounting Screw

Controller Software Programming Port

T-359 724

7. The display module will go blank briefly, then read Pro donE when the software loading has loaded. (If a problem occurs while loading the software: the display will blink the message Pro FAIL or bad 12V. Turn start-stop switch OFF and remove the card.)

8. Turn unit OFF, via start-stop switch (ST).

9. Remove the PCMCIA card from the programming/ software port and return the unit to normal operation by placing the start-stop switch in the ON position.

10. Turn power on, and wait 15 seconds. The status LED will flash quickly, and there will be no display. The controller is loading the new software into memory. This takes about 15 seconds. When complete, the controller will reset and power up normally.

11. Wait for default display, setpoint on the left, and control temperature on the right.

12. Confirm software is correct using keypad code select 18 to view Cd18 XXXX.

13. Turn power off. Operational software is loaded.

b. Procedure for loading configuration software:

1. Turn unit OFF using start-stop switch (ST).

2. Insert software/programming PCMCIA card containing the following (example) files into the program- ming/software port. (See Figure 7.13):

menuDDMM.ml3, this file allows the user to select the file/program to upload into the controller.

cfYYMMDD.ml3, multi-configuration file.

3. Turn unit ON using start-stop switch (ST).

4. Press the UP or DOWN arrow key until display reads Set UP.

5. Press the ENTER key on the keypad.

6. Press the UP or DOWN arrow key until display reads XXXX the message ruN COnFG. (If a defective card is being used the display will blink the message bAd CArd. Turn start-stop switch OFF and remove the card.)

7. Press the ENTER key on the keypad.

8. The display module will go blank briefly and then display 61001, based on the operational software installed.

9. Press the UP or DOWN ARROW key to scroll through the list to obtain the proper model dash number. (If a defective card is being used, the display will blink the message bAd CArd. Turn start-stop switch OFF and remove the card.)

10. Press the ENTER key on the keypad.

11. When the software loading has successfully completed, the display will show the message EEPrM donE. (If a problem occurs while loading the soft ware, the display will blink the message Pro FAIL or bad 12V. Turn start-stop switch OFF and remove the card.)

12. Turn unit OFF using start-stop switch (ST).

13. Remove the PCMCIA card from the programming/ software port and return the unit to normal operation by placing the start-stop switch in the ON position.

14. Confirm correct model configuration using the key pad to choose code 20 (CD20). The model displayed should match the unit serial number plate.

c. Procedure for setting the date and time:

1. Press the UP or DOWN arrow key until display reads Set TIM.

2. Press the ENTER key on the keypad.

725 T-359

3. The first value to be modified is the date in YYYY MM-DD format. The values will be entered from right to left. Press the UP or DOWN ARROW key to increase or decrease the values. The ENTER key will enter the information for the current field and move to the next value; the CODE SELECT key will allow modi- fication of the previous value.

4. Press the ENTER key on the keypad.

5. The next value to be modified is the time in HH MM format. The values will be entered from right to left. Press the UP or DOWN ARROW key to increase or decrease the values. The ENTER key will enter the information for the current field and move to the next value; the CODE SELECT key will allow modifica- tion of the previous value.

6. Press the ENTER key on the keypad. The date and time will not be committed until start up procedures are completed on the next power up.

d. Procedure for setting the container ID:

NOTE The characters will be preset to the container ID already on the controller. If none exist, the de fault will be AAAA0000000.

1. Press the UP or DOWN arrow key until display reads Set ID.

2. Press the ENTER key on the keypad.

3. The values will be entered from right to left. Press the UP or DOWN ARROW key to increase or decrease the values. The ENTER key will enter the in formation for the current field and move to the next value; the CODE SELECT key will allow modification of the previous value.

4. When the last value is entered, press the ENTER key to enter the information to the controller; the CODE SELECT key will allow modification of the previous value.

7.17.4 Removing and Installing a Control Module

a. Removal:

1. Disconnect all front wire harness connectors and move wiring out of way.

2. The lower controller mounting is slotted, loosen the top mounting screw (see Figure 7.13) and lift up and out.

3. Disconnect the back connectors and remove 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 pack aging has been designed to protect the module from both physical and electrostatic discharge damage during storage and transit.

b. Installation:

Install the module by reversing the removal steps.

Torque values for mounting screws (item 2, see Figure 7.13) are 0.23 mkg (20 inch-pounds). Torque value for the connectors is 0.12 mkg (10 inch-pounds).

7.17.5 Battery Replacement Standard Battery Location (Standard Cells):

a. Turn unit power OFF and disconnect power supply.

b. Slide bracket out and remove old batteries. (See Figure 4.4, Item 8)

c. Install new batteries and slide bracket into control box slot.

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

T-359 726

Standard Battery Location (Rechargeable Cells):

a. Turn unit power OFF and disconnect power supply.

b. Disconnect battery wire connector from control box.

c. Slide out and remove old battery and bracket. (See Figure 4.4, Item 8)

d. Slide new battery pack and bracket into the control box slot.

e. Reconnect battery wire connector to control box and replace wire ties that were removed.

7.18 Vent Position Sensor Service 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 immedi- ately reappears as active, the panel should be replaced.

The alarm should immediately go inactive, check the 4-minute stability requirement. If the alarm reoccurs after the four minutes and the panel was known to have been stable, then the sensor should be replaced.

In order to replace the VPS, the panel must be removed and replaced with another upper fresh air panel equipped with VPS.

Upon installation, a new vent position sensor assembly requires calibration as follows:

1. Rotate the vent to the 0 CMH / CFM position.

2. Code select 45 will automatically display. Press the Enter key and hold for five seconds.

3. After the enter key has been pressed the display will read CAL (for calibration).

4. Press the ALT MODE key and hold for five seconds.

5. After the calibration has been completed, Code 45 will display 0 CMH / CFM.

a. Lower Vent Position Sensor Calibration

Calibration of the Lower VPS is only required when the air makeup slide, motor or sensor has been repaired or serviced.

The VPS is calibrated using the keypad:

1. Remove the two nuts that secure the air makeup panel slide to the unit.

2. Rotate the gear clockwise until it stops.

3. Rotate the gear 1/4 turn counterclockwise.

4. Carefully reposition the slide onto the air makeup panel, given that the gear is engaged with the rail and has not moved.

5. Position slide panel to the fully closed position.

6. Code select Cd45 will automatically be shown on the left display.

7. Depress the ENTER key and hold for five seconds. CAL for calibration is displayed.

8. Depress the ALT MODE key on the keypad and hold for five seconds.

9. When calibration has been completed, Cd45 causes 0 CMH/CFM to be shown on the right display.

10. Secure the air makeup panel slide to the unit with the two nuts; stake threads.

7.19 Temperature Sensor Service Procedures for service of the return recorder, return temperature, supply recorder, supply temperature, ambient, defrost temperature, evaporator temperature, and compressor discharge temperature sensors are provided in the following sub paragraphs.

727 T-359

7.19.1 Sensor Checkout Procedure

To check a sensor reading, do the following:

a. Remove the sensor and place in a 0C (32F) ice-water bath. The ice-water bath is prepared by filling an insulated container (of sufficient size to completely immerse bulb) with ice cubes or chipped ice, then filling voids between ice with water and agitating until mixture reaches 0C (32F) measured on a laboratory ther- mometer.

b. Start 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 following.

c. Turn unit OFF and disconnect power supply.

d. Refer to Section 7.17 and remove controller to gain access to the sensor plugs.

e. 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 72 and Table 73.

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.

T-359 728

Table 72 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

729 T-359

7.19.2 Sensor Replacement

a. Turn unit power OFF and disconnect power supply.

NOTE Include white date code label when cutting out and removing defective sensors. The label could be required for warranty returns.

b. Cut cable. Slide the cap and grommet off a bulb type sensor and save for reuse. Do not cut the grommet.

c. Cut one wire of existing cable 40 mm (1-1/2 inches) shorter than the other wire.

d. Cut replacement sensor wires (opposite colors) back 40 mm (1-1/2 inches). (See Figure 7.14)

e. Strip back insulation on all wiring 6.3 mm (1/4 inch).

Table 73 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

T-359 730

Figure 7.14 Sensor Types

f. Slide a large piece of heat shrink tubing over the cable, and place the two small pieces of heat shrink tubing, one over each wire, before adding crimp fit tings as shown in Figure 7.15.

Figure 7.15 Sensor and Cable Splice

1. Cable 2. Sensor (Typical) 3. Large Heat Shrink Tubing (1) 4. Heat Shrink Tubing, 2 or 3 as required

- - - - -

Sensor 40mm (1- 1/2 inch)

6.3mm (1/4- inch)

Mounting Stud Type

Sensor

40 mm (1-1/2 inches) 6.3- mm (1/4- inch)

Bulb Type

1

2

3 4

731 T-359

g. If required, slide the cap and grommet assembly onto the replacement sensor.

h. Slip crimp fittings over dressed wires (keeping wire colors together). Make sure wires are pushed into crimp fittings as far as possible and crimp with crimping tool.

i. Solder spliced wires with a 60% tin and 40% lead Rosincore solder.

j. Slide heat shrink tubing over each splice so that ends of tubing cover both ends of crimp as shown in Figure 7.15.

k. Heat tubing to shrink over splice. Make sure all seams are sealed tightly against the wiring to prevent mois- ture seepage.

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

l. Slide large heat shrink tubing over both splices and shrink.

m. Position sensor in unit as shown in Figure 7.15 and re-check sensor resistance.

n. Reinstall sensor (refer to Section 7.19.3).

NOTE The P5 Pre-Trip test must be run to inactivate probe alarms (refer to Section 5.7).

7.19.3 Sensor Re-Installation

Sensors STS and SRS To properly position a supply sensor, the sensor must be fully inserted into the probe holder. Figure 7.16. Do not allow heat shrink covering to contact the probe holder. For proper placement of the sensor, be sure to position the enlarged positioning section of the sensor against the side of the mounting clamp. This positioning will give the sensor the optimum amount of expo sure to the supply air stream, and will allow the controller to operate correctly.

Sensors RRS and RTS Reinstall the return sensor as shown in Figure 7.17. For proper placement of the return sensor, be sure to position the enlarged positioning section of the sensor against the side of the mounting clamp.

Sensor DTS The DTS sensor must have insulating material placed completely over the sensor to ensure the coil metal tempera- ture is sensed.

Sensors ETS1 and ETS2 The ETS1 and ETS2 sensors are located in a tube holder under insulation, as illustrated in Figure 7.18. When the combo sensor is removed and reinstalled, 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.

T-359 732

Figure 7.16 Supply Sensor Positioning

Figure 7.17 Return Sensor Positioning Figure 7.18 Evaporator Temperature Sensor Positioning

(2.5)

1

2

3

4

5

6

7

8

9

10

11

12

13

1. Supply Air Stream 2. Insulation 3. Back Panel 4. Supply Sensor 5. Mounting Clamp 6. Sensor Wires 7. Drip Loop

8. Gasket Mounting Plate 9. Gasketed Support Plate

10. Gasketed Cover 11. TIR Bolts 12. STS Probe 13. SRS Probe

1.50 in. (38.1cm)

1 2

1. Mounting Clamp 2. Return Sensor

1.00 in. (25.4cm)

1

2 3

4

1. Wire Tie 2. ETS1 and 2

3. ETS Tube Holder 4. Insulation

733 T-359

Sensor, CPDS

To replace the compressor discharge sensor (see Figure 7.19) do the following:

a. Ensure the unit is disconnected from the power source and that ST is in OFF position.

b. Remove the existing sensor. Clean all silicone sealer and dielectric compound from the sensor well. Ensure well is clean and dry. Top of compressor, where the sensor seals, must also be clean and dry.

Figure 7.19 Compressor Discharge Temperature Sensor

c. Using the syringe supplied with the replacement sensor, squeeze all of the dielectric compound into the sen- sor well.

d. 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.

e. Reconnect sensor (see Figure 7.15) and run a Pre-Trip Diagnosis to test.

7.20 Electronic Partlow Temperature Recorder (If Equipped) The microprocessor-based temperature recorder is designed to interface with the DataCORDER to log tempera- ture with time. The electronic recorder will automatically record the return air, supply air, or both, based on the set- ting of temperature controller configuration code CnF37, refer to Table 44. The recorder reads and records data from the controller in present time, under normal operating conditions.

If the power has been OFF for more than thirty days, the recorder will NOT re-synchronize (the chart will not advance to present time), the pen tip will move to the currently recorded temperature, and the recorder will resume normal temperature recording.

If using the Electronic Partlow Recorder CTD part number 12-00464-xx Where xx= an even number (example: 12-00464-08)

The recorder will STOP when the power is OFF, and the pen tip will remain at the last recorded temperature on the chart. When power is applied, and the power off period is less than thirty days, the recorder will retrieve the logged data from the DataCORDER for the power off period and record it onto the chart. Thereafter, the recorder will resume normal temperature recording.

If the optional DataCORDER battery pack is being used and the charge is too low to enable recording during the power off period of less than thirty days, the pen tip will move to below the inner chart ring for the period when NO data was recorded by the DataCORDER.

If the power has been OFF for more than thirty days, the recorder will NOT re-synchronize (the chart will not advance to present time), the pen tip will move to the currently recorded temperature, and the recorder will resume normal temperature recording.

SENSOR WELL

SENSOR

SILICONE BEAD

T-359 734

7.20.1 Replacing the Recorder

a. Turn power to the unit OFF.

b. Open the recorder door (item 1, see Figure 7.20).

c. Locate the connector below the recorder (item 6), and squeeze the ears together to disconnect the plug.

d. Remove the four mounting screws (item 8), and remove the recorder.

e. Install the new recorder by reversing the above steps.

Figure 7.20 Electronic Partlow Temperature Recorder

7.20.2 Re-zeroing the Recording Thermometer

For Electronic Partlow Recorder CTD part number 12-00464-xx Where xx= an odd number (example: 12-00464-03)

NOTE Use chart CTD: part number 09-00128-00 (F), part number 09-00128-01 (C).

a. Press the Calibration button (item 7, Figure 7.20) on the bottom of the recorder. The pen tip will drive fully down scale, then move upscale to the chart ring at -29C (-20F), and stop.

1

3

4

5

6

7

8

9

10

2

1. Recorder Door 2. Change Chart Button 3. Recorder Box 4. Pen Tip 5. Stylus Arm

6. Connector 7. Calibration Button (Located underneath) 8. Mounting Screws, #10-24 x 7/16 inches long 9. Hold Down Tab

10. Chart Retaining Nut

735 T-359

b. If the tip of the pen (item 4) is on the -29C (-20F) chart ring, the recorder is in calibration, proceed to step c. If the tip of the pen is NOT on the -29C (-20F) chart ring, the operator must loosen the two screws on the bottom of the stylus arm to adjust the pen tip manually to the -29C (-20F) chart ring. Tighten the screws when adjustment is complete.

c. Press the calibration button and the pen will position itself to the correct temperature reading.

For Electronic Partlow Recorder CTD part number 12-00464-xx Where xx= an even number (example: 12-00464-08)

NOTE Use chart CTD part number 09-00128-00 (F), part number 09-00128-01 (C).

a. Press the Calibration button (item 7, Figure 7.20) on the bottom of the recorder. The pen tip will drive fully down scale, then move upscale to the chart ring at 0C (32F), and stop.

b. If the tip of the pen (item 4) is on the 0C (32F) chart ring the recorder is in calibration, proceed to step c. If the tip of the pen is NOT on the 0C (32F) chart ring, the operator must loosen the two screws on the bot- tom of the stylus arm to adjust the pen tip manually to the 0C (32F) chart ring. Tighten the screws when adjustment is complete.

c. Press the calibration button and the pen will position itself to the correct temperature reading.

7.21 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 refrig- eration unit from the highly corrosive sea atmosphere, or if the protective paint system is scratched or damaged, clean 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. Refer to the Parts List for proper paint selection.

7.22 Communications Interface Module Installation

Figure 7.21 Communications Interface Installation

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. To install the module, do the fol- lowing:

CAUTION! 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.

Communications Interface Module

CB1

T-359 736

a. CB1 is connected to the power system, see wiring schematic. Ensure that the unit power is off AND that the unit power plug is disconnected.

b. Open control box, see Figure 7.21 and remove low voltage shield. Open high voltage shield. c. 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.

d. Refit the circuit breaker panel. e. Fit the new CIM into the unit. f. Attach three wires CB21/CIA3, CB22/CIA5 and CB23/CIA7 to the CIM at connection CIA. g. Locate connectors CIA and CIB, remove plugs if re quired, and attach to the module. h. Replace the low voltage shield.

Table 74 Recommended Bolt Torque Values (Dry, Non-Lubricated for 18-8 Stainless Steel)

BOLT DIA. THREADS in-lb ft-lb N-m

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

737 T-359

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

T-359 738

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

739 T-359

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

81 T-359

SECTION 8 ELECTRICAL WIRING SCHEMATICS

8.1 Introduction This section contains the Electrical Schematics and Wiring Diagrams. The diagrams are presented as follows: Figure 8.1 provides the legend for use with Figure 8.2, the schematic diagram for standard refrigeration units. Figure 8.2 provides the basic schematic diagram for standard refrigeration units. Figure 8.3 and Figure 8.4 provides the wiring diagram for standard refrigeration units.

T-359 82

Figure 8.1 LEGEND -- Evergreen Unit Configuration

SYMBOL DESCRIPTION

AMBS AMBIENT SENSOR (C--21)

C CONTROLLER (J--19)

CB1 CIRCUIT BREAKER -- 460VOLT (H--1)

CB2 OPTIONAL CIRCUIT BREAKER -- 230VOLT (DMV OPTION) TERMINAL BLOCK WHEN CB2 NOT PRESENT (H--1)

CF CONDENSER FAN CONTACTOR (M--8, P--1)

CH COMPRESSOR CONTACTOR (M--7, M--8)

CI COMMUNICATIONS INTERFACE MODULE (OPTION) (A--3)

C--L COOL LIGHT (OPTION) (M--11)

CM CONDENSER FAN MOTOR (T--6, H--10)

CP COMPRESSOR MOTOR (T--1)

CPDS DISCHARGE TEMPERATURE SENSOR (B--21)

CR CHART RECORDER (A--15)

CS CURRENT SENSOR (L--2)

DCH DRAIN CUP HEATER (T--6)

DHBL DEFROST HEATER -- BOTTOM LEFT (T--5)

DHBR DEFROST HEATER -- BOTTOM RIGHT (T--5)

DHML DEFROST HEATER -- MIDDLE LEFT (R--5)

DHMR DEFROST HEATER -- MIDDLE RIGHT (R--5)

DHT DEFROST HEATER -- TOP (T--6)

DL DEFROST LIGHT (L--6)

DPT DISCHARGE PRESSURE TRANSDUCER (K--21)

DTS DEFROST TEMPERATURE SENSOR (C--21)

DUV DIGITAL UNLOADER VALVE (E--22)

DVM DUAL VOLT MODULE (OPTIONAL) (D--1)

DVR DUAL VOLTAGE RECEPTACLE (OPTIONAL) (E--2)

EEV ELECTRONIC EXPANSION VALVE (R--14)

EF EVAPORATOR FAN CONTACTOR--HIGH SPEED (N--9, M--12)

EM EVAPORATOR FAN MOTOR (T--9, T--11, D--12, H--12)

EPT EVAPORATOR PRESSURE TRANSDUCER (G--21)

ES EVAPORATOR FAN CONTACTOR--LOW SPEED (M--11, P--8)

ETS EVAPORATOR TEMPERATURE SENSOR (SUCTION) (D--20)

ESV ECONOMIZER SOLENOID VALVE (K--9)

F FUSE (C--6, D--6, D--18, E--18)

FLA FULL LOAD AMPS

HPS HIGH PRESSURE SWITCH (G--7)

HR HEATER CONTACTOR (P--5, M--13)

LEGEND

SYMBOL DESCRIPTION

HS HUMIDITY SENSOR (OPTIONAL) (F--21)

HTT HEAT TERMINATION THERMOSTAT (G--13)

HW HEATER WIRE TERMINAL (R--4)

ICF INTERROGATOR CONNECTOR FRONT (T--21)

ICR INTERROGATOR CONNECTOR REAR (T--22)

IP INTERNAL PROTECTOR (E--12, H--10, H--12)

IRL IN--RANGE LIGHT (OPTION) (L--14)

PA UNIT PHASE CONTACTOR (L--7, M--7, N--1)

PB UNIT PHASE CONTACTOR (N--2, L--7, M--7)

PR PROBE RECEPTACLE (USDA OPTION) (E--21, L--22, M--22)

RM REMOTE MONITORING RECEPTACLE (OPTION) (L--6, M--6, L--11, M--11, L--14, M--14)

RRS RETURN RECORDER SENSOR (C--21)

RTS RETURN TEMPERATURE SENSOR (B--21)

SPT SUCTION PRESSURE TRANSDUCER (J--21)

SRS SUPPLY RECORDER SENSOR (K--21)

ST START -- STOP SWITCH (K--4, K--5)

STS SUPPLY TEMPERATURE SENSOR (A--21)

TC CONTROLLER RELAY--COOLING (H--8)

TCC TRANSFRESH COMMUNICATIONS CONNECTOR (OPTION) (D--5)

TCP CONTROLLER RELAY -- (PHASE SEQUENCING ) (K--6, K--7)

TE CONTROLLER RELAY -- (HIGH SPEED EVAPORATOR FANS( (K--12)

TH CONTROLLER RELAY -- (HEATING) (K--13)

TI IN--RANGE RELAY (F--14)

TL CONTROLLER RELAY -- (COOL LIGHT) (K--11)

TN CONTROLLER RELAY -- (CONDENSER FAN) (K--10)

TP TEST POINT (H--7, F--8, F--9, F--10, J--10, J--12, M--15)

TR TRANSFORMER (M--3)

TRANS TRANSFORMER AUTO 230/460 (OPTION) (D--2)

TRC TRANSFRESH REAR CONNECTOR (OPTION) (E--5)

TS CONTROLLER RELAY -- (ECONOMIZER SOLENOID VALVE) (E--9)

TV CONTROLLER RELAY -- (LOW SPEED EVAPORATOR FANS) (J--11)

VPS VENT POSITIONING SENSOR (UPPER) (OPTION) (P--13)

WCR WETTING CURRENT RESISTOR (H--10)

WP WATER PRESSURE SWITCH (D--10)

83 T-359

Figure 8.2 SCHEMATIC DIAGRAM -- Evergreen Unit Configuration

T-359 84

Figure 8.3 UNIT WIRING DIAGRAM -- Evergreen Unit Configuration (Sheet 1 of 2)

85 T-359

Figure 8.4 UNIT WIRING DIAGRAM -- Evergreen Unit Configuration (Sheet 2 of 2)

91 T-359

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

Index1 T-359

INDEX

Numerics 460 Volt Cable 2-2 69NT40-561-019 General Description 3-1 69NT40-561-019 Introduction 2-1

A Abnormal currents 6-6 Abnormal pressures 6-3 Adding Refrigerant to System (Full Charge) 7-7 Adding Refrigerant to System (Partial Charge) 7-7 Adjust Fresh Air Makeup Vent 5-1 Air-Cooled Condenser Section 3-4 Alarm Configuration (dCF07 - dCF10) 4-19 Alarm Troubleshooting Sequence 4-31 Assemble the Evaporator Fan Assembly 7-14

B Battery 2-1 Battery Replacement 7-25

C Cable Restraint 2-2 Check Controller Function Codes 5-3 Checking High Pressure Switch 7-10 Checking the Refrigerant Charge 7-6 Circuit Breaker 3-6 Communications Interface Module 2-2, 3-5, 4-21 Communications Interface Module Installation 7-35 Complete Inspection 5-4 Compressor 2-1, 7-7 Compressor High Temperature, Low Pressure Protec- tion 4-13 Compressor Motor 3-6 Compressor operating in reverse 6-5 Compressor Section 3-3 Compressor/Motor Assembly 3-6 Condenser Coil 2-1, 7-11 Condenser Fan and Motor Assembly 7-11 Condenser Fan Motor 3-6 Condenser Fan Override 4-13 Condenser Grille 2-2 Configuration Identification 2-1 Configuration Software (Variables) 4-4 Connect Power 5-1 Connect Remote Monitoring Receptacle 5-3 Connection To 380/460 VAC Power 5-1 Control Box 2-1

Control Box Section 3-5 Controller 2-2, 4-3, 7-22 Controller Alarm Indications 4-32 Controller Alarms 4-14 Controller Pre-trip Test Codes 4-41 Controller Programming Procedure 7-23 Controller Sequence and Modes of Operation 4-5 Controller Software 4-4 Controller Troubleshooting 7-22

D DataBANKTM Card 4-21 DataCORDER 4-15, 5-4 DataCORDER Alarm Indications 4-48 DataCORDER Alarms 4-22 DataCORDER Communications 4-20 DataCORDER Configuration Software 4-16 DataCORDER Function Code Assignments 4-46 DataCORDER Operational Software 4-16 DataCORDER Power Up 4-19 DataCORDER Software 4-16 DataLINE 4-21 DataReader 4-20 Defrost Interval 4-11 Defrost Mode - Sequence of Operation 4-11 Defrost Pulsing 4-12 Dehumidification 2-2 Digital Unloader Valve 7-20 Disassemble the Evaporator Fan Assembly 7-14 Display Module 4-2 Drain Cup Heater, Omega 3-7 DUV Coils 12 VDC 3-7

E Economizer Expansion Valve 7-17 Economizer Expansion Valve Superheat 3-6 Economizer Solenoid Valve 7-19 EEV Nominal Resistance 3-7 Electrical Data 3-6 Electronic Expansion Valve (EEV) 7-16 Electronic expansion valve malfunction 6-5 Electronic Expansion Valve Superheat (Evaporator) 3-6 Electronic Partlow Temperature Recorder 7-33 Evacuation and Dehydration 7-5 Evaporator 2-1 Evaporator 5+1 Heater Removal and Replacement 7-12 Evaporator Coil and Heater Assembly 7-12 Evaporator Coil Heater, Standard 3-7

T-359 Index2

Evaporator Coil Heater, Straight 3-7 Evaporator Coil Replacement 7-12 Evaporator Fan and Motor Assembly 7-13 Evaporator Fan Motor(s) 3-7 Evaporator Fan Operation 2-1, 4-13 Evaporator Section 3-2 Evaporator Section Cleaning 7-15

F Failure Action 4-13 Feature Descriptions 2-1 Filter Drier 7-12 Fresh Air Makeup Vent 3-1 Frozen Mode - Economy 4-10 Frozen Mode - Heat Lockout Temperature 4-9 Frozen Mode - Standard 4-9 Frozen Mode - Temperature Control 4-9 Frozen Mode Cooling - Sequence of Operation 4-10 Fuses 3-7 Fusible Plug 3-6

G Generator Protection 4-13

H Handles 2-2 Handling Modules 7-22 Heater Termination Thermostat 3-6 High Pressure Switch 3-6, 7-10 Humidity Sensor 3-8

I Inspection (Before Loading) 5-1 Interrogator 2-2 Introduction 9-1 ISO Trip Header 4-23

K Keypad 4-2

L Labels 2-2 Logging Interval (dCF03) 4-17 Lower Vent Position Sensor Calibration 7-26

M Maintenance of Painted Surfaces 7-35 Manifold Gauge Set 7-1

Manual Defrost/Interval key operation 4-11 Microprocessor malfunction 6-4

N No evaporator air flow or restricted air flow 6-4

O Observe Unit Operation 5-5 Operational Software (Function Codes) 4-4 Option Descriptions 2-1

P Partlow Recorders (If Equipped) 5-3 Perishable Mode - Dehumidification 4-8 Perishable Mode - System Pressure Regulation 4-13 Perishable Mode Cooling - Sequence of Operation 4-7 Perishable Mode Heating - Sequence of Operation 4-7 Perishable Set Point Temperature - Economy Fan Oper- ation Mode 4-5 Perishable Set Point Temperature - Perishable Pulldown 4-5 Perishable Set Point Temperature - Standard Tempera- ture Control Mode 4-5 Perishable Set Point Temperature Control 4-6 Perishable, Dehumidification - Bulb Mode 4-8 Physical Inspection 5-3 Plate Set 2-1 Preparing Manifold Gauge/Hose Set For Use 7-2 Pressure Readout 2-1 Pre-trip Data Recording 4-20 Pre-Trip Diagnosis 5-4 Pre-trip Diagnostics 4-14 Probe Diagnostic Logic 5-5 Procedure - Complete System 7-6 Procedure - Partial System 7-6 Programming Procedure for Software Versions 5328 (menu0111.ml) 7-23 Protection Modes of Operation 4-13 Pumping Down the Unit 7-4

R Recommended Bolt Torque Values 7-36 Refrigerant Charge 7-6 Refrigerant Charge - R-134a 3-6 Refrigerant Leak Checking 7-4 Refrigeration Circuit 3-9 Refrigeration Circuit - Economized Operation 3-9 Refrigeration Circuit - Electronic Expansion Valve 3-9 Refrigeration Circuit - Standard Operation 3-9 Refrigeration System Data 3-6

Index3 T-359

Refrigeration Unit - Front Section 3-1 Remote Monitoring 2-2 Removing and Installing a Control Module 7-25 Replacing Electronic Expansion Valve and Strainer 7-17 Replacing High Pressure Switch 7-11 Replacing the Evaporator Fan Assembly 7-14 Replacing the Recorder 7-34 Re-zeroing the Recording Thermometer 7-34 Rupture Disc 3-6

S Safety and Protective Devices 3-8 Sampling Type (dCF05 & dCF06) 4-19 Sensor Checkout Procedure 7-27 Sensor Configuration (dCF02) 4-16 Sensor DTS 7-31 Sensor Re-Installation 7-31 Sensor Replacement 7-29 Sensor, CPDS 7-33 Sensors ETS1 and ETS2 7-31 Sensors RRS and RTS 7-31 Sensors STS and SRS 7-31 Sequence of Operation - Perishable Mode (Capacity Trim Heat) 4-7 Service Connections 7-2 Solenoid Valve Coils (ESV) 24 VDC 3-7 Start Temperature Recorder 5-3 Start up - Compressor Bump Start 4-5 Start up - Compressor Phase Sequence 4-5 Starting and Stopping Instructions 5-3 Starting the Unit 5-3 Start-up Inspection 5-3 Stopping the Unit 5-3

T Temperature Control Microprocessor System 4-1 Temperature Readout 2-1 Temperature Recorder 2-2 Temperature Sensor Service 7-26 Thermistor Format (dCF04) 4-17 To Display Alarm Codes 4-14 To display alarm codes 4-22 To remove Omega heater 7-13 To remove straight heater 7-13 To remove U-shaped heater 7-13 To start a pre-trip test, do the following 5-4

U Unit operates long or continuously in cooling 6-1 Unit runs but has insufficient cooling 6-2

Unit Weight 3-6 Unit will not heat or has insufficient heating 6-2 Unit will not start or starts then stops 6-1 Unit will not terminate heating 6-3 Upper Air (Fresh Air Make Up) 2-2 Upper Fresh Air Makeup Vent 5-2 USDA 2-2 USDA Cold Treatment 4-21 USDA Cold Treatment Procedure 4-21 USDA Recording 4-21 USDA/ Message Trip Comment 4-21

V Valve Override Controls 7-21 Valve Replacement 7-18 Vent Position Sensor 5-2 Vent Position Sensor Service 7-26 Vent Positionin

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