Carrier 69NT20-531-300 User Manual

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Carrier Transicold

Container Refrigeration

Model 69NT20-531-300

Streamline Scroll

T-309 Rev A

Operation &Service

OPERATION AND SERVICE MANUAL

CONTAINER REFRIGERATION UNIT

MODEL

69NT20-531-300

Streamline Scroll

Carrier Transicold. A member of the United Technologies Corporation family. Stock symbol UTX. Carrier Transicold Divsion, Carrier Corporation, P .O. Box 4805, Syracuse, N.Y. 13221 U. S. A.

ã 2002 CarrierCorporation D Printed in U. S. A. 07/02

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommendedprecautions that must be understood and applied during operationand maintenance oftheequipmentcoveredherein.Thegeneralsafetynoticesarepresentedin thefollowingthreesectionslabeled:First Aid, OperatingPrecautions and MaintenancePrecautions. A listing of thespecific warnings and cautions appearing elsewhere in the manual follows the general safety notices.

FIRST AID

Aninjury,nomatterhowslight,shouldnevergounattended.Alwaysobtainfirstaidormedicalattentionimmediately.

OPERATING PRECAUTIONS

Always wear safety glasses. Keep hands, clothing and tools clear of the evaporator and condenser fans. Noworkshouldbeperformedontheunituntilallcircuitbreakers,start-stopswitchesareturnedoff,andpowersupply

is disconnected. Always work in pairs. Never work on the equipment alone. In case of severe vibration or unusual noise, stop the unit and investigate.

MAINTENANCE PRECAUTIONS

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

Besurepoweristurnedoffbeforeworkingonmotors,controllers,solenoidvalvesandelectricalcontrolswitches.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.

Whenperforminganyarcweldingontheunitorcontainer,disconnectallwireharnessconnectorsfromthemodulesin both control boxes. Do not remove wire harness from the modules unless you aregrounded to the unit frame with a static safe wrist strap.

In case of electrical fire, open circuit switch and extinguish with CO

(never use water).

UNIT LABEL IDENTIFICATION

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

DANGER -- means an immediate hazard which WILL result in severe personal injury or death. WARNING -- means to warn against hazards or unsafe conditions which COULD result in severe personal injury or

death. CAUTION -- meansto warnagainst potential hazard or unsafe practicewhich could result in minor personal injury,

product or property damage.

SPECIFIC WARNING AND CAUTION STATEMENTS

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

WARNING

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

WARNING

Do not attempt to removepower plug(s)beforeturning OFFstart-stop switch (ST), unit circuit breaker(s) and external power source.

WARNING

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

Safety-1

T-309

WARNING

Make surethatthe unitcircuit breaker(s)(CB-1 & CB-2)and theSTAR T-STOPswitch (ST)arein the “O” (OFF) position before connecting to any electrical power source.

WARNING

Never useair for leak testing. It has been determined thatpressurized,mixturesofrefrigerant and air can undergo combustion when exposed to an ignition source.

WARNING

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

WARNING

Before disassembly of the compressor make sure to relieve the internal pressure very carefully by slightly loosening the couplings to break the seal.

WARNING

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

WARNING

Wearrubberglovesand wash thesolution fromtheskin immediatelyif accidentalcontactoccurs.Do not allow the solution to splash onto concrete.

WARNING

AlwaysturnOFF the unit circuit breakers(CB-1 & CB-2) and disconnectmain power supply before working on moving parts.

WARNING

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

WARNING

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

WARNING

Do not use a nitrogencylinder without a pressureregulator. Do not use oxygen in or near a refrigeration system as an explosion may occur.

WARNING

Do not open the condenser fan grille beforeturning power OFF and disconnecting power plug.

WARNING

The Unit Power Plug Must Be Disconnected To Remove Power From Circuit Breaker Cb1

CAUTION

Donotremovewireharnessesfromcontrollermodulesunlessyouaregroundedtotheunit framewith a static safe wrist strap.

CAUTION

Unplugallcontrollermodulewireharnessconnectorsbeforeperformingarcweldingon anypartofthe container.

CAUTION

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

CAUTION

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

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Safety-2

CAUTION

When Pre-Tripkey is pressed, economy, dehumidification and bulb mode will be deactivated. At the completion of Pre-Trip activity, economy, dehumidification and bulb mode must be reactivated.

CAUTION

When a failure occurs during automatic testing the unit will suspend operation awaiting operatorintervention.

CAUTION

When Pre--Triptest Auto 2 runs to completion without being interrupted, the unitwill terminatepretripanddisplay “Auto2”“end.”The unit will suspendoperationuntil the userdepressestheENTER key!

CAUTION

Topreventtrappingliquid refrigerantin themanifoldgaugeset be suresetis broughtto suctionpressure beforedisconnecting.

CAUTION

The scroll compressor achieves lowsuction pressure very quickly.Do not use thecompressor to evacuate the system below zero psig. Never operate the compressor with the suction or discharge service valvesclosed (frontseated).Internaldamagewillresultfromoperating the compressorina deep vacuum.

CAUTION

Use only Carrier Transicold approved Polyol Ester Oil (POE) -- Mobil ST32 compressor oil with R-134a.Buyinquantitiesofonequartor smaller.When usingthishygroscopicoil, immediatelyreseal. Do not leave container of oil open or contamination will occur.

CAUTION

Takenecessarysteps(placeplywoodover coil or useslingon motor)topreventmotorfromfallinginto condenser coil.

CAUTION

DONOTdisassemblepiston fromNEWsuctionmodulatingvalvepowerheadassembly.Doing so may result in damage to pi ston.

CAUTION

The unitmust be OFFwhenevera programming card is inserted or removed fromthe controllerprogramming port.

CAUTION

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

Safety-3

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TABLE OF CONTENTS

PARAGRAPH NUMBER Page

GENERAL SAFETY NOTICES Safety-1.....................................................

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

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

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

UNIT LABEL IDENTIFICATION Safety-1...................................................

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

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

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

1.2 CONFIGURATIONIDENTIFICATION 1-1.............................................

1.3 OPTION DESCRIPTIONS 1-1.......................................................

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

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

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

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

1.3.6 Interrogator 1-1................................................................

1.3.7 Remote Monitoring 1-1..........................................................

1.3.8 Communications 1-1............................................................

1.3.9 Compressor 1-1................................................................

1.3.10 Back Panels 1-1................................................................

1.3.11 460 Volt Cable 1-2.............................................................

1.3.12 Cable Restraint 1-2..............................................................

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

1.3.14 Evaporator 1-2.................................................................

1.3.15 Evaporator Fan Operation 1-2.....................................................

1.3.16 Labels 1-2.....................................................................

1.3.17 Plate Set 1-2...................................................................

1.3.18 Controller 1-2..................................................................

1.3.19 Stepper Drive 1-2...............................................................

1.3.20 Condenser Grille 1-2............................................................

DESCRIPTION 2-1...............................................................................

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

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

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

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

2.1.4 Compressor Section 2-3..........................................................

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

2.1.6 Control Box Section 2-5.........................................................

2.1.7 Communications InterfaceModule 2-5..............................................

2.2 REFRIGERATION SYSTEM DATA 2-6...............................................

2.3 ELECTRICAL DATA 2-7...........................................................

2.4 SAFETY AND PROTECTIVE DEVICES 2-8...........................................

2.5 REFRIGERATION CIRCUIT 2-9.....................................................

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TABLE OF CONTENTS (cont)

2.5.1 Standard Operation 2-9..........................................................

2.5.2 Economized Operation 2-9.........................................................

2.5.3 Unloaded Operation 2-9...........................................................

MICROPROCESSOR 3-1..........................................................................

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

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

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

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

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

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

3.2.2 Operational Software(Function codes) 3-4...........................................

3.3 MODES OF OPERATION 3-4.......................................................

3.3.1 TemperatureControl -- Perishable Mode 3-4..........................................

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

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

3.3.4 GeneratorProtection 3-4.........................................................

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

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

3.3.7 Perishable Mode -- Economy 3-5...................................................

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

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

3.3.10 Temperature Control -- FrozenMode 3-6.............................................

3.3.11 Frozen Mode -- Conventional 3-6..................................................

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

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

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

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

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

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

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

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

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

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

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

3.6.9 Pre-T rip Data Recording 3-10......................................................

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

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

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

3.6.13 DataCORDER Alarms 3-12........................................................

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

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TABLE OF CONTENTS (cont)

OPERATION 4-1.................................................................................

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

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

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

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

4.3.1 Upper Fresh Air Makeup Vent 4-1..................................................

4.4 CONNECT REMOTE MONITORING

RECEPTACLE 4-2......................................................................

4.5 STARTINGAND STOPPING INSTRUCTIONS 4-2......................................

4.5.1 Starting the Unit 4-2.............................................................

4.5.2 Stopping the Unit 4-2............................................................

4.6 START--UP INSPECTION 4-2.......................................................

4.6.1 Physical Inspection 4-2..........................................................

4.6.2 Check Controller Function Codes 4-2...............................................

4.6.3 Complete Inspection 4-2.........................................................

4.7 PRE-TRIP DIAGNOSIS 4-2.........................................................

4.8 OBSERVEUNIT OPERATION 4-3...................................................

4.8.1 Probe Check 4-3................................................................

4.9 SEQUENCE OF OPERATION 4-4......................................................

4.9.1 Sequence Of operation -- Compressor Phase Sequence 4-5................................

4.9.2 Sequence Of Operation -- Perishable Mode Cooling 4-5..................................

4.9.3 Sequence Of Operation --

Perishable Mode Heating 4-6...........................................................

4.9.4 Sequence Of operation -- Frozen Mode Cooling 4-6.....................................

4.9.5 Sequence Of Operation -- Defrost 4-6...............................................

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

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

5.2 UNIT OPERATES LONG OR CONTINUOUSL YIN COOLING 5-1.........................

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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TABLE OF CONTENTS (cont)

SERVICE 6-1....................................................................................

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

6.2 SERVICE VALVES 6-1.............................................................

6.3. MANIFOLD GAUGE SET 6-1.......................................................

6.4 PUMPING THE UNIT DOWN 6-2....................................................

6.5 REFRIGERANT LEAK CHECKING 6-3...............................................

6.6 EVACUATION AND DEHYDRATION 6-3.............................................

6.6.1 General 6-3....................................................................

6.6.2 Preparation 6-3.................................................................

6.6.3 Procedure - Complete system 6-3..................................................

6.6.4 Procedure - Partial System 6-4.....................................................

6.7 REFRIGERANT CHARGE 6-5.......................................................

6.7.1 Checking the Refrigerant Charge 6-5................................................

6.7.2 Adding Refrigerant to System (Full Charge) 6-5.......................................

6.7.3 Adding Refrigerant to System (Partial Charge) 6-5.....................................

6.8 COMPRESSOR -- Model RSH105 6-5.................................................

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

6.9 COMPRESSOR OIL LEVEL 6-7.....................................................

6.10 HIGH PRESSURE SWITCH 6-7......................................................

6.10.1 Replacing High Pressure Switch 6-7................................................

6.10.2 Checking High Pressure Switch 6-8................................................

6.11 CONDENSER COIL 6-8............................................................

6.12 CONDENSER FAN AND MOTOR ASSEMBLY 6-8.....................................

6.13 FILTER-DRIER 6-8................................................................

6.14 EXPANSION VALVES 6-9..........................................................

6.14.1 Checking Superheat. 6-9.........................................................

6.14.2 V alve Replacement 6-9..........................................................

6.15 EVAPORATOR COIL AND HEATER

ASSEMBLY 6-10........................................................................

6.15.1 Evaporator Coil Replacement 6-10..................................................

6.15.2 Evaporator Heater Replacement 6-10................................................

6.16 ECONOMIZER, UNLOADER, LIQUID INJECTION AND OIL RETURN SOLENOID VALVE 6-11

6.17 EVAPORATOR FAN AND MOTOR ASSEMBLY 6-11....................................

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

6.18 EVAPORATOR FAN MOTOR CAPACITORS 6-12.......................................

6.18.1 When To Check For A Defective Capacitor 6-12.......................................

6.18.2 Removing The Capacitor 6-12......................................................

6.18.3 Checking The Capacitor 6-12......................................................

6.19 VALVEOVERRIDE CONTROLS 6-13.................................................

6.20 SUCTION MODULATIONVALVE 6-13................................................

6.20.1 Precheck Procedure 6-14..........................................................

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

6.21 CONTROLLER AND EXPANSION MODULE 6-14......................................

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6.21.1 Handling Modules 6-14...........................................................

6.21.2 Controller Trouble-Shooting 6-15...................................................

6.21.3 Controller Programming Procedure 6-15..............................................

6.21.4 Removing and Installing a Module 6-16..............................................

6.22 TEMPERATURE SENSOR SERVICE 6-16..............................................

6.22.1 Sensor Checkout Procedure 6-16....................................................

6.22.2 Sensor Replacement 6-17..........................................................

6.22.3 Sensor Re--Installation 6-18........................................................

6.23 MAINTENANCE OF PAINTEDSURFACES 6-18........................................

6.24 COMPOSITE CONTROL BOX REPAIRS 6-18...........................................

6.24.1 Introduction 6-18................................................................

6.24.2 Cracks 6-19....................................................................

6.24.3 Chips And Holes 6-19............................................................

6.24.4 Inserts 6-19.....................................................................

6.24.5 Door Hinge Inserts 6-19...........................................................

6.25 COMMUNICATIONS INTERFACE MODULE INSTALLATION 6-22........................

ELECTRICAL WIRING SCHEMATIC 7-1............................................................

7.1 INTRODUCTION 7-1..............................................................

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LIST OF ILLUSTRATIONS

FIGURE NUMBER Page

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

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

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

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

Figure 2-5 Control Box Section 2-5...........................................................

Figure 2-6 RefrigerationCircuit Schematic -- Standard Operation 2-10................................

Figure 2-7 RefrigerationCircuit Schematic -- Economized Operation 2-11.............................

Figure 2-8 RefrigerationCircuit Schematic -- Unloaded Operation 2-11...............................

Figure 3- 1 TemperatureControl System 3-1...................................................

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

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

Figure 3- 4 Control and Expansion Modules 3-3.................................................

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

Figure 3- 6 Data Reader 3-11.................................................................

Figure 4-1 Make Up Air Flow Chart 4-1.......................................................

Figure 4-2 Controller Operation -- Perishable Mode 4-4...........................................

Figure 4-3 Controller Operation -- Frozen Mode 4-5..............................................

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

Figure 4-5 Perishable Mode Heating 4-6.......................................................

Figure 4-6 Frozen Mode 4-6................................................................

Figure 4-7 Defrost 4-7.....................................................................

Figure 6-1 Service Valve 6-1................................................................

Figure 6-2 Suction ServiceValve 6-1.........................................................

Figure 6-3 Manifold Gauge Set 6-1...........................................................

Figure 6-4 R-134a Manifold Gauge/Hose Set 6-2................................................

Figure 6-5. Refrigeration System ServiceConnections 6-3.........................................

Figure 6-6. Compressor Service Connections 6-4................................................

Figure 6-7 Compressor Upper Mounting 6-6....................................................

Figure 6-8 Compressor Lower Mounting 6-6...................................................

Figure 6-9 High Pressure Switch Testing 6-8...................................................

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

Figure 6-11 Evaporator Expansion Valve 6-9...................................................

Figure 6-12 Hermetic Thermostatic Expansion Valve Brazing Procedure 6-10..........................

Figure 6-13 Economizer Expansion Valve 6-10..................................................

Figure 6-14. Unloader Solenoid Valve 6-11.....................................................

Figure 6-15. Oil Return Solenoid Valve(ORV), Economizer Solenoid Valve (ESV),

Liquid Injection Solenoid Valve (LIV) 6-11...........................................

Figure 6-16. Evaporator Fan Assembly 6-12.....................................................

Figure 6-17 Suction Modulation Valve (SMV) 6-13...............................................

Figure 6-18 Controller Section of the Control Box 6-15............................................

Figure 6-19 Sensor Types 6-16...............................................................

Figure 6-20 TypicalSensor and Cable Splice 6-17................................................

Figure 6-21 Supply Sensor Positioning 6-18.....................................................

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LIST OF ILLUSTRATIONS

FIGURE NUMBER Page

Figure 6-22 Return Sensor Positioning 6-18.....................................................

Figure 6-23 Door Hinge Repair 6-19...........................................................

Figure 6-24. Insert Location 6-21.............................................................

Figure 6-25. Communications Interface Installation 6-22...........................................

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

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

Figure 7-3 WIRING DIAGRAM 7-3.........................................................

LIST OF TABLES

TABLE NUMBER Page

Table 2-1 Safety and Protective Devices 2-8.....................................................

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

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

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

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

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

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

Ta ble 3-7 Controller Pre-Trip Test Codes 3-21....................................................

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

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

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

Ta ble 6-1 Compressor Kit 6-6................................................................

Table 6-2 Sensor Temperature/ResistanceChart (+/--.002%) 6-17.....................................

Table 6-3 Crack, Chip & Hole Repair Kit 6-20....................................................

T able 6-4 Insert Repair Kit 6-20...............................................................

T able 6-5 Drill Information 6-20...............................................................

Table 6-6 Recommended Bolt Torque Values 6-22.................................................

Table 6-7 R-134a Temperature - Pressure Chart 6-23...............................................

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SECTION 1

INTRODUCTION

1.1 INTRODUCTION

The Carrier Transicold model 69NT20--531-300 units are of lightweight aluminum frame construction, designedtofitinthefrontofa containerandserveasthe container front wall.

They are one piece, self-contained, all electric units which are fitted with cooling and heating systems to provide precise temperaturecontrol.

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 power. An optional autotransformer maybefittedto allow operationon nominal190/230, 3 phase,50/60 hertz power.Power forthe 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 2i 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 controller is fitted with a keypad and display for viewingor changing operatingparameters.Thedisplay isalsoequippedwithlightstoindicatevariousmodesof operation.

1.2 CONFIGURATION IDENTIFICATION

Unit identification informationis provided on a model plate located to the left of the economizer. The plate provides the unit model number and the unit parts identification number (PID). The model number identifies the overall unit configuration while the PID provides information on specific optional equipment, factory provision to allow for field installation of optional equipment and differencesin detailed parts.

Configuration identification for the models covered hereinareprovided in the Carrier Transicold Container Unit Matrix manual, publicationT--300. Printedcopies ofthe T--300may be obtainedfrom CarrierTransicold. Also,aweeklyupdatedcopymaybefoundattheCarrier Web site, www.carrier.refrigeration.com.

1.3 OPTION DESCRIPTIONS

Various options maybefactoryorfieldfittedto thebase unit. Brief descriptions of the options are provided in the following subparagraphs.

1.3.1 Battery

The controller may be fitted with standard replaceable batteries or a rechargeable battery pack.

1.3.2 Dehumidification

The unit may be fitted with a humidity sensor. This sensor allows setting of a humidity set point in the controller. In the dehumidificationmode the controller willoperatetoreduce internal container moisturelevel.

1.3.3 Control Box

The control box is constructed of composite material and may be fitted with a lockable door.

1.3.4 Temperature Readout

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

1.3.5 Pressure Readout

Theunitmaybefittedwithfactoryinstalledsuction and discharge pressure gauges. The unit is fitted with suctionanddischargetransducers.Thereadingsmaybe viewed on the controller display.

1.3.6 Interrogator

UnitsthatusetheDataCORDERfunctionarefittedwith interrogator receptacles for connection of equipment to download the recorded data. Two receptacles may be fitted, one accessible from the front of the unit and the other mounted inside the container (with the USDA receptacles).

1.3.7 Remote Monitoring

The unit may be fitted with a remote monitoring receptacle. This item allows connection of remote indicators for COOL, DEFROST and IN RANGE.

1.3.8 Communications

Theunitmay be fittedwitha communications interface module. The communications interface module is a slave module which allows communication with a master central monitoring station. The module will respondto communicationand return informationover the main power line. Refer to the ship master system technical manual for further information.

1.3.9 Compressor

The unit is fitted with a scroll compressor.

1.3.10 Back Panels

Backpanel designs that maybe fittedinclude panels of aluminumandstainlesssteel.Panels maybe fitted with access doors and/or hinge mounting.

1-1 T-309

1.3.11 460 Volt Cable

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

1.3.12 Cable Restraint

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

1.3.13 Upper Air (Fresh Air Make Up)

The unit may be fitted with an upper fresh air makeup assembly. These assemblies are supplied in two designs, the standard design and the micro design. The openings may also be fitted with screens.

1.3.14 Evaporator

Theunitis fittedwith anevaporatorcoiland a hermetic thermal expansion valve.

1.3.15 Evaporator Fan Operation

The units are fitted with Normal Evaporator Fan Operation, opening of an evaporator fan internal protector will shut down the unit.

1.3.16 Labels

OperatingInstruction and Function Code listing labels will differ depending on the options installed. For

example, additional operating instructions arerequired to describe start--up of a unit equipped with an autotransformer. Where the labels are available with additional languages, they are listed in the parts list.

1.3.17 Plate Set

Each unit is equipped with a tethered set of wiring schematic and wiring diagram plates. The plate sets are ordered using a seven digit base part numberandatwodigit dashnumber. (See UnitMatrix

Manual, T-300)

1.3.18 Controller

Replacement controllers may be ordered as a universal un--configured controller (without configuration software) or configured.

1.3.19 Stepper Drive

All the units covered by this manual have suction modulatingvalveswhichacttocontrolsystemcapacity. Unitsindicatedasbeingfittedwith“stepperdrive”have digital control motors fitted to the suction modulating valve to open and close the valve in steps as required.

1.3.20 Condenser Grille

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

T-309

1-2

SECTION 2

DESCRIPTION

2.1 GENERAL DESCRIPTION

2.1.1 Refrigeration Unit -- Front Section

The unit is designed so that the majority of the components are accessible from the front, see Figure 2-1. Theupperaccesspanels allowentryintothe evaporator section, and the center access panel allows access to the evaporator expansion valve, unloader

valve, suction modulation valve and evaporator coil heaters.Theunitmodelnumber,serialnumberandparts identificationnumbercanbefoundon the serialplateto the left of the economizer.

2.1.2 Fresh Air Makeup Vent

Thefunctionof the upperorlower makeup air vent isto provide ventilation for commodities that require fresh air circulation.

1. Access Panel (Evap. Fan #1)

2. Access Panel (Heaters, Suction Modulating Valve, Unloader Valve & Evaporator Expansion Valve)

3. Fork Lift Pockets

4. Control Box

5. Compressor

6. Receiver or Water Cooled Condenser

7. Economizer

8. Unit Serial Number, Model Number and

Figure 2-1 Refrigeration Unit -- Front Section

Parts Identification Number (PID) Plate

9. Power Cables and Plug

10. Condenser Fan

11. Interrogator Connector (Front left)

12. Blank Cover (Temperature Recorder Location)

13. Blank Cover (Lower Fresh Air Makeup Vent Location)

14. Upper Fresh Air Makeup Vent

15. Access Panel (Evap. Fan #2)

16. Compressor Protection Panel (cutaway view)

2-1

T-309

2.1.3 Evaporator Section

The evaporatorsection (Fi gure 2-2)contains the return recorder sensor, return temperature sensor, evaporator expansion valve, unloader valve, suction modulation valve, dual-speed evaporator fans (EM1 and EM2), evaporator coil and heater, defrost heaters, defrost temperature sensor, heat termination thermostat and suction temperature sensor.

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

Theevaporatorcomponents are accessiblebyremoving the upper rear panel (as shown in the illustration) or by removing the front access panels.

1. Evaporator Fan Motor #1

2. Return Recorder/Temperature Sensor

3. Humidity Sensor

4. Evaporator Fan Motor #2

5. Defrost Temperature Sensor

6. Heater Termination Thermostat

7. Evaporator Coil

8. Evaporator Coil Heaters

9. Evaporator Expansion Valve Bulb

Figure 2-2 Evaporator Section

10. Evaporator Expansion Valve

11. Low Side Access Valve

12. Suction Modulating Valve

13. Suction Temperature Sensor

14. To Compressor

15. From Coil

16. To Coil

17. Unloader Solenoid Valve

2-2T -309

2.1.4 Compressor Section

The compressor section includes the compressor (with high pressure switch) and the oil separator.

This section also contains the oil return solenoid, compressor power plug, the discharge pressure

transducer, discharge temperature sensor and the suction pressure transducers.

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

1. Compressor Guard

2. Supply Temperature/Supply Recorder Sensor Assembly

3. Ambient Sensor

4. Supply Air Thermometer Port (location)

5. Oil Drain

6. Compressor

7. Compressor Sight Glass

8 Compressor Power Plug

9. Discharge Service Valve

10. High Pressure Switch

11. Access Valve

Figure 2-3 Compressor Section

Discharge Connection (Hidden)

Economizer Connection

Suction Connection

Oil Return Connection

12. Economizer Service Valve

13. Suction Service Valve

14. Discharge Temperature Sensor

15. Oil Return Service Valve

16. Discharge Pressure Transducer

17. Oil Return Solenoid Valve

18. Oil Separator

19. From Economizer

20. To Condenser

21. From Suction Modulating Valve

22. Suction Strainer

23. Suction Pressure Transducer

2-3

T-309

2.1.5 Air Cooled Condenser Section

The air cooled condenser section (Figure 2-4) consists of the condenser fan, condenser coil, receiver, sight glass/moisture indicator, liquid line service valve, filter-drier and fusible plug.

Thecondenserfanpullsair in thebottom ofthe coiland it is discharged horizontally out through the condenser fan grille.

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

1. Grille and Venturi Assembly

2. Condenser Fan

3. Key

4. Condenser Fan Motor

5. Condenser Coil

6. Condenser Motor Mounting Bracket

7. Condenser Coil Cover

8. Economizer

9. To Evaporator Expansion Valve

10. Liquid Injection Solenoid Valve

11. From Condenser

12. To Condenser

13. To Compressor Economizer Connection

14. To Unloader Solenoid Valve

Figure 2-4 Condenser Section

22 21

15. From Compressor Discharge

16. Discharge Pressure Transducer

17. Oil Separator

18. To Oil Return Solenoid

19. Receiver

20. Sight Glass/Moisture Indicator

21. Sight Glass

22. Fusible Plug

23. Access Valve

24. Liquid Line Service Valve

25. Filter-Drier

26. Economizer Expansion Valve

27. Economizer Solenoid Valve

2-4T -309

2.1.6 Control Box Section

The control box (Figure 2-5) includes the manual operationswitches;circuitbreaker(CB-1);compressor, fan and heater contactors; control power transformer; fuses;key pad;display module; currentsensormodule; controller module expansion module and the communications interface module.

2.1.7 Communications Interface Module

The communications interface module is a slave module which allow communication with a master centralmonitoring station. The module will respond to communication and return information over the main powerline.Referto themastersystemtechnicalmanual for further information.

12 3 4 5 6 7

1920 151718

1. Compressor Phase A Contactor

2. Compressor Phase B Contactor

3. Heater Contactor

4. Display Module

5. Communications Interface Module

6. Controller/DataCORDER Module (Controller)

7. Expansion Module

8. Key Pad

9. Start-Stop Switch

10. Remote Monitoring Receptacle

Figure 2-5 Control Box Section

1 1. Manual Defrost Switch

12. Condenser Fan Switch

13. Controller Battery Pack

14. Interrogator Connector (Box Location)

15. Control Transformer

16. Evaporator Fan Contactor - High

17. Evaporator Fan Contactor - Low

18. Condenser Fan Contactor

19. Circuit Breaker -- 460V

20. Current Sensor Module

2-5

121316

10 911

T-309

2.2 REFRIGERATION SYSTEM DATA

a.Compressor/Moto

d.H

igh

ibleP

i.R

k.W

Assembly

b. Evaporator Expansion

Valve Superheat

c. Economizer Expansion

Valve Superheat

eaterTermination

f. Refrigerant Charge

g.Fus h. Sight Glass/Moisture Indicator

j. Unit Weight

ressureSwitc

upture

aterPressureSwitc

ermostat

Model RSH105 Weight (Dry) 46.5 kg (103 lb) Approved Oil Mobil ST32 Oil Charge 2957 ml (100 ounces)

The oil level range, with the compressor off,

Oil Sight Glass

should be between the bottom and one-eighth level of the sight glass.

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

4.4to6.7_C(8to12_F)

temperature

4.4 to 11.1 _C(8to20_F)

Opens 54 (¦ 3) _C = 130 (¦ 5) _F Closes 38 (¦ 4) _C = 100 (¦ 7) _F Cutout 25 (¦ 1.0) kg/cm@ = 350 (¦ 10) psig Cut-In 18 (¦ 0.7) kg/cm@ = 250 (¦ 10) psig Unit Configuration Charge Requirements -- R-134a

4--RowCoil

Water-Cooled Condenser

Receiver

5.33 kg

(11.75 lbs)

4.99kg

(11.0 lbs) Melting point 99 _C = (210 _F) Torque 6.2 to 6.9 mkg (45 to 50 ft-lbs) Torque 8.9 to 9.7 mkg (65 to 70 ft-lbs) Bursts at 35 ¦ 5% kg/cm@ = (500 ¦ 5% psig) Torque 6.2 to 6.9 mkg (45 to 50 ft-lbs)

Refer t o unit model number plate. Cut-In 0.5 ¦ 0.2 kg/cm@ (7 ¦ 3psig) Cutout 1.6 ¦ 0.4 kg/cm@ (22 ¦ 5psig)

2-6T -309

2.3 ELECTRICAL DAT A

a.CircuitBreake

c.CondenserFa

d.EvaporatorCoi

e.EvaporatorFan

f.Fuses

a. Circuit Breaker

b. Compressor

Motor

d. Evaporator Coil

Heaters

Motor(s)

f. Fuses

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

Full Load Amps (FLA) 13 amps @ 460 vac

380 vac, Single Phase,

50 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. Number of Heaters 4 Rating 750 watts +5/--10% each @ 230 vac Resistance (cold) 66.8 to 77.2 ohms @ 20 _C(68_F) Type Sheath

380 vac/50 hz 460 vac/60 hz

Full Load Amps

High Speed

Full Load Amps

Low Speed

Nominal Horsepower

High Speed

Nominal Horsepower

Low Speed

Rotations Per Minute

High Speed

Rotations Per Minute

Low Speed Voltage and Frequency 360 -- 460 vac ± 1.25 hz 400 -- 500 vac ± 1.5 hz Voltage & Frequency us-

ing power autotransformer Bearing Lubrication Factory lubricated, additional grease not required Rotation CW when viewed from shaft end Control Circuit 10 amps (F3) Controller/DataCORDER 5amps(F1&F2) Expansion Module 10 amps (F4)

180 -- 230 vac ± 1.25hz 200 -- 250 vac ± 1.5 hz

1.6 2.0

0.8 1.0

0.70 0.84

0.09 0.11

2850 rpm 3450 rpm

1425 rpm 1750 rpm

460 vac, Single Phase,

60 hz

2-7

T-309

PARAGRAPH 2.3 -- Continued

idityS

Orange wire Power Red wire Output Brown wire Ground Input voltage 5vdc

g.Hum

ensor

Output voltage 0to3.3vdc

30% 0.99 V 50% 1.65 V 70% 2.31 V 90% 2.97 V

Output voltage readings verses relative humidity (RH) percentage:

2.4 SAFETY AND PROTECTIVE DEVICES

Unit components are protected from damage by safety and protective devices listed in t he following table. Thesedevicesmonitortheunitoperatingconditionsand open a set of electrical contacts when an unsafe condition occurs.

Open safetyswitch contacts oneitherorbothofdevices

Table 2-1 Safety and Protective Devices

UNSAFE CONDITION

IP-CP or HPS will shut down the compressor. Opensafetyswitch contacts ondeviceIP-CM will shut

down the condenser fan motor. Theentirerefrigerationunit willshutdown ifoneofthe

following safety devices open: (a) Circuit Breaker(s); (b)Fuse(F3/15A);or(c)EvaporatorFanMotorInternal Protector(s) -- (IP-EM).

DEVICE DEVICE SETTING

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

Excessive current draw Circuit Breaker (CB-2, 50 amp) --Manual Reset Tripsat 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

Excessive current draw by the controller

Excessive current draw by the expansion module

Excessive condenser fan motor winding temperature

Fuse (F3) 10 amp rating

Fuse (F1 & F2) 5 amp rating

Fuse (F4) 10 amp rating

Internal Protector (IP-CM) -- Automatic Reset N/A

Excessive compressor motor winding temperature

Excessive evaporator fan motor(s) winding temperature

Abnormal pressures/temperatures in the high refrigerant side

Abnormally high discharge pressure

Internal Protector (IP-CP) -- Automatic Reset N/A

Internal Protector(s) (IP-EM) -- Automatic Reset N/A Fusible Plug -- Used on the Receiver

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

93 _C = (200 _F) 35 kg/cm@ = (500 psig)

denser High Pressure Switch (HPS)

2-8T -309

Opens at 25 kg/cm@ (350 psig)

2.5 REFRIGERATION CIRCUIT

2.5.1 Standard Operation

Starting at the compressor, (see Figure 2-6, upper schematic) the suction gas is compressed to a higher pressure and temperature.

Inthestandardmode,boththeeconomizerandunloader solenoid valves are closed. The gas flows through the discharge service valve into the oil separator. In the separator,oil is removed from the refrigerantand stored forreturntothecompressorwhentheoil returnsolenoid valveisopenedbythecontroller.Theoilreturnsolenoid valveisanormallyopenvalvewhichallowsreturnofoil during the off cycle. The refrigerant gas continues into the air-cooled condenser. When operating with the air-cooled condenser active, air flowing across the coil fins and tubes cools the gas to saturation temperature. By removing latent heat, the gas condenses to a high pressure/high temperature liquid and flows to the receiver which stores the additional charge necessary for low temperature operation.

Whenoperatingwiththewatercooledcondenseractive (see Figure 2-6, lower schematic), the refrigerant gas passes through the air cooled condenser and enters the watercooled condenser shell. The waterflowinginside thetubing coolsthe gasto saturationtemperatureinthe same manner as the air passing over the air cooled condenser. The refrigerant condenses on the outside of the tubes and exits as a high temperature liquid. The water cooled condenser also acts as a receiver, storing excess refrigerant.

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

Theevaporatorexpansionvalveisactivatedbythebulb strapped to the suction line near the evaporator outlet. The valve maintains a constant superheat at the coil outlet regardless of load conditions.

On systems fitted with a water pressure switch, the condenser fan will be off when there is sufficient pressure to open the switch. If water pressure drops belowthe switch cut out setting, thecondenser fanwill be automatically started. When operating a system fitted with a condenser fan switch, the condenser fan willbeoffwhentheswitch isplaced in the“O”position. The condenser fan will be on when theswitch is placed in the “I” position.

2.5.2 Economized Operation

Intheeconomizedmodethefrozenrangeandpulldown capacityoftheunitisincreasedbysubcoolingtheliquid refrigerant entering the evaporator expansion valve. Overall efficiency is increased because the gas leaving the economizer enters the compressor at a higher pressure, therefore requiring less energy to compress it to the required condensing conditions.

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

Liquid refrigerant for use in the economizer circuit is taken from the main liquid line as it leaves the filter--drier(seeFigure 2-7).Theflowis activatedwhen thecontroller energizesthe economizer solenoid valve. The liquid refrigerant flows through the economizer expansion valve and the economizer internal passages absorbingheatfromtheliquid refrigerantflowingtothe evaporator expansion valve. The resultant “medium” temperature/pressure gas enters the compressor at the economizer service valve.

2.5.3 Unloaded Operation

The system will operate in the unloaded mode during periods of low load, during periods of required discharge pressure or current limiting, and during start--up.

During unloaded operation, flow of refrigerantthrough the main refrigerant system is identical to the standard mode. (The economizersolenoid valve isde--energized [closed] by the controller.)

In the unloaded mode, a portion of the mid--stage compressed gas is bypassed to decrease compressor capacity. The flow is activated when the controller opens the unloader solenoid valve (see Figure 2-7. Opening of the valve creates a bypass from the economizerservicevalvethroughtheunloadersolenoid valve and into the suction line on the outlet side of the suction pressure modulation valve.

Asloadonthesystemdecreases,thesuctionmodulating valve decreases flow of refrigerant to the compressor. This action balances the compressor capacity with the loadandpreventsoperation with low coiltemperatures. In this mode of operation, the liquid injection solenoid valve will open as required to provide sufficientliquid refrigerant flow into the suction line for cooling of the compressor motor.

2-9

T-309

EVAPORATOR

STANDARD OPERATION WITH RECEIVER

LOW SIDE ACCESS VALVE

FILTER DRIER

ECONOMIZER

TXV

LIQUID LINE SERVICE CONNECTION

CONDENSER

ESV

FUSIBLE PLUG

TXV BULB

TXV

USV

LIV

ECONOMIZER TXV BULB

ECONOMIZER

OIL SEPARATOR

RECEIVER

SIGHTGLASS

MOISTURE INDICATOR

DISCHARGE LIQUID SUCTION

DPT

CPDS

ORV

OIL RETURN SERVICE VALVE

SMV

COMPRESSOR

DISCHARGE

SERVICE

CONNECTION

HPS

ECONOMIZER SERVICE CONNECTION

SUCTIONSERVICE CONNECTION

SPT

STS

FILTER DRIER

STANDARD OPERATION WITH WATER COOLED CONDENSER

ECONOMIZER

TXV

LIQUID LINE SERVICE CONNECTION

EVAPORATOR

CONDENSER

ECONOMIZER TXV BULB

ECONOMIZER

ESV

SIGHTGLASS/

MOISTURE INDICATOR

TXV

RUPTURE DISC

WATER COOLED CONDENSER

TXV BULB

LIV

LOW SIDE ACCESS VALVE

USV

DPT

CPDS

ORV

OIL RETURN SERVICE VALVE

SMV

COMPRESSOR

DISCHARGE

SERVICE

CONNECTION

HPS

SPT

QUENCH

TXV

BULB

ECONOMIZER SERVICE CONNECTION

SUCTIONSERVICE CONNECTION

CPSS

Figure 2-6 Refrigeration Circuit Schematic -- Standard Operation

2-10T-309

EVAPORATOR

LOW SIDE ACCESS VALVE

CONDENSER

ESV

ECONOMIZER

TXV

LIQUID LINE SERVICE CONNECTION

ECONOMIZER TXV BULB

ECONOMIZER

RECEIVER

LIQUID ECONOMIZER PRESSURE

TXV BULB

TXV

LIV

OIL SEPARATOR

SMV

ECONOMIZER SERVICE CONNECTION

Figure 2-7 Refrigeration Circuit Schematic -- Economized Operation

TXV BULB

TXV

LIV

ECONOMIZER TXV BULB

OIL SEPARATOR

RECEIVER

SMV

USV

SUCTIONSERVICE CONNECTION

LIQUID ECONOMIZER PRESSURE

SUCTION

Figure 2-8 Refrigeration Circuit Schematic -- Unloaded Operation

2-11

T-309

SECTION 3

MICROPROCESSOR

3.1 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM

The temperature control Micro-Link 2i microprocessor system (see Figure 3- 1) consists of a key pad, display module, the control module & expansion module set (controller)and interconnecting wiring. The controller houses the temperature control software and the DataCORDER Software. The temperature control software functions to operate the unit components as required to provide the desired cargo temperature and humidity. The DataCORDER software functions to

record unitoperatingparameters and cargo temperature parameters for future retrieval. Coverage of the temperaturecontrolsoftwarebeginswithparagraph3.2. Coverageof theDataCORDER software is providedin paragraph 3.6.

The key pad and display module serve to provide user accessand readoutsfor bothofthe controller functions, temperaturecontrol and DataCORDER. The functions are accessed by key pad selections and viewed on the displaymodule.Thecomponentsaredesignedtopermit ease of installation and removal.

C O N T R O L L E R

TEMPERATURE CONTROL SOFTWARE

CONFIGURATION

SOFTWARE

CONFIGURATION

VARIABLE

(CnF##)

CONTROL MODULE DISPLAY MODULE

EXPANSION MODULE

KEY PAD

OPERATIONAL

SOFTWARE

FUNCTION CODE (Cd)

DataCORDER SOFTWARE

ALARMS

(AL<70)

DISPLAY

PRE--TRIP INTERROGATION

CONNECTOR

DATAREADER

CONFIGURATION

SOFTWARE

CONFIGURATION

VARIABLE

(dCF## read only)

OPERATIONAL

SOFTWARE

FUNCTION CODE (dC)

Figure 3- 1 Temperature Control System

ALARMS

(AL>69)

DISPLAY

STORAGE

MEMORY

(Scrollback)

3-1

DATA

DISPLAY

Computer Device

With DataLine

Software

T-309

3.1.1 Key Pad

Thekey pad (Figure 3- 2)is mounted on the right-hand side of the control box. The key pad consists of eleven pushbuttonswitchesthatactas the user’sinterfacewith the controller. Descriptions of the switch functions are provided in Table 3-1.

CODE

SELECT

ALARM

LIST

RETURN

SUPPLY

BATTERY

POWER

Figure 3- 2 Key Pad

COOL HEAT DEFROST IN RANGEALARM SUPPLY RETURN

PRE

TRIP

DEFROST INTERVAL

ENTER

ALT.

MODE

Table 3-1 Key Pad Function

KEY FUNCTION

Code Select Accesses function codes.

Pre-Trip

Alarm List

Defrost

Interval

Enter

Arrow Up

Arrow

Down

Return/

Supply

Displaysthe pre-trip selection menu. Discontinues pre-trip in progress.

Displaysalarm list and clears the alarm queue.

Displaysselected defrost interval. Confirmsa selection or saves a selection

to the controller. Change or scroll a selection upward Pre-

trip advance or test interruption. Change or scroll a selection downward.

Pre-trip repeat backward. Displays non-controlling probe tempera-

ture (momentary display). Displaysalternate English/Metricscale

(momentary display). When set to _F, pressure is displayed in psig and vacuum in “/hg. “P” appears after the value to in-

_C/_F

dicate 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 and function code selection if AC power is not connected.

This key is pressed to switch the functions from the temperature software to the Da-

ALT Mode

taCORDERSoftware. The remaining keys function the same as described above except the readings or changes are made to the DataCORDER programming..

SETPOINT/Code AIR TEMPERATURE/Data

Figure 3- 3 Display Module

3.1.2 Display Module

The display module (Figure 3- 3) consists of two backlightedfivedigit LCD displaysandsevenindicator lights. The i ndicator lights include:

1. Cool -- White LED: Energized when the refrigerant

compressor is energized.

2. Heat-- OrangeLED:Energized toindicateheaterop-

eration in the heat or defrost mode.

3. Defrost-- OrangeLED: Energizedwhentheunit isin

the defrost mode.

4. In-Range -- Green LED: Energized whe n the con-

trolled temperature probe is within specified tolerance of set point.

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--YellowLED:Energizedwhenthesupplyair probe is used for control. When this LED is illuminated,the temperaturedisplayed in the AIR TEMPERATURE display is the reading at the supply air probe. ThisLED will flash if dehumidificationor humidification is enabled.

6. Return -- YellowLED:Energizedwhenthereturnair

probe is used for control. When this LED is illuminated, the temperature displayed in the AIR TEMPERA TUREdisplayis thereading atthe returnairprobe. This LED will flash if dehumidification or humidification is enabled.

7. Alarm-- Red LED: Energizedwhenthereis anactive

or an inactive shutdown alarm in the alarm queue

3-2T -309

33 3 3 345 67

1. Mounting Screw

2. Micro-Link 2i Control/DataCORDER Module

3. Connectors

4. Test Points

5. Fuses

3.1.3 Controller

Figure 3- 4 Control and Expansion Modules

3 3 3

CAUTION

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

CAUTION

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

NOTE

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

The Micro--Link 2i controller is a dual module microprocessoras shown inFigure 3- 4. Itis fittedwith test points, harness connectors and a software card programming port.

3.2 CONTROLLER SOFTWARE

The controller software is a custom designed program that is subdivided into the Configuration Software and the Operational Software. The controller software performs the following functions:

a. Control supply or return air temperature to required

limits, provide modulated refrigeration operation, economized operation, unloaded operation, electric heatcontrolanddefrost. Defrost isperformedtoclear build up of frost and ice and ensure proper air flow across the coil.

b. Providedefaultindependentreadoutsofsetpointand

supply or return air temperatures.

6. Control Circuit Power Connection (Location: In back of controller)

7. Software Programming Port

8. Battery Pack

9. Expansion Module

c. Provide abilityto readand (ifapplicable)modifythe

Configuration Software Variables, Operating Software Function Codes and Alarm Code Indications.

d. ProvideaPre-Tripstep-by-stepcheckoutofrefrigera-

tion unit performance including: proper component operation,electronicand refrigerationcontroloperation, heater operation, probe calibration, pressure limiting and current limiting settings.

e. Provide battery powered ability to access or change

selected codes and set point without AC power connected

f. Providetheabilitytoreprogramthe softwarethrough

theuseofamemorycard. Thememorycardautomaticallydownloadsnewsoftwaretothecontrollerwhen inserted.

3.2.1 Configuration Software (Configuration Variables)

The Configuration Software is a variable listing of the components available for use by the Operational Software. This software is factory installed in accordance withthe equipmentfitted and options listed on the original purchase order. Changes to the Configuration Software are required only when a new controller hase been installed or a physical change has beenmadetothe unit suchasthe additionor removalof an option. A Configuration Variable list is provided in Table 3-4. Change to the factory installed ConfigurationSoftwareis achievedvia a configuration card or communications.

3-3

T-309

3.2.2 Operational Software (Function codes)

The Operational Software is the actual operation programming of the controller which activates or deactivates components inaccordancewith currentunit operating conditions and operator selected modes of operation.

TheprogrammingisdividedintofunctionCodes.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 Table3-5.

Toaccess 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 30 seconds.

3.3 MODES OF OPERATION

The Operational Software responds to various inputs. These inputs come from the temperature and pressure sensors,thetemperaturesetpoint,the settings of thethe configuration variables and the function code assignments. The action t aken by the Operational Software will change if any one of the inputs changes. Overall interaction of the inputs is described as a “mode” of operation. The modes of operation include, perishable (chill) mode and frozen mode. Descriptions ofthe controllerinteractionand modesof operationare provided in the following sub paragraphs.

3.3.1 Temperature Control -- Perishable Mode

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

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

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

3.3.2 Defrost Interval

Function code Cd27 may be operator set to initiate defrostatintervalsof3, 6,9, 12or24hours. It mayalso be set to OFF (no defrost). The factory default is 12 hours. (Refer to Table 3-5).

3.3.3 Failure Action

Function code Cd29 may be operator set to allow continuedoperation in the event the control sensors are readingout of range. The factory default is full system shutdown. (Refer to Table 3-5).

3.3.4 Generator Protection

Function codes Cd31(Stagger Start, Offset Time) and Cd32 (Current Limit) may be operator set to control startupsequenceofmultipleunitsandoperatingcurrent draw.Thefactorydefaultallowsondemandstarting(no delay) of units and normal current draw. Refer to Table 3-5.

3.3.5 Compressor High Temperature, Low Pressure Protection.

The controller monitors compressor suction and discharge temperatures and pressures. If the discharge temperature exceedsa certain limit, the liquidinjection valve is opened to provide sufficient liquid refrigerant flow into the economizer line to reduce the discharge temperature. If the liquid injection is unable to reduce the discharge temperature sufficiently and the temperature exceeds the allowed limit, the compressor willcycle off on a 3 minute timer. The compressorwill alsocycleoffinasimilarmannerifthe suction pressure fallsbelowtheallowedlimit.Condenserandevaporator fans continue to operate during t he compressor off cycle.

3.3.6 Perishable Mode -- Conventional

The unit is capable of maintaining supply air temperaturet o within ¦0.25_C(¦0.5_F)of set point. Supply air temperature is controlled by positioning of the suction modulation valve (SMV), cycling of the compressor and cycling of the heaters.

When cooling from a temperature that is more than

2.5_C (4.5_F)abovesetpoint, t he systemwill bein the

perishable pull down mode. It will be in economized operation with a target S MV position of 100% open. However, pressure and current limit functions may restrict the valve, if either exceeds the preset value.

Once set point is reached, the unit will transition to the perishable steady state mode. This results in unloaded operationwith some restriction of the SMV. The SMV will continue to close and restrict refrigerant flow until the capacity of the unit and the load are balanced.

If the SMV is at minimum modulation, the controller has determined that cooling is not required, or the controllerlogicdeterminessuctionpressureisatthelow 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 temperaturerises above set point +0.2_C, the unit will transition back to the perishable steady state mode

If the temperature drops to 0.5_C (0.9_F) below set point, t he unit will transition to the perishable heating

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mode and the heaters will be energized . The unit will transition back to the perishable idle mode when the temperaturerises to 0.2_C (0.4_F) below the set point and the heaters will de-energize

3.3.7 Perishable Mode -- Economy

Theeconomy mode is an extensionof the conventional mode. The mode is activated when the setting of function code Cd34 is “ON”. Economy mode is provided for power saving purposes. Economy mode could be utilized in the transportation of temperature tolerant cargo or non-respiration items which do not require high airflow for removing respiration heat. Thereisno active display indicatorthateconomy mode has been activated. To check for economy mode, perform a manual display of code Cd34.

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

At the start of each cooling or heating cycle, the evaporator fans will be run in high speed for three minutes. They will then be switched to low speed any time the supply air temperature is within ¦ 0.25_C (0.45_F)ofthesetpointandthereturnairtemperatureis less than or equal to the supply air temperature + 3_C (5.4_F). The fans will continue to run in low speed for onehour.Attheendofthehour,theevaporatorfanswill switchbackto highspeedandthecyclewillberepeated. Ifbulb mode is active, theeconomy fanactivity will be overwritten.

3.3.8 Perishable Mode -- Dehumidification

The dehumidification mode is provided to reduce the humidity levels inside the container. The mode is activated when a humidity value is set at at function codeCd33. The display moduleSUPPLY 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 temperatureis less than 0.25_C aboveset point.

3. Theheaterdebouncetimer(threeminutes)hastimed out.

4. Heater termination thermostat (HTT) is closed.

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

In the dehumidification mode power is applied to the defrost and drain pan heaters. This added heat load

causes the controller t o open the suction modulating valve to match the increased heat load while still holding the supply air temperature very close to the set point.

Opening t he modulating valve reduces the temperature oftheevaporatorcoil surface,whichincreasestherateat which water is condensed from the passing air. Removing water from the air reduces the relative humidity. When the relative humidity sensed is 2% belowtheset point , the controllerde-energizestheheat relay. The controller will continue to cycle heating to maintainrelativehumiditybelowtheselectedsetpoint. If the mode is terminated by a condition other than the humidity sensor, e.g., an out-of-range or compressor shutdown condition, the heat relay is de-energized immediately.

Two timers are activatedin the dehumidificationmode toprevent rapid cycling and consequent contactorwear. They are:

1. Heater debounce timer (three minutes).

2. Out-of-range timer (five minutes). The heater debounce timer is started whenever the

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

The out-of-range timer is started to maintain heater operationduring atemporary out-of-rangecondition.If the supply air temperature remains outside of the user selectedin-rangesettingformorethanfiveminutes,the heaters will be de-energized to allow the system to recover. The out-of-range timer starts as soon as the temperature exceeds thein-range tolerancevalue set by function code Cd30.

3.3.9 Perishable, Dehumidification -- Bulb Mode

Bulb mode is an extension of the dehumidification modewhichallows changes to theevaporatorfanspeed and/or defrost termination set points.

Bulb mode is active when configuration code Cd35 is set to “Bulb”. Once thebulbmode is activated, theuser maythenchangethedehumidificationmodeevaporator fan operation from the default (speed alternates from low tohigh each hour) toconstant low or constant high speed. This is done by toggling function code Cd36 fromitsdefaultof“alt”to“Lo”or“Hi”asdesired.Iflow speedevaporatorfan operationis selected,thisgivesthe user the additional capability of selecting dehumidificationset points from 60 to 95% (instead of the normal 65 to 95%).

In addition, if bulb mode is active, function codeCd37 may be set to override the previous defrost termination thermostat settings. (Refer to paragraph 4.9.5.) The temperatureatwhichthedefrostterminationthermostat will be considered “open” may be changed [in 0.1_C (0.2_F) increments] to any value between 25.6_C (78_F)and4_C(39.2_F).Thetemperatureatwhichthe defrosttermination thermostat is considered closed for interval timer start or demand defrost is 10_Cfor “open” values from 25.6_C(78_F) down to a 10_C setting. For “open” values lower than 10_C, the “closed” values will decrease to the same value as the “open” setting. Bulb mode is terminated when:

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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 m ode is disabled by any of the above, the evaporatorfanoperationfordehumidificationrevertsto “alt”andtheDTS terminationsettingresetstothevalue determinedbycontrollerconfigurationvariableCnF41.

3.3.10 Temperature Control -- Frozen Mode

With configuration variable CnF26 (Heat Lockout Temperature)setto--10_Cthefrozenmodeofoperation is active with set points at or below --10_C(+14_F). Withthe variableset to --5_C,the frozenmodeis active at or below --5_C(+23_F).

When in the frozen mode the controller maintains the return air temperature at set point, the RETURN indicatorlightwillbeilluminatedonthedisplaymodule 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.

3.3.11 Frozen Mode -- Conventional

Frozen range cargos are not sensitive to minor temperature changes. The method of temperature control employed in this range takes advantage of this facttogreatlyimprovetheenergyefficiencyof the unit. Temperaturecontrolinthefrozenrangeisaccomplished bycyclingthecompressoronandoffastheloaddemand requires.

When cooling from a temperature that is more than

2.5_C (4.5_F)abovesetpoint, t he systemwill bein the

frozenpull downmode. It will transition to economized operation with a target S MV position of 100% open. However, pressure and current limit functions may restrict the valve, if either exceeds the preset value.

Once set point is reached, the unit will transition to the frozen steady state mode. (Economized operation with maximumallowed suctionmodulating valve opening.)

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

If the temperature drops 10_Cbelow set point, the unit will transition t o the frozen “heating” mode. In the frozenheating mode the evaporator fans are brought to high speed. The unit will transition back to the frozen steadystatemodewhenthetemperaturerisesbacktothe transition point.

3.3.12 Frozen Mode -- Economy

In order to activate economy frozen mode operation, a frozen set point temperature must be selected. The economymodeis activewhenfunctioncodeCd34isset

to “ON”. When economy mode frozen is active, the system will perform normal frozen mode operations except that the entire refrigeration system, excluding the controller, will be turned off when the control temperatureis less than or equal to the set point -- 2_C. After an off-cycle period of 60 minutes, the unit will turn on high speed evaporator fans for three minutes, and then check the control temperature. If the control temperature is greater than or equal to the set point +

0.2_C., theunit will restarttherefrigerationsystem and continue to cool until the previously mentioned off-cycle temperature criteria are met. If the control temperatureis less than the set point + 0. 2_C, the unit will turn off the evaporator fans and restart another 60 minute off-cycle.

3.4 CONTROLLER ALARMS

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

The alarm philosophy balances the protection of the refrigeration unit and that of the refrigerated cargo.The action taken when an error isdetected alwaysconsiders thesurvivalof the cargo.Rechecksare made to confirm that an error actually exists.

Somealarmsrequiringcompressorshutdownhavetime delaysbeforeand aftertotry t o keep the compressoron 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 13, 17, 20, 21, 22, 23, 24, 25, 26, and 27.

b. If a detectable problem is found to exist, its alarm

code will be alternately displayed with the set point on the left display.

c. The usershouldscroll through thealarmlist to deter-

minewhatalarmsexist or haveexisted. Alarms must bediagnosedand correctedbeforetheAlarmListcan

be cleared. To Display Alarm Codes : a. While in the Default Display mode, press the

ALARMLISTkey.ThisaccessestheAlarm ListDis-

playMode,whichdisplaysanyalarmsarchivedinthe

Alarm Queue. b. The alarm queue stores up to 16 alarms in the se-

quence in which they occurred. The user may scroll

through the list by depressing an ARROW key. c. The left display will show “AL##,” where ## is the

alarm number sequentially in the queue. d. The right display will show the actual alarm code.

“AA##”will display for an activealarm, where “##”

isthealarmcode. Or “IA##”willdisplay for aninac-

tive alarm. See Table3-6.

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e. “END” is displayed to indicate the end of the alarm

list if any alarms are active.

f. “CLEAr” is displayed if all alarmsare inactive. The

alarmqueuemaythan be clearedbypressingtheENTER key. The alarm list will clear and “

-- -- -- -- -- ”

will be displayed.

3.5. UNIT PRE-TRIP DIAGNOSTICS

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

CAUTION

Pre-tripinspectionshould not be performed with critical temperaturecargoes inthe container.

CAUTION

When Pre-Trip keyis pressed, economy, dehumidification and bulb mode will be deactivated.Atthecompletionof Pre-Tripactivity, economy, dehumidification and bulb mode must be reactivated.

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

At the end of a pre-trip test, the message “P,” “rSLts” (pretestresults)will be displayed. Pressingthe ENTER keywillallowthe usertoseethe resultsforall subtests. The results will be displayed as “PASS”or “FAIL”for all the tests run to completion.

Adetaileddescriptionofthepre-triptestsandtestcodes isprovidedinTable3-7.detailedoperatinginstructions are provided in paragraph 4.7.

3.6 DataCORDER

3.6.1 Description

The Carrier Transicold “DataCORDER,” software is integratedinto thecontrollerand servesto eliminatethe temperature recorder and paper chart. The DataCORDER functions may be accessed by key pad selectionsandviewedonthedisplaymodule.Theunitis also fitted with interrogation connections (see Figure 3- 1) which may be used with the Carrier Transicold Data Reader to down load data. A personal computer with Carrier Transicold Data View 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 InterrogationConnections Power supply (battery pack).

The DataCORDER performs the following functions: a. Logs data at 15, 30, 60 or 120 minute intervals and

storestwoyears’ofdata(basedononehourinterval). b. Records and displays alarms on the display module. c. Records results of pre--trip testing. d. RecordsDataCORDERandtemperaturecontrolsoft-

ware generated data and events as follows:

Container ID Change Software Upgrades Alarm Activity BatteryLow (Battery Pack) Data Retrieval Defrost Start and End DehumidificationStart and End Power Loss (w/wo battery pack) Power Up (w/wo battery pack) Remote Probe Temperatures in the Container

(USDA Cold treatmentand Cargo probe recording) Return Air Temperature Set Point Change Supply Air Temperature RealTimeClockBattery(InternalBattery)Replace-

ment Real TimeClock Modification Trip Start ISO Trip Header (When entered via Interrogation

program) Economy Mode Start and End “Auto 2” Pre-Trip Start and End Bulb Mode Start Bulb Mode changes Bulb Mode End USDA TripComment HumidificationStart and End USDA Probe Calibration

3.6.2 DataCORDER Software

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

a. Operational Software

The Operational Software reads and interprets inputs for use by the Configuration Software. The inputs are labeled Function Codes. There are 35 functions (see Table 3-8) which the operator may access to examine the current input data or stored data. To access these codes, do the following:

1 Press the ALT. MODE & CODE SELECT keys. 2 Press an arrowkeyuntil the leftwindow displaysthe

desiredcode number.The right window will display

the value of this item for five seconds beforereturn-

ing to t he normal display mode. 3 If a longer time is desired, press the ENTER key to

extend the time to 30 seconds.

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Table 3-2 DataCORDER Configuration Variables

CONFIGURATION NO.

TITLE DEFAULT OPTION

dCF01 (Future Use) -- -- -- -dCF02 Sensor Configuration 2 2,5,6,9,54,64,94 dCF03 Logging Interval (Minutes) 60 15,30,60,120 dCF04 Thermistor Format Short Low, Normal 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

b. Configuration Software

The configuration software controls the recording and alarmfunctionsoftheDataCORDER.Reprogramming tothefactoryinstalledconfigurationisachievedviathe same configuration card as the unit control module software. Changes to the unit DataCORDER configuration may be made made using the Data View integration device. A listing of the configuration variables is provided in Table3-2. Descriptions of DataCORDER operation for each variable setting are provided in the following paragraphs.

3.6.3 Sensor Configuration (dCF02)

Two modes of operation may be configured, the Standard Mode and the Generic Mode.

a. Standard Mode

In the standard mode, the user may configure the DataCORDER to record data using one of seven standard configurations. Standard configuration variables, with descriptions, are listed in Table 3-3. Thesixthermistorinputs (supply,return,USDA#1,#2, #3 and cargoprobe) andthe humidity sensor input will be generated by the DataCORDER. An example of a report using a standard configuration is shown in Figure 3- 5.

NOTE

The DataCORDER software uses the supply and return recorder

sensors (SRS,RRS). The temperature control software uses the supply and return temperature

b. Generic Mode

sensors (STS,RTS) .

Thegeneric recordingmode allowsuserselectionof 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 CarrierTransicoldData Retrieval Program.

1. Control mode

2. Control temperature

3. Frequency

4. Humidity

5. Phase A current

6. Phase B current

7. Phase C current

8. Main voltage

9. Suction modulation valve percentage

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

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

12. Ambient sensor

13. Compressor suction sensor

14. Compressor discharge sensor

15. Return temperature sensor

16. Supply temperature sensor

17 Defrost temperature sensor

18. Discharge pressure transducer

19. Suction pressure transducer

20. Condenser pressure transducer

Table 3-3 DataCORDER Standard Configurations

Standard

Config.

2sensors

(dCF02=2)

5sensors

(dCF02=5)

6sensors

(dCF02=6)

9sensors

(dCF02=9)

6sensors

(dCF02=54)

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

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

3 USDA thermistor inputs 1 humidity input

Not Applicable 2 thermistor inputs(supply & return)

3 USDA thermistor inputs 1 cargo probe (thermistor input)

Description

2 thermistor inputs(supply & return)

7sensors

(dCF02=64)

3 USDA thermistor inputs 1 humidity input 1 cargo probe (thermistor input)

2 thermistor inputs(supply & return)

10 sensors

(dCF02=94)

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

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Raw Data Report for ABC1234567

May31, 2001 to Jun 04, 2001

SystemConfigurationat the TimeofInterrogation: Interrogated On Sept 05, 2001

Extracted by DataLineRev 1.0.0

ControllerSoftware:5120 ControllerSerial#:04163552

Billof Lading#: 1 Origin: Origin Date: Destination: Discharge Date: Comment:DataLineTool

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

May31, 2001 Setpoint: 1.66,Container : Serial : 04189552 9 SensorsLogged at15 MinuteInterval Sensor Format Resolution

Figure 3- 5 Standard Configuration Download Report

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3.6.4

Logging Interval (dCF03)

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

3.6.5 Thermistor Format (dCF04)

The user may configure the format in which the thermistorreadingsarerecorded. Theshortresolutionis a1byteformatandthelongresolutionisa2byteformat. Theshortrequireslessmemoryandrecordstemperature in0.25°C(0.45°F)stepswhenintheperishablemodeor

0.5°C (0.9°F) steps when in the frozen mode. The long records temperature in 0.01°C (0.02°F) steps for the entire range.

3.6.6 Sampling Type (dCF05 & dCF06)

Three types of data sampling are available, average, snapshot and USDA. When configured to average, the average of readings taken every minute over the recording period is recorded. When configured to snapshot, the sensor reading at the log intervale time is recorded. When USDA is configured the supply and return temperature readings are averaged and the 3 USDA probe readings are snapshot.

3.6.7 Alarm Configuration (dCF07 -- dCF10)

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

Ifaprobealarm is configuredtoOFF,thenthealarmfor this probe is always disabled.

Ifaprobealarm isconfiguredto ON, thentheassociated 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 everytrip. If all theprobes aredisconnected, noalarms areactivated. As soon as one of the probesis installed, then all of the alarmsareenabledandtheremainingprobesthat arenot installed will give active alarm indications.

The DataCORDER will record the initiation of a pre-trip test (refer to paragraph 3.5) and the results of each of the tests included in pre--trip. The data is time-stamped and may be extracted via the Data Retrievalprogram. Refer to Table 3-9 for a description of the data stored in the DataCORDER for each corresponding Pre-Trip test.

3.6.8

DataCORDER Power-Up

The DataCORDER may be powered up in any one of four ways:

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

2. ControllerDCbatterypackpower:Ifabatterypack is installed, the DataCORDER will power up for communicationwhenan interrogationcableis plugged into an interrogation receptacle.

3. ExternalDC 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, theDataCORDER will powerup whenthe 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 checkpasses,theController willenergizeand performa software battery voltage check before DataCORDER logging. If either test fails, the real time clock battery power-up will be disabled until the next AC power cycle. FurtherDataCORDER temperaturelogging will be prohibited until that time.

An alarm will be generated when the battery voltage transitions from good to bad indicating that the battery pack needs recharging. If the alarm condition persists for more than 24 hours on continuous AC power, the battery pack needs replacement.

3.6.9 Pre-Trip Data Recording

3.6.10 DataCORDER Communications

Data retrieval from the DataCORDER can be accomplished by using one of the following; DataReader, DataLine/DataView or a communications interfacemodule.

a. DataReader

The Carrier Transicold Data Reader (seeFigure 3- 6)is asimpletooperatehandhelddevicedesignedtoextract data from the DataCORDER and then upload it to a personal computer. The Data Reader has the ability to storemultipledatafiles.RefertoDataRetrievalmanual 62-02575 for a more detailed explanation of the DataReader

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DataReader

Figure 3- 6 Data Reader

b. DataView

The DataView software for a personal computer is supplied on a floppy disk. This software allows interrogation, configuration variable assignment, screen view of the data, hard copy report generation, cold treatment probe calibration, cold treatment initialization and file management. Refer to Data Retrieval manual 62-02575 for a more detailed explanation of the DataView interrogation software.

c. Communications Interface Module

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

With a remote monitoring unit installed, all functions andselectablefeatures thatareaccessibleattheunitmay be performed at the master station. Retrieval of all DataCORDERreportsmayalso beperformed. Referto the master system technical manual for further information.

d. DataLine

The DataLINE software for a personal computer is supplied on both floppy disks and CD. This software allows interrogation, configuration variable assignment, screen view of the data, hard copy report generation, cold treatment probe calibration and file management.RefertoDataRetrievalmanual62-10629 for a more detailed explanation of the DataLINE interrogation software. The DataLine manual may be found on the net at www.contaner.carrier.com

3.6.11 USDA Cold Treatment

Exposing infested fruit to temperatures of 2.2 degrees Celsius (36_F) or below for specific periods results in the mortality of the various stages of this group of insects.

In response to the demand to replace fumigation with this environmentally sound process, Carrier has integrated Cold Treatment capability into its microprocessorsystem. These units have the ability to maintain supply air temperature within one-quarter degreeCelsius ofsetpoint and recordminutechangesin product temperature within the DataCORDER memory, thus meeting USDA criteria. Information on USDA is provided in the following subparagraphs

a. USDA Recording

A special type of recording is used for USDA cold treatment purposes. Cold treatment recording requires threeremotetemperatureprobes beplaced atprescribed locations in the cargo. Provision is made to connect these probes to the DataCORDER via receptacles located at therearleft-handside ofthe unit.Four orfive receptacles areprovided. Thefour three-pinreceptacles are for the probes. The five pin receptacle is the rear connection for the Interrogator. The probe receptacles are sized to accept plugs with tricam coupling locking devices. A label on the back panel of the unit shows which receptacle is used for each probe.

Thestandard DataCORDER report displays the supply and return air temperatures. The cold treatment report displaysUSDA #1, #2, #3 andthe supplyand returnair temperatures.Coldtreatment recordingis backed upby abattery so recordingcan continue if AC power is lost.

b. USDA/ Message Trip Comment

Aspecialfeature is incorporatedin DataLine/DataView which allows the user to enter a USDA (or other) message in the header of a data report. The maximum messagelengthis78 characters.Onlyone messagewill be recorded per day.

3.6.12 USDA Cold Treatment Procedure

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

a. Calibrate the three USDA probes by ice bathing the

probes and performing the calibration function with the DataReader,DataVieworDataLine. Thiscalibration procedure determines the probe offsets and storesthem in the controllerforuse in generatingthe cold treatment report. Refer to the Data Retrieval manual 62-02575 for more details.

b. Pre-coolthecontainertothetreatmenttemperatureor

below.

c..InstalltheDataCORDERmodulebatterypack(ifnot

already installed).

Sustained cold temperature has been employed as an effective postharvest method for the control of Mediterranean and certain other tropical fruit flies.

d. Place the threeprobes. The probes are placedinto the

pulpoftheproduct(atthelocationsdefinedinthefollowing table) as the product is loaded.

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Sensor 1

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

Place in pulp of the product five feet from the end of the load for 40 foot con-

Sensor 2

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

Place in pulp of product five feet from the end of the load for 40 foot containers

Sensor 3

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 onehalf the height of the load.

e. To initiate USDA Recording, connect the personal

computer and perform the configuration as follows, using either the Data Viewor Data Line 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”

3.6.13 DataCORDER Alarms

The alarm display i s an independent DataCORDER function. If an operating parameter is outside of the expected range or a component does not return the correct values back to the DataCORDER an alarm is generated.The DataCORDER contains a bufferofupto eight alarms. A listing of the DataCORDER alarms is provided in Table3-10, page 3-27. Refer to paragraph

3.6.7 for configuration information. To display alarm codes: a. While in the Default Display mode, press the ALT.

MODE&ALARMLISTkeys. Thisaccesses the DataCORDER Alarm List Display Mode, which displays any alarms stored in the Alarm Queue.

b. ToscrolltotheendofthealarmlistpresstheUP AR-

ROW. 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##,” ifthealarm is active, where ## is the alarmnumber.“IA##,”willshowifthealarmisinactive

d. “END” is displayed to indicate the end of the alarm

list if any alarms are active. “CLEAr” is displayedif all the alarms in the list are inactive.

e. If no alarms are active, the Alarm Queue may be

cleared. The exception to thisrule is the DataCORDERAlarm QueueFull alarm(AL91),whichdoesnot

haveto be inactive in order to clear thealarm list. To Clear the Alarm List:

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

2. PresstheUP/DOWNARROWkeyuntil “CLEAr”is displayed.

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

-- -- -- -- -- ” will be displayed.

“

4. Pressthe ALARM LIST key.“AL” will show on the leftdisplayand“

-- -- -- -- -- ”ontheright displaywhen

there are no alarms in the list.

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

3.6.14 ISO Trip Header

DataLine provides the user with an interface to view/modify current settings of the ISO trip header through the ISO TripHeader screen. TheISO TripHeaderscreen is displayed when the user clicks on the “ISO Trip Header” button in the “Trip Functions” Group Box on the System Toolsscreen.

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

IftheconnectionisestablishedwiththeDataCorder,the current contents of the ISO Trip Header from the DataCorder will be displayed in each field. If the connection is not established with the DataCorder, all fields on the screenwill be displayed as “X’s”.Ifat 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 connectionhas been madewiththeDataCorder,clickon the “Send” button to send the modified parameter values.

Themaximumallowed lengthof theISOTrip Header is 128 characters.If the user tries to refresh the screen or close the utility without sending the changes made on the screen to the DataCorder, the user is alerted with a message.

3-12T-309

Table 3-4 Controller Configuration Variables

NOTES

1. Configuration numbers not listed are not used in this application. These items may appear when loading configurationsoftware to the controllerbut changes will not be recognized by the controller programming.

CONFIGURATION

NUMBER

TITLE DEFAULT OPTION

CnF02 Evaporator Fan Speed dS (Dual) SS (Single) CnF04 Dehumidification Mode On OFF

CnF11 Defrost “Off” Selection noOFF OFF CnF16 DataCORDER Present On (Yes) OFF (No) CnF22 Economy Mode Option OFF Std, Full CnF23 Defrost Interval Timer Save Option noSAv SAv CnF24 Long Pre Trip Test Sequence Enabled On Off CnF25 Pre-T rip Te st Points/Results Recording Option rSLtS dAtA CnF26 Heat Lockout Change Option Set to --10_C Set to --5_C CnF28 Bulb Mode Option NOr bULb CnF31 Probe Check Option Std SPEC CnF33 Snap Freeze Option OFF SnAP CnF34 Degree Celsius Lockout Option bOth _F CnF37 Electronic Temperature Recorder rEtUR (Return) suPPl, BOth

3-13

T-309

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

Code

No.

TITLE DESCRIPTION

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

Display Only Functions

Cd01

Suction Modulation Valve Opening (%)

Cd02 Not Applicable Not used Cd03

Cd04

Compressor Motor Current

Line Current, PhaseA

Cd05

Line Current, PhaseB

Cd06

Line Current,

PhaseC Cd07 Main Power Voltage The main supply voltage is displayed. Cd08

Cd09 Cd10 Cd11 Cd12

Main Power Fre-

quency

Ambient Tempera-

ture

Compressor Suction

Temperature

Compressor Dis-

charge Temperature

Compressor Suction

Pressure Cd13 Not Applicable Not used

Cd14

Compressor Dis-

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

Cd16 Cd17

Compressor Motor

Hour Meter

Relative Humidity

(%) Cd18 Software Revision # Thesoftware revision number is displayed.

Cd19 Battery Check

Cd20 Config/Model # Cd21 Economizer Valve The status of the valve is displayed (Open - Closed).

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

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.

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.

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).

The ambient sensor reading is displayed. Compressor suction temperature sensor reading i s displayed. Compressor discharge temperature sensor reading is displayed. Compressor suction pressure transducer reading is displayed.

Compressor discharge pressure transducer reading is displayed.

Records total hours of compressor run time. Totalhours are recordedin increments of 10 hours (i.e., 3000 hours is displayed as 300).

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

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

This code indicates the dash number of the model for which the Controller is configured (i.e., if the unit is a 69NT40-531-100, the display will show “31100”).

3-14T-309

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

Cd22 Compressor State The status of the compressor is displayed (Off, On). Cd23 Evaporator Fan Displays the current evaporator fan state (high, low or off).

Cd24

Cd25

Cd26

Controlled

Atmosphere State

Compressor Run

TimeRemaining

Until Defrost

Defrost Temperature

Sensor Reading

Not used in this application 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. Defrost temperature sensor reading is displayed.

Configurable Functions

NOTE

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

The defrost interval is the time between defrost cycles. Five selectablevalues are available: 3, 6, 9, 12 or 24 hours. The factory default value is 12 hours. Following a start--up or after termination of a defrost, the time will not begin counting down until the defrost temperaturesensor (DTS) reading falls below set point. If the reading of DTS rises above set point any time during the timer count down, the interval is reset and the countdown begins over. If DTS fails, alarm code AL60 is activated and control switches over to the the return temperature sensor. The controller will act in the same manner as with the DTS except the return temperaturesensor reading will be used. DefrostInterval Timer Value(Configuration variable CnF23): If the softwareis configured to “SAv” (save) for this option, then the value of the defrost interval timer will be saved at power down and restored at power up. This option prevents short power interruptions from resetting an almost expired defrost interval, and possibly delaying a needed defrost cycle.

Cd27

Defrost Interval

(Hours)

Cd28

Cd29

TemperatureUnits

(_Cor_F)

Failure Action

(Mode)

Cd30 In-Range Tolerance

NOTE

The defrost interval timer counts only during compressor run time.

This code determines the temperature units (_Cor_F) which will be used for all temperature displays. The user selects _Cor_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 Configuration Variable CnF34 is set to _F.

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-- FullCooling(compressorison,economizedoperation.SMVsubjecttopressure

and current limit.)

B -- PartialCooling(Compressoris on,standardoperation.SMVsubjecttopressure

and current limit.)

C -- EvaporatorFanOnly (Compressor is off,evaporator fans on high speed, not ap-

plicable with frozen set points.

D -- Full System Shutdown -- Factory Default (shut down every component in the

unit)

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

3-15

T-309

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

The stagger start offset time is the amount of time that the unit will delay at start-

Cd31

Stagger Start Offset

Time(Seconds)

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

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. This is

Cd32

Current Limit

(Amperes)

accomplished by reducing the SMV position until current draw is reduced to the set point. When desirable, the limit can be lowered. Note, however, that capacity is also reduced. The five values for 460vac operation are: 15, 17, 19, 21 (Factory Default), 23

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 “-- -- -- -- --”willdisplay.Thevaluecanbesetto“OFF.”“TEST,”ora 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

Cd33

Perishable Mode

Dehumidification

Control (% RH)

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.

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

Cd35 Bulb Mode

display “Nor” and the user will be unable to change it. After a dehumidification set point has been selected and entered for code Cd33, the user may then change code Cd35 to “bulb.” After bulb has been selected and entered, the user may then utilize function codes Cd36 and Cd37 to make the desired changes.

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

Cd36

Evaporator Speed

Select

display cannot be changed. If a dehumidification set point has been selected along with bulb mode then “alt” may be selected for alternating speed, “Lo” for low speed evaporator fan only, or “Hi” for high speed evaporator fan only. If a setting other than “alt” has been selected and bulb mode is deactivated in any manner, then selection reverts back to “alt.”

This code, as with function code Cd36, is used with bulb mode and dehumidification. If bulb mode is active, this code allows the user to change the temperature defrost will terminate. It allows the user to change the setting within a range of 4_C to 25.6_Cin0.1_C (0.2_F) increments. This value is changed using the UP/ DOWN ARROW keys, followed by the ENTER key when the desired value is

Cd37

Defrost Termination

TemperatureSetting

(Bulb Mode)

displayed. If bulb mode is deactivated, the DTS setting returns to the default.

Display Only Functions -- Continued

Code Cd38 will display the current secondary supply temperature sensor reading

Cd38

Cd39

Cd40

Secondary Supply

Temperature Sensor

Secondary Return

Temperature Sensor

Container Identifica-

tion Number

Cd41 ValveOverride Cd42 Oil Return Valve The status of the valve is displayed (Open - Closed).

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.

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

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.

SERVICE FUNCTION: This code is used for troubleshooting and allows manual positioning of the economizer, unloader, suction modulation and oil return valves. Refer to paragraph 6.19 for operating instructions.

3-16T-309

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

Code

No.

TITLE DESCRIPTION

Alarm 13 is triggered if the control module has lost communication with the expansion module for more than five minutes or communication fails within the

AL13 Expansion Module

first 15 seconds on power up. This alarm triggers failure action C (evaporator fan only) or D (all machinery off) of Function Code Cd29 if the unit has a perishable set point. Failureaction D (all machinery off) is triggered i f the unit has a frozen set point

Alarm 14 is triggered if the electronic phase detection system is unable to determine the correct phase relationship. DIRCHECK will be displayed while the relationship i s determined. If the system is unable to determine the proper relationship alarm 14 will remain active. Additiotnal information on phase detection may be displayed at Function C ode Cd41. If the right most digit of Code Cd41 is

AL14

Phase Sequence

Failure -- Electronic

3 or 4, this indicates incorrect motor or sensor wiring. If the right most digit is 5, this indicates a failed current sensor assembly.

AL15 Loss Cooling Future Expansion

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

AL16

Compressor Current

High

Alarm 17 is triggered if a compressor start in both directions fails to generate sufficient pressure differential. The controller will attempt restart every twenty

AL17

Phase Sequence

Failure -- Pressure

minutes and deactivate the alarm if successful. This alarm triggers failure action C (evaporator fan only) or D (all machinery off) of Function Code Cd29 if the unit has a perishable set point. Failure action D (all machinery off) is triggered if the unit has a frozen set point

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

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

Alarm 20 is triggered by control power fuse (F3) opening and will cause the software shutdown of all control units. This alarm will remain active until the fuse is replaced.

AL18

AL19

AL20

DischargePressure

High

DischargeTempera-

ture High

Control Circuit Fuse

Open (24 vac)

Alarm 21 is triggered by one of the fuses (F 1/F2) being opened on 18 volts AC

AL21

Micro Circuit Fuse

Open (18 vac)

power supply to the Controller.The suction modulation valve (SMV) will be opened and current limiting is halted. Temperature control will be maintained by cycling the compressor.

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

AL22

Evaporator Fan Mo-

tor Safety

Alarm 23 is triggered if low current draw is detected on phase B and IPCP, HPS or IPEM is not tripped. If the compressor should be running, the controller will initiate a start up every five minutes and trigger off if current reappears. If the

AL23 Loss of Phase B

evaporator fan motors only should be running, the alarm will trigger off is current reappears. This alarm triggers failure action C (evaporator fan only) or D (all machinery off) of Function Code Cd29 if the unit has a perishable set point. Failure action D (all machinery off) is triggered if t he unit has a frozen set point

Alarm 24 is triggered when compressor is not drawing any current. It also trig-

AL24

Compressor Motor

Safety

gers failure action ”C” or ”D” set by function Code 29 for perishable setpoint, or ”D” for frozen setpoint. This alarm will remain active until compressor draws current.

3-17

T-309

AL25

Condenser Fan Mo-

tor Safety

All Supply and Re-

AL26

turn temperature

Control Sensors

Failure

AL27

AL28

A/D Accuracy Fail-

ure

Low Suction Pres-

sure

AL51 AlarmList Failure

AL52 AlarmListFull

AL53 Battery Pack Failure

Primary Supply

AL54

Temperature Sensor

Failure (STS)

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

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

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

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

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

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

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

Alarm 53 is caused by the battery pack charge being too low to provide sufficient power for battery-backed recording. Renew replaceable batteries. 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 to deactivate the alarm

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

NOTE

AL55

DataCORDER

Failure

The P5 Pre-Trip test must be run to inactivate the alarm This alarm activates to indicate the DataCORDER has a software failure. To

clear this alarm, reconfigure the unit to the current model number. This failure may be the result of a voltage dip in access of 25%.

3-18T-309

Primary Return

AL56

Temperature Sensor

Failure (RTS)

AL57

AL58

AL59

AL60

Ambient Tempera-

ture Sensor Failure

Compressor High

Pressure Safety

Heat Termination

Thermostat

Defrost Temperature

Sensor Failure

AL61 Heaters Failure

AL62

Compressor C ircuit

Failure

AL63 CurrentOver Limit

AL64

AL65 AL66

AL67

AL69

DischargeTempera-

ture Over Limit

DischargePressure

Transducer Failure

Suction Pressure

Transducer Failure

Humidity Sensor

Failure

Suction Temperature

Sensor Failure

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

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

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm. Alarm 57 is triggered by an ambient temperature reading outside the valid range

from --50_C(--58_F) to +70_C (+158_F). Alarm 58 is triggered when the compressor high discharge pressure safety switch

remains open for at least one minute. This alarm will remain active until the pressure switch resets, at which time the compressor will restart.

Alarm 59 is triggered by the opening of the heat termination thermostat and will result in the disabling of the heater. This alarm will remain active until the thermostat resets.

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

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

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

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

Alarm 64 is triggered if the discharge temperature sensed is outside the range of

-- 6 0 _C(--76_F) to 175_C (347_F), or if the sensor is out of range. This is a dis- play alarm and has no associated failure action.

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

Alarm 66 is triggered if a suction pressure transducer is out of range. This is a display alarm and has no associated failure action.

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

Alarm 69 is triggered by a suction temperaturesensor reading outside the valid range of --60_C(--76_F) to 150_C (302_F). This is a display alarm and has no associated failure action.

3-19

T-309

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

ERR#M

NOTE

If the Controlleris configured for four probes without a DataCORDER, the DataCORDER alarms AL70 and AL71 will be processed as Controller alarms AL70 and AL71. Referto Table 3-10.

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

ERROR DESCRIPTION

Indicates that the Controller working memory has failed.

Indicates a problem with the Controller program. The Controller program has entered a mode whereby

the Controller program has stopped executing. The on board timers are no longer operational.

Timed items such as; defrost, etc. may not work. Internal multi-purpose counters have failed. These

counters are used for timers and other items. The Controller’s Analog to Digital (A-D) converter

has failed.

ERR

Entr StPt

Internal

croprocessor

Failure

Enter Setpoint

(Press Arrow &

Enter)

ERR 0 -- RAM failure EER 1 -- Program

Memory failure EER 2 -- Wa tchdog

time--out EER 3 -- On board timer

failure EER 4 -- Internal counter

failure EER 5 -- A-D failure

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

Low Main Voltage

(Function Codes

Cd27--38 disabled

and NO alarm

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

stored.)

3-20T-309

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

Code

No.

TITLE DESCRIPTION

“Auto” or “Auto1” menu includes the: P0, P1, P 2, P3, P4, P5, P6 and rSLts. “Auto2” menu includes P0, P1, P2, P3, P4, P5, P6, P7, P8, P9, P10 and rSLts.

P0--0 Pre-TripInitiated

P1-0 Heaters Turned On

P1-1 Heaters Turned Off

P2-0 Condenser Fan On

P2-1 CondenserFan Off

Low Speed Evapora-

P3-0

P3-1

P4-0

P4-1

P5-0

tor Fans

Low Speed Evapora-

tor Fan Motors On

Low Speed Evapora-

tor Fan Motors Off

High Speed Evapo-

rator Fan Motors On

High Speed Evapo-

rator Fan Motors Off

Supply/Return Probe

Test

NOTE

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.

Setup: Heater must start in t he 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. 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. Requirements: Waterpressure 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.

Setup: Condenser fan i s turned OFF, a current draw test is done after 10 sec-

onds. Pass/Fail Criteria: Passes if current draw change is within the range specified.

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

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. Fails if AL11 or AL12 activates during test.

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. Fails if AL11 or AL12 activates during test.

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. Fails if AL11 or AL12 activates during test.

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. Fails if AL11 or AL12 activates during test.

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

NOTE

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

3-21

T-309

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

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

P5-1 Supply P robe Test

P5-2 Return Probe Test

Refrigerant Probes,

Compressor

and

Refrigeration valves

P6-0 P6-1 P6-2 P6-3 P6-4 P6-5 P6-6

Discharge

Thermistor Test

Suction

Thermistor Test

DischargePressure

Sensor Test

Suction Pressure

Sensor Test

Compressor Current

Draw Test

Suction Modulation

Valve Test

Economizer

Valve Test

P6-7 Unloader Valve Test

NOTE

Ifthistestfails,“P5-1”andFAILwill be displayed. If both Probetests(this andtheSUPPLY/RETURN TEST) pass, becauseof themultiple tests,the display will read ’P 5’ ’PASS’.

Requirements: For units equipped with secondary return probe only. Pass/Fail Criteria: The temperature differenc e between primary and secondary

probe (return) is compared.

NOTES

1. If this test fails, “P5-2”and “FAIL” will be displayed. If bothProbetests (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.

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

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

If alarm 69 is activated any time during the first 45 second period of Step 1, the test fails.

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

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

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

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

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

Suction pressure is measured during Steps 6 and 7. If suction pressure does not increase, the test fails.

3-22T-309

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

P7-0

P7-1

P8-0

P8-1

High Pressure Switch Closed

High Pressure

Switch Open

Perishable Mode

Heat Test

Perishable Mode

Pull Down Test

Perishable Mode

P8-2

Maintain Tempera-

ture Test

P9-0 Defrost Test

NOTE

P7-0 through P10 are included with the “Auto2” only.

NOTE

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

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

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.

Setup: If the container temperature is below 15.6°C(60_F), the set point is changed to 15.6°C, and a 180 minute timer is started. The left display will read “P8-0.” The control will then heat the container until 15.6°C is reached. If the container t emperature is above 15.6°C 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.”

Requirements: Control temperature must be at least 15.6°C(60_F). Setup: The set point is changed to 0°C(32_F), and a 180 minute timer is

started. The left display will read “P8-1,” the right display will show the supply air temperature. The unit will then start to pull down the temperature to the 0°C set point. Pass/Fail Criteria: The test passes if the container temperature reaches set point before the 180 minute timer expires.

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

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

3-23

T-309

P10-0

P10-1

P10-2

Frozen Mode

Heat Test

Frozen Mode Pull

Down Test

Frozen Mode

Maintain

Temperature Test

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

Setup: If the container temperature is below 7.2_C(45_F), the set point is changedto7.2_C and a 180 minute timer is started. The control will then be placed in the equivalent of normal heating. If the container temperature is above

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

Requirements: Control temperature must be at least 7.2_C(45_F) Setup: The set point is changed to -- 17.8_C(0_F). The system will then attempt

to pull don the Control temperatureto 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 --0.3_C (0.17_F) before the 180 minute timer expires the test fails and will auto--repeat by starting P10--0 over..

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

3-24T-309

Table 3-8 DataCORDER Function Code Assignments

NOTE

Inapplicable Functions Display “-- -- -- -- --”

To Access: Press ALT. MODE key

Code

No.

dC1 dC2

dC3-5

dC6-13

dC14

Recorder Supply Temperature

Recorder Return Temperature

USDA 1,2,3 Temperatures

Network Data Points 1-8

CargoProbe4Temperature

TITLE DESCRIPTION

Current reading of the supply recorder sensor. Current reading of the return recorder sensor . Current readings of the three USDA probes.

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.

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.

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.

dC20-24

Temperature Sensors 1-5 Calibration

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

The DataCORDER serial number consists of eight characters. Function code

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

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 DataCORDER starts to overwrite the existing data.

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

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.

dC30

Date of last Trip start

Shows the current status of the optional battery pack.

dC31 Battery Test

PASS: Battery pack is fully charged. FAIL: B attery pack voltage is low.

dC32 Time: Hour, Minute Current time on the real time clock (RTC)in the DataCORDER. dC33 Date: Month, Day Current date (month and day) on the RTC in the DataCORDER. dC34 Date: Year Current year on the RTC in the DataCORDER.

dC35

Cargo Probe 4 Calibration

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

3-25

T-309

Table 3-9 DataCORDER Pre-Trip Result Records

Test

No.

TITLE DA TA

1-0 Heater On Pass/Fail/SkipResult, Change in current for Phase A, B and C 1-1 Heater Off Pass/Fail/Skip R esult, Change in currents for Phase A, B and C

2-0 Condenser Fan On

Pass/Fail/Skip Result, Waterpressure switch (WPS) -- Open/Closed, Change in currents for Phase A, B and C

2-1 Condenser Fan Off Pass/Fail/Skip Result, Change in currentsfor Phase A, B and C 3-0

3-1 4-0 4-1

Low Speed Evaporator Fan On

High Speed Evaporator Fan On

Pass/Fail/Skip Result, Change in currents for Phase A, B and C Pass/Fail/Skip Result, Change in currents for Phase A, B and C Pass/Fail/Skip Result, Change in currents for Phase A, B and C Pass/Fail/Skip Result, Change in currents for Phase A, B and C

5-0 Supply/Return Probe Test Pass/Fail/SkipResult, STS, RTS, SRS and RRS 5-1 Secondary Supply Probe Test Pass/Fail/Skip 5-2 Secondary Return Probe Test Pass/Fail/Skip 6-0 DischargeThermistor Test Pass/Fail/Skip 6-1 Suction Thermistor Test Pass/Fail/Skip

6-2

DischargePressure Sensor Test

Pass/Fail/Skip 6-3 Suction Pressure Sensor Test Pass/Fail/Skip 6-4

Compressor Current Draw Test

Pass/Fail/Skip 6-5 Suction Modulation valve Test Pass/Fail/Skip

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

7-0 High Pressure Switch Closed 7-1 High Pressure Switch Open

Pass/Fail/Skip Result, AMBS, DPT or CPT (if equipped)

Input values that component opens

Pass/Fail/Skip R esult, STS, DPT or CPT (if equipped)

Input values that component closes 8-0 Perishable Mode Heat Test Pass/Fail/Skip R esult, STS, time it takes to heat to 16_C(60_F)

8-1 8-2 9-0 Defrost Test

Perishable Mode Pull Down Test

PerishableMode Maintain Test

Pass/Fail/Skip Result, STS, time it takes to pull down to 0_C(32_F)

Pass/Fail/Skip Result, Averaged DataCORDER supply temperature

(SRS) over last recording interval.

Pass/Fail/Skip Result, DTS reading at end of test, line voltage, line

frequency, time in defrost.

10-0 Frozen Mode Heat Test Pass/Fail/Skip Result, STS, time unit is in heat. 10-1 Frozen Mode Pull Down Test Pass/Fail/Skip Result, STS, time to pull down unit to --17.8_C(0_F).

10-2 Frozen Mode Maintain Test

Pass/Fail/Skip R esult, AveragedDataCORDER return temperature

(RRS) over last recording interval.

3-26T-309

Table 3-10 DataCORDER Alarm Indications

To Access: Press ALT. MODE key

Code No. TITLE DESCRIPTION

The supply recorder sensor reading is outside of the range of --50_Cto 70_C(--58_F to +158_F) or, the probe check logic has determined there is a fault with this sensor.

NOTE

dAL70

Recorder Supply TemperatureOut of Range

The P5 Pre-Trip test must be run to inactivate the alarm. The return recorder sensor reading is outside of the range of --50_Cto

70_C(--58_F to +158_F) or, the probe check logic has determined there is

dAL71

Recorder Return Temperature Out of Range

a fault with this sensor.

NOTE

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

dAL72-74 dAL75

USDA Temperatures 1, 2, 3 Out of Range

Cargo Probe 4 Out of Range

The USDA probe temperature reading is sensed outside of --50 to 70°C (--58to158°F) range.

The cargo probe temperature reading is outside of -- 50 to 70°C(--58to 158°F) range.

dAL76, 77 Future Expansion These alarms are for future expansion, and are not in use at this time.

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 8 additional network data points. An alarm number (AL78 to AL85) is assigned to each configured point. When an alarm occurs, the DataCORDER must be

dAL78-85

Network Data Point 1 -- 8 Out of Range

interrogatedto identify the data point assigned. When a humidity sensor is installed, it is usually assigned to AL78.

dAL86 R TC Battery Low

The Real Time Clock (RTC) backup battery is too low to adequately maintain the RTC reading.

An invalid date or time has been detected. This situation may be corrected

dAL87 RTC Failure

by changing the Real Time Clock (RTC) to a valid value using the DataView.

dAL88 dAL89 Flash Memory Error

DataCORDER EEPROM Failure

A write of critical DataCORDER information to the EEPROM has failed. 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 AlarmListFull The DataCORDER alarm queue is determined to be full (eight alarms).

3-27

T-309

SECTION 4

OPERATION

4.1 INSPECTION (Before Starting)

WARNING

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

a. If containeris empty,check inside for the following:

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

2. Checkcontainerpanels,insulationanddoorsealsfor damage. Effect permanent or temporary repairs.

3. Visuallycheckevaporatorfanmotormountingbolts for proper securement (refer to paragraph 6.17).

4. Checkfordirtorgreaseonevaporatorfan or fandeck and clean if necessary.

5. Check evaporator coil for cleanliness or obstructions. Wash with fresh water.

6. Check defrostdrain pansand drain lines forobstructions and clear if necessary. Wash with fresh water.

7. Checkpanelsonrefrigerationunitforlooseboltsand condition of panels. Make sure T.I.R.devices arein place on access panels.

b. Check condenser coil for cleanliness. Wash with

fresh water.

c. Open control box door. Check for loose electrical

connections or hardware. d. Checkcolor of moisture-liquid indicator. e. Check oil level in compressor sight glass.

4.2 CONNECT POWER

WARNING

Do not attemptto removepower plug(s)before turning OFF start-stop switch (ST), unit circuit breaker(s) and external power source.

4.3 ADJUST FRESH AIR MAKEUP VENT

The purpose of the fresh air makeup vent is to provide ventilation for commodities that require fresh air circulation. The vent must be closed whentransporting frozen foods.

Air exchange depends on static pressure differential, whichwillvarydependingon the containerandhowthe container is loaded.

4.3.1 Upper Fresh Air Makeup Vent

Two slots and a stop are designed into the disc for air flowadjustments.The firstslot allowsfora0to30%air flow, and the second slot allows for a 30 to 100% air flow. To adjust the percentage of air flow, loosen the wingnut and rotatethediscuntil the desiredpercentage of air flow matches with the arrow. Tighten the wing nut. Toclearthe gap between the slots, loosenthe wing nut until the disc clears the stop. F igure 4-1 gives air exchangevalues for an empty container. Higher values can be expected for a fully loaded container.

AIR

FLOW

(CMH)

240

210

180

150

120

69NT FRESH AIR M AKEUP

ZERO EXTERNAL STATIC50HZ

For 60HZ operation multiply curves by 1.2

T-BAR

1-!/2”

T-BAR

2-%/8”

T-BAR

3”

WARNING

Makesurethepowerplugs arecleananddry before connecting to any power receptacle.

4.2.1 Connection To 380/460 vac Power

1. Make sure start-stop switch (ST, on control panel)

and circuit breaker (CB-1, in the control box) are in

position “0” (OFF).

2. Plug the 460 vac (yellow) cable into a de-energized

380/460 vac, 3-phase power source. Energize the

power source. Place circuit breaker (CB-1) in posi-

tion “I” (ON). Close and secure control box door.

4-1

0 102030405060708090100

PERCENT OPEN

Figure 4-1 Make Up Air Flow Chart

T-309

4.4 CONNECT REMOTE MONITORING

RECEPTACLE

If remote monitoring is required, connect remote monitorplugat unitreceptacle.(Seeitem 9,Figure 2-5.) When the remote monitor plug is connected to the remote monitoring receptacle, the following remote circuits are energized:

CIRCUIT FUNCTION

Sockets B to A Energizes remote cool light Sockets C to A Energizes remote defrost light Sockets D to A Energizes remote in-range light

1. Depress the ALT MODE key and scroll to Code dC30.

2. Depress and hold the ENTER key for five seconds.

3. The “Trip Start” event will be entered in the DataCORDER.

4.6.3 Complete Inspection

Allow unit to run for 5 minutes to stabilize conditions andperform apre--tripdiagnosis inaccordance withthe following paragraph.

4.7 PRE-TRIP DIAGNOSIS

4.5 STARTING AND STOPPING INSTRUCTIONS

WARNING

Make sure that the unit circuit breaker(s) (CB-1 & CB-2) and the START-STOP switch(ST) arein the“O”(OFF)positionbefore connecting to any electrical power source.

4.5.1 Starting the Unit

1. Withpowerproperlyapplied, the freshair damperset and (if required) the water cooled condenser connected, (refer to paragraphs 4.2 & 4.3) place the START-STOP switch to “I” (ON).

NOTE

Withinthe first30seconds the electronicphase detection system will check for proper compressor rotation. If rotation is not correct, the compressorwillbe stopped andrestartedin the oppositedirection.If thecompressorisproducing unusually loud and continuous noise after the first 30 seconds of operation, stop the unit and investigate.

2. Continue with Start Up Inspection, paragraph 4.6.

4.5.2 Stopping the Unit

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

4.6 START--UP INSPECTION

4.6.1 Physical Inspection

a. Check rotation of condenser and evaporator fans. b. Check compressoroil level. (Refer to paragraph 6.9.)

4.6.2 Check Controller Function Codes

Checkand, if required, resetcontrollerFunction Codes (Cd27 through Cd39) in accordance with desired operating parameters. Refer to paragraph 3.2.2.

DataCORDER

a. Check and, if required, set the DataCORDER Con-

figuration in accordance with desired recording parameter. Refer to paragraph3.6.3.

b. Enter a “Trip Start”. To enter a “trip Start”, do the

following:

CAUTION

Pre-tripinspectionshould not be performed with critical temperaturecargoes inthe container.

CAUTION

When Pre-Trip keyis pressed, economy, dehumidification and bulb mode will be deactivated.Atthecompletionof Pre-Tripactivity, economy, dehumidification and bulb mode must be reactivated.

Pre-Trip diagnosis provides automatic testing of the unit components using internal measurements and comparisonlogic. 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 usermay have theoption ofselecting 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.Whenonlytheshortsequenceisconfigureditwill appear as “AUtO” in the display, otherwise “AUtO1” will indicate the short sequence and “AUtO2” will indicatethelong sequence.The testshortsequencewill runtestsP0 throughP6. Thelongtestsequencewillrun tests P0 through P10.

Adetailed description of the pre-triptestcodes is listed in Table 3-7, page 3-21. If no selection is made, the pre-trip menu selection process will terminate automatically. However, dehumidification and bulb mode must be reactivatedmanually if required.

Scrolling down to the “rSLts” code and pressing ENTER will allow the user to scrollthrough theresults ofthelastpre--triptestingrun.Ifnopre--testinghasbeen run(oranindividual t est has not beenrun)sincetheunit was powered up “--------” will be displayed.

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

NOTE

1. Prior to startingtests,verifythatunitvoltage (Function Code Cd 07) is within tolerance and unit amperage draw (Function Codes Cd04, Cd05, Cd06) are within expected limits. Otherwise, tests may fail incorrectly.

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

T-309 4-2

3. Pre-trip may also be i nitiated via

communications.Theoperationis the same asforthekey pad initiationdescribedbelow except that should a test fail, the pre-trip mode will automatically terminate. When initiatedviacommunications,atestmaynot be interrupted with an arrow key, but the pre-trip mode can be terminated with the PRE-TRIP key.

a. Press the PRE-TRIP key. This accesses a test selec-

tion menu.

b. TO RUN AN AUTOMATIC TEST: Scroll through

the selections by pressing the UP ARROW or DOWNARROWkeys to displayAUTO,AUTO1or AUTO 2 as desired and then press the AUTO key.

1. The unit will execute the series of tests without any need for direct user interface. These tests vary in length, depending on the component under test.

2. Whiletestsarerunning,“P#-#”willappearontheleft

display, where the #’s indicate the test number and sub-test. The right display will show a countdown time in minutes and seconds, indicating how much time there is left remaining in the test.

CAUTION

When a failure occurs during automatic testing the unit will susp end operation awaiting operator intervention.

Whenanautomatictestfails,itwillberepeatedonce. Arepeated testfailurewillcause“FAIL”to be shown ontherightdisplay,withthecorrespondingtestnumber to the left. The user may then press the DOWN ARROWtorepeatthetest,theUPARROWtoskipto the next test or the PRE--TRIP key to terminate testing. The unit will wait indefinitely, until the user manually enters a command.

CAUTION

When Pre--Trip test Auto 2 runs to completionwithoutbeing interrupted,the unit will terminate pre-trip and display “Auto 2” “end.”The unit willsuspendoperationuntil the user depresses the ENTER key!

Whenan Auto 1 runs to completionwithoutafailure, theunit will exitthepre-tripmode, andreturn to normal control operation. However, dehumidification and bulb mode must be reactivated manually if required.

c. TO RUN AN INDIVIDUAL TEST : Scroll through

the selections by pressing the UP ARROW or DOWN ARROW keys to display an individual test code. Pressing ENTER when the desiredtest codeis displayed.

1. Individually selected tests, otherthan the LED/Display test, will perform the operations necessary to verify the operation of the component. At t he conclusion, PASSor FAILwill bedisplayed. Thismessage 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-tripand return tocontrol mode operation.

2. While the tests are being executed, theuser may terminatethepre-tripdiagnosticsbypressingandholding 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.

3. Throughout the duration of any pre-trip test except the P-7 high pressure switch tests, the current and pressure limiting processes are active .

d. Pre-Trip Test Results At the end of the pre-trip test selection menu, the

message “P,” “rSLts” (pre--trip results) will be displayed.Pressing the ENTER key will allow the user tosee the resultsfor all subtests(i.e., 1-0, 1-1, etc). The resultswillbedisplayedas“PASS”or“FAIL”forallthe testsrun to completion since power up. If a test has not beenrunsincepowerup, “

-- -- -- -- -- ”willbedisplayed.

Once all pre--test activity is completed, dehumidification and bulb mode must be reactivated manually if required.

4.8 OBSERVE UNIT OPERATION

4.8.1 Probe Check

IftheDataCORDERisofforin alarmthecontrollerwill revertto a four probe configuration which includes the DataCORDER supply and return air probes as the secondary controller probes. The controller continuously performs probe diagnosis testing which compares the four probes. If the probe diagnosis result indicates a probe problem exists, the controller will performa probe check to identify the probe(s) in error.

a. Probe Diagnostic Logic -- Standard Iftheprobecheckoption(controllerconfigurationcode

CnF31) is configured for standard, the criteria used for comparisonbetweentheprimaryandsecondarycontrol probes is:

1_C(1.8_F)forperishableset points or2_C(3.6_F) for frozen set points.

If25 ormoreof30readingstakenwithina 30minute periodareoutsideof the limit, thena defrost isinitiated and a probe check is performed.

Inthis configuration, a probecheckwillbe runas a part of every normal (time initiated) defrost.

b. Probe Diagnostic Logic -- Special If the probe check option is configured for special the

abovecriteriaareapplicable.Adefrostwithprobecheck will be initiated if 25 of 30 readings or 10 consecutive readings are outside of the limits

Inthis configuration, a probe check will not be run asa part of a normal defrost, but only as a part of a defrost initiated due to a diagnostic reading outside of the limits.

c.The30minutetimerwillberesetateachofthefollow-

ing conditions:

4-3

T-309

1. At every power up.

2. At the end of every defrost.

3. After every diagnostic check that does not fall outside of the limits as outlined above.

d. Probe Check A defrost cycle probe check is accomplished by

energizing just the evaporatormotors for eight minutes at the end of the normal defrost. At the endof the eight minute period the probes will be compared to a set of predeterminedlimits. The defrostindicatorwillremain on throughout this period.

Any probe(s) determined to be outside the limits will cause the appropriate alarm code(s) to be displayed to identify which probe(s) needs to be replaced. The P5 Pre-Trip test must be run to inactivate alarms.

4.9 SEQUENCE OF OPERATION

General operation sequences for cooling, heating and defrost are provided in the following subparagraphs. Schematic representation of controller action are providedin

Figure 4-2 and Figure 4-3. RefertoSection3

for detailed descriptions of special events and timers thatareincorporatedbythe controllerin specificmodes of operation.

PULL DOWN

START UNLOADED,

TRANSITION TO

ECONOMIZED

OPERATION

UNLOADED OPERATION

AIR CIRCULATION

HEATING

+2.5_C (4.5_F)

+.20_C

SET POINT

--0.20_C

-- 0 . 5 _C

(0.9_F)

FALLING

TEMPERA TURE

MODULATED

COOLING

UNLOADED

AIR CIRCULATION

HEATING

+2.5_C

(4.5_F)

+.20_C

SET POINT

--0.20_C

-- 0 . 5 _C

(0.9_F)

RISING

TEMPERA TURE

MODULATED

COOLING

UNLOADED

AIR CIRCULATION

HEATING

NOTE: TEMPERATURES INDICATIONS ARE ABOVE OR BELOW SET POINT

Figure 4-2 Controller Operation -- Perishable Mode

T-309 4-4

FALLING

TEMPERA TURE

START UNLOADED,

TRANSITION TO

ECONOMIZED

OPERATION

RISING

TEMPERA TURE

COOLING

ECONOMIZED

+.20_C

SET POINT

--0.20_C

AIR CIRCULATION

NOTE: TEMPERATURES INDICATIONS ARE ABOVE OR BELOW SET POINT

Figure 4-3 Controller Operation -- Frozen Mode

ENERGIZED DE--ENERGIZED

FORFULL DIAGRAM AND LEGEND,SEE SECTION7

POWER TO

CONTROLLER

SIGNAL TO

CONTROLLER

NOTE:HIGH SPEED EVAPORATORFANSHOWN. FOR LOW SPEED CONTACTTE IS DE--ENERGIZED AND CONTACT TV IS ENERGIZED

CONTROL TRANSFORMER

USV

ESV

Figure 4-4 Perishable Mode

4.9.1 Sequence Of operation -- Compressor Phase

Sequence

The controller logic will check for proper compressor rotation. If the compressor is rotating in the wrong direction, the controller will energize or de --energize relay T6 as required (see Figure 4-4). Energizing relay T6willswitchoperationfromcompressorcontactorPA to compressor contactor PB. De--energizing relay T6

will switch operationfrom compressorcontactor PB to compressorcontactorPA.Compressorcontactors PAis wired to run the compressor on L1, L2, and L3. Compressor contactor PB is wired to run the compressor on L2, L1 and L3 thus providing reverse rotation .

4.9.2 Sequence Of Operation -- Perishable Mode Cooling

NOTE

IntheConventional PerishableMode of operationtheevaporatormotorsrun in highspeed.In theEconomy PerishableMode thefan speed is varied.

a. With supply air temperature above set point and de-

creasing,the unit will be cooling with the condenser fanmotor(CF), compressormotor(PAor PB), evaporatorfanmotors(EF)energizedandtheCOOLlight illuminated. (See Figure 4-4.) Also, if current or pressurelimiting is not active, the controller will energize relay TS to open the economizer solenoid valve(ESV) and placethe unitin economizedoperation.

b. When the air temperature decreases to a predeter-

minedtoleranceabove set point, the in-range light is illuminated.

c. As the air temperature continues to fall, modulating

coolingstarts at approximately2.5_C (4.5_F) above set point. (See Figure 4-2.) At set point, relay TS is de--energized to close theeconomizer solenoid valve and relay TU is energizedto open the unoladersole-

4-5

T-309

noid valve changing from economized operation to unloaded operation. (As shown in Figure 4-5)

d. The controllermonitors the supply air.Oncethesup-

plyairfallsbelowsetpointthecontrollerperiodically recordsthesupplyairtemperature,setpointandtime. Acalculationisthenperformedto determinetemperature drift from set point over time.

e. If the calculation determines cooling is no longer re-

quired,contactsTDandTNareopenedtode-energize compressormotor andcondenserfanmotor.Thecool light is also de-energized.

f. Theevaporatorfanmotorscontinuetoruntocirculate

air throughout the container. The in-range light remains illuminated as long as the supply air is within toleranceof set point.

g. If the supply air temperature increases to 0.2_C

(0.4_F) above set point andthe threeminuteofftime has elapsed, relays TD, TU and TN are energized to restart the compressor and condenser fan motors in unloaded operation. The cool light is also illuminated.

ENERGIZED DE--ENERGIZED

FORFULL DIAGRAM AND LEGEND,SEE SECTION7

CONTROL TRANSFORMER

rator fans continue to run to circulate air throughout the container.

c. A safety heater termination thermostat (HTT), at-

tached to an evaporator coil support, will open the heating circuit if overheating occurs.

4.9.4 Sequence Of operation -- Frozen Mode Cooling

a. With supply air temperature above set point and de-

creasing,theunit will transitionto economizedcooling 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 4-6.)

b.When the air temperature decreases to a predeter-

minedtoleranceabove set point, the in-range light is illuminated.

ENERGIZED DE--ENERGIZED

FORFULL DIAGRAM AND LEGEND,SEE SECTION7

POWER TO

CONTROLLER

CONTROL TRANSFORMER

POWER TO

CONTROLLER

SIGNAL TO

CONTROLLER

NOTE:HIGH SPEED EVAPORATORFANSHOWN. FOR LOW SPEED CONTACTTE IS DE--ENERGIZED AND CONTACT TV IS ENERGIZED

USV

ESV

Figure 4-5 Perishable Mode Heating

4.9.3 Sequence Of Operation -Perishable Mode Heating

a. Ifthe air temperaturedecreases 0.5_C(0.9_F) below

set point, the system enters the heating mode. (See Figure 4-2). The controller closes contacts TH (see Figure 4-5)to allowpowerflowthrough the heattermination t hermostat (HTT) to energize the heaters (HR).TheHEATlightisalsoilluminated.Theevaporator fans continue to run to circulate air throughout the container.

b. When the temperature rises to 0.2_C (0.4_F) above

set point, contact TH opens to de--energize the heaters.The HEAT lightis alsode--energized.Theevapo-

SIGNAL TO

CONTROLLER

USV

ESV

Figure 4-6 Frozen Mode

c. When the return air temperature decreases to 0.2_C

(0.4_F) below setpoint, contactsTD, TS and TN are opened to de-energize the compressor, economizer solenoid valve and condenser fan motors. The cool light is also de-energized.

d. The evaporator fan motors continue to run in low

speed to circulate air throughout the container. The in-range light remains illuminated as long as the return air is within tolerance of set point.

e. When return air temperatureis 10_C(18_F) ormore

below set point, the evaporator fans are brought to high speed.

f. When the return air temperature increases to 0.2_C

(0.4_F) above set point andthe threeminuteofftime has elapsed, relays TD, TS and TN are energizes to restartthe compressorandcondenserfanmotors.The cool light is illuminated.

4.9.5 Sequence Of Operation -- Defrost

The defrost cycle may consist of up to three distinct operations.Thefirst is de-icingofthecoil,the secondis a probe check cycle and the third is snap freeze.

T-309 4-6

Defrost may be initiated by any one of the following methods:

1. The manual defrost switch (MDS) is closed by the

user.

2. The user sends a defrost command by communica-

tions.

3. The defrost interval timer (controller function code

Cd27) reaches the defrost interval set by the user.

4. The controller probe diagnostic logic determines

thataprobecheckisnecessary basedonthetemperature values currently reported by the supply and return probes.

5. If the controller is programmed with the Demand

Defrostoption (Future) andthe option is set to “IN” the unit will enterdefrost if it has been in operation for over 2.5 hours without reaching set point.

ENERGIZED DE--ENERGIZED

FORFULL DIAGRAM AND LEGEND,SEE SECTION7

POWER TO

CONTROLLER

TD T6

CONTROL TRANSFORMER

If the controller is programmed with the Lower DTT setting option the defrost termination thermostat set pointmaybeconfiguredtothedefaultof 25.6_C(78_F) orloweredto18_C(64_F).Whenarequestfordefrostis made by use of the manual defrost switch, communications or probe check the unit will enter defrost if the defrost temperature thermostat reading is at or below the defrost termination thermostat setting. Defrost will terminate with the defrost temperature sensor reading rises above the defrost termination thermostat setting. When a request for defrost is made bythedefrostintermaletimeror bydemanddefrost,the defrosttemperaturesetting setting mustbe below 10_C (50_F).

Whenthe defrost mode is initiatedthe controlleropens contacts TD, TN and TE (or TV) to de-energize the compressor, condenser fan and evaporator fans. The COOL light is also de--energized.

The controller then closes TH to supply power to the heaters. The defrost light is illuminated.

Whenthedefrost temperaturesensorreadingrises tothe defrost termination thermostat setting, the de--i cing operation i s terminated.

If defrost does not terminate correctly and temperature reaches the set point of theheat termination thermostat (HTT) the thermostat will open to de--energize the heaters.If termination does not occurwithin 2.0 hours, the controller will terminate defrost. An alarm will be given of a possible DTS failure.

SIGNAL TO

CONTROLLER

USV

ESV

Figure 4-7 Defrost

Defrost may be initiated any time the defrost temperature sensor reading falls below the controller defrost termination thermostat set point. Defrost will terminate when the defrost temperature sensor reading risesabovethedefrostterminationthermostat set point. The defrost termination thermostat is not a physical component. It is a controller setting that acts as a thermostat, “closing” (allowing defrost) when the defrosttemperaturesensorreadingisbelowthesetpoint and“opening”(terminatingorpreventingdefrost)when thesensortemperaturereadingis aboveset point. When the unit is operating in bulb mode (refer to paragraph

3.3.9), special settings may be applicable.

If probe check (controller function code CnF31) is configured to special, the unit will proceed to the next operation (snapfreeze or terminatedefrost).If thecode is configuredto standard, the unit will perform a probe check. The purpose of the probe check is to detect malfunctions or drift in the sensed temperature that is too small to be detected by the normal sensor out of rangetests. Thesystemwillrunforeightminutesinthis condition.Attheend ofthe eight minutes, probealarms will be set or cleared based on the conditions seen.

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

Ifcontrollerfunction codeCnF33 is configured tosnap freeze, the controller will sequence to this operation. The snap freeze consists of running the compressor without the evaporatorfans in operation for a periodof four minutes with the suction modulation valve fully open. When the snap freeze is completed, defrost is formally terminated.

4-7

T-309

SECTION 5

Nopowertounit

Component(s)NotOperatin

Compressorhum

s,butdoesno

TROUBLESHOOTING

CONDITION POSSIBLE CAUSE

5.1 UNIT WILL NOT START OR STARTS THEN STOPS

External power source OFF Turn on

No power to unit

oss of control power

Component(s) Not Operating

Compressor hums,but does not start

Start-Stop switch OFF or defective Check Circuit breaker tripped or OFF Check Circuit breaker OFF or defective Check Control transformer defective Replace Fuse (F3) blown Check Start-Stop switch OFF or defective Check Evaporator fan motor internal protector open 6.17 Condenser fan motor internal protector open 6.12 Compressor internal protector open 6.8 High pressure switch open 5.7 Heat termination t hermostat open Replace Loss of communication with expansion module Check Wiring Malfunction of current sensor Replace Low line voltage Check Single phasing Check Shorted or grounded motor windings 6.8 Compressor seized 6.8

REMEDY/

REFERENCE

SECTION

5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING

Hot load Normal

Container

Defectivebox insulation or air leak Repair Shortage of refrigerant 6.7.1 Evaporator coil covered with ice 5.6 Evaporator coil plugged with debris 6.15 Evaporator fan(s) rotating backwards 6.15/6.17 Defective evaporator fan motor/capacitor 6.18 Air bypass around evaporator coil Check Controller set too low Reset

Refrigeration System

Compressor service valves or liquid line shutoff valve partially closed

Dirty condenser 6.11 Compressor worn 6.8 Current limit (function code Cd32) set to wrong value 3.5.5 Suction modulation valve lost track of step count Powercycle Suction modulation valve malfunction 6.20 Economizer solenoid valve or TXV malfunction 6.14, 6.19 Unloader valve stuck open 6.19

Open valves completely

5-1

T-309

CONDITION POSSIBLE CAUSE

Nooperationofanykin

Nocontrolpowe

Unitwillnotheatorhasinsuffi

Unitfailstostopheatin

Willnotinitiatedefros

5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING

Abnormal pressures 5.7 Abnormal temperatures 5.15 Abnormal currents 5.16 Controller malfunction 5.9 Evaporator fan or motor defective 6.17 Shortage of refrigerant 6.7.1

Refrigeration System

Suction modulation valve lost track of step count Powercycle Suction modulation valve malfunction 6.20 Compressor service valves or liquid line shutoff valve par-

tially closed Economizer solenoid valve or TXV malfunction 6.14, 6.19 Unloader valve stuck open 6.19 Frost on coil 5.10

5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING

Start-Stop switch OFF or defective Check

No operation of any kind

Circuit breaker OFF or defective Check External power source OFF Turn ON Circuit breaker or fuse defective Replace Control Transformer defective Replace

No control power

Evaporator fan internal motor protector open 6.17 Heat relay defective Check Heater termination thermostat open 6.15 Heater(s) defective 6.15 Heater contactor or coil defective Replace Evaporator fan motor(s) defective or rotating backwards 6.15/6.17

Unitwill not heat or has i nsufficient heat

Evaporator fan motor contactor defective Replace Controller malfunction 5.9 Defectivewiring Replace Loose terminal connections Tighten Low line voltage 2.3

REMEDY/

REFERENCE

SECTION

Open valves completely

5.5 UNIT WILL NOT TERMINATE HEATING

Controller improperly set Reset Controller malfunction 5.9 Heater termination thermostat remains closed along with

the heat relay

5.6 UNIT WILL NOT DEFROST PROPERLY

6.15

Defrost timer malfunction (Cd27) Table 3-5 Loose terminal connections Tighten/

Willnot initiate defrost automatically

Defectivewiring Replace Defrost temperature sensor defective or heat termination

thermostat open

Replace

Heater contactor or coil defective Replace

5-2T -309

CONDITION POSSIBLE CAUSE

Willnotinitiatedefros

Lowsuctionpressur

izew

Compresso

CondenserorEvaporatorFa

5.6 UNIT WILL NOT DEFROST PROPERLY -- Continued

REMEDY/

REFERENCE

SECTION

Willnot initiate defrost manually

Initiates but relay (DR) drops out

Manual defrost switch defective Replace Defrost temperature sensor open 4.9.5

Low line voltage 2.3 Heater contactor or coil defective Replace

Initiates but does not defrost

Heater(s) burned out 6.15

Frequent defrost Wet load Normal

5.7 ABNORMAL PRESSURES (COOLING)

Condenser coil dirty 6.11 Condenser fan rotating backwards 6.12 Condenser fan inoperative 6.12

High discharge pressure

Refrigerant overcharge or noncondensibles 6.7.1 Discharge service valve partially closed Open Suction modulation valve malfunction 6.20 Faulty suction pressure transducer Replace Suction service valve partially closed Open Filter-drier partially plugged 6.13 Low refrigerant charge 6.7.1

Low suction pressure

Expansion valve defective 6.14 No evaporator air flow or restricted air flow 6.15 Excessive frost on evaporator coil 5.6 Evaporator fan(s) rotating backwards 2.3 Suction modulation valve malfunction 6.20

Suction and discharge pressures tendto equa

en unitis

operating

Compressor operating in reverse 5.14 Compressor cycling/stopped Check

5.8 ABNORMAL NOISE OR VIBRATIONS

Compressor start up after an extended shutdown Brief chattering when manually shut down Compressor operating in reverse 5.14

Compressor

Loose mounting bolts or worn resilient mounts Tighten/Replace Loose upper mounting 6.8.1 step r. Liquid slugging 6.14 Insufficient oil 6.9 Bent, loose or striking venturi Check

Condenser or Evaporator Fan

Worn motor bearings 6.12/6.17 Bent motor shaft 6.12/6.17

5-3

Normal

T-309

CONDITION POSSIBLE CAUSE

Willnotcontro

5.9 CONTROLLER MALFUNCTION

Defective Sensor 6.22 Defectivewiring Check

Willnot control

Fuse (F1, F2, F3) blown Replace Stepper motor suction modulation valve circuit malfunction 6.20 Low refrigerant charge 6.7

5.10 NO EVAPORA T OR AIR FLOW OR RESTRICTED AIR FLOW

REMEDY/

REFERENCE

SECTION

Evaporator coil blocked

Dirty coil 6.15 Evaporator fan motor internal protector open 6.17 Evaporator fan motor(s) defective 6.17

Frost on coil 5.6

No or partial evaporator air flo

Evaporator fan(s) loose or defective 6.17 Evaporator fan contactor defective Replace

5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION

Low refrigerant charge 6.7.1 External equalizerline plugged Open Wax, oil or dirt plugging valve or orifice Ice formation at

valve seat

Low suction pressure with high superheat

Superheat not correct 6.7.1 Power assembly failure Loss of element/bulb charge Broken capillary Foreign material in valve

Superheat setting too low 6.14 High suction pressurewith lo superhea

External equalizerline plugged Ice holding valve open Open

Foreign material in valve 6.14 Liquid slugging in compressor

Pin and seat of expansion valve eroded or held open by for-

eign material

Improper bulb location or installation Fluctuating suction pressure

Low superheat setting

6.14

5.12 AUTOTRANSFORMER MALFUNCTION

Circuit breaker (CB-1 or CB-2) tripped Check Unitwill not start

5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH

Power source not turned ON Check

Waterpressure switch malfunction Check Condenser fan starts and stops

Watersupply interruption Check

5-4T -309

CONDITION POSSIBLE CAUSE

Electrica

Check

Highdischargetemperatur

Low

5.14 COMPRESSOR OPERATING IN REVERSE

REFERENCE

CAUTION

Allowingthescrollcompressortooperatein reversefor morethan two minuteswill resultin internal compressor damage. Turn the start--stop switch OFF immediately .

Incorrect wiring of compressor

Electrical

Incorrect wiring of compressor contactor(s)

Check

Incorrect wiring of current sensor

5.15 ABNORMAL TEMPERATURES

Dischargetemperature sensor drifting high Replace Failed economizer, TXV or solenoid valve Replace

High discharge temperature

Plugged economizer,TXV or solenoid valve Replace Loose or insufficiently clamped sensor Replace Failed liquid injection solenoid valve Replace Dischargetemperature sensor drifting low Replace

suction temperature

5.16 ABNORMAL CURRENTS

Loose or insufficiently clamped sensor Replace

REMEDY/

SECTION

Unit reads abnormal currents Current sensor wiring Check

5-5

T-309

SECTION 6

SERVICE

NOTE

Toavoiddamageto theearth’sozonelayer,usearefrigerantrecoverysystemwheneverremovingrefrigerant. When working with refrigerants you must comply with all local government environmental laws. In the U.S.A., refer to EPA section 608.

WARNING

Neveruseair for leak testing.Ithas beendetermined that pressurized, mixtures of refrigerant and air can undergo combustion when exposed to an ignition source.

6.1 SECTION LAYOUT

Serviceprocedures are provided herein beginning with refrigeration system service, then refrigeration system component service, electrical system service, temperature recorder serviceand general service. Refer to the TableOf Contents to locate specific topics.

6.2 SERVICE VALVES

The compressor suction, compressor discharge, compressor economizer, oil return and the liquid line service valves (see Figure 6-1) are provided with a double seat and an access valve which enable servicing of the compressor and refrigerant lines. Turning the valve stem clockwise (all the way forward) will frontseat the valve to close off the line connection and open a path to the access valve. Turning the stem counterclockwise (all the way out) will backseat the valveto open the line connection and close offthe path to the access valve.

With the valve stem midway between frontseat and backseat,both of the servicevalveconnectionsareopen to the access valve path.

For example, the valve stem is first fully backseated whenconnectingamanifoldgaugetomeasurepressure. Then,the valveis opened1/4 to 1/2 turnto measurethe pressure.

VALVE FRONTSEATED (Clockwise)

1. Line Connection

2. Access Valve

3. Stem Cap

Figure 6-2 Suction Service Valve

SUCTION PRESSURE GAUGE

OPENED (Backseated ) HAND VALVE

A. CONNECTION TO LOW SIDE OF SYSTEM B. CONNECTION TO EITHER:

REFRIGERANT CYLINDER OR OIL CONTAINER

C. CONNECTION TO HIGH SIDE OF SYSTEM

VALVE BACKSEATED (Counterclockwise)

4. Valve stem

5. Compressor Inlet

Connection

DISCHARGE PRESSURE GAUGE

CLOSED (Frontseated) HAND VALVE

VALVE FRONTSEATED (Clockwise)

1. Line Connection

2. Access Valve

3. Stem Cap

Figure 6-1 Service Valve

VALVE BACKSEATED (Counterclockwise)

4. Valve stem

5. Compressor Or Filter Drier Inlet Connection

Figure 6-3 Manifold Gauge Set

6.3. MANIFOLD GAUGE SET

The manifold gauge set (see Figure 6-3) is used to determine system operating pressure, add refrigerant charge, and to equalize or evacuate the system.

When the suction pressure hand valve is frontseated (turnedall the wayin),thesuction(low)pressurecanbe checked. When the discharge pressure hand valve is frontseated, the discharge (high) pressure can be checked. When both valves are open (turned counter-clockwiseallthe way out),high pressurevapor will flow into the low side. When the suction pressure valveis open and the dischargepressurevalveshut, the

6-1

T-309

system can be charged. Oil can also be added to the system.

A R-134a manifold gauge/hose set with self-sealing hoses (see Figure 6-4) is required for service of the models covered within this manual. The manifold gauge/hose set is available from Carrier Transicold. (Carrier Transicold P/N 07-00294-00, which includes items1through6,Figure 6-4.)Toperformserviceusing the manifold gage/hose set, do the following:

2. Connect the field service coupling (see Figure 6-4) to the access valve.

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

4. To read system pressures: slightly midseat the service valve.

5. Repeat the proceduretoconnecttheothersideofthe gauge set.

a. Preparing Manifold Gauge/Hose Set For Use

1. Ifthemanifoldgauge/hosesetisneworwasexposed to the atmosphere it will need to be evacuated to remove contaminants and air as follows:

2. Back seat (turncounterclockwise)bothfieldservice couplings (see Figure 6-4) and midseat both hand valves.

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

SUCTION PRESSURE GAUGE

OPENED (Backseated ) HAND VALVE

To Low Side Access Valve

BLUE

Blue Knob

1. Manifold Gauge Set

2. Hose Fitting (0.5-16 Acme)

3. Refrigeration and/or Evacuation Hose . (SAE J2196/R-134a)

4. Hose Fitting w/O-ring (M14 x 1.5)

5. High Side Field Service Coupling

6. Low Side Field Service Coupling

Figure 6-4 R-134a Manifold Gauge/Hose Set

YELLOW

DISCHARGE PRESSURE GAUGE

(Frontseated)

HAND VAL VE

To High Side Access Valve

RED

CLOSED

Red Knob

7. Evacuate to 10 inches of vacuum and then charge withR-134ato aslightlypositivepressureof0.1kg/ cm@ (1.0 psig).

8. Front seat both manifold gauge set valves and disconnect from cylinder. The gauge set is now ready for use.

b. Connecting Manifold Gauge/Hose Set To connect the manifold gauge/hose set for reading

pressures, do the following:

1. Remove service valve stem cap and check to make sure it is backseated.Remove access valvecap.

Figure 6-1)

(See

CAUTION

Toprevent trapping liquid refrigerantinthe manifold gauge set be sure set is brought to suction pressure before disconnecting.

c. Removing the Manifold Gauge Set

1. While the compressor is still ON, backseatthe high side service valve.

2. Midseat bothhand valveson themanifold gauge set and allow the pressure in the manifold gauge set to bedrawndowntolowsidepressure.Thisreturnsany liquidthatmaybeinthehighsidehosetothesystem.

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

4. Install both servicevalvestem capsand serviceport caps (finger-tight only).

6.4 PUMPING THE UNIT DOWN

To service the filter-drier, economizer, expansion valves, moisture-liquid indicator, suction modulation valve, economizer solenoid valve, unloader solenoid valve or evaporator coil, pump the refrigerant into the high side as follows:

CAUTION

The scroll compressor achieves low suction pressure very quickly. Do not operate the compressor in a deepvacuum,internaldamage will result.

a. Attach manifoldgauge setto the compressorsuction

and discharge service valves. Referto paragraph 6.3.

b. Start the unit and run in the frozenmode (controller

set below --10°C)for10to15minutes.

c. Check functioncodeCd21 (refertoparagraph3.2.2).

The economizer solenoid valve should be open. If not, continue to run until the valve opens.

d. Frontseat the oil return service valve then, frontseat

theliquidlineservicevalve.Placestart-stopswitchin theOFFposition whenthe suctionreaches apositive pressure of 0.1 kg/cm@ (1.0 psig).

e. Frontseat the economizer service valve and then

frontseat the suction and discharge service valves. Therefrigerantwillbetrappedbetweenthecompressor suction service valve and the liquid line valve.

f. Before opening up any part of the system, a slight

positivepressure should be indicatedon thepressure

6-2T -309

gauge. If a vacuum is indicated, emit refrigerant by crackingtheliquidlinevalvemomentarilytobuildup a slight positive pressure.

g. Whenopeningupthe refrigerantsystem, certainparts

mayfrost.Allowthe parttowarmtoambienttemperature before dismantling. This avoids internal condensation which puts moisture in the system.

h. After repairs have been made, be sure to perform a

refrigerant leak check (refer to paragraph 6.5), and evacuate and dehydrate the low side (refer to paragraph 6.6).

i. Check refrigerant charge (refer to paragraph 6.7).

6.5 REFRIGERANT LEAK CHECKING

WARNING

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

a. The recommended procedure for finding leaks in a

systemiswithaR-134aelectronicleakdetector.Testingjointswithsoapsudsissatisfactoryonlyforlocating large leaks.

b. If thesystemiswithoutrefrigerant,chargethesystem

with refrigerant 134a to build up pressure between

2.1to 3.5 kg/cm@(30to50 psig).Toensurecomplete pressurization of the system, refrigerant should be charged at the compressor suction and economizer servicevalvesandtheliquid line servicevalve.Also, the area between the suction modulating valve and evaporatorexpansionvalvemaynot be open to these chargingpoints. Pressurebetween these components maybechecked at thelow sideaccess valve(item 11, Figure 2-2) or by checking that the suction modulating valve is more than 10% open at controller function code Cd01. The suction modulating valve may beopenedbyuseofthecontrollerfunctioncodeCd41 valve override control (refer to paragraph 6.19). Removerefrigerantcylinder and leak-checkallconnections.

6.6 EVACUATION AND DEHYDRATION

6.6.1 General

Moisture is the deadly enemy of refrigerationsystems. The presence of moisture in a refrigerationsystem can have many undesirable effects. The most common are copper plating,acid sludge formation,“freezing-up” of meteringdevicesby freewater,and formation of acids, resulting in metal corrosion.

6.6.2 Preparation

a. Evacuate and dehydrate only afterpressure leaktest.

(Refer to paragraph 6.5.)

b. Essential tools to properly evacuate and dehydrate

anysystem include avacuum pump(8 m

/hr= 5cfm volume displacement) and an electronic vacuum gauge. (The pump is available from Carrier Transicold, P/N 07-00176-11.)

c. If possible, keep the ambient temperature above

15.6_C(60_F) to speed evaporation of moisture. If the ambient temperature is lower than 15.6_C (60_F), ice might form before moisture removal is complete.Heatlampsoralternatesourcesofheatmay be used to raise the system temperature.

d. Additional timemaybesavedduringacompletesys-

tem pump down by replaceing the filter-drier with a sectionof coppertubing and the appropriatefittings. Installation of a new drier may be performedduring the charging procedure.

NOTE

Only refrigerant 134a should be used to pressurize the system. Any other gas or vapor will contaminate the system, which will require additional purging and evacuation of the system.

c. If required, remove refrigerant using a refrigerant

recovery system and repair any leaks.

d. Evacuate and dehydrate theunit. (Referto paragraph

6.6.)

e. Charge unit per paragraph 6.7.

1. Liquid Service Valve

2. Receiver or Water Cooled Condenser

3. Compressor

4. Discharge Service Valve

5. Economizer Service Valve

Figure 6-5. Refrigeration System Service

Connections

6.6.3 Procedure - Complete system

6-3

10. Refrigerant Cylinder 1 1. Reclaimer

6. Suction Service Valve

7. Vacuum Pump

8. Electronic Vacuum Gauge

9. Manifold Gauge Set

T-309

a. Remove all refrigerant using a refrigerant recovery

system.

b. The recommendedmethodtoevacuateanddehydrate

the system isto connectevacuationhosesatthe compressor suction, compressor economizer and liquid line service valve (see F igure 6-5). Be sure the service hoses are suited for evacuation purposes.

c. The area between the suction modulating valve and

evaporator expansion valve may not be open to the access valves. To ensure evacuation of this area, checkthat the suction modulatingvalveis morethan 10% open at controller function code Cd01. If required, the suction modulating valve may be opened by use of the controller function code Cd41 valve overridecontrol.Ifpoweris not availabletoopen the valve, the area may be evacuated by connecting an additional hoseat the lowside access valve (item 11, Figure 2-2).

d. Testtheevacuationsetupfor leaksbybackseatingthe

unit service valves and drawing a deep vacuum with thevacuumpumpandgaugevalvesopen.Shut offthe pump and check to see if the vacuum holds. Repair

leaks if necessary. e. Midseat the refrigerant system service valves. f. Openthevacuumpumpandelectronicvacuumgauge

valves,if they arenotalreadyopen. Start the vacuum

pump. Evacuate unit until the electronic vacuum

gauge indicates 2000 microns. Close the electronic

vacuumgaugeand vacuumpump valves. Shut offthe

vacuumpump.Waitafewminutestobesurethevac-

uum holds. g. Break the vacuum with clean dry refrigerant 134a

gas. Raise system pressure to approximately 0.2 kg/

cm@ (2 psig), monitoring it with the compound

gauge. h. Removerefrigerant using a refrigerant recoverysys-

tem. i. Repeat steps f.and g. one time. j. Removethecoppertubing and changethefilter-drier.

Evacuate unit to 500 microns. Close the electronic

vacuumgaugeand vacuumpump valves. Shut offthe

vacuum pump. Wait five minutes to see if vacuum

holds. This procedure checks for residual moisture

and/or leaks. k. With a vacuumstill inthe unit, the refrigerantcharge

may be drawn intothe system from arefrigerant con-

tainer on weight scales. Continue to paragraph 6.7

1. Receiver or Water Cooled Condenser

2. Compressor

3. Discharge Service Valve

4. Economizer Service Valve

Figure 6-6. Compressor Service Connections

6.6.4 Procedure - Partial System

5. Suction Service Valve

6. Vacuum Pump

7. Electronic Vacuum Gauge

8. Manifold Gauge Set

9. Refrigerant Cylinder

10. Reclaimer

a. If the refrigerant charge has been removed from the

compressorforservice,evacuateonlythecompressor by connecting the evacuation set--upat thecompressor servicevalves. (SeeFigure 6-6.) Follow evacuation procedures of the preceding paragraph except leave compressor service valves frontseated until evacuation is completed.

b. If refrigerantcharge has been removed from the low

side only, evacuate the low side by connecting the evacuation set--up at the compressor suction and economizer service valves and the liquid service valveexceptleavethe servicevalvesfrontseateduntil evacuation is completed.

c. Once evacuation has been completed and the pump

has been isolated, fullybackseatthe service valves to isolate the service connections and then continue with checking and, if required, adding refrigerant in accordance with normal procedures

6-4T -309

6.7 REFRIGERANT CHARGE

6.7.1 Checking the Refrigerant Charge

e. Start unit in cooling mode. Run approximately 10

minutes and check the refrigerant charge.

6.7.3 Adding Refrigerant to System (Partial Charge)

NOTE

Toavoiddamageto the earth’sozone layer,use arefrigerant recoverysystemwhenever removing refrigerant. When working with refrigerants you must comply with all l ocal government environmental laws. In the U.S. A., refer to EPAsection 608.

a. Connect the gauge manifold to the compressor dis-

chargeandsuctionservicevalves.Forunitsoperating on a water cooled condenser, change over to air cooled operation.

b. Bring the container temperature to approximately

1.7_C(35_F)or--17.8_C(0_F). Thensetthecontrol- lerset point to --25_C(--13_F) to ensurethat the suc- tion modulation valve is fully open. (Position of the suctionmodulatingvalvemay be checkedatcontroller function code Cd01.)

c. Partially block the condenser coil inlet air. Increase

theareablockeduntilthe compressordischargepressureisraisedtoapproximately12kg/cm@(175psig).

d. Onunitsequipped withareceiver,the levelshouldbe

betweenthe glasses. On units equipped with a water cooledcondenser,the level should beat the center of theglass.Iftherefrigerantlevelisnot correct,continuewiththefollowing paragraphstoaddorremoverefrigerant as required.

a. Examine the unit refrigerant systemfor any evidence

of leaks. Repair as necessary. (Refer to paragraph

6.5.) b. Maintain the conditions outlined in paragraph 6.7.1 c. Fully backseat the suction servicevalve and remove

the service port cap.

d. Connect charginglinebetween suction servicevalve

port and cylinder of refrigerant R-134a. Open VAPOR valve.

e. Partially frontseat (turn clockwise) the suction ser-

vicevalveandslowly add chargeuntil therefrigerant appearsattheproperlevel. Be carefulnottofrontseat the suction valve fully,if the compressor is operated in a vacuum internal damage may result.

6.8 COMPRESSOR -- Model RSH105

WARNING

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

WARNING

Beforedisassembly of the compressormake sure to relieve the internal pressure very carefullyby slightly loosening the couplings to break the seal.

6.7.2 Adding Refrigerant to System (Full Charge)

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

paragraph 6.6.)

b. Placecylinder of R-134aon scale and connectcharg-

ing line from cylinder to liquid line valve. Purge charginglineatliquidlinevalveandthennoteweight of cylinder and refrigerant.

c. Open liquidvalveoncylinder.Open liquid linevalve

half-wayandallow theliquid refrigerantto flowinto theunituntilthecorrectweightofrefrigerant(referto paragraph

2.2) has been added as indicated byscales.

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. (Refer to section paragraph 6.7.3)

d. Backseatmanualliquid line valve(toclose offgauge

port). Close liquid valve on cylinder.

CAUTION

The scroll compressor achieves low suction pressure very quickly. Do not use the compressor to evacuate the system below zero psig. Neveroperate thecompressor with the suction or discharge service valves closed (frontseated). Internal damage will result from operating the compressor in a deep vacuum.

6.8.1 Removal and Replacement of Compressor

NOTE

Servicecompressorcontains anitrogencharge. Due to the hygroscopic nature of the oil, time the compressor is left open to the atmosphere should be minimized as much as possible.

a. Procure areplacementcompressor kit.A listof items

contained in the compressor kit is provided in Table 6-1.

b. If thecompressoris operational, pumpthe unitdown

(refer to paragraph 6.4).

6-5

T-309

Table 6-1 Compressor Kit

Item

Component Qty

1 Compressor 1 2 Service Valve Seal 3 3 Mylar Washers 4 4 Wire Tie 2 5 Oil Sight Glass Plug 1 6 Resilient Mount 4 7 Upper Shock Mount Ring 1 8 Upper Shock Mount Bushing 1 9 Compressor Power Plug O--Ring 1

10 SST Washers 8

c. If the compressor is not operational, turn the unit

start--stop switch (ST) and unit circuit breaker (CB--1)OFF.Disconnectpowertotheunitandfront-seatthedischarge,suction,economizer,andoilreturn service valves. Remove all remaining refrigerantfrom the compressor using a refrigerant recovery system. Connect hoses to suction, economizer and discharge service valves ports. Evacuate compressor to 500 microns (75.9 cm Hg vacuum = 29.9 inches Hg vacuum).

d. Make sure power to the unit is OFF and unit power

plug disconnected. Disconnect the power plug from the compressor.

e. Loosenandbreakthesealatfittings from thesuction,

discharge, economizer, and the oil return service valves. Remove fittings and discard service valve seals, retain oil return valve O--ring.

f. Remove the entire compressor upper mounting

bracket assembly,(see Figure 6-7) by removing the fourcapscrewsattachingittotheunitandthe32--mm bolt from the compressor m ounting bracket.

Upper Shock Mount Bushing(KitItem8)

32mm Bolt

Figure 6-7 Compressor Upper Mounting

Upper Shock Mount Ring (Kit Item 7)

Shoulder Bolt

SST Washer (Kit Item 10)

Resilient Mount (Kit Item 6)

SST Washer (Kit Item 10)

Mylar Washer (Kit Item 3)

Mylar Protector (Retain)

Base Plate (Retain)

Mylar Protector (Retain)

Figure 6-8 Compressor Lower Mounting

g. Replace the upper mounting bracket shock mount

ring and bushing (kit items 7and 8). Reassemblethe bracketinthesame manneras theoriginal and torque the shoulder bolt to 2.8 mkg (20 ft--lbs.).

h. Remove the male coupling from the top of the sight

glassontheoldcompressorandhandassembletothe oil return valve coupling for safe keeping. Plug the top of the replacement compressor sight glass with the plug (kit item 5) to prevent spilling oil.

i. Remove the lowermounting bolts and hardware(see

Figure 6-8). Using plugs from replacementcompressor,plug connectionsonoldcompressor.Removethe old compressor. Refer to paragraph 2.2for compressor weight. Return plugsto replacementcompressor .

j. The replacement compressor is shipped with an oil

chargeof591ml (20 ounces). Before sliding the new compressorintheunit, removetheoilsightglassplug and (using a small funnel) charge the compressor with an additional 1893ml (64 ounces) Castrol--IcematicSW20(POEoil).Reassembletheoilsightglass plugtoavoidspillingoilwhenslidingthecompressor in the unit.

k. Securethebaseplateandmylarprotectorstothecom-

pressorwithwireties(kititem 4), andplacethecompressor in the unit.

l. Cut and remove the wire ties that were used to hold

the base plate and protectors to the compressor. Using new resilient mounts, SST washers and mylar washers(kititems3, 6& 10).Installthe fourmounting screws loosely.

m.Installthemalecoupling(removedinsteph.)intothe

sight glass port.

6-6T -309

n. Place the new service seals (kit item 2) at the com-

pressorserviceports, connectthe four service valves loosely.

o. Torquethefourresilientmountscrewsto6.2mkg(45

ft--lbs).

p. Torque the four service valves to:

Service Valve Torque

Suction or Discharge 11 to 13.8 mkg

(80 to 100 ft--lbs.)

Economizer 6.9to8.3mkg

(50to60ft--lbs.)

Oil Return 1.4to1.66mkg

(10to12ft--lbs.)

q. Reassemble the top mounting bracket (see

Figure 6-7) by hand tightening the 32--mm (1¼

--inch) bolt andtorquingthe fourmounting screwsto

0.9 mkg (6.5 ft--lbs). Align the mounting so that the ringandbushing assemblyarefreewithnocompression.

r. Torquethe32mm bolt to 1. 5 mkg (11ft--lbs.).While

maintaining the free movement of the shock mount, torque the four mounting screws to 0.9 mkg (6.5 ft-lbs.).

s. Replace the power plug O--Ring with new ring (kit

item9).Insertthe powerplugintothecompressorfitting. Be sure plug is fully seated into the fitting and then thread the coupling nut a minimum of 5 turns.

t. Leakcheckandevacuatethe compressorto 1000 mi-

crons. Refer to paragraphs

6.5 and 6.6

u. Runthe unit for at least 15 minutes and check the oil

and refrigerant levels. Refer to paragraphs 6.7 and

6.9.

5 TurnStart/Stopswitch offandallowoilto draininto

compressor sump. Oil level must be visible in the sightglass.Ifitisnotvisible,oilmustbeaddedtothe compressor.

b. Adding Oil with Compressor in System

1. The recommendedmethod is to add oil using an oil

pump at the oil return service valve (see item

Figure 2-3

)

15,

2. In anemergencywhereanoil pumpis not available,

oilmaybedrawnintothecompressorthrough theoil return service valve.

Connect the suction connection of t he gauge manifold to the compressor oil return valve port, and immersethe common connectionofthe gaugemanifold in an open container of refrigeration oil. Extreme care must be taken to ensure the manifold common connection remains immersed in oil at all times.Otherwiseairandmoisturewillbedrawninto the compressor. Crack the oil return service valve andgaugevalvetoventasmallamountofrefrigerant throughthecommon connectionandtheoil to purge the lines of air. Close the gauge manifold valve.

Withtheunit running,turn thesuction servicevalve toward frontseat and induce a vacuum in the compressor crankcase. Do not allow the compressor to pull below 127mm/hg (5 “/hg). SLOWLY crack the suction gauge manifold valve and oil will flow throughtheoilreturnservicevalveintothecompressor. Add oil as necessary .

3 Rununit for20 minutes in cooling mode. C heck oil

level at the compressor sight glass.

c. Removing Oil from the Compressor:

1 If the oil level is above the sight glass, oil must be

removed from the compressor.

6.9 COMPRESSOR OIL LEVEL

CAUTION

Use onl y Carrier Transicold approved Polyol Ester Oil (POE) -- Mobil ST32 compressoroil with R-134a. Bu y in quantities of onequartorsmaller. When using this hygroscopic oil, immediately reseal. Do not leave container of oil open or contamination will occur.

a. Checking the Oil Level in the Compressor

1 Ideally, ambient temperature should be between

40_F and 100_F.

2 Operatethe unit in cooling modeforat least 20 min-

utes.

3 Checkthe controller function code Cd1 for the suc-

tion modulation valve(SMV) position. It should be at least 20% open.

4 Locate the oil sight glasson the sideof the compres-

sor (item

7, Figure 2-3).

2 Perform a compressor pump down, refer to section

6.4.

3 Removetheoilplug,anddrainoiluntil alevelcanbe

seen in the sight glass.

4 Rununit for20 minutes in cooling mode. C heck oil

level at the compressor sight glass.

6.10 HIGH PRESSURE SWITCH

6.10.1 Replacing High Pressure Switch

a. Turn unit start-stop switch OFF. Frontseat the suc-

tion, discharge, economizer and oil return service valvesto isolatecompressor. Remove the refrigerant from the compressor.

b. Disconnect wiring from defective switch. The high

pressure switch is located on the discharge service valve and is removed by turning counterclockwise. (See Figure 2-3.)

c. Install a new high pressure switch after verifying

switch settings. (Refer to paragraph 6.10.2.)

d. Evacuate and dehydrate the compressor per para-

graph 6.6.

6-7

T-309

6.10.2 Checking High Pressure Switch

WARNING

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

NOTE

The high pressure switch is non-adjustable.

c. Unsolder discharge line and remove the line to the

receiver or water-cooled condenser.

d. Remove coil mounting hardware and remove the

coil. e. Install replacement coil and solder connections. f. Leak-check the coil connections per paragraphpara-

graph 6.5. Evacuate the unit per paragraph 6.6 then

chargethe unit with refrigerant per paragraph 6.7.

6.12 CONDENSER FAN AND MOTOR ASSEMBLY

a. Remove switch as outlined in paragraph6.10.1 b. C onnect ohmmeter or continuity light across switch

terminals. Ohm meter will indicate no resistance or continuity light will be illuminated if the switch closed after relieving compressor pressure.

c. Connect hose to a cylinder of dry nitrogen. (See

Figure 6-9.)

Figure 6-9 High Pressure Switch Testing

1. Cylinder Valve and Gauge

2. Pressure Regulator

3. Nitrogen Cylinder

4. Pressure Gauge (0 to 36 kg/cm@ = 0 to 400 psig)

5. Bleed-Off Valve

6. 1/4 inch Connection

d. Set nitrogen pressure regulator at 26.4 kg/cm@ (375

psig) with bleed-off valve closed. e. Cl ose valve on cylinder and open bleed-off valve. f. Open cylindervalve. Slowly closebleed-offvalveto

increasepressureon switch. The switch should open

at a static pressure up to 25 kg/cm@ (350 psig). If a

lightisused,lightwillgoout.Ifanohmmeterisused,

the meter will indicate open circuit. g. Slowlyopenbleed-offvalvetodecreasethepressure.

The switch should close at 18 kg/cm@ (250 psig).

6.11 CONDENSER COIL

WARNING

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

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

a. Open condenser fan screen guard. b. Loosen two square head set screws on fan. (Thread

sealer has been applied to set screws at installation.) Disconnect wiring from motor junction box.

CAUTION

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

c. Remove motor mounting hardware and replace the

motor. It is recommendedthat new locknuts be used when replacing motor. Connect wiring per wiring diagram.

d. Install fan loosely on motor shaft (hub side in). DO

NOTUSEFORCE.If necessary,tapthehubonly,not the hub nuts or bolts. Install venturi. Apply “Loctite H”tofansetscrews.Adjust fan withinventurisothat the outer edge of the fan is within 2.0 ± .07 mm (0.08”¦ 0.03”)fromthe outside ofthe orificeopen-

ing. Spin fan by hand to check clearance. e. Close and secure condenser fan screen guard. f. Apply power to unit and check fan rotation. If fan

motor rotates backward, reverse wire numbers 5 and

The condenser consists of a series of parallel copper tubes expanded into copper fins. The condenser coil mustbecleanedwithfreshwaterorsteamsotheairflow is not restricted. To replacethe coil, do the following:

WARNING

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.

6.13 FIL TER-DRIER

Onunitsequippedwitha water-cooledcondenser,ifthe sight glass appears to be flashing or bubbles are constantly moving through the sight glass when the suction modulation valve is fully open, the unit may havea low refrigerantchargeor thefilter-driercouldbe partially plugged.

a. To Check Filter-Drier

1. Testforarestrictedorpluggedfilter-drierbyfeeling

the liquid line inlet and outlet connections of the driercartridge.If theoutletside feels cooler than the inlet side, then the filter-drier should be changed.

6-8T -309

2. Check the moisture-liquid indicator if the indicator showsahighlevelofmoisture,thefilter-driershould be replaced.

b. To Replace Filter-Drier

1. Pump down the unit (refer to paragraph 6.4 and replacefilter-drier.

2. Evacuate the low sidein accordancewith paragraph

6.6.

3. Afterunitisin operation,inspectformoistureinsystem and check charge.

6.14 EXPAN SION VALVES

Two expansion valves are used, the evaporator expansion valve (item 9, Figure 2-2), and the

economizer expansion valve (item 26, Figure 2-4) .

The expansionvalvesareautomaticdeviceswhichmaintain constant superheat of the refrigerant gas leaving at the pointof bulb attachmentregardlessof suctionpressure.

The valve functions are:

1. Automatic control of the refrigerant flow to match

the load.

2. Prevention of liquid refrigerant entering the com-

pressor.

a. Open the heater access panel (see Figure 2-1) to ex-

pose the evaporator expansion valve.

b. Attacha temperaturesensornearthe expansionvalve

bulb and insulate. Make surethe suctionline is clean and that firm contact is made with the sensor.

c. Connect anaccurate gaugetothe serviceportdirectly

upstream of the suction m odulating valve.

d. Setthe temperaturesetpointto --18_C(0_F), andrun

unit until conditions stabilize.

e. The readingsmaycyclefromahigh toalowreading.

Take readings of temperature and pressure every three to five minutes for a total of 5or 6 readings

f. From thetemperature/pressure chart (Table 6-7), de-

termine the saturation temperature corresponding to the evaporator outlet test pressures at the suction modulation valve.

g. Subtract the saturation temperatures determined in

stepf. fromthe temperaturesmeasuredinstep e.. The difference is the superheat of the suction gas. Determinethe averagesuperheatIt should be 4.5 to 6.7°C (8 to 12 °F)

6.14.2 Valve Replacement

a. Removing the Expansion Valve

Unless the valve is defective, it seldom requires maintenance other than periodic inspection to ensure thatthethermalbulbistightlysecuredtothesuctionline and wrapped with insulating compound. (See Figure 6-10.)

1. Suction Line

2. TXV Bulb Clamp

Figure 6-10 Thermostatic Expansion Valve Bulb

6.14.1 Checking Superheat.

3. Nut and Bolt

4. TXV Bulb

NOTE

Propersuperheatmeasurementfortheevaporator expansion valve should be completed at

-- 1 8 _C(0_F) container box temperature where possible. If the economizer valve is suspect, it should be replaced.

NOTES

1. TheTXV’sarehermeticvalvesanddonot have adjustable superheat.

2. Allconnections on the evaporator TXV are bi---metallic, copper on the inside and stainless on the outside. When brazing, bi---metallic connections heat up very quickly.

1. Evaporator Expansion Valve

2. Non-adjustable Superheat Stem

3. Equalizer Connection

4. Inlet Connection

5. Outlet Connection

6. Expansion Valve Bulb

Figure 6-11 Evaporator Expansion Valve

6-9

T-309

Copper Tube (Apply heat for 10-15 seconds)

Braze Rod (’Sil-Phos” = 5.5% Silver, 6% Phosphorus)

Bi-metallic Tube Connection (Apply heat for 2-5 seconds)

Figure 6-12 Hermetic Thermostatic Expansion Valve Brazing Procedure

INLET

OUTLET

Figure 6-13 Economizer Expansion Valve

1. Pump down the unit per paragraph 6.4.

2. Removecushionclampslocatedon theinletandoutlet lines.

3. Unbrazetheequalizerconnection(ifapplicable),the outlet connection and then the inlet connection.

4. Remove insulation (Presstite)fromexpansionvalve bulb.

5. Unstrapthebulb,locatedbelowthecenterofthesuction line (4 o’clock position), andremovethe valve.

b. Installing the Expansion Valve

1. Clean the suction line with sandpaper before installing bulb to ensure properheat transfer. Apply thermal grease to the indentation in the suction line.

2. Strap the thermal bulb to the suction line, making sure bulb is placed firmly into the suction line. See Figure 6-10 for bulb placement.

3. Insulate the thermalbulb.

4. The economizer expansion valves should be wrapped in a soaked cloth for brazing. See Figure 6-12. Braze inlet connection to inlet line

5. Braze outlet connection to outlet line.

6. Reinstall the cushion clamps on inlet and outlet lines.

Use of a wet cloth is not necessary due to rapid heat dissipation of the bi--metallic connections

7. If applicable, braze the equalizer connection to the equalizer line.

8. Check superheat (refer to step 6.14.1).

6.15 EVAPORATOR COIL AND HEATER

ASSEMBLY

The evaporator section, including the coil, should be cleaned regularly. The preferred cleaning fluid is fresh waterorsteam.AnotherrecommendedcleanerisOakite 202 or similar, following manufacturer’s instructions.

The two drain pan hoses are routed behind the condenser fan motor and compressor. The drain pan line(s) must be open to ensure adequate drainage.

6.15.1 Evaporator Coil Replacement

a. Pump unit down. (Refer to paragraph 6.4.) b. With power OFF and power plug removed, remove

thescrews securingthepanel coveringtheevaporator

section (upper panel). c. Disconnect the defrost heater wiring. d. Disconnect the defrost temperature sensor (see Fig-

ure Figure 2-2 from the coil. . e. Remove middle coil support. f. Remove the mounting hardware from the coil. g. Unsolder the twocoil connections, oneat thedistrib-

utor and the other at the coil header. h. After defective coil is removed from unit, remove

defrost heaters and install on replacement coil. i. Install coil assembly by reversing above steps. j. Leak check connections perparagraph 6.5. Evacuate

the unit per paragraph6.6 and add refrigerant charge

per paragraph 6.7.

6.15.2 Evaporator Heater Replacement

a.Beforeservicingunit,makesuretheunitcircuitbreak-

ers(CB-1&CB-2)andthe start-stopswitch(ST)are

intheOFFposition,andthatthepowerplugandcable

are disconnected. b. Remove the lower access panel (Figure 2-1) by

removing the T.I.R. locking device lockwire and

mounting screws.

6-10T-309

c. Determine which heater(s) need replacing by check-

ing resistance on each heater. Refer to paragraph 2.3

for heater resistance values d. Remove hold-down clamp securing heaters to coil. e. Lift the bent end of the heater (with the opposite end

down and away from coil). Move heater to the side

enough to clear the heater end support and remove.

2 Be sure electrical power is removed from the unit.

Disconnect leads. Remove top screw and washer. Lift off coil. (See Figure 6-14 or Figure 6-15)

3 Unbraze valve from unit and braze new valve in

place

4 Install coil. Evacuate low side and place unit back

in operation. Check charge.

6.16 ECONOMIZER, UNLOADER, LIQUID INJEC-

TION AND OIL RETURN SOLENOID VALVE

a. Replacing the Coil

NOTE

Thecoil maybereplaced withoutremovingthe refrigerant.

1 Be sure electrical power is removed from the unit.

Disconnect leads. Remove top screw and washer. Lift off coil. (See Figure 6-14 or Figure 6-15)

2 Verify coil type, voltage and frequency of old and

newcoil.This informationappearsonthecoilhousing.

Replacing Valve Internal Parts (Unloader

Solenoid Only)

1 Pump down the unit. Refer to paragraph 6.4. 2 Be sure electrical power is removed from the unit.

Disconnect leads. Remove top screw and washer. Lift off coil. (See Figure 6-14)

3 Remove the top screw (see Figure 6-14), washer ,

and coil assembly. 4 Loosen the enclosing tube locknut. 5 Remove enclosing tube and locknut assembly. The

gasket is inside the enclosing tube. 6 Removeseatdisc from inside of bodyand checkfor

obstructions and foreign material.

1 2

6 7

8 9

1. Top Screw

2. Washer

3. Coil

4. Locknut

5. Enclosing Tube

Figure 6-14. Unloader Solenoid Valve

1 2

6. Gasket

7. Stem and Plunger

8. Seat Disc

9. Body

7 Placetheseatdiscintothevalvebodywiththesmall-

er diameter end facing up. 8 Install stem and plunger. 9 Placethe enclosing tube locknut over the enclosing

tube. Install spacerover enclosingtubemakingsure

it is seated properly in the enclosing tube locknut.

Tightenenclosing tube locknut to a torque value of

2.78 mkg (20 ft-lb). Do not overtighten. 10 Install coil assembly, washer and top screw. 11 Evacuateanddehydratethesystem.(Refertosection

6.6.) Charge unit with refrigerant per section 6.7. 12 Start unit and check operation.

Replacing Valve

1 To replace the unloader, liquid injection or econo-

mizervalve,pumpdowntheunit.Refertoparagraph

6.4. To replace the oil return valve, remove the re-

frigerant charge.

1. Slotted Screw

2. Washer

3. Coil

Figure 6-15. Oil Return Solenoid Valve (ORV),

Economizer Solenoid Valve (ESV), Liquid

Injection Solenoid Valve (LIV)

6.17 EVAPORATOR FAN AND MOTOR ASSEMBLY

4. Enclosing Tube and Body

The evaporator fans circulate air throughout the containerby pulling airin the top of the unit. The air is forced through the evaporator coil where it is either heatedor cooled and thendischarged out the bottom of

6-11

T-309

the refrigeration unit into the container. The fan motor bearings are factory lubricated and do not require additional grease.

6.17.1 Replacing The Evaporator Fan Assembly

WARNING

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

a. Remove upper access panel (see Figure 2-2) by

removing mounting bolts and T.I.R. locking device. Reach insideof unit and removetheTy-Rapsecuring thewire harness loop. Then unplug the connectorby twisting to unlock and pulling to separate.NOTE: It maybeeasiertounplug theconnectorwiththemotor assembly partially pulled out (after step b).

b. Removethe four mounting bolts that secure the mo-

tor--fan assembly to the unit.

c. Slide the fan assembly out from the unit and place it

on a sturdy work surface. d. Remove the motor and fan from the assembly. e. Replace the motor. f. Lubricate the fan motor shaft with a graphite--oil

solution (Never--Seez) and apply thread sealer (Loc-

tite H, brown in color) to the two fan set screws.

Installfanonthemotorshaft,sothatthecouplingsur-

face will be even with the end of the m otor shaft. g. Install the fan assembly in reverse order of removal.

Apply power momentarily to check for proper fan

rotation(refertoparagraph2.3).Ifthefanspinsback-

wards, than motor wiring or motor is defective. Replace access panel making sure that panel does not

leak. Lock--wire the T.I.R. locking device(s).

4 5 6

1. Bracket

2. Flat washer, 3/8

3. Bolt, 3/8-16 x 1.00

4. Locknut, 5/16-18

5. Flat washer, 5/16

6. Cap Screw, Hxhd 5/16-18 x 1.25

7. Fan

8. Shim

9. Evaporator Motor

Figure 6-16. Evaporator Fan Assembly

6.18 EVAPORATOR FAN MOTOR CAPACITORS

The evaporator fan motors are of the permanent-split capacitor type. The motor is equipped with one capacitor used in the high speed circuit and another capacitor used for the low speed circuit.

6.18.1 When To Check For A Defective Capacitor

a. Fan motor willnot changespeed.Forexample:in the

conventionalperishablemode,themotorsshouldrun in high speed. In the economy perishable mode they shouldswitchspeedsand in the frozenmode,themotors should run in low speed.

NOTE

The evaporator fan motors will always start in high speed.

b. Motor running in wrong direction (after checking for correct wiring application).

c. Motor will not start, and IP-EM’s are not open.

6.18.2 Removing The Capacitor

WARNING

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

The capacitors are located on the motor and above the evaporator fan deck they may be removed by two methods:

1 If container is empty, open upper rear panel of the

unit. Thecapacitormaybeservicedafterdisconnecting power plug.

2 If container is full, turn the unit power OFF anddis-

connect power plug. Remove the evaporator fan motor access panel. (See see Figure 2-1). For removal of theevaporator fanassembly,refer to section 6.17.

WARNING

WithpowerOFFdischargethecapacitorbeforedisconnectingthe circuitwiring.

6.18.3 Checking The Capacitor

If the capacitor is suspected of malfunction, you may choosetosimplyreplaceit. Direct replacementrequires a capacitor of the same value. Two methods for checking capacitor function are:

1. Volt-ohmmeter set on RX 10,000 ohms. Connect ohmmeter leads across the capacitorterminals

and observe the meter needle. If the capacitor is good, the needle will make a rapid swing toward zero resistance and thengradually swing back toward a very high resistance reading.

If the capacitor has failed open, the ohmmeter needle will not move when the meter probes touch the terminals. If the capacitor is shorted, the needle will swing to zero resistance position and stay there.

2. Capacitor analyzer: The function of the analyzer is to read the microfarad

valueof acapacitorand to detect insulation breakdown

6-12T-309

under load conditions. The important advantages of a

(py

)

(g)

(qg

analyzer are its ability to locate capacitors that have failedto hold their microfaradratings, or those that are breaking down internally during operation. It is also useful in identifying capacitors when their microfarad rating marks have become unreadable.

6.19 VAL VE OVERRIDE CONTROLS

CAUTION

DONOTdisassemblepiston fromNEWsuction modulating valve powerhead assembly. Doing so may result in damage to piston.

Controller function code Cd41 is a configurable code that allows timed operation of the automaticvalves for troubleshooting.Threetestsequencesareprovided.The first, capacity mode (CAP), allows alignment of the unloader and economizer solenoid valves in the standard, unloaded and economized operating configurations. The second, SMV % Setting (SM) allows opening of the suction modulating valve to various percentages and the third, Oil Valve Setting (OIL)andLiquidValveSetting(LIV)allowsopeningor closing of the oil return solenoid valve and the liquid injection solenoid valve. A fourth selection is also provided to enter a time period of up to three 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 willnot 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. PresstheCODESELECTkeythenpressanARROW

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 remaining.UseanARROWkeyto scrollto thedesired test. Press the ENTER key and SELCt will appearin the left display.

c. Use an ARROW key to scroll to the desiredsetting,

and then press the ENTER key. Selectionsavailable for each of the tests are provided in the following table.

d. If the timer is not operating, follow theabove proce-

dure to display the timer. Use an ARROW key to scrolltothedesiredtimeintervalandpressENTERto start the timer.

e. The above described sequence maybe repeated dur-

ing the timer cycle to change to another override.

Right Display Available Selections

CAP

(Capacity Mode)

Economizer = Closed)

Economizer = closed)

(SMV% Setting)

OIL

(Oil Valve Setting)

(Liquid Valve Setting, if

6.20 SUCTION MODULATION VALVE

LIV

applicable)

tIM

(Timer)

000(0 minutes/0 Seconds)

In 30 second increments to

300(3 minutes/ 0 seconds)

AUtO

(Normal Control)

UnLd

(Unloader = Open

Std

(Unloader = closed

ECOn

(Unloader = closed

Economizer = open)

AUtO

(Normal Control)

0 3 4

6 12 25 50

100

AUto

(Normal Control)

OPEn

AUto

(Normal Control)

OPEn

On start up of the unit, the valve will reset to a known open position. This is accomplished by assuming the valve was fully open, driving it fully closed, resetting the percentage open to zero, then opening to a known 10% staging position.

FROM COIL

FROM UNLOADER

Figure 6-17 Suction Modulation Valve (SMV)

2-1/8 inch Nut

TO COMPRESSOR

6-13

T-309

6.20.1 Precheck Procedure

a. Check unit for abnormal operation. b. Check charge. If refrigerant is low repair as required

and again check operation.

c. If sufficient capacity cannot be maintained or unit is

tripping excessively on high pressure switch (HPS) in high ambients, check coils and clean if required.

d. If capacity or control cannot be maintained turn unit

OFF, then back ON. This will reset the valve in the event the controller lost communication with the valve, and may correct the problem.

NOTE

Carefully listen to the valve. During reset, the valve will make a ratcheting noise that may be heard or felt as it is attempting to close. If this canbeheard or felt, itindicates that thecontrolleranddrivemoduleareattemptingtoclosethe valve, and may serve as aquick indication t hat the drive is in working order.

e. Operation ofthe valvemaybechecked usingthecon-

troller valve override program, function code Cd41. Refer to paragraph 6.19 for valve override test instructions.

6.20.2 Checking The Stepper valve

a. Checking with ohmmeter Disconnect the four pin connector to the stepper SMV.

With a reliable digital ohmmeter, check the winding resistance.In normalambient,the valveshould have72 to 84 ohms measured on the red/green (a-b terminals) and on the white/black (c-d terminals) leads. If an infinite or zero reading occurs, check connections and replacethe m otor.

b. CheckingwithSMA-12 portablestepper drive tester The SMA-12 portable s tepper drive tester (Carrier

Transicold P/N 07-00375-00) is a battery operated stepperdrivewhichwillopenandclosetheSMV, which allows a more thorough check of the operating mechanism.

To check operation:

1. Stoptheunit,disconnectthefourpinconnectorfrom thesteppermoduletothevalve(see

Figure 6-17)and

attachtheSMA-12stepperdrivetotheconnectorgoingtothevalve.

2. Set the SMA-12pulse per second(PPS)to onePPS and either open or close valve. Each LED should lightsequentiallyuntilallfourarelit.AnyLEDfail-

ing to light indicatesanopen on that legwhich indicatesa poor connectionoranopen coil. Repair or replace as required to achieve proper operation.

CAUTION

The scroll compressor achieves low suction pressure very quickly. Do not operate the compressor in a deepvacuum,internaldamage will result.

3. Restart unit, set the steprateto200PPS onSMA-12 forthevalve,andclosesteppervalvewhilewatching the suction gauge. Within one minute t he suction pressurewillgointo avacuum.This is anindication that the valve is moving.

4. If no change in suction pressure is detected, check for resistance (refer to step 6.20.2), and check connectionsforpropercontinuityandretest.Ifthevalve is functioning and all connections and motor resistance are good, check the controller and expansion module.

CAUTION

DONOTdisassemblepiston fromNEWsuction modulating valve powerhead assembly. Doing so may result in damage to piston.

5. If the valve is determinedas faulty after completing theabovesteps,performalowsidepump down. Removevalvepowerheadassembly,andreplacewith a NEWvalvepowerheadassembly,torquenutto35ftlb, evacuate low side, and open all service valves.

6.21 CONTROLLER AND EXPANSION MODULE

6.21.1 Handling Modules

CAUTION

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

CAUTION

Unplug all module connectors before performingarc 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 replacinga module, when doing any arc welding on the unit, or when service to the refrigeration unit requires handling and removal of a module.

6-14T-309

1. Controller Software Programming Port

2. Mounting Screw

3. Controller

4. Expansion Module

5. Test Points

Figure 6-18 Controller Section of the Control Box

a. Obtain a grounding wrist strap (Carrier Transicold

part number 07--00--304-- 00)and a static dissipation mat (Carrier Transicold part number 07--00304--00. The wrist strap, when properly grounded, will 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 strapon wrist andattach the ground endto any

exposed unpainted metal area on the refrigeration

unit frame (bolts, screws, etc.). d. Carefullyremovethemodule.Donottouchanyofthe

electrical connections if possible. Place the module

on the static mat. e. The strapshouldbe worn duringanyserviceworkon

a module, even when it is placed on the mat.

6.21.2 Controller Trouble-Shooting

Agroupoftestpoints(TP,seeFigure 6-18)areprovided on the controllerfor trouble-shooting electricalcircuits (seeschematicdiagram, section 7). Adescriptionofthe test points follows:

NOTE

Use a digital voltmeter to measure ac voltage between TP’s and ground (TP9), except for TP8.

TP1

Thistestpoint enablesthe user to checkif thecontroller unloader solenoid valve relay (TU) is open or closed.

TP2

This test point enables the user to check if the high pressure switch (HPS) is open or closed.

TP3

This test point enables the user to check if the water pressure switch (WP) contact is open or closed.

TP 4

This test point enables the user to check if the internal protectorforthecondenserfanmotor(IP-CM)is openor closed.

TP 5

This test point enables the user to check if the internal protectors for the evaporator fan motors (IP-EM1 or IP-EM2) are open or closed.

TP 6

This test point is not used in this application.

TP 7

Thistestpoint enablesthe user to checkif thecontroller economizersolenoidvalve relay(TS) is open orclosed

TP 8

This test point enables the user to check power to the suction modulator valve.

TP 9

This test point is the chassis (unit frame) ground connection.

TP 10

This test point enables the user to check if the heat terminationthermostat(HTT)contactis open or closed.

6.21.3 Controller Programming Procedure

Toloadnewsoftwareintothemodule,theprogramming card is inserted into the programming/software port.

CAUTION

The unit mustbe OFF whenever aprogramming card is inserted or removed from the controller programming port.

NOTE

Themetal door on the programmingcard must be facing to the left when inserting.

a. Procedure for loading Operational Software

1. Turn unit OFF, via start-stop switch (ST).

2. Insert the programming card for Operational Software into the programming/software port. (See Figure 6-18)

3. Turn unit ON, via start-stop switch (ST).

4. The Display module will alternate back and forth between the messages “rEV XXXX” and “Press EntR”. (If a defectivecard isbeingused the Display willblink the message“bAdCArd”. Turnstart-stop switch OFF and remove the card.)

6-15

T-309

5. Press the ENTER key on the keypad.

3 Disconnectthebackconnectorsandremovemodule.

6. TheDisplaywillshowthemessage“ProSoFt.”This message will last for up to one minute.

7. The Display module will 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 startstop switch OFF and remove the card.)

8. Turn unit OFF, via start-stop switch (ST).

9. Remove the programming card from the programming/softwareportandreturnthe unit to normaloperation by placing the start-stop switch in the ON position.

b. Procedurefor loading ConfigurationSoftware

1. Turn unit OFF using start-stop switch (ST).

2. Insert the programming card, for Configuration Software,into the programming/softwareport. (See Figure 6-18.)

3. Turn unit ON using start-stop switch (ST).

4. The Display module will show “nt40” on the left LCD display and “531###” on the right LCD display.“###”willindicatethe dash numberforagiven unit model number,usethe UP orDOWN ARROW key to scroll through the list to obtain the proper model dash number. For example, to program a model number 69NT40-531-05, press the UP or DOWN ARROW key until the right display shows “nt40” on the right display and “53105” on the left. (If a defective card is being used, the Display will blink the message “bAd CArd”. Turn start-stop switch OFF and remove the card.)

5. Press the ENTER key on the keypad.

4 When removing the replacement module from its

packaging, notehowitispackaged.Whenreturning theold module for service,placeit in the packaging in thesame manner as the replacement. Thepackaging has been designed to protect the module from both physical and electrostatic discharge damage

during storage and transit. b.Installation: Install the module by reversing the removal steps. Torque values for mounting screws (item 2, see

Figure 6-18) are 0.23 mkg (20 inch-pounds). Torque value for the connectors is 0.12 mkg (10 inch-pounds).

6.22 TEMPERATURE SENSOR SERVICE

Procedures for service of the Return Recorder, Return Temperature, Supply Recorder, Supply Temperature, Ambient, Defrost Temperature, Compressor Discharge and Compressor Suction temperature sensors are provided in the following sub paragraphs.

6.22.1 Sensor Checkout Procedure

Mounting Stud Type

40 mm (1 1/2 inch)

6.3 mm (1/4 inch)

40 mm (1-1/2 inches)

6.3 mm (1/4 inch)

Bulb Type

Dual Sensor

Sensor

40 mm (1-1/2 inches)

6. When the software loading has successfully completed, the Display will show the message “EEPrM donE.” (If a problem occurs while loading the software,theDisplaywillblinkthemessage“ProFAIL” or “bad 12V.” Turn start-stop switch OFF and remove the card.)

7. Turn unit OFF using start-stop switch (ST).

8. Remove the programming card from the programming/softwareportandreturnthe unit to normaloperation by placing the start-stop switch in the ON position.

6.21.4 Removing and Installing a Module

a. Removal:

1. Disconnect all front wire harness connectors and move wiring out of way.

2 The lower controller mounting is slotted, loosen the

topmountingscrew(seeFigure 6-18) andliftupand out.

6.3 mm (1/4 inch)

Figure 6-19 Sensor Types

Tocheck a sensor reading, do the following: a. Removethesensorandplacein a0_C(32_F)ice-wa-

ter bath. The ice-water bath is preparedby filling an insulated container (of sufficient size to completely immersebulb)withicecubesor chippedice,thenfilling voids between ice with water and agitating until mixture reaches 0_C(32_F) measured on a labora- tory thermometer.

b. Start unit and check sensor reading on the control

panel.Thereadingshould be0_C(32_F).Ifthe read- ing is correct, reinstall sensor; if it is not, continue

with the following. c. Turn unit OF F and disconnect power supply. d. Refertoparagraph6.21andremovecontrollertogain

access to the sensor plugs.

6-16T-309

Table 6-2 Sensor Temperature/Resistance Chart

(+/--.002%)

Temperature

____C ____F

Resistance

(Ohms)

AMBS,

CPSS, DTS, RTS, RRS, STS,

SRS

CPDS

-- 3 0 -- 2 2 177,000 1,770,000

-- 2 5 -- 1 3 130,400 1,340,000

-- 2 0 -- 4 97,070 970,700

-- 1 5 5 72,900 729,000

-- 1 0 14 55,330 553,000

-- 5 23 43,200 423,300 0 32 32,650 326,500 5 41 25,390 253,900

10 50 19,900 199,000 15 59 15,700 157,100 20 68 12,490 124,900 25 77 10,000 100,000 30 86 8,060 80,600 35 95 6,530 65,300 40 104 5,330 53,300 45 113 4,370 43,700 50 122 3,600 36,000 55 131 2,900 29,000 60 140 2,490 24,900 65 149 2,080 20,800 65 158 1,750 17,500

e. Using the plug connector marked “EC”, that is con-

nectedto the back of the controller, locate the sensor wires (RRS, RTS, SRS, STS, AMBS, DTS, CPDS ORCPSSasrequired).Followthosewirestotheconnector and using the pins of the plug, measure the resistance. V alues are provided in Table 6-2.

Dueto the variationsand inaccuracies in ohmmeters, thermometers or other test equipment, a reading within 2% of the chart value would indicate a good sensor.If asensor is defective, theresistancereading will usually be much higher or lower than the resistance values given.

6.22.2 Sensor Replacement

a. Turn unit power OFF, disconnect power supply and

remove sensor assembly from unit.

b. Cut wire(s) 5 cm (2 inches) from shoulder of defec-

tive sensor and discard the defective probe only.

c. Cut one wire of existing cable 40 mm (1-1/2 inch)

shorter than the other wire.

d. Cut one replacement sensor wire (opposite color)

back 40 mm (1-1/2 inch). (See Figure 6-19.) e. Strip backinsulationon all wiring 6.3mm (1/4 inch). f. Slide a large piece of heat shrink tubing over the

cable, and place the two small pieces of heat shrink

tubing, one over each wire, before adding crimp fit-

tings as shown in Figure 6-20.

Sensor (Typical)

Heat Shrink

Cable

Large Heat Shrink Tubing (1)

Figure 6-20 Typical Sensor and Cable Splice

Tubing (3)

g. Slip crimp fittings over dressed wires (keeping wire

colors together). Make sure wires are pushed into

crimpfittingsasfaraspossibleandcrimpwithcrimp-

ing tool. h. Solder spliced wires with a 60% tin and 40% lead

Rosincore solder. i. Slide heat shrink tubing over splice so that ends of

tubing cover both ends of crimp as shown in

Figure 6-20. j. Heattubingtoshrinkoversplice.Makesureallseams

are sealedtightly against thewiringto prevent mois-

ture. k. Slide large heat shrink tubing over both splices and

shrink.

CAUTION

Do not allow moisture to enter wire splice area as this may affect thesensorresistance.

l. Position sensor in unit as shown in m.Figure 6-21

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. and re--check sensor resistance.

n. Reinstall sensor, refer to paragraph 6.22.3.

NOTE

The P5 Pre-Trip test must be run to inactivate probe alarms (refer to paragraph 4.7).

6-17

T-309

T.I.R. Bolts

Supply Air Stream

Insulation

STS probe

Back Panel

Supply Sensor

Mounting Clamp

Sensor Wires

Gasketed Cover

Gasketed Support Plate

6.22.3 Sensor Re--Installation a. Sensors STS and SRS

2.5” Drip Loop

Figure 6-21 Supply Sensor Positioning

Gasket Mounting Plate

Toproperlyposition asupplysensor,thesensormustbe fully inserted into the probe holder. Do not allow heat shrink covering to contact the probeholder. Forproper placement ofthe sensor,besure topositiontheenlarged positioning section of the sensor against the the side of the mounting clamp. This positioning will give the sensor the optimum amount of exposure to the supply air stream, and will allow the Controller to operate correctly. See Figure 6-21.

b Sensors RRS and RTS

Reinstallthereturnsensorasshownin Figure 6-22. For proper placement of the return sensor, be sure to position the enlarged positioning section of the sensor against the the side of the mounting clamp.

SRS probe

c Sensor DTS

The DTS sensor must have insulating material placed completely over the sensor to insure the coil metal temperature is sensed.

6.23 MAINTENANCE OF PAINTED SURFACES

The refrigeration unit is protected by a special paint system against the corrosive atmosphere in which it normallyoperates.However,should thepaint systembe damaged, thebase metalcancorrode. Inorder toprotect the refrigeration unit from the highly corrosive sea atmosphere, or if the protective paint system is scratched or damaged, clean area to bare metal using a wirebrush,emerypaperorequivalentcleaningmethod. Immediately following cleaning, apply 2--part epoxy paint to the area. and allow to dry. After the first coat dries, apply a second coat.

Mounting Clamp

Figure 6-22 Return Sensor Positioning

Return Sensor

1.50 in. (38.1cm)

6.24 COMPOSITE CONTROL BOX REPAIRS

6.24.1 Introduction

This procedure provides instructions for repair of the Carrier Transicold composite control box. Damage to the control box may be in the form of a chip or hole, a crack, a damaged thread insert or damage to the door hingeinserts.Generally,theobjectoftherepairmustbe to ensuresufficient strength is restoredto the damaged area and t he repair must keep the box water tight. Informationon repairkitsandrepairprocedures foreach typeofdamageis providedin the followingparagraphs. Ambient temperature must be above 7°C(45°F) for proper curing of epoxy repairs.

6-18T-309

6.24.2 Cracks

Cracks in thecontrol box arerepairedusing a fiberglass patch over the damaged area. Materials required are includedintheFiberglassPatchKitsuppliedwithCrack Repair Kit, Carrier Transicold part number 76-00724-00SV (see Table6-3).

a. The surface must be cleanand dry.Roughen the sur-

face with sandpaper to ensure a good bond.

b. Cut the fiberglass cloth to allow a 25mm (1--inch)

overlap around the area to be repaired.

c. Stretch and position the cloth over the area to be re-

paired and secureit with masking tape.

d. Make up sufficient epoxy glue to cover the cloth by

mixingequalpartsofresin andhardener.Saturatethe cloth with the epoxy glue, spreading evenly.

e. Remove the tape and overlap the edge of the cloth

approximately 6 to 12 mm (1/4” to 1/2”) with glue.

f. Epoxy will dry in 45--60 minutes. When completely

cured (12 hours), use sandpaper to smooth edges of the patch.

6.24.3 Chips And Holes

Chips and holes in the control box are repaired using a piece of aluminum or stainless steel to cover the damagedarea.Thematerialcanbecuttosuitandriveted in place. An adhesive sealant must be usedto make the repairwatertight.Theadhesivesealant(Sikaflex221)is included in Crack Repair Kit Carrier Transicold part number76-00724-00SV(seeTable6-3).Do notusean acetone based silicone sealant (Which can be identified by a vinegar--like odor).

The damaged insert must be removed from the control box. Table 6-5 identifiesthe drill size and drill depthto beusedforeachinsert.Astopringshould beusedonthe drill bit to limit the depth.

a. Center the drill bit on the insert and drill to the pre-

scribed depth. b. Remove the chips from the drilled hole. c. Mix t he two component epoxy and fill the hole 1/2

way to the top with epoxy. d. Press the insert in until it is flush with the surface. e. Wipe away any excess epoxy. The part is ready for

service after the bond material has hardened and is

tack free (approximately 20 minutes)

6.24.5 Door Hinge Inserts

Ifthedoorhinges havebeenpulledfromthecontrolbox drillandreinstallthe hingeasshownin Figure 6-23and described in the following steps.

a. To make up the patch, cut a piece of aluminum or

stainlesssteelso thatit will overlap thedamaged area by at least 40 mm (1 1/2”) on all sides.

b. C hoose rivet locations and drillthe rivet holes in the

correspondinglocationsonthecontrolbox and patch piece.

c. Apply theadhesive sealant around the damagedarea

to form a s eal between the control box and the patch

piece. d. Rivet the patch piece in place. e. File smooth any rough edges (including rivets) that

may come into contact with wires.

6.24.4 Inserts

The threaded brass inserts that are molded into the control box will need to be replaced if the threads become stripped, or if the insert becomes loose. The inserts and epoxy are contained in repair kit, Carrier Transicold part number 76-50084-00 (see Table 6-4). There are 6 different inserts used in the control box. Refer to Figure 6-24 for the locations of the various inserts.

NOTE

Anepoxyapplicationgunisalsoneeded,Carri-

er Transicold part number 07 -- 00391 -- 00.

Figure 6-23 Door Hinge Repair

Materials needed:

1. Cut two square pieces of 3 mm thick (1/8 inch) aluminum or stainless steel approximately 40 mm (1 5/8”) square. These squares will serve as backing plates.

2. Twonuts, bolts (10 -- 24 x 1”) and washers foreach insert that needs repair.

a. Drill a 1/4” holein the center of each square backing

plate.

b. Pass the bolts through the bolts holes in the door

hinge, then through the control box at the location where the hinge insert pulled out.

c. From inside the controlbox, slide the backing plates

over the bolts and secure in place with the washers and nuts.

6-19

T-309

Table 6-3 Crack, Chip & Hole Repair Kit

ITEM DESCRIPTION PART NUMBER Qty

1 Crack Repair Kit -- Includes 76--00724--00SV 1 2 Fiberglass Patch Kit (Loctite FK--98 or 80265)... 76--00724--00Z 10 3 Sikaflex 221 Adhesive Sealant (Sikaflex 232--361)... 02--00067--02Z 10 4 Instruction Sheet... 98--02339--00 10

Table 6-4 Insert Repair Kit

ITEM DESCRIPTION PART NUMBER Qty

1 Insert Repair Kit -- Includes 76--50084--00 1 2 Insert - 17.53 x 9.91 mm (..690 x .390 in) 1/4--20 Threads... 34--06231--01 10 3 Insert - 15.88 x 6.35 mm (.625 x .250 in) 10-24 Threads... 34--06231--03 10 4 Insert - 25.15 x 7.54 mm (.990 x .297 in) 10-24 Threads... 34--06231--04 10 5 Insert - 10.16 x 9.53 mm (.400 x .375 in) 10-24 Threads... 34--06231--05 10 6 Insert - 12.7 x 9.91 mm (.5 x .390 in) 1/4--20 Threads... 34--06231--06 10 7 Insert - 9.53 x 6.76 mm (.375 x .266 in) 10-24 Threads... 34--06231--07 10 8 Durabond Epoxy E20--HP (Loctite 29314)... 02--0082--00 1 9 Static Mixing Tube (Loctite 983440)... 07--00390--00 1

10 Instruction Sheet... 98--02338--00 1

Note: Insert repair procedures require use of an Application Gun, Carrier part number 07--00391--00

Table 6-5 Drill Information

Item

Insert part number Drill size and depth

1 34- 06231- 01 10.3 mm x 17.8 mm deep (.404 in. x .700 in. deep) 2 34- 06231- 03 6.8 mm x 16.3 mm deep (.266 in. x .640 in. deep) 3 34- 06231- 04 7.9 mm x 25.4 mm deep (.3125 in. x 1.0 in. deep) 4 34- 06231- 05 6.9 mm (.270 in.) Drill completely through. 5 34- 06231- 06 10.3 mm (.404 in.) Drill completely through. 6 34- 06231- 07 6.8 mm (.266 in.) Drill completely through.

6-20T-309

Figure 6-24. Insert Location

6-21

INSERT PART NUMBERS 34--06231--## WHERE THE ## IS AS INDICATED

T-309

6.25 COMMUNICA TIONS INTERFACE MODULE INSTALLATION

CB1

Communications interface Module

c.. Remove the circuit breaker panel, with circuit

breaker, from the control box.

d.. Locate, wires CB21/CIA3, CB22/CIA5 and

CB23/CIA7 that have been tied back in the wire harness.Removetheprotectiveheatshrinkfromthe ends of the wires.

e.. Attach the three wires as addressed to the LOAD

side of the circuit breaker. f.. Refit the circuit breaker panel. g. Fit the new RMU into the unit. h. Remove plugs CIA, CIB and CID from thewiring

harness and attach to the module. .i. Replace the low voltage shield.

Table 6-6 Recommended Bolt Torque Values

Figure 6-25. Communications Interface

Installation

Units with communication interface module provision havetherequiredwiringinstalled.Theprovisionwiring kit (part number 76--00685--00), includes three pre--addressed wires installed between the circuit breakerandcommunicationinterfacemodulelocations. These wires are to be connected to the module and circuit breaker to allow the module to communicate over the power system. To install the module, do the following:

WARNING

The Unit Power Plug Must Be Disconnected To Remove Power From Circuit Breaker Cb1

a.. CB1 is connected to the power system, see wiring

schematic. Ensure that the unit power is off AND that the unit power plug is disconnected.

b.. Open control box, see Figure 6-25 and remove low

voltage shield. Open high voltage shield.

BOLT DIA.

#4 #6 #8

#10

1/4

5/16

3/8

7/16

1/2

9/16

5/8 3/4

NONFREE SPINNING (LOCKNUTS ETC.)

1/4

5/16

3/8

7/16

1/2

9/16

5/8 3/4

THREADS TORQUE MKG

FREE SPINNING

40 32 32 24 20 18 16 14 13 12 11 10

20 18 16 14 13 12 11 10

5.2 in-lbs

9.6 in-lbs 20 in-lbs 23 in-lbs 75 in-lbs

11 ft-lbs 20 ft-lbs 31 ft-lbs 43 ft-lbs 57 ft-lbs 92 ft-lbs

124 ft-lbs

82.5 in-lbs

145.2 in-lbs

22.0 ft-lbs

34.1 ft-lbs

47.3 ft-lbs

62.7 ft-lbs

101.2 ft-lbs

136.4 ft-lbs

0.05

0.11

0.23

0.26

0.86

1.52

2.76

4.28

5.94

7.88

12.72

17.14

0.95

1.67

3.04

4.71

6.54

8.67

13.99

18.86

6-22T-309

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

Temperature

____F ____C “/hg cm/hg kg/cm@@@@ bar

Vacuum

-- 4 0 -- 4 0 14.6 49.4 37.08 0.49 .35 .37 12.3 41.6 31.25 0.42

-- 3 0 -- 3 4 9.7 32.8 24.64 0.33

-- 2 5 -- 3 2 6.7 22.7 17.00 0.23

-- 2 0 -- 2 9 3.5 11.9 8.89 0.12

-- 1 8 -- 2 8 2.1 7.1 5.33 0.07

-- 1 6 -- 2 7 0.6 2.0 1.52 0.02

Temperature Pressure

____F ____C psig kPa kg/cm@@@@ bar

-- 1 4 -- 2 6 0.4 1.1 0.03 0.03

-- 1 2 -- 2 4 1.2 8.3 0.08 0.08

-- 1 0 -- 2 3 2.0 13.8 0.14 0.14

-- 8 -- 2 2 2.9 20.0 0.20 0.20

-- 6 -- 2 1 3.7 25.5 0.26 0.26

-- 4 -- 2 0 4.6 31.7 0.32 0.32

-- 2 -- 1 9 5.6 36.6 0.39 0.39 0 -- 1 8 6.5 44.8 0.46 0.45 2 -- 1 7 7.6 52.4 0.53 0.52 4 -- 1 6 8.6 59.3 0.60 0.59 6 -- 1 4 9.7 66.9 0.68 0.67 8 -- 1 3 10.8 74.5 0.76 0.74

10 -- 1 2 12.0 82.7 0.84 0.83 12 -- 11 13.2 91.0 0.93 0.91 14 -- 1 0 14.5 100.0 1.02 1.00 16 -- 9 15.8 108.9 1.11 1.09 18 -- 8 17.1 117.9 1.20 1.18 20 -- 7 18.5 127.6 1.30 1.28 22 -- 6 19.9 137.2 1.40 1.37 24 -- 4 21.4 147.6 1.50 1.48 26 -- 3 22.9 157.9 1.61 1.58

Temperature Pressure

____F ____C psig kPa kg/cm@@@@ bar

28 -- 2 24.5 168.9 1.72 1.69 30 -- 1 26.1 180.0 1.84 1.80 32 0 27.8 191.7 1.95 1.92 34 1 29.6 204.1 2.08 2.04 36 2 31.3 215.8 2.20 2.16 38 3 33.2 228.9 2.33 2.29 40 4 35.1 242.0 2.47 2.42 45 7 40.1 276.5 2.82 2.76 50 10 45.5 313.7 3.20 3.14 55 13 51.2 353.0 3.60 3.53 60 16 57.4 395.8 4.04 3.96 65 18 64.1 441.0 4.51 4.42 70 21 71.1 490.2 5.00 4.90 75 24 78.7 542.6 5.53 5.43 80 27 86.7 597.8 6.10 5.98 85 29 95.3 657.1 6.70 6.57 90 32 104.3 719.1 7.33 7.19

95 35 114.0 786.0 8.01 7.86 100 38 124.2 856.4 8.73 8.56 105 41 135.0 930.8 9.49 9.31 110 43 146.4 1009 10.29 10.09 115 46 158.4 1092 11.14 10.92 120 49 171.2 1180 12.04 11.80 125 52 184.6 1273 12.98 12.73 130 54 198.7 1370 13.97 13.70 135 57 213.6 1473 15.02 14.73 140 60 229.2 1580 16.11 15.80 145 63 245.6 1693 17.27 16.93 150 66 262.9 1813 18.48 18.13 155 68 281.1 1938 19.76 19.37

6-23

T-309

SECTION 7

ELECTRICAL WIRING SCHEMATIC

7.1 INTRODUCTION

This section contains the Electrical Schematics and Wiring Diagrams. The diagrams are presented as follows: Figure 7-1 Provides the legend for use with all figures. Figure 7-2 Provides the basic schematic diagram. Figure 7-3 Provides t he basic wiring diagram. Sequence of operation descriptions for the various modes of operation are provided in paragraph 4.9

SYMBOL DESCRIPTION (Schematic Location)

LEGEND

AMBS AMBIENT SENSOR (C--21) C CONTROLLERS (H-21, H-23) CB1 CIRCUITBREAKER -- 460 VOLT (J--1) CB2 CIRCUITBREAKER -- AUTOTRANSFORMER (C--1) CF CONDENSER FAN CONTACTOR (M--12, N--5) CI COMMUNICATIONS INTERFACEMODULE (A--3) CL COOL LIGHT (J--7) CM CONDENSER FANMOTOR (H--12, T-5) CP COMPRESSOR MOTOR (T--1) CPDS COMPRESSOR DISCHARGE SENSOR (A--22) CPSS COMPRESSOR SUCTION SENSOR (D--21) CR CHART RECORDER [TEMPERATURE RECORDER]

CS CURRENT SENSOR (M--1) DHBL DEFROST HEATER -- BOTTOM LEFT (T--4) DHBR DEFROST HEATER -- BOTTOM RIGHT (R--4) DHTL DEFROST HEATER -- TOP LEFT (T--4) DHTR DEFROST HEATER -- TOP RIGHT (R--4) DL DEFROST LIGHT (J--6) DPT DISCHARGE PRESSURE TRANSDUCER (J--22) DTS DEFROST TEMPERATURESENSOR (B--22) DVM DUAL VOLTAGE MODULE (D--1) DVR DUAL VOLTAGE RECEPTACLE (F--1) E1 EVAPORATOR FANCONTACTOR [HIGH]

EM EVAPORATOR FANMOTOR (E--13,G--13,T--8,T--11) ES EVAPORATOR FAN CONTACTOR [LOW]

ESV ECONOMIZER SOLENOID VALVE (K--17) F FUSE (C--6,D--20,E--20,H--4) FLA FULL LOAD AMPS HPS HIGH PRESSURE SWITCH (G--11) HR HEATERCONTACTOR (L--15,N--3) HS HUMIDITY SENSOR (F--21) HTT HEAT TERMINATION THERMOSTAT (G--15) IC INTERROGATOR CONNECTOR [FRONT/REAR]

IP INTERNAL PROTECTOR (E--13,G--13,H--12) IRL IN RANGE LIGHT (J8) LIV LIQUID INJECTION SOLENOID VALVE (K-18) MDS MANUAL DEFROST SWITCH (E--19)

(K-16)

(L--13,L--14,P--7,P--10)

( M-- 1 4, P -- 7, P -- 11 )

(P--22,P--21)

SYMBOL DESCRIPTION (Schematic Location)

ORV OIL RETURN SOLENOID VALVE (N--24,H-9) PA COMPRESSOR PHASE CONTACTOR (L--11,M--10,P1) PB COMPRESSOR PHASE CONTACTOR (L--10,M--11,P2) PR PROBE RECEPTACLE [USDA]

RM REMOTE MONITORING RECEPTACLE

RRS RETURN RECORDER SENSOR (K--21) RTS RETURN TEMPERATURE SENSOR (B--21) SMV SUCTION MODULATING VALVE (K--24) SPT SUCTION PRESSURE TRANSDUCER (H--21) SRS SUPPLY RECORDER SENSOR (K--22) ST START -- STOP SWITCH (K--4) STS SUPPLY TEMPERATURE SENSOR (A--21) TCC TransFRESH COMMUNICATIONS

TD CONTROLLER RELAY -- COOLING (H11) TE CONTROLLER RELAY -- HIGH

TFC TransFRESHCONTROLLER (G--5) TH CONTROLLER RELAY -- HEATING(K--15) TN CONTROLLER RELAY -- CONDENSER FAN (K--12) TP TEST POINT (F--17,G--12,H--11,J--12,

TR TRANSFORMER (M--3) TRANS AUTO TRANSFORMER 230/460 (D--1) TRC TransFRESH REAR CONNECTOR (E--5) TS CONTROLLER RELAY -- ECONOMIZER SOLENOID

TT CONTROLLER RELAY -- COOLING (C--11) TU CONTROLLER RELAY -- UNLOADER SOLENOID

TV CONTROLLER RELAY -- LOW SPEED EVAPORATOR

T1 CONTROLLER RELAY -- RM COOL (G --7) T2 CONTROLLER RELAY -- RM DEFROST (G--6) T4 CONTROLLER RELAY -- RM INRANGE (G--8) T6 CONTROLLER RELAY -- COMPRESSOR PHASE

USV UNLOADER SOLENOID VALVE(K--16) WP WATER PRESSURE SWITCH (E--12)

D--21,L--22,M--22)

(J-6,J--7,K--6,K--7,K--8)

CONNECTOR (D-4)

SPEED EVAPORATOR FANS (K--13)

J--13,J--15,M--19)

VALVE (E--17)

VALVE (E--16)

FANS (K--14)

SEQUENCING (K--10,K--11)

Figure 7-1 LEGEND

7-1

T-309

Figure 7-2 SCHEMATIC DIAGRAM

7-2T -309

Figure 7-3 WIRING DIAGRAM (Sheet 1 of 2)

7-3

T-309

Figure 7-3 WIRING DIAGRAM (Sheet 2 of 2)

7-4T -309

INDEX

Air Cooled Condenser Section, 2-4 Alarm, 3-6, 3-10, 3-12, 3-17, 3-27

Battery, 1-1

Capacitors, 6-12 Checking Superheat, 6-9 Communications, 1-1 Communications InterfaceModule, 3-11, 6-21 Compressor, 1-1, 6-5 Compressor Phase Sequence, 4-5 Compressor Section, 2-3 Condenser Coil, 1-1, 6-8 Condenser Fan, 6-8

Evacuation, 6-3 Evaporator, 6-10 Evaporator Fan, 6-12 Evaporator Section, 2-2 Expansion Module, 3-1, 6-14 Expansion Valves, 6-10

Failure Action, 3-4 Filter--Drier, 6-8 Fresh Air Makeup, 2-1, 4-1 Frozen Mode, 4-6 Frozen Mode -- Conventional, 3-6 Frozen Mode -- Economy, 3-6 Function Code, 3-14, 3-25

Configuration Identification, 1-1 Configuration Software, 3-3, 3-8 Configuration Variables, 3-13 Control Box, 1-1, 2-5, 6-18 Controller, 3-3, 6-14 Controller Software, 3-3

DataCORDER, 3-7, 3-10, 4-2 DataCORDER Software, 3-7 DataReader, 3-11 DataView, 3-11 Defrost Interval, 3-4 Defrost Mode, 4-7 Dehumidification, 1-1 Display Module, 3-2

General Description, 2-1 Generator Protection, 3-4

Heat Lockout, 3-4, 3-6 Heater, 6-10 Heating Mode, 4-6 High Pressure Switch, 6-7

Inspection, 4-1, 4-2 Interrogator, 1-1 Introduction, 1-1

Index-1 T-309

INDEX

Key Pad, 3-2

Leak Checking, 6-3 Logging Interval, 3-10

Manifold Gauge Set, 6-1 MicroporcessorSystem, 3-1 Modes Of Operation, 3-4

Oil, 6-7 Operational Software, 3-4, 3-7

Refrigeration Circuit, 2-10 RefrigerationSystem Data, 2-6 Refrigeration Unit -- Front Section, 2-1 Remote Monitoring, 1-1

Safety and Protective Devices, 2-8 Sampling Type, 3-10 Scroll Back , 3-10 Sensor Configuration, 3-8 Sequence Of Operation, 4-5 Service Valves, 6-1 Solenoid Valves, 6-10 Starting, 4-2 Stopping, 4-2 Suction Modulating Valve, 6-13

Option Descriptions, 1-1

Painted Surfaces, 6-17 Perishable Mode -- Bulb, 3-5 Perishable Mode -- Conventional, 3-4 Perishable Mode -- Dehumidification, 3-5 Perishable Mode -- Economy, 3-5 Power, 4-1 Pre--Trip, 3-7, 3-10, 3-21, 3-26, 4-2 Pressure Readout, 1-1 Probe Check, 4-3 Pumping Down, 6-2

Refrigerant Charge, 6-4

TemperatureControl, 3-4, 3-6 Temperature Sensor, 6-17 Thermistor F ormat, 3-10 Torque Values, 6-21

Upper Air, 1-2

Valve Override Controls, 6-12

Wiring Schematic, 7-1

T-309

Index-2

Carrier 69NT20-531-300 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual