Carrier T340 REV B User Manual

Container Refrigeration

OPERATION AND SERVICE

for

69NT40-561-001 to 199

Container Refrigeration Units

T--340 Rev B

OPERATION AND SERVICE MANUAL

CONTAINER REFRIGERATION UNIT

Models

69NT40--561--001 to 199

TABLE OF CONTENTS

PARAGRAPH NUMBER Page

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

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

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

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

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

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

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

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

1.3 FEATURE DESCRIPTIONS 1--1............................................................

1.3.1 Control Box 1--1......................................................................

1.3.2 Temperature Readout 1--1..............................................................

1.3.3 Pressure Readout 1--1.................................................................

1.3.4 Compressor 1--1......................................................................

1.3.5 Condenser Coil 1--1...................................................................

1.3.6 Evaporator 1--1.......................................................................

1.3.7 Evaporator Fan Operation 1--1..........................................................

1.3.8 Plate Set 1--1.........................................................................

1.4 OPTION DESCRIPTIONS 1--1.............................................................

1.4.1 Battery 1--1...........................................................................

1.4.2 Dehumidification 1--1..................................................................

1.4.3 USDA 1--1...........................................................................

1.4.4 Interrogator 1-- 1.......................................................................

1.4.5 Remote Monitoring 1--1................................................................

1.4.6 Communications Interface Module 1--2...................................................

1.4.7 Autotransformer 1--2...................................................................

1.4.8 Temperature Recorder 1--2.............................................................

1.4.9 Handles 1--2..........................................................................

1.4.10 Thermometer Port 1--2.................................................................

1.4.11 Water Cooling 1--2....................................................................

1.4.12 Back Panels 1--2......................................................................

1.4.13 460 Volt Cable 1--2....................................................................

1.4.14 230 Volt Cable 1--2....................................................................

1.4.15 Cable Restraint 1--2...................................................................

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

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

1.4.18 Labels 1--2...........................................................................

1.4.19 Controller 1--2

1.4.20 Condenser Grille 1--2..................................................................

1.4.21 Emergency Bypass 1--2................................................................

1.4.22 eAutoFresh 1--2.......................................................................

........................................................................

i T-340

TABLE OF CONTENTS (Continued)

PARAGRAPH NUMBER Page

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

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

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

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

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

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

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

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

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

2.5.3 Electronic Expansion Valve 2--10.........................................................

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

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

3.1.1 Keypad 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 (V ariables) 3--3...................................................

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

3.3 CONTROLLER SEQUENCE AND MODES OF OPERATION 3-- 4...............................

3.3.1 Start up -- Compressor Phase Sequence 3--4.............................................

3.3.2 Start up -- Compressor Bump Start 3--4..................................................

3.3.3 Perishable Set Point Temperature -- Perishable Pulldown 3--4...............................

3.3.4 Perishable Set Point Temperature -- Standard Temperature Control Mode 3--4.................

3.3.5 Perishable Set Point Temperature -- Economy Fan Operation Mode 3--4......................

3.3.6 Perishable Set Point Temperature Control 3--4............................................

3.3.7 Perishable Mode Cooling -- Sequence of Operation 3--5....................................

3.3.8 Perishable Mode Heating -- Sequence of Operation 3--6....................................

3.3.9 Sequence of Operation -- Perishable Mode (Capacity Trim Heat) 3--6........................

3.3.10 Perishable Mode -- Dehumidification 3--6.................................................

3.3.11 Perishable, Dehumidification -- Bulb Mode 3--7............................................

3.3.12 Frozen Mode -- Pulldown 3--7...........................................................

3.3.13 Frozen Mode -- T emperature Control 3--7.................................................

3.3.14 Frozen Mode -- Standard 3--7...........................................................

3.3.15 Frozen Mode -- Heat Lockout Temperature 3--7...........................................

3.3.16 Frozen Mode -- Economy 3--7...........................................................

3.3.17 Frozen Mode Cooling -- Sequence of Operation 3--8.......................................

3.3.18 Defrost Interval 3--9

...................................................................

T-340

ii

TABLE OF CONTENTS (Continued)

PARAGRAPH NUMBER Page

3.3.19 Defrost Mode -- Sequence of Operation 3--9..............................................

3.4 PROTECTION MODES OF OPERATION 3--10................................................

3.4.1 Evaporator Fan Operation 3--10..........................................................

3.4.2 Failure Action 3--10.....................................................................

3.4.3 Generator Protection 3--10..............................................................

3.4.4 Compressor High Temperature, Low Pressure Protection 3--10...............................

3.4.5 Perishable Mode -- System Pressure Regulation 3--10.......................................

3.4.6 Condenser Fan Override 3--10...........................................................

3.5 CONTROLLER ALARMS 3--10..............................................................

3.6 UNIT PRE--TRIP DIAGNOSTICS 3--11.......................................................

3.7 DataCORDER 3-- 11........................................................................

3.7.1 Description 3--11.......................................................................

3.7.2 DataCORDER Software 3--1 1............................................................

3.7.3 Sensor Configuration (dCF02) 3--12......................................................

3.7.4 Logging Interval (dCF03) 3--12...........................................................

3.7.5 Thermistor Format (dCF04) 3--12.........................................................

3.7.6 Sampling Type (dCF05 & dCF06) 3--14...................................................

3.7.7 Alarm Configuration (dCF07 -- dCF10) 3--14...............................................

3.7.8 DataCORDER Power Up 3--14...........................................................

3.7.9 Pre--trip Data Recording 3--14............................................................

3.7.10 DataCORDER Communications 3--14.....................................................

3.7.11 USDA Cold Treatment 3--15.............................................................

3.7.12 USDA Cold Treatment Procedure 3--15...................................................

3.7.13 DataCORDER Alarms 3--16.............................................................

3.7.14 ISO Trip Header 3--16..................................................................

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

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

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

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

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

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

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

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

4.3.3 Vent Position Sensor 4--2..............................................................

4.4 eAutoFresh OPERATION 4--3..............................................................

4.4.1 eAutoFresh Pre--Trip Inspection 4--3.....................................................

4.4.2 eAutoFresh Start--Up Procedure 4--3....................................................

4.4.3 eAutoFresh Operation 4--3.............................................................

4.4.4 eAutoFresh Modes of Operation 4--3.....................................................

4.5 CONNECT WA TER--COOLED CONDENSER 4--4............................................

4.5.1 Water--Cooled Condenser with Water Pressure Switch 4--4.................................

4.5.2 Water--Cooled Condenser with Condenser Fan Switch 4--4.................................

4.6 CONNECT REMOTE MONITORING RECEPTACLE 4--5......................................

iii T-340

TABLE OF CONTENTS (Continued)

PARAGRAPH NUMBER Page

4.7 STARTING AND STOPPING INSTRUCTIONS 4--5...........................................

4.7.1 Starting the Unit 4--5...................................................................

4.7.2 Stopping the Unit 4--5..................................................................

4.8 START--UP INSPECTION 4--5.............................................................

4.8.1 Physical Inspection 4--5................................................................

4.8.2 Check Controller Function Codes 4--5....................................................

4.8.3 Start T emperature Recorder 4--5........................................................

4.8.4 Complete Inspection 4-- 5...............................................................

4.9 PRE--TRIP DIAGNOSIS 4--5...............................................................

4.10 OBSERVE UNIT OPERATION 4--6.........................................................

4.10.1 Probe Diagnostic Logic 4--6............................................................

4.11 EMERGENCY BYPASS OPERATION 4--7...................................................

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

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

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

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

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 UNIT WILL NOT DEFROST PROPERLY (Continued) 5--3.....................................

5.8 ABNORMAL PRESSURES 5-- 3............................................................

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

5.10 MICROPROCESSOR MALFUNCTION 5--3..................................................

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

5.12 EAUTOFRESH NOT OPERATING 5--4......................................................

5.13 ELECTRONIC EXPANSION V ALVE MALFUNCTION 5--4......................................

5.14 AUTOTRANSFORMER MALFUNCTION 5--5................................................

5.15 WATER--COOLED CONDENSER OR WATER PRESSURE SWITCH 5--5.......................

5.16 COMPRESSOR OPERATING IN REVERSE 5--5.............................................

5.17 ABNORMAL TEMPERATURES 5--5........................................................

5.18 ABNORMAL CURRENTS 5--5..............................................................

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

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

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

6.3 REFRIGERATION SYSTEM SERVICE-UNITS WITH STANDARD PIPING (with Service Valves) 6--2

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

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

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

6.3.4 Evacuation and Dehydration 6--3........................................................

6.3.5 Refrigerant Charge 6-- 4................................................................

6.4 COMPRESSOR 6--4......................................................................

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

T-340

iv

TABLE OF CONTENTS (Continued)

PARAGRAPH NUMBER Page

6.5 HIGH PRESSURE SWITCH 6--6...........................................................

6.5.1 Checking High Pressure Switch 6--6.....................................................

6.5.2 Replacing High Pressure Switch 6--6.....................................................

6.6 CONDENSER COIL 6--6..................................................................

6.7 CONDENSER FAN AND MOTOR ASSEMBLY 6--6...........................................

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

6.9 FILTER DRIER 6--9.......................................................................

6.10 EVAPORATOR COIL AND HEATER ASSEMBLY 6--9.........................................

6.10.1 Evaporator Coil Replacement 6--9.......................................................

6.10.2 Evaporator Heater Removal and Replacement 6--9........................................

6.11 EVAPORATOR FAN AND MOTOR ASSEMBLY 6--10..........................................

6.11.1 Replacing the Evaporator Fan Assembly 6--10.............................................

6.11.2 Disassemble the Evaporator Fan Assembly 6--10...........................................

6.11.3 Assemble the Evaporator Fan Assembly 6--10.............................................

6.12 EVAPORATOR SECTION CLEANING 6--11...................................................

6.13 eAutoFresh SERVICE 6--11.................................................................

6.13.1 Servicing the eAutoFresh Air Filter 6--1 1...................................................

6.13.2 Checking eAutoFresh Drive System 6--11.................................................

6.13.3 Checking the Controller 6--12............................................................

6.13.4 Servicing the eAutoFresh Drive System 6--12..............................................

6.14 ELECTRONIC EXPANSION VALVE 6-- 14.....................................................

6.14.1 Replacing Electronic Expansion Valve and Screen 6--14.....................................

6.15 ECONOMIZER EXPANSION VALVE 6--14....................................................

6.15.1 Valve Replacement 6--14................................................................

6.16 ECONOMIZER SOLENOID VALVE 6-- 15.....................................................

6.17 DIGITAL UNLOADER VALVE 6--15..........................................................

6.18 VALVE OVERRIDE CONTROLS 6--16........................................................

6.19 AUTOTRANSFORMER 6--18...............................................................

6.20 CONTROLLER 6-- 18.......................................................................

6.20.1 Handling Modules 6--18.................................................................

6.20.2 Controller Troubleshooting 6--18..........................................................

6.20.3 Controller Programming Procedure 6--19..................................................

6.20.4 Removing and Installing a Module 6--21...................................................

6.20.5 Battery Replacement 6--21..............................................................

6.21 VENT POSITION SENSOR SERVICE 6--21...................................................

6.22 TEMPERATURE SENSOR SERVICE 6--22...................................................

6.22.1 Sensor Checkout Procedure 6--22........................................................

6.22.2 Sensor Replacement 6--25..............................................................

6.22.3 Sensor Re-Installation 6--25.............................................................

6.23 ELECTRONIC PAR TLOW TEMPERATURE RECORDER 6--27..................................

6.24 MAINTENANCE OF PAINTED SURFACES 6--29..............................................

6.25 COMMUNICATIONS INTERFACE MODULE INSTALLATION 6--29..............................

ELECTRICAL WIRING SCHEMATICS 7--1...........................................................

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

v T-340

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

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

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

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

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

Figure 3--1 T emperature Control System 3--1.........................................................

Figure 3--2 Keypad 3--2...........................................................................

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

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

Figure 3--5 Controller Operation -- Perishable Mode 3--5...............................................

Figure 3--6 Perishable Mode -- Cooling 3--5..........................................................

Figure 3--7 Perishable Mode Heating 3--6............................................................

Figure 3--8 Controller Operation -- Frozen Mode 3--8..................................................

Figure3--9FrozenMode 3-- 8......................................................................

Figure 3--10 Defrost 3--10..........................................................................

Figure 3--11 Standard Configuration Download Report 3--13.............................................

Figure 3--12 Data Reader 3--15......................................................................

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

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

Figure 4--3 Diagram of Emergency Bypass Connections 4--7...........................................

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

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

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

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

Figure 6--5 Compressor Kit 6--5....................................................................

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

Figure 6--7 Water-Cooled Condenser Cleaning - Forced Circulation 6--8.................................

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

Figure 6--9 5+1 Heater Arrangement -- Omega Heater 6--9.............................................

Figure 6--10 Evaporator Fan Assembly 6--10..........................................................

Figure 6--11 Stepper Components 6--12..............................................................

Figure 6--12 Jumper Assembly 6-- 12.................................................................

Figure 6--13 Motor Cup Replacement 6--13...........................................................

Figure 6--14 Electronic Expansion Valve 6--14.........................................................

Figure 6--15 Economizer Expansion V alve 6--14.......................................................

Figure 6--16 Coil View of Economizer Solenoid Valve (ESV) 6--15........................................

Figure 6--17 View of Digital Unloader Valve (DUV) Assembly 6--15.......................................

Figure 6--18 Controller Section of the Control Box 6--19.................................................

Figure 6--19 Sensor Types

6--25.....................................................................

T-340

vi

LIST OF ILLUSTRATIONS (Continued)

FIGURE NUMBER Page

Figure 6--20 Sensor and Cable Splice 6--25...........................................................

Figure 6--21 Supply Sensor Positioning 6--26..........................................................

Figure 6--22 Return Sensor Positioning 6--26..........................................................

Figure 6--23 Evaporator Temperature Sensor Positioning 6--26..........................................

Figure 6--24 Compressor Discharge Temperature Sensor 6--27..........................................

Figure 6--25 Electronic Partlow Temperature Recorder 6--28.............................................

Figure 6--26 Communications Interface Installation 6--29................................................

Figure 7--1 LEGEND -- Standard Unit Configuration 7--2...............................................

Figure 7--2 SCHEMATIC DIAGRAM -- Standard Unit Configuration 7--3..................................

Figure 7--3 LEGEND -- Configuration Includes Available Options

Figure 7--4 SCHEMATIC DIAGRAM -- Configuration Includes Available Options

Figure 7--5 LEGEND -- Configuration Includes eAutoFresh & Emergency Bypass Options 7--6..............

Figure 7--6 SCHEMATIC DIAGRAM -- Configuration Includes eAutoFresh & Emergency Bypass Options 7--7.

Figure 7--7 SCHEMATIC AND WIRING DIAGRAM -- Upper Vent Position Sensor (VPS) Option 7--8.........

Figure 7--8 SCHEMATIC AND WIRING DIAGRAM -- Lower Vent Position Sensor (VPS) Option 7--9.........

Figure 7--9 UNIT WIRING DIAGRAM -- Standard Unit Configuration with 3--Phase Condenser Fan Motors 7--10
Figure 7--10 UNIT WIRING DIAGRAM -- Configuration Includes 2 Phase Condenser Fan Motor

Figure 7--11 UNIT WIRING DIAGRAM -- Configuration Includes eAutoFresh & Emergency Bypass Options 7--14

(Except Vent Positioning System, eAutoFresh & Emergency Bypass Options) 7--4.............

(Except Vent Positioning System, eAutoFresh & Emergency Bypass Options) 7--5.............

and Optional Heater Arrangement 7--12...................................................

LIST OF TABLES

TABLE NUMBER Page

Table 2--1 Safety and Protective Devices 2--9.........................................................

Table 3--1 Keypad Function 3--2.....................................................................

Table 3--2 DataCORDER Configuration Variables 3--12..................................................

Table 3--3 DataCORDER Standard Configurations 3--14.................................................

Table 3--4 Controller Configuration Variables 3--17......................................................

Table 3--5 Controller Function Codes 3--18.............................................................

Table 3--6 Controller Alarm Indications 3--22...........................................................

Table 3--7 Controller Pre--trip Test Codes 3--27.........................................................

Table 3--8 DataCORDER Function Code Assignments 3--31..............................................

Table 3--9 DataCORDER Pre--trip Result Records 3--32.................................................

Table 3--10 DataCORDER Alarm Indications 3--33......................................................

Table 6--1 Valve Override Control Displays 6--17........................................................

Table 6--2 Sensor Resistance 6--23...................................................................

Table 6--3 Sensor Resistance (CPDS) 6--24............................................................

Table 6--4 Recommended Bolt Torque Values 6--29.....................................................

Table 6--5 R-134a Temperature - Pressure Chart 6--30..................................................

vii T-340

SAFETY SUMMARY

GENERAL SAFETY NOTICES

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

FIRST AID

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

OPERATING PRECAUTIONS

Always wear safety glasses.

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

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

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

CAUTION - means to warn against potential hazard or
unsafe practice that couldresult inminor personal injury,
product or property damage.

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

DANGER

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

WARNING

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

MAINTENANCE PRECAUTIONS

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

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

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

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

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

SPECIFIC WARNING AND CAUTION STATEMENTS

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

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

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

(never use water).

2

WARNING

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

WARNING

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

WARNING

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

WARNING

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

Safety--1

T--340

WARNING

CAUTION

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

WARNING

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

WARNING

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

WARNING

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

Charge wate r--cooled condense r or receiv­er according to nameplate specifications to
ensure optimal unit performance.

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.

CAUTION

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

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 - thiswill cause
spattering and excessive heat.

WARNING

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

WARNING

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

WARNING

Installation requires wiring to the main unit
circuit breaker, CB1. Make sure the power to
the unit is off and power plug disconnected
before beginning installation.

CAUTION

Pre-tr ip inspection should not be per­formed with critical temperature cargoes in
the containe r.

CAUTION

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

CAUTION

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

CAUTION

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

T--340

Safety--2

CAUTION

CAUTION

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

CAUTION

Allowing the scroll compressor to operate
in reverse for more than two minutes willre­sult in internal compressor damage. Turn
the start-stop switch OFF immediately.

CAUTION

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

CAUTION

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

CAUTION

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

CAUTION

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

CAUTION

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

CAUTION

The scroll compressor achieves low suc­tion pressure very quickly. Do not use the
compressor to evacuate the system below
0 psig. Never operate the compressor with
the suction or discharge service valves
closed (frontseated). Internal damage will
result from operating the compressor in a
deep vacuum.

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

CAUTION

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

Safety--3

T--340

SECTION 1

INTRODUCTION

1.1 INTRODUCTION

The Carrier Transicold model 69NT40--561--001 to 199
series units are of lightweight aluminum frame
construction, designed to fit in the front of a container
and serve as the container’s front wall.

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

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

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

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

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

1.2 CONFIGURATION IDENTIFICATION

Unit identification information is provided on a plate
located to the left of the receiver or water--cooled
condenser, on the back wall of the condenser section.
The plate provides the unit model number, the unit serial
number and the unit parts identification number (PID).
The model number identifies the overall unit
configuration, while the PID number provides
information on specific optional equipment, factory
provisioned to allow for field installation of optional
equipment and differences in detailed parts.

1.3 FEATURE DESCRIPTIONS

1.3.1 Control Box

Units are equipped with either an aluminum or
composite material box, and may be fitted with a
lockable door.

1.3.2 Temperature Readout

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

1.3.3 Pressure Readout

The unit is fitted with evaporator and discharge
transducers. The transducer readings may be viewed
on the controller display.

1.3.4 Compressor

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

1.3.5 Condenser Coil

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

1.3.6 Evaporator

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

1.3.7 Evaporator Fan Operation

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

1.3.8 Plate Set

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

1.4 OPTION DESCRIPTIONS

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

1.4.1 Battery

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

1.4.2 Dehumidification

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

1.4.3 USDA

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

1.4.4 Interrogator

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

1.4.5 Remote Monitoring

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

1--1 T--340

1.4.6 Communications Interface Module

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

1.4.7 Autotransformer

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

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

1.4.8 Temperature Recorder

The unit may be fitted with an electronic temperature
recording device.

1.4.9 Handles

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

1.4.10 Thermometer Port

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

1.4.11 Water Cooling

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

1.4.12 Back Panels

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

1.4.13 460 Volt Cable

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

1.4.14 230 Volt Cable

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

1.4.15 Cable Restraint

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

1.4.16 Upper Air (Fresh Air Make Up)

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

1.4.17 Lower Air (Fresh Air Make Up)

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

1.4.18 Labels

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

1.4.19 Controller

Two replacement controllers are available:

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

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

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

Controllers will be factory--equipped with the latest
version of operational software, but will NOT be
configured for a specific model number and will need to
be configured at the time of installation or sale.

1.4.20 Condenser Grille

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

1.4.21 Emergency Bypass

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

1.4.22 eAutoFresh

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

T--340

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).
The unit model number, serial number and parts identifi­cation number can be found on the serial plate to the left
of the receiver or water--cooled condenser on the back
wall of the condenser section.

19

2.1.2 Fresh Air Makeup Vent

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

The optional eAutoFresh vent system is to moderate the
atmospheric level in the container in response to cargo
respiration. When transporting frozen cargo loads the
vent will be closed. The upper left access panel contains
the vent slide and motor assembly. It may be removed to
allow entry into the evaporator section where the CO
sensor and drive pack are located.

2

18

17

16

15

14

13

12

11

10

1. Access Panel (Evap. Fan #1)

2. Fork Lift Pockets

3. Control Box

4. Compressor

5. Ambient Sensor (AMBS)

6. Economizer

7. Filter Drier

8. Receiver or Water Cooled Condenser

9. Unit Serial Number, Model Number and
Parts Identification Number (PID) Plate

10. Power Cables and Plug (Location)

11. Condenser Fan

Figure 2--1 Refrigeration Unit -- Front Section

1

2

3

4

9

8

12. Autotransformer (Location)

13. TransFRESH Communications Connector

14. Interrogator Connector (Front left)

15. Temperature Recorder

16. Lower Fresh Air Makeup Vent Location

17. TIR (Transports Internationaux Routiers)

18. Upper Fresh Air Makeup Vent or eAutoFresh

19. Access Panel (Evap. Fan #2)

7

(Blank Cover Shown)

Sealing Provisions -- Typical All Panels

(Automatic Vent) panel

5

6

2--1

T-340

2.1.3 Evaporator Section

The evaporator section (Figure 2--2) contains the return
temperature sensor, humidity sensor, electronic expan­sion valve, dual speed evaporator fans (EM1 and EM2),
evaporator coil and heaters, defrost temperature sen­sor, heat termination thermostat and evaporator tem­perature sensors (ETS1 and ETS2).

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

15

14

13

discharging it at the bottom.

If unit is equipped with eAutoFresh, system compon­ents are mounted in addition to the standard refrigera­tion unit components. The stepper motor component is
installed in the vent; the air filter, CO
motor drive and CO

sensing lines are installed on the

2

sensor, stepper

2

rib of the upper grill.

Most evaporator components are accessible by remov­ing the upper rear panel (as shown in the illustration) or
by removing the evaporator fan access panels (see
Figure 2--1, Items 1 and 19.

12

10

11

4

3

2

1

9

16

21

20

19

6

18

17

7

8

1. Evaporator Fan Motor #1 (EM1)

2. Return Recorder Sensor/Temperature Sensor
(RRS/RTS)

3. Humidity Sensor (HS)

4. Evaporator Fan Motor #2 (EM2)

5. Evaporator Coil

6. Evaporator Coil Heaters (Underside of Coil)

7. Heater Termination Thermostat (HTT)

8. Defrost Temperature Sensor (DTS)

9. Electronic Expansion Valve (EEV)

10. Evaporator Temperature Sensors (Location)
(ETS1 and ETS2)

Figure 2--2 Evaporator Section

5

11. Air Filter

12. CO

13. CO

14. CO

Sensor Sensing Line

2

Sensor (COS)

2

Sensor Outlet Line

2

15. Stepper Motor Drive (SD)

16. Stepper Motor (AF)

17. Interrogator Connector (Rear) (ICR)

18. USDA Probe Receptacle PR2

19. USDA Probe Receptacle PR1

20. USDA Probe Receptacle PR3

21. Cargo Probe Receptacle PR4

2--2T-340

2.1.4 Compressor Section

The compressor section includes the compressor,
digital unloader valve (DUV), high pressure switch,
discharge pressure transducer (DPT), evaporator

15

pressure transducer (EPT) and the suction pressure
transducer (SPT).

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

11

1

10

9

12

8

13

14

2

3

4

5

6

1. Compressor

2. Compressor Discharge Temperature Sensor
(CPDS) (Location)

3. Discharge Connection

4. Suction Connection (Location)

5. Compressor Terminal Box

6. Oil Drain (Location)

7. Economizer Connection

8. Discharge Pressure Transducer (DPT)

Figure 2--3 Compressor Section

7

9. Suction Pressure Transducer (SPT)

10. Digital Unloader Valve (DUV)

11. Evaporator Pressure Transducer (EPT)

12. Discharge Service Valve

13. High Pressure Switch (HPS)

14. Suction Service Valve

15. Supply Temperature/Supply Recorder Sensor
Assembly (STS/SRS)

2--3

T-340

2.1.5 Air-- Cooled Condenser Section

The air--cooled condenser section (Figure 2--4)
consists of the condenser fan, condenser coil, receiver,
liquid line service valve, filter drier, fusible plug,
economizer, economizer expansion valve, economizer

solenoid valve (ESV), and sight glass/moisture
indicator.

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

2

1

3

4

5

6

89 10

7

1. Grille and Venturi Assembly

2. Condenser Fan

3. Key

4. Condenser Fan Motor

5. Condenser Coil

6. Condenser Coil Cover

7. Receiver

8. Sight Glass

15

14

13

9. Filter Drier

10. Economizer

11. Economizer Solenoid Valve (ESV)

12. Economizer Expansion Valve

13. Service Access Valve

14. Liquid Level/Moisture Indicator

15. Fusible Plug

Figure 2--4 Air--Cooled Condenser Section

2--4T-340

11

12

2.1.6 Water-- Cooled Condenser Section

The water--cooled condenser section (Figure 2--5) con­sists of a water--cooled condenser , sight glass, rupture
disc, filter drier, water couplings, water pressure switch,

economizer, economizer expansion valve, economizer
solenoid valve (ESV), and moisture/liquid indicator.

The water--cooled condenser replaces the standard unit
receiver.

23 4

1

5

12

1. Water--Cooled Condenser

2. Rupture Disc

3. Moisture/Liquid Indicator

4. Filter Drier

5. Economizer

6. Economizer Solenoid Valve (ESV)

11

Figure 2--5 Water--Cooled Condenser Section

10 9

7. Economizer Expansion Valve

8. Coupling (Water In)

9. Liquid Line Service Valve/Connection

10. Self Draining Coupling (Water Out)

11. Water Pressure Switch (WP)

12. Sight Glass

8

6

7

2--5

T-340

2.1.7 Control Box Section

2.1.8 Communications Interface Module

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

1567

32

4

The optional communications interface module is a
slave module that allows communication with a master
central monitoring station. The module will respond to
communication and return information over the main
power line. Refer to the master central monitoring sta­tion technical manual for additional information.

8

15

1617 12

1. Compressor Contactor -- CH

2. Compressor Phase A Contactor -- PA

3. Compressor Phase B Contactor -- PB

4. Heater Contactor -- HR

5. Display Module

6. Communications Interface Module

7. Controller/DataCORDER Module (Controller)

8. Key Pad

9. Remote Monitoring Receptacle

14 13

Figure 2--6 Control Box Section

10

10. Controller Battery Pack (Standard Location)
1 1. Interrogator Connector (Box Location)

12. Control Transformer

13. High Speed Evaporator Fan Contactor -- EF

14. Low Speed Evaporator Fan Contactor -- ES

15. Condenser Fan Contactor -- CF

16. Circuit Breaker -- 460V

17. Current Sensor Module

2--6T-340

911

2.2 REFRIGERATION SYSTEM DATA

Model Number ZMD26KVE-- TFD --272

a. Compressor/Motor

Assembly

b. Electronic Expansion Valve

Superheat (Evaporator)

c. Economizer Expansion

Valve Superheat

d. Heater Termination Thermostat

e. High Pressure Switch

Weight (With Oil) 42.9 kg (95 lb)
Approved Oil Uniqema Emkarate RL--32--3MAF
Oil Charge 1774 ml (60 ounces)
Verify at --18_C

(0F) container box
temperature

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

Opens 54_ (+/-- 3) C = 130_ (+/-- 5) F
Closes 38_ (+/-- 4) C = 100_ (+/-- 7) F
Cutout 25 (+/-- 1.0) kg/cm2= 350 (+/-- 10) psig
Cut--In 18 (+/-- 0.7) kg/cm2= 250 (+/-- 10) psig

4.4to6.7_C(8to12_F)

4.4to11.1_C(8to20_F)

CAUTION

Charge wa t e r--cooled condenser or receiver according to nameplate specifications to ensure
optimal unit per for m ance.

Unit Configuration Charge R e quir ements

Water--Cooled

f. Refrigerant Charge -- R--134a

g. Fusible Plug

h. Rupture Disc

i. Unit Weight Refer to unit model number plate.

j. Water Pressure Switch

Condenser

Receiver

Melting point 99_C = (210_F)
Torque 6.2to6.9mkg(45to50ft--lbs)
Bursts at 35 +/-- 5% kg/cm2= (500 +/-- 5% psig)
Torque 6.2to6.9mkg(45to50ft--lbs)

Cut--In 0.5 +/-- 0.2 kg/cm2(7 +/-- 3 psig)
Cutout 1.6 +/-- 0.4 kg/cm2(22 +/-- 5 psig)

5.44 kg
(12 lbs)

4.99 kg
(11 lbs)

2--7

T-340

2.3 ELECTRICAL DATA

a. Circuit Breaker

b. Compressor

Motor

c. Condenser Fan

Motor

d. Evaporator Coil

Heaters

e. Evaporator Fan

Motor(s)

f. Fuses

g. Vent Positioning

Sensor

h. Solenoid V alv e

Coils (ESV)
24 VDC

i. DUV Coils

12 VDC

j. EEV Nominal

Resistance

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

460 VAC, Single Phase,

60 Hz

Full Load Amps 1.3 amps 1.6 amps
Horsepower 0.43 hp 0.75 hp
Rotations Per Minute 1425 rpm 1725 rpm
Voltage and Frequency 360 -- 460 VAC +/-- 2.5 Hz 400 -- 500 VAC +/-- 2.5 Hz
Bearing Lubrication Factory lubricated, additional grease not required.
Rotation Counter--clockwise when viewed from shaft end.
Number of Heaters 6
Rating 750 watts +5/--10% each @ 230 VAC
Resistance (cold) 66.8 to 77.2 ohms @ 20_C(68_F)
Type Sheath

380 VAC/3 PH/50 Hz 460 VAC/3 PH/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

1.0 1.2

0.6 0.6

0.49 0.84

0.06 0.11

2850 rpm 3450 rpm

1425 rpm 1725 rpm

Voltage and Frequency 360 -- 460 VAC +/-- 1.25 Hz 400 -- 500 VAC +/-- 1.5 Hz
Bearing Lubrication Factory lubricated, additional grease not required
Rotation CW when viewed from shaft end
Control Circuit 7.5 amps (F3A,F3B)
Controller/DataCORDER 5amps(F1&F2)
Emergency Bypass 10 amps (FEB)
Electrical Output 0.5 VDC to 4.5 VDC over 90 degree range
Supply Voltage 5 VDC +/-- 10%
Supply Current 5mA(typical)
Nominal Resistance @

77_F(25_C)

7.7 ohms +/-- 5%

Maximum Current Draw 0.7 amps
Nominal Resistance @

77_F(20_C)

14.8 ohms +/-- 5%

Maximum Current Draw 929 mA
Coil Feed to Ground

(Gray Wire)

47 ohms

Coil Feed to Coil Feed 95 ohms

2--8T-340

Section 2.3 -- ELECTRICAL DAT A--CONTINUED

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

k. Humidity Sensor

Output voltage 0to3.3VDC

Output voltage readings verses relative humidity (RH) percentage:

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

2.4 SAFETY AND PROTECTIVE DEVICES

Unit components are protected from damage by safety
and protective devices listed in Table 2--1. These de­vices monitor the unit operating conditions and open a
set of electrical contacts when an unsafe condition oc­curs.

Open safety switch contacts on either or both of devices
IP--CP or HPS will shut down the compressor.

Table 2--1 Safety and Protective Devices

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

The entire refrigeration unit will shut down if one of the
following safety devices open: (a) circuit breaker(s); (b)
fuse (F3A/F3B, 7.5A); or (c) evaporator fan motor in­ternal protector(s) -- (IP).

UNSAFE CONDITION

DEVICE DEVICE SETTING

Circuit Breaker (CB--1) -- Manual Reset Tripsat29amps(460VAC)

Excessive current draw Circuit B reak er (CB--2, 50 a mp) -- Manual Reset Trips at 62.5 amps (230 VAC)

Circuit B reak er (CB--2, 70 a mp) -- 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
Emergency Bypass module

Excessive condenser fan
motor winding temperature

Excessive compressor motor
winding temperature

Excessive evaporator fan
motor(s) winding temperature

Abnormal pressures/tempera­tures in the high refrigerant
side

Abnormally high discharge
pressure

Fuse(F3A&F3B) 7.5 amp rating

Fuse (F1 & F2) 5 amp rating

Fuse (FEB) 10 amp rating

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

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

Internal Protector(s) (IP--EM) -- Automatic Reset N/A

FusiblePlug--UsedontheReceiver

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

99_C = (210_F)

35 kg/cm

2

= (500 psig)

denser

High Pressure Switch (HPS)

Opens at 25 kg/cm
(350 psig)

2

2--9

T-340

2.5 REFRIGERATION CIRCUIT

2.5.1 Standard Operation

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

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

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

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

On systems fitted with a water pressure switch, the con­denser fan will be off when there is sufficient pressure to
open the switch. If water pressure drops below the
switch cut out setting, the condenser fan will automatic­ally start.

During the standard mode of operation, the normally
closed digital unloader valve (DUV) controls the system

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

2.5.2 Economized Operation

In the economized mode, (see Figure 2--8) the frozen
and pull down capacity of the unit is increased by sub­cooling the liquid refrigerant entering the electronic ex­pansion valve. Overall efficiency is increased because
the gas leaving the economizer enters the compressor
at a higher pressure, therefore requiring less energy to
compress it to the required condensing conditions.

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

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

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

2.5.3 Electronic Expansion Valve

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

2--10T-340

ECONOMIZER
SOLENOID
VALV E

ECONOMIZER

TXV

FILTER
DRIER

LIQUID LINE
SERVICE
VALV E

STANDARD OPERATION WITH RECEIVER

EVAPORATOR

CONDENSER

ECONOMIZER

ECON.

TXV

SENSING

BULB

SIGHT

GLASS

LIQUID LEVEL/

MOISTURE

INDICATOR

COMBO

ETS1 AND 2

RECEIVER

DISCHARGE
PRESSURE
TRANSDUCER

ELECTRONIC
EXPANSION
VALV E

DIGITAL
UNLOADER
VALV E

COMPRESSOR

DISCHARGE
TEMPERATURE
SENSOR

DISCHARGE
SERVICE
VALV E

EVAPORATOR
PRESSURE
TRANSDUCER

SUCTION
PRESSURE
TRANSDUCER

SUCTION
SERVICE
VALV E

STANDARD OPERATION WITH W ATER--COOLED CONDENSER

ECONOMIZER
SOLENOID
VALV E

ECONOMIZER

TXV

FILTER
DRIER

LIQUID LINE
SERVICE
VALV E

EVAPORATOR

CONDENSER

ECONOMIZER

MOISTURE
INDICATOR

WATER-- COOLE D

ETS1 AND 2

CONDENSER

DISCHARGE
PRESSURE
TRANSDUCER

SIGHT
GLASS

ELECTRONIC
EXPANSION
VALV E

DIGITAL
UNLOADER
VALV E

COMPRESSOR

DISCHARGE LIQUID

DISCHARGE
TEMPERATURE
SENSOR

DISCHARGE
SERVICE
VALV E

EVAPORATOR
PRESSURE
TRANSDUCER

SUCTION
PRESSURE
TRANSDUCER

SUCTION
SERVICE
VALV E

SUCTION

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

2--11

T-340

ECONOMIZER
SOLENOID
VALV E

ECONOMIZER

TXV

LIQUID LINE
SERVICE
VALV E

ECONOMIZER

ECON.

TXV

SENSING

BULB

RECEIVER

ELECTRONIC
EXPANSION
VALV E

COMPRESSOR

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

LIQUID

ECONOMIZER
PRESSURE

2--12T-340

SECTION 3

MICROPROCESSOR

3.1 TEMPERATURE CONTROL
MICROPROCESSOR SYSTEM

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

CONTROL MODULE

TEMPERATURE CONTROL SOFTWARE

cargo temperature parameters for future retrieval. Cover­age of the temperature control software begins with para­graph 3.2. Coverage of the DataCORDER software is
provided in paragraph 3.7.

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

DISPLAY MODULE

KEYPAD

CONFIGURATION

SOFTWARE

CONFIGURATION

VARIABLE

(CnF##)

DataCORDER SOFTWARE

CONFIGURATION

SOFTWARE

CONFIGURATION

VARIABLE

(dCF## read only)

OPERATIONAL

SOFTWARE

FUNCTION
CODE (Cd)

OPERATIONAL

SOFTWARE

FUNCTION
CODE (dC)

ALARMS

(AL<70)

TO

DISPLAY

ALARMS

(AL>68)

TO

DISPLAY

PRE--TRIP

DATA

STORAGE

MEMORY

TO

DISPLAY

(Scrollback)

INTERROGATION
CONNECTOR

DATAREADER

Computer Device

With DataLINE

Software

PCMCIA CARD

Figure 3--1 Temperature Control System

3--1

T-340

3.1.1 Keypad

Table 3--1 Keypad Function

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

1

3

2

4

5

6

8

10

1. Code Select

2. Pre--trip

3. Alarm List

4. Manual Defrost/
Interval

7

9

11

6. UP Arrow

7. DOWN Arrow

8. Return/Supply

9. Celsius/Fahrenheit

10. Battery Power

Figure 3--2 Keypad

3.1.2 Display Module

The display module (Figure 3--3) consists of two 5--digit
displays and seven indicator lights. The indicator lights
include:

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

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

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

4. In--Range -- Green LED: Ene rgized whe n the con­trol led tempe rature probe is within specified tolerance
of set point.

KEY

FUNCTION

Code Select Accesses function codes.

Pre--trip

Alarm List

Manual
Defrost/

Interval

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

Displays alarm list and clears the
alarm queue.

Displays selected defrost mode. De­pressing and holding the Defrost in­terval key for five (5) seconds will ini­tiate defrost using the same logic as
if the optional manual defrost switch
was toggled on.

Enter

Arrow Up

Arrow Down

Return/

Supply

Confirms a 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 tem­perature (momentary display).

Displays alternate English/Metric
scale (momentary display). When set
to F, pressure is displayed in psig and

Celsius /

Fahrenheit

vacuum in “/hg.” “P” appears after the
value to indicate psig and “i” appears
for inches of mercury.

When set to C, pressure readings are
in bars. “b” appears after the value to
indicate bars.

Battery

Power

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

This key is pressed to switch the
functions from the temperature soft­ware to the DataCORDER Software.

ALT. Mode

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

NOTE

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

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

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

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

3--2T-340

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

Figure 3--3 Display Module

3.1.3 Controller

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.

CAUTION

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

NOTE

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

The Micro--Link 3 controller is a dual module micropro­cessor as shown in Figure 3--4. It is fitted with test
points, harness connectors and a software card pro­gramming port.

3.2 CONTROLLER SOFTWARE

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

a. Control supply or return air temperature to required

limits, provide modulated refrigeration operation,
economized operation, unloaded operation, electric
heat control and defrost. Defrost is performed to clear
buildup of frost and ice and ensure proper air flow
across the coil.

b. Provide default independent readouts of set point and

supply or return air temperatures.

c. Provide ability to read and (if applicable) modify the

configuration software variables, operating software
Function Codes and Alarm Code indications.

d. Provide a Pre--trip step--by--step checkout of refrig-

eration unit performance including: proper compo­nent operation, electronic and refrigeration control
operation, 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. Provide the ability to reprogram the software through

the use of a memory card.

3.2.1 Configuration Software (Variables)

The configuration software is a variable listing of the
components available for use by the operational soft­ware. This software is factory installed in accordance
with the equipment fitted and options listed on the origi­nal purchase order. Changes to the configuration soft­ware are required only when a new controller has been
installed or a physical change has been made to the unit
such as the addition or removal of an option. A configu­ration variable list is provided in Table 3--4. Change to
the factory--installed configuration software is achieved
via a configuration card or by communications.

3.2.2 Operational Software (Function Codes)

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

1. Mounting Screw

2. Micro--Link 3 Control/DataCORDER Module

3. Connectors

4. Test Points

Figure 3--4 Control Module

5. Fuses

6. Control Circuit Power Connection

7. Software Programming Port

8. Battery Pack (Standard Location)

3--3

812 33 3 3 345 67

T-340

The programming is divided into function codes. Some
of the codes are read only while the remaining codes
may be user configured. The value of the user configur­able codes can be assigned in accordance with user de­sired mode of operation. A list of the function codes is
provided in Table 3--5.

To access the function codes, perform the following:

a. Press the CODE SELECT key, then press an arrow

key until the left window displays the desired code
number.

b. The right window will display the value of this item for

five seconds before returning to the normal display
mode.

c. If a longer time is desired, press the ENTER key to ex-

tendthetimetofiveminutes.

3.3 CONTROLLER SEQUENCE AND MODES OF
OPERATION

General operation sequences for cooling, heating and
defrost are provided in the following sub--paragraphs.
Schematic representation of controller action is
provided in Figure 3--5.

The operational software responds to various inputs.
These inputs come from the temperature and pressure
sensors, the temperature set point, the settings of the
configuration variables and the function code assign­ments. The action taken by the operational software will
change if any one of the inputs change. Overall interac­tion of the inputs is described as a “mode” of operation.
The modes of operation include perishable (chill) mode
and frozen mode. Descriptions of the controller interac­tion and modes of operation are provided in the following
sub paragraphs.

3.3.1 Start up -- Compressor Phase Sequence

The controller logic will check for proper phase sequen­cing and compressor rotation. If sequencing is allowing
the compressor and three--phase evaporator fan motor
to rotate in the wrong direction, the controller will ener­gize or de--energize relay TCP as required (see Figure
7--2). Relay TCP will switch its contacts, energizing or
de--energizing relays PA and PB. Relay PA is wired to
energize the circuits(s) on L1, L2 and L3. Relay PB is
wired to energize the circuit(s) on L3, L2, and L1, thus
providing reverse rotation.

3.3.2 Start up -- Compressor Bump Start

The controller logic will initiate a compressor bump start
procedure to clear refrigerant from the compressor. If
suction and discharge pressures have equalized, the
compressor will perform three compressor bump starts.
A compressor bump start may occur after a defrost has
been completed.

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

3.3.3 Perishable Set Point Temperature --

Perishable Pulldown

When cooling from a temperature that is more than

2.5_C(4.5_F) above set point, the system will be in the

perishable pulldown mode in economized operation.
However, pressure and current limit functions may re­strict the valve if either exceeds the preset value.

3.3.4 Perishable Set Point Temperature -­Standard Temperature Control Mode

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

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

If the controller has determined that cooling is not re­quired or the controller logic determines suction pres­sure is at the low pressure limit, the unit will transition to
the perishable idle mode. The compressor is turned off
and the evaporator fans continue to run to circulate air
throughout the container. If temperature rises above set
point +0.2_C, the unit will transition back to the perish­able steady state mode

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

3.3.5 Perishable Set Point Temperature -­Economy Fa n Oper ation Mode

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

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

At the start of each cooling or heating cycle, the evapo­rator fans will run in high speed for three minutes. They
will then be switched to low speed any time the supply
air temperature is within +/- - 0.2_C (0.36_F) of the set
point and the return air temperature is less than or equal
to the supply air temperature +3_C(5.4_F). The fans will
continue to run in low speed for one hour. At the end of
the hour, the evaporator fans will switch back to high
speed and the cycle will be repeated. If bulb mode is ac­tive, the economy fan activity will be overridden.

3.3.6 Perishable Set Point Temperature Cont rol

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

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

3--4T-340