Carrier VECTOR 6500 Operation & Service Manual

T railer & Rail Refrigeration

EVAPORATOR

CONDENSER

EVXV

RECEIVER

OPERATION & SER VICE

MANUAL

VECTOR 6500

Single--Temp Trailer and Rail

Refrigeration Units

With Advancet Microprocessor

62--11389 Rev A Change 09/11

for

OPERATION & SERVICE

MANUAL

for

VECTOR 6500

Single−Temp Trailer and Rail

Refrigeration Units

With Advance Microprocessor

TABLE OF CONTENTS

PARAGRAPH NUMBER Page

SAFETY PRECAUTIONS 1−1.....................................................................

1.1 SAFETY PRECAUTIONS 1−1..............................................................

1.2 SPECIFIC WARNING AND CAUTION STATEMENTS 1−2.....................................

1.3 SAFETY DECALS 1−6....................................................................

UNIT DESCRIPTION 2−1..........................................................................

2.1 INTRODUCTION 2−1.....................................................................

2.2 GENERAL DESCRIPTION 2−1.............................................................

2.3 CONDENSING SECTION 2−7.............................................................

2.3.1 Engine 2−7...........................................................................

2.3.2 Engine Air System 2−7................................................................

2.3.3 Engine Controls: 2−7..................................................................

a. Engine Speed Control Unit (ENSCU) 2−7..............................................

b. Fuel/Speed Actuator (FSA) 2−7.......................................................

c. Engine Speed Sensor (ENSSN) 2−7...................................................

d. Engine Oil Pressure Switch (ENOPS) 2−7..............................................

e. Engine Coolant Temperature Sensor (ENCT) 2−7.......................................

f. Engine Oil Level Switch (ENOLS) 2−7.................................................

2.3.4 Generator (GEN) 2−7..................................................................

2.3.5 Compressor 2−7......................................................................

2.3.6 Unloaders 2−7.......................................................................

a. Major Working Parts 2−7.............................................................

b. Unloaded Operation 2−8.............................................................

c. Loaded Operation 2−9...............................................................

2.3.7 Compressor Switches, Transducers and Sensors 2−9......................................

a. Compressor Discharge Pressure Transducer (CDP) 2−9.................................

b. Compressor Suction Pressure Transducer (CSP) 2−9....................................

c. Compressor Discharge Temperature Sensor (CDT) 2−9..................................

d. Compressor Suction Temperature Sensor (CST) 2−10....................................

e. High Pressure Switch (HP1) 2−10......................................................

2.3.8 Condenser Coil 2−10...................................................................

2.3.9 Ambient Air Temperature Sensor (AAT) 2−10..............................................

2.3.10 Filter-Drier 2−10.......................................................................

2.3.11 Receiver 2−10.........................................................................

2.4 EVAPORATOR SECTION 2−10.............................................................

2.4.1 Evaporator Coil 2−10...................................................................

2.4.2 Electronic Expansion Valve (EVXV) 2−10..................................................

2.4.3 Heat Exchanger 2−10...................................................................

2.4.4 Compressor Suction Modulation Valve (CSMV) 2−10........................................

2.4.5 Evaporator Switches, Transducers and Sensors 2−10.......................................

a. Evaporator Outlet Pressure Transducer (EVOP) 2−10.....................................

b. Evaporator High Temperature Switch (1EVHTS) 2−10.....................................

c. Evaporator Outlet Temperature Sensor (EVOT) 2−10.....................................

d. Defrost Termination Temperature Sensor (1DTT) 2−10....................................

e. Return Air Temperature Sensor (1RAT) 2−10............................................

f. Supply Air Temperature Sensor (1SAT) 2−11............................................

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2.5 SYSTEM OPERATING CONTROLS AND COMPONENTS 2−11.................................

2.5.1 Multiple Languages 2−11................................................................

2.5.2 Automatic Start-Stop 2−11..............................................................

2.5.3 Special Features 2−11..................................................................

2.5.4 Component Description And Location 2−11................................................

a. Control Module 2−11.................................................................

b. Main Display, MessageCenter & Indicator Lights 2−13....................................

c. Switch Board 2−14...................................................................

d. Keypad 2−14........................................................................

2.6 ELECTRONIC MODULES 2−15.............................................................

2.6.1 Overload Ground Fault Module (OGF) 2−15...............................................

2.6.2 Phase Reversal Module (PRM) 2−15.....................................................

2.7 OPTIONS 2−15...........................................................................

2.7.1 Light Bar 2−15.........................................................................

2.7.2 Remote Switch(es) 2−15................................................................

2.7.3 Remote Temperature Sensors 2−16......................................................

2.7.4 Remote Control Panel 2−16.............................................................

2.8 ENGINE DATA 2−16.......................................................................

2.9 COMPRESSOR DATA 2−17................................................................

2.10 REFRIGERATION SYSTEM DATA 2−17......................................................

2.11 ELECTRICAL DATA 2−17...................................................................

2.12 COMPONENT RESISTANCE & CURRENT DRAW DATA 2−18..................................

2.13 SAFETY DEVICES 2−19...................................................................

2.14 REFRIGERANT CIRCUIT DURING COOLING 2−20...........................................

2.15 REFRIGERANT CIRCUIT - HEATING AND DEFROSTING 2−20................................

OPERATION 3−1.................................................................................

3.1 STARTING - ENGINE OPERATION 3−1.....................................................

3.2 STARTING - STANDBY OPERATION 3−2...................................................

3.3 SELF TEST 3−4..........................................................................

3.4 PRETRIP 3−5............................................................................

3.5 CHANGING SET POINT 3−8..............................................................

3.6 START-STOP OPERATION 3−9............................................................

3.7 CONTINUOUS OPERATION 3−10...........................................................

3.8 SLEEP MODE 3−11.......................................................................

3.9 MANUAL DEFROST 3−13..................................................................

3.10 TRIP START 3−14.........................................................................

3.11 VIEW ACTIVE ALARMS 3−15...............................................................

3.12 VIEW INACTIVE ALARMS 3−16.............................................................

3.13 UNIT DATA 3−17..........................................................................

3.14 VIEW HOUR METERS 3−20................................................................

3.15 FUNCTIONAL PARAMETERS 3−21.........................................................

3.16 LANGUAGE SELECTION 3−25.............................................................

3.17 INTELLISET 3−26.........................................................................

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3.18 STOPPING UNIT 3−29.....................................................................

3.19 DataLink DATA RECORDER 3−30...........................................................

3.19.1 Microprocessor Information 3−30.........................................................

3.19.2 Data Recording 3−30...................................................................

3.19.3 Data Downloading 3−30.................................................................

3.19.4 DataLink Data Recorder Power-Up 3−30..................................................

3.20 OPTIONS 3−31...........................................................................

3.20.1 DataTrak 3−31.........................................................................

3.20.2 Remote Control Panel 3−32..............................................................

a.Starting Unit with Remote Control Panel 3−33.............................................

b. Changing Set Point With Remote Control Panel 3−33......................................

c.Lock / Unlock the Remote Control Panel 3−34.............................................

d. Pre-setting Set Point With Remote Control Panel 3−34....................................

e. Removing Pre-Set Set Points With Remote Control Panel 3−35.............................

ENGINE/STANDBY/TEMPERATURE CONTROL 4−1.................................................

4.1 INTRODUCTION 4−1.....................................................................

4.2 ENGINE/STANDBY OPERATION 4−1.......................................................

4.2.1 Standby Start-Up 4−1..................................................................

4.2.2 Engine Start-Up 4−1...................................................................

4.2.3 Transition To High Speed 4−2...........................................................

4.3 TEMPERATURE CONTROL 4−2...........................................................

4.3.1 Temperature Determination 4−2.........................................................

4.3.2 Perishable And Frozen Set Point Ranges. 4−3............................................

4.3.3 Pull Down/Pull-Up 4−3.................................................................

4.3.4. Defrost 4−3..........................................................................

4.3.5. Overrides 4−3........................................................................

4.4 START-STOP OPERATION 4−3............................................................

4.4.1 Start-Stop Configuration 4−3............................................................

4.4.2 Stop Parameters 4−4..................................................................

1. It has run for the selected Minimum Run Time 4−4......................................

2. The engine coolant temperature has warmed 4−4.......................................

3. The battery is fully charged - Voltage 4−4..............................................

4. The battery is fully charged - Amperage 4−4............................................

5. The compartment temperature requirement is satisfied 4−4...............................

4.4.3 Re-Start Parameters 4−5...............................................................

1. Engine coolant temperature drops below selected microprocessor Configuration value 4−5...

2. Battery voltage falls below selected microprocessor Configuration value 4−5................

3. The Maximum Off Time has expired 4−5...............................................

4. The Minimum Off Time has expired 4−5................................................

5. Compartment temperature has exceeded the Override Functional Parameter value 4−5......

4.5 CONTINUOUS OPERATION 4−5...........................................................

4.5.1. Introduction 4−5......................................................................

4.5.2. Continuous Operation 4−5..............................................................

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4.6 DEFROST 4−8...........................................................................

4.6.1 Defrost Initiation And Start 4−8...........................................................

a. Defrost based on coil condition 4−8....................................................

b. Defrost based on time: 4−8...........................................................

4.6.2 Defrost Modes 4−8.....................................................................

a. Normal Defrost Mode 4−8............................................................

b. Natural Defrost Mode 4−8............................................................

4.6.3 Defrost Termination 4−8.................................................................

4.7. USER SELECTED OVERRIDE OPERATION 4−9.............................................

4.7.1 Supply Air Limit Control 4−9............................................................

4.7.2 Temperature Range Lock 1 & 2 4−10.....................................................

4.7.3 ProductShield 4−11.....................................................................

4.8. PREPROGRAMMED SOFTWARE OVERRIDES. 4−13.........................................

4.8.1 Cargo Protect Mode. 4−13..............................................................

4.8.2 Compressor Minimum Operating Time 4−13...............................................

4.8.3 Engine Speed Overrides 4−13...........................................................

4.8.4 Unloader Control Overrides 4−14.........................................................

4.8.5 Defrost Safety Override 4−16............................................................

MICROPROCESSOR INTERFACE 5−1..............................................................

5.1 INTERFACE METHODS 5−1...............................................................

5.2 TECHNICIAN INTERFACE 5−1............................................................

5.2.1 Configuration Mode 5−2................................................................

5.2.2 Component Test Mode 5−2.............................................................

5.2.3 Service Mode 5−3.....................................................................

5.3 PC MODE 5−3...........................................................................

5.4 PC CARDS 5−4..........................................................................

5.4.1 Handling PC Cards 5−4................................................................

5.4.2 Program PC Card 5−5.................................................................

5.4.3 Configuration PC Card 5−6.............................................................

5.4.4 Option PC Card 5−6...................................................................

5.4.5 Download PC Card 5−6................................................................

5.5 REEFERMANAGER & REPORTS 5−6......................................................

5.5.1 Introduction 5−6......................................................................

a. ReeferManager 5−7.................................................................

b. Reports 5−7........................................................................

c. Connecting Computer and Microprocessor: 5−7.........................................

5.6 MICROPROCESSOR DISPLAY DIAGNOSTICS 5−8..........................................

5.7 MICROPROCESSOR REPLACEMENT & SETUP 5−8........................................

5.7.1 Pre-Replacement Steps 5−9............................................................

5.7.2 Microprocessor Replacement 5−9.......................................................

5.7.3 Microprocessor Setup 5−10..............................................................

5.7.4 Configurations Via Keypad 5−11.........................................................

5.7.5 Functional Parameters Via Keypad 5−11..................................................

5.7.6 DataLink Data Recorder Via ReeferManager 5−11..........................................

5.7.7 Microprocessor Final Checkout 5−11.....................................................

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TABLE OF CONTENTS − Continued

PARAGRAPH NUMBER Page

MESSAGECENTER 6−1...........................................................................

6.1 MESSAGECENTER MESSAGES 6−1.......................................................

ALARM TROUBLESHOOTING 7−1.................................................................

7.1 INTRODUCTION 7−1.....................................................................

7.2 NOTES 7−2..............................................................................

7.3 DRIVER / OPERATOR ALARMS 7−3..........................................................

1 LOW FUEL LEVEL WARNING 7−3.....................................................

2 LOW ENGINE OIL LEVEL WARNING 7−3...............................................

7.4 SHUTDOWN ALARMS 7−4..................................................................

11 LOW ENGINE OIL PRESSURE 7−4....................................................

12 HIGH COOLANT TEMPERATURE 7−5.................................................

13 HIGH DISCHARGE PRESSURE (ALARM 75 WILL ALSO ACTIVATE) 7−7..................

14 HIGH A/C AMPS 7−8.................................................................

15 BATTERY VOLTAGE TOO HIGH 7−9...................................................

16 BATTERY VOLTAGE TOO LOW 7−10...................................................

17 HIGH COMP DISCHARGE TEMP 7−11..................................................

18 LOW REFRIGERANT PRESSURE 7−12.................................................

19 LOW FUEL SHUTDOWN 7−14..........................................................

20 MAXIMUM COMPRESSOR ALARMS 7−15...............................................

21 TECHNICIAN RESET REQUIRED 7−15..................................................

22 LOW SUCTION SUPERHEAT 7−16.....................................................

23 A/C CURRENT OVER LIMIT 7−18.......................................................

27 HIGH SUCTION PRESSURE 7−20......................................................

28 CHECK REFRIGERATION SYSTEM 7−21...............................................

7.5 START UP / ENGINE ALARMS 7−22...........................................................

30 FAILED TO RUN MINIMUM TIME 7−22..................................................

31 FAILED TO START - AUTO MODE 7−23.................................................

34 ENGINE FAILED TO STOP 7−25........................................................

35 CHECK STARTER CIRCUIT 7−26.......................................................

36 CHECK COOLANT TEMPERATURE 7−27...............................................

37 CHECK LOW SPEED RPM 7−28........................................................

38 CHECK HIGH SPEED RPM 7−29.......................................................

39 CHECK ENGINE RPM 7−31............................................................

40 CHECK GLOW PLUGS (This alarm applies to the Intake Air Heater) 7−33....................

41 ENGINE STALLED 7−34...............................................................

7.6 WARNING / STATUS ALARMS 7−36...........................................................

51 ALTERNATOR NOT CHARGING (This alarm applies to the Battery Charger) 7−36.............

53 BOX TEMP OUT OF RANGE 7−37......................................................

54 DEFROST NOT COMPLETE 7−39......................................................

55 CHECK DEFROST AIR SWITCH 7−40...................................................

57 CHECK REMOTE SWITCH 1 (REMS1) 7−41.............................................

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58 CHECK REMOTE SWITCH 2 (REMS2) 7−42.............................................

59 DATALOGGER (DataLink data recorder) NOT RECORDING 7−43...........................

60 DATALOGGER (DataLink data recorder) TIME WRONG 7−44...............................

61 DOOR OPEN (DS1) 7−45..............................................................

7.7 ELECTRICAL ALARMS 7−46..................................................................

71 BAD F2 OR F3 FUSE 7−46.............................................................

73 NO A/C POWER-CHECK POWER CORD 7−47...........................................

75 COMP MOTOR OVERLOAD 7−48......................................................

76 CONDENSER MOTOR OVERHEATED 7−49.............................................

77 EVAP MOTOR OVERHEATED 7−51.....................................................

84 CHECK REMOTE ALARM LIGHT 7−53..................................................

85 CHECK UL1 CIRCUIT 7−54............................................................

86 CHECK UL2 CIRCUIT 7−55............................................................

89 CHECK REMOTE AUTO LIGHT (Light Bar) 7−56..........................................

91 CHECK 1HTCON1 RELAY COIL 7−56...................................................

92 CHECK 1HTCON2 RELAY COIL 7−57...................................................

93 CHECK START UP BUZZER 7−58......................................................

94 CHECK COMP CONTACTOR 1 7−58....................................................

95 CHECK CDCON RELAY COIL 7−59.....................................................

96 CHECK GENCONR RELAY COIL 7−60..................................................

98 CHECK HIGH TEMP THERMOSTAT 7−61...............................................

99 CHECK STANDBY CONTACTOR 7−62..................................................

100 OVERLOAD/GROUND FAULT 7−63.....................................................

109 CHECK 1EVCON RELAY COIL 7−64....................................................

7.8 SENSOR ALARMS 7−65......................................................................

121 CHECK AMBIENT AIR SENSOR 7−65...................................................

122 CHECK RETURN AIR SENSOR 7−66...................................................

123 CHECK SUPPLY AIR SENSOR 7−67....................................................

124 CHECK DEFROST TERM 1 SENSOR 7−68..............................................

125 CHECK COMP DISCHARGE SENSOR 7−69.............................................

126 CHECK FUEL SENSOR CIRCUIT 7−69..................................................

127 CHECK SUCTION TEMP SENSOR 7−70................................................

128 LOW/UNBALANCED A/C AMPS 7−70...................................................

129 CHECK ENG COOLANT SENSOR 7−71.................................................

130 CHECK ENGINE RPM SENSOR 7−72...................................................

131 CHECK EVAP TEMP SENSOR 7−73....................................................

133 CHECK REMOTE TEMP SENSOR 1 7−74...............................................

134 CHECK REMOTE TEMP SENSOR 2 7−74...............................................

135 CHECK REMOTE TEMP SENSOR 3 7−74...............................................

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TABLE OF CONTENTS − Continued

PARAGRAPH NUMBER Page

7.9 PRETRIP ALARMS 7−75.....................................................................

P141 PRETRIP STOPPED BY USER 7−75....................................................

P144 CHECK UL1 CIRCUIT 7−75............................................................

P145 CHECK SPEED SOL CIRCUIT 7−76.....................................................

P151 CHECK GLOW PLUG CIRCUIT (This applies to the Intake Air Heater) 7−77..................

P152 CHECK FUEL SOLENOID CIRC 7−77...................................................

P153 CHECK RETURN AIR SENSOR 7−78...................................................

P154 CHECK SUPPLY AIR SENSOR 7−78....................................................

P155 CHECK COOLANT TEMP SENSOR 7−78................................................

P156 CHECK BATTERY VOLTS 7−78.........................................................

P157 CHECK BATTERY CURRENT 7−79.....................................................

P158 CHECK AMBIENT AIR SENSOR 7−79...................................................

P159 CHECK DEFROST TERM 1 SENSOR 7−80..............................................

P160 CHECK DISCHARGE TEMP SENSOR 7−80..............................................

P161 CHECK SUCTION TEMP SENSOR (CST) 7−80...........................................

P164 CHECK UL2 CIRCUIT 7−80............................................................

P174 CHECK LOW SPEED RPM 7−81.......................................................

P175 CHECK HIGH SPEED RPM 7−82.......................................................

P177 CHECK EVAP SUPERHEAT 7−84.......................................................

P178 CHECK UL1 7−85.....................................................................

P180 CHECK SUCTION MOD VALVE 7−86....................................................

P186 CHECK EVAP OUTLET TEMP 7−87.....................................................

P187 CHECK HEATER 1 CIRCUIT 7−87......................................................

P188 CHECK HEATER 2 CIRCUIT 7−89......................................................

P189 CHECK EVAPORATOR FAN MOTOR 7−91...............................................

P190 CHECK CONDENSER FAN MOTOR 7−93...............................................

P191 CHECK UL2 7−94.....................................................................

P206 CHECK CONDENSER FAN CIRCUIT 7−95...............................................

P207 CHECK COMPRESSOR CONTACT CIRC 7−95...........................................

P208 CHECK GENERATOR CONT CIRC 7−96................................................

P209 CHECK STANDBY CONT CIRCUIT 7−97................................................

7.10 MAINTENANCE ALARMS 7−98..............................................................

223 ENGINE MAINTENANCE DUE 7−98.....................................................

224 STANDBY MAINTENANCE DUE 7−98...................................................

225 GENERAL MAINTENANCE DUE 7−99...................................................

226 SERVICE SOON-PM #1 DUE 7−99......................................................

227 SERVICE SOON-PM #2 DUE 7−100......................................................

228 SERVICE SOON-PM #3 DUE 7−100......................................................

229 SERVICE SOON-PM #4 DUE 7−101......................................................

230 SERVICE SOON-PM #5 DUE 7−101......................................................

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7.11 MICROPROCESSOR ALARMS 7−102..........................................................

232 SETPOINT ERROR 7−102..............................................................

233 MODEL # ERROR 7−102................................................................

237 FUNCTION PARAMETERS ERROR 7−103................................................

238 CONFIGURATIONS 1 ERROR 7−104.....................................................

242 DIS PRESS CALIBRATE ERROR 7−105..................................................

243 SUCTION/EVAP CALIBRATE ERROR 7−106..............................................

245 CANNOT SAVE SETTING 7−107.........................................................

246 EEPROM WRITE FAILURE 7−107........................................................

248 CONFIGURATION MODE / HP2 ERROR 7−108............................................

249 MICROPROCESSOR ERROR 7−109.....................................................

SERVICE 8−1....................................................................................

8.1 SECTION LAYOUT 8−1...................................................................

8.2 SCHEDULED MAINTENANCE 8−1.........................................................

8.3 PRE TRIP INSPECTION 8−1..............................................................

8.4 EXTERNAL SURFACE SERVICE 8−5.......................................................

8.4.1 Grille Insert Removal 8−5..............................................................

8.4.2 Surround Removal 8−5................................................................

8.4.3 Door Latch Maintenance And Replacement 8−6...........................................

a. Door Latch Maintenance 8−6.........................................................

b. Cable Replacement 8−6.............................................................

8.4.4 Display & Keypad Assembly 8−6........................................................

a. Disassembly 8−6...................................................................

b. Reassembly 8−7....................................................................

8.5 ENGINE AND ENGINE RELATED SYSTEMS SERVICE 8−7...................................

8.5.1 Fuel System 8−7......................................................................

8.5.2 Priming The Fuel System 8−8..........................................................

8.5.3 Mechanical Fuel Pump Screen 8−8......................................................

8.5.4 Electric Fuel Pump Screen 8−9.........................................................

8.5.5 Fuel Filter 8−9........................................................................

8.5.6 Fuel Level Sensor (FLS) 8−9...........................................................

8.5.7 Fuel Heater 8−10......................................................................

8.5.8 Engine Oil And Oil Filter 8−10............................................................

a. To Check The Engine Oil Level: 8−10...................................................

b. To Change Engine Oil: 8−11...........................................................

c. To Change Engine Oil Filter: 8−11......................................................

8.5.9 Air Cleaner 8−11.......................................................................

8.5.10 Intake Air Heater 8−12..................................................................

a. Troubleshooting The Intake Air Heater (IAH) 8−12........................................

b. Replacing The Intake Air Heater 8−12..................................................

8.5.11 Speed Control System 8−12.............................................................

8.5.12 Cooling System 8−13...................................................................

a. Cleaning and Flushing 8−13...........................................................

b. Radiator Replacement 8−13...........................................................

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8.5.13 Water Pump V-Belt 8−14................................................................

8.5.14 Crankcase Breather 8−14...............................................................

8.6 REFRIGERANT SYSTEM SERVICE 8−14....................................................

8.6.1 Refrigerant System Service Connections 8−14.............................................

8.6.2 Servicing The Refrigerant Charge 8−15...................................................

a. Checking Charge Level 8−15..........................................................

b. Checking For Noncondensibles 8−15...................................................

c. Removing Charge 8−15...............................................................

d. Pumping Down The Low Side 8−16.....................................................

e. Pumping Down The Compressor 8−16..................................................

f. Adjusting The Charge Level 8−16......................................................

g. Adding a Complete Charge 8−17.......................................................

8.6.3 Leak Checking 8−17....................................................................

a. Leak Checking a Charged System 8−17.................................................

b. Leak Checking a System Without Charge 8−17..........................................

c. Leak Checking With Low Side Pumped Down 8−18.......................................

d. Leak Checking Compressor 8−18......................................................

8.6.4 Evacuation And Dehydration 8−19........................................................

a. Evacuation of the Complete System 8−19...............................................

b. Evacuation of the Low Side 8−20.......................................................

c. Evacuation of the Compressor 8−20....................................................

8.7 COMPRESSOR AND UNLOADER SERVICE 8−20............................................

8.7.1 Repair or Replacement Determination 8−20................................................

8.7.2 Removal and Replacement of Compressor 8−21...........................................

8.7.3 Cylinder Head and Valve Plate Service 8−22...............................................

8.7.4 Oil Pump And Bearing Head 8−23........................................................

8.7.5 Compressor Oil Level 8−24..............................................................

a. Checking Compressor Oil Level 8−24...................................................

b. Adding Oil With Compressor In System 8−24............................................

c. Removing Oil From The Compressor 8−25..............................................

8.7.6 Unloaders 8−25........................................................................

a. Unloader Checkout procedure 8−25....................................................

b. Unloader Coil Replacement 8−25.......................................................

c. Replacing Unloader Valve Internal Parts 8−26............................................

d. Unloader Valve Replacement 8−26.....................................................

8.8 REFRIGERANT SYSTEM COMPONENT SERVICE 8−26......................................

8.8.1 Evaporator Coil 8−26...................................................................

8.8.2 Condenser Coil 8−27...................................................................

a. Cleaning 8−27.......................................................................

b. Condenser Coil Replacement 8−27.....................................................

8.8.3 Filter-Drier 8−28.......................................................................

a. Check Filter-Drier 8−28...............................................................

b. Replace Filter-Drier 8−28..............................................................

8.8.4 Replacing Receiver Sight Glass Or Fusible Plug 8−28.......................................

8.8.5 Compressor Suction Modulation Valve (CSMV) 8−28........................................

8.8.6 Electronic Expansion Valve 8−29.........................................................

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8.8.7 High Pressure Switch 8−31..............................................................

8.8.8 Pressure Transducers 8−31.............................................................

8.8.9 Defrost Air Switch 8−31.................................................................

8.9 ELECTRICAL SYSTEM COMPONENT SERVICE 8−32........................................

8.9.1 Megohmmeter Test Procedure 8−32......................................................

8.9.2 Phase Reversal Module (PRM) 8−33.....................................................

8.9.3 Light Bar 8−34.........................................................................

8.9.4 Overload Ground Fault (OGF) 8−34......................................................

a. Operation 8−34......................................................................

b. OGF Checkout Procedure 8−34........................................................

8.9.5 Evaporator Heaters 8−34................................................................

8.9.6 Evaporator Blower & Motor 8−35.........................................................

8.9.7 Condenser Fan Assemblies 8−36........................................................

8.9.8 Battery Charger (BTYC) 8−37............................................................

8.9.9 Generator (GEN) 8−37..................................................................

a. Preventive Maintenance and Operating Precautions 8−37.................................

b. Generator Removal 8−38.............................................................

c. Generator Assembly Procedure 8−40...................................................

8.9.10 Sensor Checkout 8−41..................................................................

UNIT TROUBLESHOOTING 9−1...................................................................

9.1 ENGINE 9−1.............................................................................

9.1.1 Engine Will Not Start 9−1..............................................................

9.1.2 Engine Starts Then Stops 9−2..........................................................

9.1.3 Engine Will Not Shut Off 9−2...........................................................

9.1.4 Starter Motor Malfunction 9−2..........................................................

9.1.5 Malfunction In The Engine Starting Circuit 9−2............................................

9.1.6 Miscellaneous Engine Troubleshooting 9−3...............................................

9.2 BATTERY CHARGER 9−3.................................................................

9.3 GENERATOR 9−4........................................................................

9.4 REFRIGERATION / TEMPERATURE CONTROL 9−4.........................................

9.4.1 Unit Will Not Cool 9−4.................................................................

9.4.3 Unit Operates Long Or Continuously In Cooling 9−4.......................................

9.4.4 Unit Will Not Terminate Cooling 9−5.....................................................

9.4.6 Unit Will Not Terminate Heating 9−5.....................................................

9.4.7 Defrost Cycle Malfunction 9−5..........................................................

9.4.8 Abnormal Pressure 9−6................................................................

9.4.9 Abnormal Noise 9−6...................................................................

9.4.10 No Evaporator Air Flow Or Restricted Air Flow 9−6........................................

9.4.11 Evaporator Expansion Valve (EVXV) Malfunction 9−7......................................

9.4.12 Compressor Suction Modulation Valve (CSMV) Malfunction 9−7.............................

9.5 Speed Control System Diagnostics 9−8......................................................

9.6 Microprocessor Diagnostics 9−13............................................................

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PARAGRAPH NUMBER Page

WIRING 10−1......................................................................................

10.1 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED

ENGINE/OFF/STANDBY 10−1..............................................................

10.2 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED

START/RUN-OFF 10−6....................................................................

10.3 CONTROL BOX INTERIOR SPLICE POINTS FOR UNITS WITH A MAIN POWER SWITCH

LABELED ENGINE/OFF/STANDBY 10−11.....................................................

10.4 CONTROL BOX INTERIOR SPLICE POINTS FOR UNITS WITH A MAIN POWER SWITCH

LABELED START/RUN-OFF 10−12...........................................................

10.5 DISPLAY TEST POINTS 10−13..............................................................

10.6 WIRING SCHEMATICS 10−13...............................................................

xi

62−11389

LIST OF ILLUSTRATIONS

FIGURE NUMBER Page

Figure 1−1 Lockout/Tagout 1−1....................................................................

Figure 2−1 Front View - Refrigeration System Components 2−2........................................

Figure 2−2 Road Side/Rear Compressor View - Refrigeration System Components 2−3...................

Figure 2−3 Front View - Engine Components 2−4.....................................................

Figure 2−4 Evaporator Section - Grille Removed 2−5..................................................

Figure 2−5 Control Box 2−6........................................................................

Figure 2−6 Engine Speed Control Unit 2−7..........................................................

Figure 2−7 Compressor Cylinder Head Unloaded 2−8.................................................

Figure 2−8 Compressor Cylinder Head Loaded 2−9...................................................

Figure 2−9 Control Module 2−12.....................................................................

Figure 2−10 Display And Keypad Assembly 2−13......................................................

Figure 2−11 OGF Module 2−15......................................................................

Figure 2−12 PRM Module 2−15.....................................................................

Figure 2−13 Light Bar 2−15.........................................................................

Figure 2−14 Refrigerant Circuit 2−21.................................................................

Figure 4−1 Auto Start Sequence 4−1................................................................

Figure 4−2 Continuous Operation Switch Points with Eco Mode set to NO 4−6...........................

Figure 4−3 Continuous Operation Switch Points with Eco Mode set to YES 4−7..........................

Figure 4−4 Range Lock Settings - Non Overlapping 4−10...............................................

Figure 4−5 Range Lock Settings - Overlapping 4−11...................................................

Figure 4−6 Evaporator Pressure Chart 4−15..........................................................

Figure 5−1 Technicians Interface Connection 5−1.....................................................

Figure 5−2 PC Mode Connection 5−4...............................................................

Figure 5−3 PC Card Interaction 5−5................................................................

Figure 5−4 ReeferManager & Reports Connection 5−7................................................

Figure 5−5 Connector 6MP Connections 5−8.........................................................

Figure 5−6 Display Test Points 5−8.................................................................

Figure 8−1 Grille Insert Removal And Door Latch Maintenance 8−5.....................................

Figure 8−2 Surround Removal 8−6.................................................................

Figure 8−3 Door Latch Cable Removal 8−6..........................................................

Figure 8−4 Display and Keypad Assembly 8−7.......................................................

Figure 8−5 Fuel System Diagram 8−8...............................................................

Figure 8−6 Fuel Bleed Components 8−8.............................................................

Figure 8−7 Mechanical Fuel Pump 8−9..............................................................

Figure 8−8 Electric Fuel Pump 8−9.................................................................

Figure 8−9 Fuel Level Sensor 8−10..................................................................

Figure 8−10 Engine Oil Level 8−11..................................................................

Figure 8−11 Engine Oil Flow Diagram 8−11...........................................................

Figure 8−12 Oil Drain Tool 8−11.....................................................................

Figure 8−13 Intake Air Heater 8−12..................................................................

Figure 8−14 Electronic Speed Control Components 8−12...............................................

Figure 8−15 Condenser And Radiator Assemblies 8−13................................................

Figure 8−16 Water Pump V-Belt 8−14................................................................

62−11389

xii

LIST OF ILLUSTRATIONS − Continued

FIGURE NUMBER Page

Figure 8−17 Engine Crankcase Breather 8−14........................................................

Figure 8−18 Refrigerant System Service Equipment 8−15...............................................

Figure 8−19 Compressor - model 06D 8−21...........................................................

Figure 8−20 Cylinder Head & Valve Plate 8−22........................................................

Figure 8−21 Checking Suction Valve 8−23............................................................

Figure 8−22 Oil Pump and Bearing Head Assembly 8−23...............................................

Figure 8−23 Oil Pump 8−24.........................................................................

Figure 8−24 Unloader Coil 8−25.....................................................................

Figure 8−25 Condenser/Radiator Assembly 8−27......................................................

Figure 8−26 Suction modulation valve (CSMV) 8−28...................................................

Figure 8−27 CSMV Coil 8−29.......................................................................

Figure 8−28 Electronic expansion valve 8−30.........................................................

Figure 8−29 Electronic Expansion Valve 8−30.........................................................

Figure 8−30 Typical Setup for Testing High Pressure Switch 8−31........................................

Figure 8−31 Defrost Air Switch Test Setup 8−32.......................................................

Figure 8−32 Megohmmeter Connection to Ground Plate 8−33...........................................

Figure 8−33 High Voltage Contactors 8−33...........................................................

Figure 8−34 Light Bar Connections 8−34.............................................................

Figure 8−35 Overload Ground Fault Connections 8−34.................................................

Figure 8−36 Evaporator Blower Assembly 8−35.......................................................

Figure 8−37 Condenser Fan Assembly 8−36..........................................................

Figure 8−38 Generator Assembly 8−40...............................................................

Figure 8−39 Bolt Hole Pattern For Bell Housing and Crankshaft 8−40.....................................

Figure 9−1 ENSCU Diagnostic Tree - 1 Long, 1 Short LED Code 9−9...................................

Figure 9−2 ENSCU Diagnostic Tree - 2 Long, 1 Short LED Code 9−10...................................

Figure 9−3 ENSCU Diagnostic Tree - 2 Long, 3 Short LED Code 9−11...................................

Figure 9−4 ENSCU Diagnostic Tree - 2 Long, 7 Short LED Code 9−12...................................

Figure 9−5 Micro Diagnostic Tree - Condition 1 - Main Power Switch On - Unit Does Not Operate 9−14.......

Figure 9−6 Micro Diagnostic Tree - Condition 2 - Main Power Switch On - Unit Operates But Not Properly 9−15

Figure 9−7 Micro Diagnostic Tree - Condition 3 - Main Power Switch Off - Unit Fails To Stop 9−16............

Figure 9−8 Micro Diagnostic Tree - Condition 4 - Unit Will Not Run In High Speed 9−17.....................

Figure 9−9 Micro Diagnostic Tree - Condition 5 - Unit Will Not Run In Low Speed 9−18.....................

Figure 9−10 Micro Diagnostic Tree - Condition 6 - DataLink Data Recorder Data Download

Problems When Using ReeferManager and a Download Cable. Data File Analysis

Problems Using Reports 9−19..........................................................

Figure 9−11 Microprocessor Diagnostic Tree - Condition 7 - PC Card Problems 9−20.......................

Figure 9−12 Micro Diagnostic Tree - Condition 8 - Programming Problems With PC Cards 9−21.............

xiii

62−11389

LIST OF TABLES

TABLE NUMBER Page

Table 2-1 Model Chart 2−1.........................................................................

Table 2-2 Additional Support Manuals 2−1............................................................

Table 3-1 Unit Data 3−17............................................................................

Table 3-2 Functional Parameters 3−22................................................................

Table 4−1 Intake Air Heat Time 4−2..................................................................

Table 5−1 Component Test 5−3.....................................................................

Table 5−2 Microprocessor Configurations 5−12.........................................................

Table 8−1 Maintenance Schedule 8−2................................................................

Table 8−2 Pre Trip Inspection 8−4...................................................................

Table 8−3 CSMV Connections 8−28...................................................................

Table 8−4 EVXV Connections 8−30...................................................................

Table 8−5 Sensor Resistance 8−42...................................................................

Table 8−6 Sensor Resistance (CDT) 8−43.............................................................

Table 8−7 Temperature Pressure Chart 8−44...........................................................

Table 9−1 ENSCU LED Fault Chart 9−8..............................................................

Table 9−2 Microprocessor Diagnostics 9−13...........................................................

62−11389

xiv

SECTION 1 − SAFETY PRECAUTIONS

PARAGRAPH NUMBER Page

1.1 SAFETY PRECAUTIONS 1−1.........................................................

1.2 SPECIFIC WARNING AND CAUTION STATEMENTS 1−2.................................

1.3 SAFETY DECALS 1−6................................................................

1

1

62−11389

SECTION 1

SAFETY PRECAUTIONS

1.1 SAFETY PRECAUTIONS

Your Carrier Transicold refrigeration unit has been
designed with the safety of the operator in mind. During
normal operation, all moving parts are fully enclosed to
help prevent injury. During all pre-trip inspections, daily
inspections, and problem troubleshooting, you may be
exposed to moving parts. Please stay clear of all moving
parts when the unit is in operation and when the Main
Power Switch is not in the OFF position.

CAUTION

Under no circumstances should a techni­cian electrically probe the microprocessor
at any point, other than the connector termi­nals where the harness attaches. Micropro­cessor components operate at different
voltage levels and at extremely low current
levels. Improper use of voltmeters, jumper
wires, continuity testers, etc. could perma­nently damage the microprocessor.

CAUTION

Most electronic components are suscepti­ble to damage caused by electrical static
discharge (ESD). In certain cases, the hu­man body can have enough static electric­ity to cause resultant damage to the compo­nents by touch. This is especially true of the
integrated circuits found on the micropro­cessor.

Refrigerants

The refrigerant contained in the refrigeration system of
this unit can cause frostbite, severe burns, or blindness
when in direct contact with the skin or eyes. For this
reason (and because of legislation regarding the
handling of refrigerants) we recommend that you
contact your nearest Carrier Transicold authorized
repair facility whenever service of the refrigerant system
is required.

Battery

This unit is equipped with a lead-acid type battery. The
battery normally vents small amounts of flammable
hydrogen gas. Do not smoke when checking the battery.
A battery explosion can cause serious physical harm
and/or blindness.

Standby Power

Be aware of HIGH VOLTAGE supplied at the power
plug. Even with the unit off, power is present from the
plug to the inside of the control box. Whenever practical,
disconnect the high voltage source when performing
service or maintenance procedures and lockout/tagout
the receptacle in accordance with your companies
procedures. The recommended lockout device (Carrier
part number 07−60129−00) is shown in Figure 1−1.

Automatic Start-Stop

Your refrigeration unit is equipped with auto-start in both
Start-Stop and Continuous Operation. The unit may
start at any time the Main Power Switch is not in the OFF
position. A buzzer will sound for 5 seconds before the
unit is started. When performing any check of the
refrigeration unit (e.g., checking the belt, checking the
oil), make certain that the Main Power Switch is in the
OFF position.

Engine Coolant

The engine is equipped with a pressurized cooling
system including a pressurized coolant bottle. Under
normal operating conditions, the coolant in the engine
and radiator is under high pressure and is very hot.
Contact with hot coolant can cause severe burns. Do
not remove the cap from a hot radiator or bottle. If the
cap must be removed, cover it with a rag and remove
very slowly in order to release the pressure without
spray.

Figure 1−1 Lockout/Tagout

1−1

62-11389

1.2 SPECIFIC WARNING AND CAUTION
STATEMENTS

WARNING

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 - warns against an immediate hazard which
WILL result in severe personal injury or death.

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

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

The following statements are specifically applicable to
this 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.

WARNING

Advance microprocessor equipped units
may start automatically at any time the Main
Power switch is not in the OFF position.
Also, the unit may be fitted with two way
communication equipment that will allow
starting of the unit from a remote location
even though the switch is in the OFF posi­tion.

Ensure the power plug is clean and dry
before connecting to any electrical outlet /
receptacle.

WARNING

Do not connect power plug to any electri­cal outlet without checking that it meets
the 460/3/ 60 and 30 Amp electrical
requirements of the unit.

WARNING

Always place the Main Power switch in
the OFF position and turn off the high
voltage power supply before disconnect­ing the high voltage power plug from the
unit.

WARNING

If the unit is in Standby Operation and
powered, voltage will be applied to high
voltage components (i.e. the fan motor con­tactor) and those components will operate
(i.e. the fan blades will turn) when those
components are energized using Compon­ent Test Mode.

WARNING

WARNING

Be aware of HIGH VOLTAGE supplied at the
power plug or from the generator. When
performing service or maintenance proced­ures: ensure any two way communication is
disabled in accordance with the manufac­turer’s instruction, ensure the Main Power
Switch is in the OFF position and, whenever
practical, disconnect the high voltage
source, lockout/tagout the receptacle and
disconnect the negative battery connec­tion. NEVER dis-assemble the generator:
HIGH MAGNETIC FIELD INSIDE! This field
can interfere with cardiac implants such as
pacemakers and defibrillators.

WARNING

Under no circumstances should ether or
any other starting aids be used to start
engine.

Do not toggle the Main Power switch out of
the OFF position when in PC Mode or the
unit will start.

WARNING

Do not remove the cap from a hot radiator or
bottle; if the cap must be removed, do so
very slowly in order to release the pressure
without spray.

WARNING

Caution and good electrical practices must
be used when working around and with
high voltage circuits.

WARNING

Disconnect batteries before doing any elec­trical welding on unit or chassis to which
unit is attached (trailer, container, rail car,
metal building, etc).

62-11389

1−2

WARNING

WARNING

Use the required protective eye wear and
clothing when working with solvents.

WARNING

Beware of moving poly V-belt and belt driv­en components.

WARNING

When working with belts, beware of pinch
points.

WARNING

Do not use a nitrogen cylinder without a
pressure regulator. Cylinder pressure is
approximately 2350 psig (159.9 bar). Do not
use oxygen in or near a refrigerant system
as an explosion may occur. (See
Figure 8−30)

Do not direct water or steam into the gener­ator openings. Do not allow any soap and
water solutions to enter the generator.

WARNING

Generators of this type should not be
“flashed.” Operation with external voltage
source or momentary shorting of leads will
damage the generator and may cause in­jury.

CAUTION

Under no circumstances should anyone at­tempt to repair the keypad, display or in­ternal control module components. Should
a problem develop with these components,
contact your nearest Carrier Transicold
dealer for replacement.

CAUTION

WARNING

Do not unscrew replacement compressor
lifting eyelet/blankoff plate mounting
capscrews all the way before breaking seal.
Entrapped pressure could result in injury.

WARNING

Do not unscrew cylinder head mounting
capscrews all the way before breaking seal.
Entrapped pressure could result in injury.

WARNING

Do not unscrew unloader enclosing tube
nut all the way before breaking seal.
Entrapped pressure could result in injury.

WARNING

Do not unscrew unloader valve body
mounting bolts all the way before breaking
seal. Entrapped pressure could result in
injury.

Use only ethylene glycol anti-freeze (with
inhibitors) in system as glycol by itself will
damage the cooling system. Always add
pre-mixed 50/50 anti-freeze and water to ra­diator / engine. Never exceed more than a
60% concentration of anti-freeze. Use a low
silicate anti-freeze meeting GM specifica­tions GM 6038M for standard life coolant or
use Texaco Havoline extended life coolant
or any other extended life coolant which is
Dexcool approved and has 5/150 (5 years /
150,000 miles) on the label.

CAUTION

Service Mode MUST be used whenever re­moving refrigerant charge, refrigerant leak
checking or evacuating.

CAUTION

The display and MessageCenter may be­have differently during the software loading
process, depending on the version of soft­ware currently in the microprocessor. DO
NOT INTERRUPT THE SOFTWARE INSTAL­LATION PROCESS ONCE IT HAS STARTED.
Also, do not place the Main Power switch in
the OFF position during the initial power up
following a software upgrade.

1−3

62-11389

CAUTION

CAUTION

Most electronic components are suscepti­ble to damage caused by electrical static
discharge (ESD). In certain cases, the hu­man body can have enough static electric­ity to cause resultant damage to the compo­nents by touch. This is especially true of the
integrated circuits found in the Advance mi­croprocessor.

CAUTION

Under no circumstances should a techni­cian electrically probe the microprocessor
at any point, other than the connector termi­nals where the harness attaches. Micropro­cessor components operate at different
voltage levels and at extremely low current
levels. Improper use of voltmeters, jumper
wires, continuity testers, etc. could perma­nently damage the microprocessor.

Do not over torque display & keypad pan
head screws. Torque all screws to 60 inlbs
(6.8 Nm).

CAUTION

Running the engine for an extended period
of time with the manual plunger up can
cause a priming pump failure

CAUTION

Torque fuel level sensor mounting screws
to 15 to 18 inch/pounds. DO NOT over tight­en, as little as 20 inch/pounds will damage
the sensor.

CAUTION

When changing oil filters, the new filters
should be primed (partially filled) with clean
oil if possible. If the filters are not primed,
the engine may operate for a period with no
oil supplied to the bearings.

CAUTION

When setting the microprocessor time,
ensure that the clock you are using is accur­ate. Also, some customers are located in
different time zones from the repair loca­tion. If you know the owners desired loca­tion time, enter that time. If you don’t, enter
the current time at your location.

CAUTION

DO NOT leave the circuit energized for the
full 5 minutes if full amperage is shown, as
the intake air heater element life will be
greatly shortened.

CAUTION

CAUTION

NEVER POUR COLD WATER INTO A HOT
ENGINE, however hot water can always be
added to a cold engine.

CAUTION

Only a refrigerant cylinder that has previ­ously been used with R404A should be con­nected to this refrigeration unit.

CAUTION

Only a refrigerant cylinder containing
R404A should be connected to this refriger­ation unit in order to pressurize the system.
However, dry nitrogen may be used to in­crease pressure. Any other gas or vapor will
contaminate the system and require addi­tional removal and evacuation.

Unit uses R404A and POE oil. The use of in­ert gas brazing procedures is mandatory for
all Carrier Transicold refrigeration units;
otherwise compressor failure will occur.
For more information Refer to Technical
Procedure 98-50553-00 Inert Gas Brazing

62-11389

CAUTION

Do not vapor charge R404A. Only liquid
charging through the liquid line service
valve is acceptable.

1−4

CAUTION

CAUTION

Ensure that thrust washer does not fall off
dowel pins while installing oil pump.

CAUTION

An overcharge of oil will reduce system ca­pacity and possibly cause internal com­pressor damage.

CAUTION

Use only Carrier Transicold approved Poly­ol Ester Oil (POE). Buy quantities of one gal­lon or less. When using this hygroscopic
oil, immediately reseal. Do not leave con­tainer of oil open or contamination will oc­cur.

CAUTION

Extreme care must be taken to ensure the
hose is immersed in the oil at all times.
Otherwise air and moisture will be drawn
into the compressor.

Do not bend the copper tubing on the con­denser coil when installing the new con­denser. Bend the unit tubing if tubes do not
align correctly.

CAUTION

Before connecting a megohmmeter, place
the Main Power switch in the OFF position.
Disconnect the high voltage source, lock­out/tagout the receptacle and disconnect
the negative battery connection. Isolate the
microprocessor by disconnecting all con­nectors and wires going to it. Observe Na­tional Electric Manufacturer’s Association
(NEMA) rules and test equipment manufac­turers instructions.

CAUTION

A mica shim (Carrier Transicold part num­ber 54-00630-25) must be installed before
removal of the generator. The generator is
to be removed as one piece, with the shim in
place. DO NOT attempt to remove the rotor
from the stator.

1−5

62-11389

1.3 SAFETY DECALS

THE RECEIVER KING VALVE
(LIQUID LINE SERVICE VALVE)
AND DISCHARGE SERVICE
VALVES MUST BE OPENED
BEFORE STARTING ENGINE

62-11389

62-03953-01

( NOTE: This tag is attached to the liquid line ser­vice valve and discharge service valve at assembly)

1−6

CONTAINS HOT SURFACES THAT WILL IGNITE COMBUSTIBLES
AND FLAMMABLE MATERIALS SUCH AS BIRD NESTS, LEAVES,
TREE LIMBS OR MAINTENANCE MATERIALS SUCH AS SHOP
RAGS. DO NOT OPERATE WITHOUT INSPECTION. FIRES AND
SERIOUS INJURIES MAY RESULT.

SAFETY INSTRUCTIONS

INSPECT UNIT DAILY PRIOR TO OPERATION. REMOVE ANY
COMBUSTIBLE FOREIGN MATERIAL. ENSURE FACTORY
INSTALLED ENCLOSURES AND PROTECTIVE EQUIPMENT ARE
IN PLACE AND IN WORKING CONDITION

62-11282-00 REV - & 62-11283-00 REV B

62-03957-00 & -01 High Voltage

62-03958-00 Heat Warning

SEPARATION OF GENERATOR

ROTOR AND STATOR WILL

CREATE A STRONG MAGNETIC

FIELD THAT CAN INTERFERE

WITH CARDIAC IMPLANTS

SUCH AS PACEMAKERS

AND DEFIBRILLATORS

62-10358-00 REV A

NOTE:
The unit may be equipped with a
DIESEL/OFF/STANDBY switch (DOES)
or a START/RUN-OFF switch (SROS).
The unit may start if the applicable
switch is not in the OFF position.

1−7

62-11389

62-11389

1−8

THIS UNIT CHARGED WITH

R-404A

CAUTION !

COMPRESSOR MUST BE CHARGED WITH

P.O.E. OIL ONLY: CTD P/N: 07-00317-00

MOBIL ARCTIC P.N: EAL63

CTD P.N: 62-03797-11

1−9

62-11389

SECTION 2 −UNIT DESCRIPTION

PARAGRAPH NUMBER Page

2.1 INTRODUCTION 2−1.................................................................

2.2 GENERAL DESCRIPTION 2−1.........................................................

2.3 CONDENSING SECTION 2−7.........................................................

2.3.1 Engine 2−7......................................................................

2.3.2 Engine Air System 2−7............................................................

2.3.3 Engine Controls: 2−7.............................................................

2.3.4 Generator (GEN) 2−7.............................................................

2.3.5 Compressor 2−7.................................................................

2.3.6 Unloaders 2−7...................................................................

2.3.7 Compressor Switches, Transducers and Sensors 2−9.................................

2.3.8 Condenser Coil 2−10...............................................................

2.3.9 Ambient Air Temperature Sensor (AAT) 2−10..........................................

2.3.10 Filter-Drier 2−10...................................................................

2.3.11 Receiver 2−10....................................................................

2.4 EVAPORATOR SECTION 2−10.........................................................

2.4.1 Evaporator Coil 2−10..............................................................

2.4.2 Electronic Expansion Valve (EVXV) 2−10.............................................

2.4.3 Heat Exchanger 2−10..............................................................

2.4.4 Compressor Suction Modulation Valve (CSMV) 2−10...................................

2.4.5 Evaporator Switches, Transducers and Sensors 2−10..................................

2.5 SYSTEM OPERATING CONTROLS AND COMPONENTS 2−11............................

2.5.1 Multiple Languages 2−11...........................................................

2.5.2 Automatic Start-Stop 2

2.5.3 Special Features 2−11.............................................................

2.5.4 Component Description And Location 2−11...........................................

2.6 ELECTRONIC MODULES 2−15.........................................................

2.6.1 Overload Ground Fault Module (OGF) 2−15...........................................

2.6.2 Phase Reversal Module (PRM) 2−15.................................................

2.7 OPTIONS 2−15.......................................................................

2.7.1 Light Bar 2−15....................................................................

2.7.2 Remote Switch(es) 2−15...........................................................

2.7.3 Remote Temperature Sensors 2−16..................................................

2.7.4 Remote Control Panel 2−16.........................................................

2.8 ENGINE DATA 2−16...................................................................

2.9 COMPRESSOR DATA 2−17............................................................

2.10 REFRIGERATION SYSTEM DATA 2−17..................................................

2.11 ELECTRICAL DATA 2−17..............................................................

2.12 COMPONENT RESISTANCE & CURRENT DRAW DATA 2−18..............................

2.13 SAFETY DEVICES 2−19...............................................................

2.14 REFRIGERANT CIRCUIT DURING COOLING 2−20.......................................

2.15 REFRIGERANT CIRCUIT - HEATING AND DEFROSTING 2−20............................

−11..........................................................

1

2

62−11389

SECTION 2

UNIT DESCRIPTION

2.1 INTRODUCTION

WARNING

Advance microprocessor equipped units
may start automatically at any time the Main
Power switch is not in the OFF position.
Also, the unit may be fitted with two way
communication equipment that will allow
starting of the unit from a remote location
even though the switch is in the OFF posi­tion.

WARNING

Be aware of HIGH VOLTAGE supplied at the
power plug or from the generator. When
performing service or maintenance proced­ures: ensure any two way communication is
disabled in accordance with the manufac­turer’s instruction, ensure the Main Power
Switch is in the OFF position and, whenever
practical, disconnect the high voltage
source, lockout/tagout the receptacle and
disconnect the negative battery connec­tion. NEVER dis-assemble the generator:
HIGH MAGNETIC FIELD INSIDE! This field
can interfere with cardiac implants such as
pacemakers and defibrillators.

This manual contains operating data, electrical data and
service instructions for the Vector 6500 refrigeration
system. Refer to Table 2-1 for model information.

Additional support manuals are listed in Table 2-2.
The unit model/serial number plate is located inside the

unit on the frame as shown in Figure 2−1.

9

unit. The unit is used on insulated refrigerated compart­ments to maintain cargo temperatures within very close
limits.

Electrical power is supplied to the unit from a power plug
or by the A-C generator which is driven by the engine.
The generator provides nominal 480V/3Ø/60Hz power
when the engine is in high speed and nominal
350V/3Ø/45Hz power in low speed.

The control box includes manual switches, micropro­cessor, fuses, and associated wiring. The unit can be
equipped with an optional remote light bar which mounts
separately on the front roadside corner of the trailer.

Temperature control is provided by the Carrier
Transicold Advance microprocessor (Refer to Section

2.5). Once the microprocessor is set at the desired tem­perature, the unit will operate automatically to maintain
the desired temperature within very close limits. The
control system automatically selects high and low
speed cooling or high and low speed heating as neces­sary to maintain the desired temperature within the refri­gerated compartment.

The auto Start-Stop operation provides automatic cycl­ing of the diesel engine, which in turn offers an energy
efficient alternative to continuous operation of the en­gine with control of temperature by alternate cooling and
heating of the supply air (evaporator outlet air). The auto
Start-Stop feature is standard equipment.

The unit can be described as having three major sec­tions:

 the condensing section (Figure 2−1 & Figure 2−2),

which includes the engine generator drive package
(Figure 2−3).

2.2 GENERAL DESCRIPTION

The Vector 6500 unit is a hybrid diesel/electric, fully
charged, pre-wired, refrigeration/heating “nosemount”

Model

NDP532*6JB0 14 6.4 06D 41cfm V2203-L-DI-E3B-CTD-5 1800 1350

R-404A

LB KG High Low

Manual Number Type of Manual

 the evaporator section (Figure 2−4).

 the controls (Items 11 through 14, Figure 2−3:

Figure 2−5 & Figure 2−9).

Table 2-1 Model Chart

Compressor Engine

Table 2-2 Additional Support Manuals

62-11369 Parts Look Up System (PLUS disc)
62-11405 Operator’s Manual
62-11406 Easy To Run

2−1

Engine Speed

62-11389

10

9

1

2

8

7

6

5

1. Condenser & Radiator

2. Ambient Air Temperature Sensor
(ATT - behind grille)

3. Model/Serial Number Nameplate

4. Power Supply Receptacle
(PSR - Under Unit)

Figure 2−1 Front View - Refrigeration System Components

3

4

5. Compressor Sight Glass

6. Compressor (C)

7. Front Unloader Valve (UL1)

8. Compressor Suction Temperature Sensor (CST)

9. Compressor Suction Modulation Valve (CSMV)

10. Condenser Fans and Motors (CDM1 & CDM2)

62-11389

2−2

9

1

2

3

4

10

5

9

8

7

6

11

12 Note: Junction box may be located on front or rear of compressor

1. Defrost Air Switch (DAS)

2. Receiver & Sight Glasses

3. Filter-Drier

4. Liquid Line Service Valve

5. Compressor Suction Service Valve

6. Compressor Discharge Service Valve

7. Compressor Discharge Temperature
Sensor (CDT)

Figure 2−2 Road Side/Rear Compressor View - Refrigeration System Components

8. Compressor Discharge Pressure
Transducer (CDP)

9. High Pressure Switch (HP1)

10. Compressor Suction Pressure
Transducer (CSP)

11. Rear Unloader Solenoid Valve (UL2)

12. Compressor Junction Box (IPC location)

2−3

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