Carrier VECTOR 6500 Operation & Service Manual

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Page 1

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

Page 2

OPERATION & SERVICE

MANUAL

for

VECTOR 6500

Single−Temp Trailer and Rail

Refrigeration Units

With Advance Microprocessor

Page 3

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

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

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Page 15

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

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

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Page 17

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

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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

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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

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).

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Page 20

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

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CAUTION

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

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

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CAUTION

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

1−4

Page 22

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

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1.3 SAFETY DECALS

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

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62-03953-01

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

1−6

Page 24

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

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Page 26

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

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

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SECTION 2

UNIT DESCRIPTION

2.1 INTRODUCTION

WARNING

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.

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

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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

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)

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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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1. Exhaust (Location)

2. Coolant Bottle (Location)

3. Air Cleaner & Air Cleaner Service Indicator (Behind bracket)

4 Engine Speed Control Unit (ENSCU)

5. Engine Coolant Temperature Sensor (ENCT)

6. Intake Air Heater (IAH)

7. Fuel/Speed Actuator (FSA)

8. Control Box (Refer to Figure 2−5)

9. Engine Speed Sensor (ENSSN)

10. Engine Oil Pressure Switch (ENOPS)

11. Display

12. Switch Board

Figure 2−3 Front View - Engine Components

13. Keypad Door

14. Serial Download Port (SLP)

15. Lube Oil Filter

16. Engine Oil Level Switch (ENOLS)

17. Lube Oil Fill & Dipstick

18. Lube Oil Drain

19. Starter Motor (SM)

20. Generator (GEN)

21. Battery Tray

22. Battery Charger (BTYC) and Second Battery Charger (BTYC2) Mounting

23. Fuel Heater (FH - Location)

24. Fuel Filter

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Page 32

1. Defrost Termination Temperature Sensor (DTT - Located on curbside tube sheet)

2. Evaporator Air Nozzle

3. Evaporator Fan/Motor Assembly (EVM)

4. Evaporator Fan/Motor Wiring

5. Supply Air Temperature Sensor (1SAT)

6. Electronic Expansion Valve (EVXV)

7. Evaporator Outlet Pressure Transducer (EVOP)

EVXV IS LOCATED CLOSER TO THE CENTER OF THE COIL ON EARLY UNITS

8. Evaporator Outlet Temperature Sensor (EVOT

- On suction line under insulation)

9. Evaporator High Temperature Switch (1EVHTS

- Located on roadside tube sheet)

10. Evaporator Coil

11. Return Air Temperature Sensor (1RAT)

12. Heat Exchanger

13. Electric Heaters (HTR1, HTR2)

Figure 2−4 Evaporator Section - Grille Removed

2−5

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1. Heat Contactor 1 (1HTCON1)

2. Fuse (F28)

3. Fuse (F27)

4. Fuse (F26)

5. Fuse (F12)

6. Fuse (F11)

7. Fuse (F10)

8. Fuse (F8)

9. Fuse (F7)

10. Fuse (F29)

11. AC Current Sensor (CT2,3,4)

12. Phase Reversal Module (PRM)

13. Fuel Heater Relay (FHR)

14. Power Supply Contactor Relay (PSCONR)

15. Generator Contactor Relay (GENCONR)

16. Compressor Contactor Relay (CCONR)

17. Main Fuse (F5)

18. Air Heater Relay (IAHR or GPR)

Figure 2−5 Control Box

CONTROL BOX

19. Starter Solenoid Relay (SSR)

20. Buzzer (B)

21. Fuse (F19)

22. Display

23. Microprocessor (MP)

24. Fuse - Standby Contactor Power (F9)

25. Microprocessor Power Fuse (F6)

26. Power Supply Contactor (PSCON)

27. Power Supply Contactor 2 (PSCON2)

28. Generator Contactor (GENCON)

29. Overload Ground Fault (OGF)

30. Condenser Motor Contactor (CDCON)

31. Evaporator Motor Contactor (1EVCON)

32. Heat Contactor 2 (1HTCON2)

33. Compressor Contactor (CCON)

34. Run Control Relay (RCR - Used With Remote Control Panel Only)

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2.3 CONDENSING SECTION

The condensing section (see Figure 2−1 & Figure 2−2) consists of an engine-generator drive package, compressor, condenser fans, condenser coil, radiator, refrigerant controls, defrost air switch, piping, wiring, and associated components.

The engine-generator drive package (see Figure 2−3) includes the engine, generator, air cleaner, muffler, coolant system, fuel system, oil filter system and engine sensors.

2.3.1 Engine

The engine is a four cylinder diesel which gives excellent fuel economy and has easy starting characteristics. It is equipped with spin-on lube oil and fuel oil filters for easier filter changes. The fuel filter may also be equipped with a thermostatically controlled fuel heater. The engine cooling system consists of the radiator (which is mounted with the condenser coil) and coolant overflow bottle. The system is also fitted with an electronic battery charger which converts generator or standby alternating current to direct current for battery charging. Refer to Section 2.8 for engine data.

2.3.2 Engine Air System

The air cleaner prolongs the life and performance of the engine by preventing dirt and grit from getting into the engine and causing excessive wear on all operating parts. It is the responsibility of the operator to give the air cleaner equipment regular and constant attention in accordance with the instructions. An optional air cleaner service indicator may be connected to the intake manifold. Its function is to indicate when the air cleaner requires replacement. (Refer to section 8.5.9.)

2.3.3 Engine Controls:

a. Engine Speed Control Unit (ENSCU)

The ENSCU (see Figure 2−6) is a microprocessor based unit which controls the fuel supply to, and speed of, the engine in accordance with the position of the Main Power Switch and speed relay. The unit has an LED which may be used to diagnose failures within the electronic speed control system. Refer to Section 9.5 for information on diagnostic failures. The ENSCU sends engine speed information to the microprocessor to be displayed in the Unit Data and recorded in the DataLink data recorder. The ENSCU is mounted on the air cleaner bracket.

LED

Figure 2−6 Engine Speed Control Unit

b. Fuel/Speed Actuator (FSA)

The FSA combines the fuel shutoff solenoid and speed control solenoid into one component. Fuel supply to the injectors and engine speed is controlled by varying rod position in accordance with the signal from the ENSCU. The FSA is located on the front of the injection pump.

c. Engine Speed Sensor (ENSSN)

The ENSSN provides the ENSCU with information on the speed at which the engine is running. The ENSSN is located in the gear case cover above the oil filter.

d. Engine Oil Pressure Switch (ENOPS)

The ENOPS is normally open and closes on pressure rise to signal to the microprocessor the engine has sufficient oil pressure for operation. There is a 15 second delay after the engine starts to allow the oil pressure to build up before the microprocessor looks at the input from this switch. The switch is located in the oil filter mounting assembly.

e. Engine Coolant Temperature Sensor (ENCT)

The ENCT provides the microprocessor with engine coolant temperature information to be displayed, recorded in the DataLink data recorder and used to control the refrigeration system. The sensor is located on the starter side of the engine near the #4 Injector.

f. Engine Oil Level Switch (ENOLS)

The ENOLS provides the microprocessor with engine oil level information to be displayed, recorded in the DataLink data recorder and used to control the refrigeration system. The switch is located in the oil pan, just to the right of the lube oil fill & dipstick.

2.3.4 Generator (GEN)

The generator is directly bolted to the engine and supplies nominal 460V/3Ø/60Hz power when the engine is in high speed and nominal 300V/3Ø/45Hz power in low speed.

2.3.5 Compressor

The compressor assembly includes the refrigerant compressor, suction and discharge service valves, high pressure switch, compressor discharge temperature sensor and the suction and discharge pressure transducers. The compressor draws refrigerant gas from the evaporator and delivers it to the condenser at an increased temperature and pressure. The pressure is such that refrigerant heat can be absorbed by the surrounding air at ambient temperatures.

2.3.6 Unloaders

The compressor is equipped with unloaders as standard equipment. Unloaders are used as a compressor capacity control to unload the cylinder banks during periods of reduced cooling loads. This provides closer temperature control and reduces the power required to operate the compressor; thus reducing fuel consumption.

a. Major Working Parts

 Solenoid and valve system.  Spring loaded piston type bypass valve.  Spring loaded discharge check valve (located on the

valve plate).

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1. Solenoid Valve

2. Valve Stem

3. Gas Bypass Port

4. Spring Guide

5. Spring

6. Piston

7. Bypass Valve

8. Bleed Orifice

Figure 2−7 Compressor Cylinder Head Unloaded

b. Unloaded Operation

Pressure from the discharge manifold (item 15, Figure 2−7) passes through the strainer (9) and bleed orifice (8) to the back of the bypass valve piston (6). Unless bled away, this pressure would tend to close the piston against the spring (5) pressure and load the cylinders in that head.

With the solenoid valve (1) energized the solenoid valve stem (2) will open the gas bypass port (3).

Discharge pressure will be bled to the suction manifold (10) through the opened gas bypass port . A reduction in pressure on the bypass piston valve will take place because the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice (8).

9. Strainer

10. Suction Manifold

11. Cylinder Discharge Valve

12. Valve Plate

13. Cylinder Suction Valve

14. Discharge Check Valve Assembly

15. Discharge Manifold

When the pressure behind the piston has been reduced sufficiently, the valve spring will force the piston back, opening the gas bypass from the discharge manifold to the suction manifold.

Discharge pressure in the discharge manifold will close the discharge piston check valve assembly (14) isolating the compressor discharge manifold from the individual cylinder bank manifold.

The unloaded cylinder bank will continue to operate fully unloaded until the solenoid valve is de-energized and the gas bypass port is closed.

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4 5

1. Solenoid Valve

2. Valve Stem

3. Gas Bypass Port

4. Spring Guide

5. Spring

6. Piston

7. Bypass Valve

8. Bleed Orifice

Figure 2−8 Compressor Cylinder Head Loaded

c. Loaded Operation

With the solenoid valve (1, Figure 2−8) de-energized the solenoid valve stem will close the gas bypass port (3).

Pressure from the discharge manifold (item 15) through the strainer (9) and bleed orifice (8) will build behind the piston (6).

This increased pressure will overcome the bypass valve spring (5) tension and force the piston (6) forward closing the gas bypass from the discharge manifold to the suction manifold (10).

Cylinder discharge pressure will force the discharge check valve assembly (14) open. Refrigerant gas will then flow into the compressor discharge manifold.

The loaded cylinder bank will continue to operate fully loaded until the solenoid valve is energized and the gas bypass port is opened.

9. Strainer

10. Suction Manifold

11. Cylinder Discharge Valve

12. Valve Plate

13. Cylinder Suction Valve

14. Discharge Check Valve Assembly

15. Discharge Manifold

2.3.7 Compressor Switches, Transducers and Sensors

a. Compressor Discharge Pressure Transducer

(CDP)

The CDP provides a signal to the microprocessor equivalent to pressure leaving the compressor. The reading is displayed, recorded in the DataLink data recorder and used to control the refrigeration system. It is located on the compressor center head.

b. Compressor Suction Pressure Transducer

(CSP)

The CSP provides a signal to the microprocessor equivalent to pressure entering the compressor cylinders. The reading is displayed, recorded in the DataLink data recorder and used to control the refrigeration system. It is located on the front of the compressor.

c. Compressor Discharge Temperature Sensor

(CDT)

The CDT provides a signal to the microprocessor equivalent to the temperature of the gas leaving the compressor. The reading is displayed, recorded in the DataLink data recorder and used to control the refrigeration system. It is located on the compressor center head.

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d. Compressor Suction Temperature Sensor (CST) The CST provides a signal to the microprocessor

equivalent to to the temperature of the gas entering the compressor suction service valve. It is located on the line entering the valve.

e. High Pressure Switch (HP1)

The HP1 is normally closed and opens on pressure rise to signal to the microprocessor to shutdown the engine, or shutdown the system if operating on standby power. It is located on the compressor center head.

2.3.8 Condenser Coil

The condenser coil is a microchannel type and acts as a heat exchanger in which the compressed refrigerant gas is lowered in temperature and condensed into a liquid. Air movement over the condenser is provided by two electric motor driven fans mounted in the condensing section.

2.3.9 Ambient Air Temperature Sensor (AAT) The AAT provides microprocessor with condenser

entering air temperature information to be displayed, recorded in the DataLink data recorder and used to control the refrigeration system. The sensor is located behind the front grill.

2.3.10 Filter-Drier

The filter-drier is a cylindrical shell containing a drying agent and filter screen. It is installed in the liquid line and functions to keep the system clean and remove moisture from the refrigerant.

2.3.11 Receiver

Liquid refrigerant from the condenser flows into the receiver. The receiver serves as a liquid reservoir when there are surges due to load changes in the system; as a storage space when pumping down the system and as a liquid seal against the entrance of refrigerant gas into the liquid line. The receiver is provided with two bull’s-eye sight glasses, for the observation of liquid level & moisture content, and a fusible plug.

2.4 EVAPORATOR SECTION

The evaporator (See Figure 2−4) fits into a rectangular opening in the upper portion of the front wall of the refrigerated compartment. When installed, the evaporator section is located inside the compartment, and the condensing section is outside.

The evaporator assembly consists of an evaporator coil, evaporator fan motor, electronic expansion valve, coil heaters, heat exchanger, defrost termination temperature sensor the supply and return air sensors and a high temperature switch.

Heating and defrost is accomplished by electric heaters mounted on the coil.

Automatic evaporator coil defrosting is initiated by either a differential air switch (which senses the pressure drop across the coil) or by the defrost timer in the microprocessor.

2.4.1 Evaporator Coil

The evaporator is a tube in fin type. The operation of the compressor maintains a reduced pressure within the coil. At this reduced pressure, the liquid refrigerant evaporates at a temperature sufficiently low enough to absorb heat from the air. The electric heaters (HTR1 & HTR2) are mounted on the inlet side of the coil.

2.4.2 Electronic Expansion Valve (EVXV)

The EVXV is an electronic device which controls the flow of liquid to the evaporator according to changes in superheat of the refrigerant leaving the evaporator. The expansion valve maintains a relatively constant degree of superheat in the gas leaving the evaporator regardless of suction pressure. The valve has a dual function automatic expansion control and prevention of liquid return to the compressor.

2.4.3 Heat Exchanger

The heat exchanger is the tube in tube type and is installed in the main suction line and liquid line. The suction gas is used to cool the warm liquid refrigerant within the heat exchanger. This results in greater system efficiency.

2.4.4 Compressor Suction Modulation Valve (CSMV)

The CSMV opens and closes as required for capacity control of the refrigeration system cooling cycle. It is located in the suction line at the exit of the evaporator assembly.

2.4.5 Evaporator Switches, Transducers and Sensors

a. Evaporator Outlet Pressure Transducer (EVOP)

The EVOP provides the microprocessor with evaporator outlet pressure information to be displayed, recorded in the DataLink data recorder and used to control the refrigeration system. It is located in the suction line near the electronic expansion valve.

b. Evaporator High Temperature Switch (1EVHTS)

1EVHTS is a safety switch which opens on a temperature rise to de-energize the electric heaters if the temperature reaches the cut-out point. It is located on the roadside tube sheet of the evaporator coil

c. Evaporator Outlet Temperature Sensor (EVOT)

The EVOT provides the microprocessor with evaporator outlet temperature information to be displayed, recorded in the DataLink data recorder and used to control the refrigeration system. It is located on the suction line near the electronic expansion valve.

d. Defrost Termination Temperature Sensor (1DTT)

The 1DTT is located on the curbside tube sheet of the evaporator coil. It provides the microprocessor with evaporator temperature information to be displayed, recorded in the DataLink data recorder and used to determine termination of defrost.

e. Return Air Temperature Sensor (1RAT)

The 1RAT is a temperature control probe which provides the microprocessor with information on the temperature of the air entering the evaporator section. The

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reading is displayed, recorded in the DataLink data recorder and used to control the refrigeration system. It is located on on a bracket behind the center of the return air grille.

f. Supply Air Temperature Sensor (1SAT)

The 1SAT is a temperature control probe which provides the microprocessor with information on the temperature of the air leaving the evaporator section. The reading is displayed, recorded in the DataLink data recorder and used to control the refrigeration system. It is located in the roadside of the supply air outlet housing.

2.5 SYSTEM OPERATING CONTROLS AND COMPONENTS

Temperature control is provided by the Carrier Transicold Advance microprocessor. Once the microprocessor is set at the desired temperature, the unit will operate automatically to maintain the desired temperature within very close limits.

2.5.1 Multiple Languages

Messages in the MessageCenter can be displayed in English, French, Spanish or Portuguese.

Press and hold the Select Key for 6 seconds to view or change the current language selection. Refer to Section

3.15 for more information on language selection.

2.5.2 Automatic Start-Stop

Standard equipment includes an auto start-stop feature. This feature 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).

2.5.3 Special Features

The following additional special features are incorporated into the Carrier Transicold Advance Microprocessor:

 An LCD display MessageCenter which clearly dis-

plays all information in dot matrix form.

 Unit Operation & Alarms are displayed in text (not in

codes).

 Unit Data and Functional Parameters.  Programmable Maintenance Hour Meters (resettable

from the Keypad).

 Bright LED Alarm & Indicator Lights.  Fully Automated Pretrip.  Automated Micro Self-test.  DataLink data recorder (date & time can be set from

the Keypad).

 Trip Start to record date/time of trip in DataLink data

recorder memory.

 PC card functionality for downloading data, upgrad-

ing operational software, and Configuration set up.

 FET (Field Effect Transistor) indicating LEDs that are

illuminated when a circuit is energized.

 Automatic Engine Starting.  Functional Parameter locks.  Alarms are stored in microprocessor memory for fu-

ture reference.

2.5.4 Component Description And Location

The hardware associated with the Advance microprocessor includes the control module, display, keypad and switch board. The hardware is housed, for driver access, in the control box on the lower roadside corner of the unit.

CAUTION

a. Control Module

The control module (see Figure 2−9) consists of the microprocessor (with status LEDs), 3 fuses (F1, F2, & F3), a DC current sensor (CT1), 2 relays (RR & SR), 2 status LED’s (LED30 & LED31), 6 input/output connectors (QC), 6 digital input/output connectors (MP), a programming card slot (with status LED’s) and twenty three FET indicating LEDs.

The microprocessor is totally self contained and does not contain any serviceable components. Microprocessor activity can be determined by observing the LED’s and FET’s (see Figure 2−9 and Table 5−1). If the microprocessor is calling for a circuit to be energized, the indicator is illuminated.

The PC card slot allows programming of the microprocessor using Carrier Transicold PC Cards. The microprocessor automatically detects the presence and type of PC Card inserted and responds accordingly. The different types of PC Cards are:

 Download Card for copying unit data from DataLink

data recorder.

 Options PC Card for installing optional software

programs such as DataTrak or IntelliSet.

 Configuration PC Card for setting the Microprocessor

Functions, Configurations, IntelliSets and DataLink data recorder Configurations.

 Program PC Card for upgrading the microprocessor

software.

There are three LEDs associated with the function of the PC card slot. These are:

• A green Micro Status LED which will blink steadily

once per second indicating that the microprocessor is operating and will blink every 0.5 seconds if there is no software or if it is loading software.

• A green (PC) Card Status LED which comes on when

there is a PC card inserted in the slot. This LED will:

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1. Blink once per second when data is being transferred to, or from, the PC Card. Will be on steady when the operation is complete indicating the PC Card may be removed.

2. During Download, after Card is read and identified, card status LED blinks 2 seconds on and 2 seconds off until the = key is pressed to start the programming from the card to the micro. Once the data transfer to the micro begins, the Card Status LED and the Micro Status LED will blink together 1/2 second on and 1/2 second off until the data transfer is complete, then

the Micro Status LED will continue at the 1/2 second rate and the Card Status LED will come on solid and remain on solid until the card is removed from the slot.

• A red (PC) Card Fault LED blinks if there is a problem

transferring data from the PC card that has been plugged into the PC card slot. The red LED will continue to blink until the PC card is removed. The LED will also blink if there is an error reading the card. Check the MessageCenter for description of error.

RUN RELAY (RR - Board Relay K2) & LED28

PC CARD FAULT LED (RED)

1MP (WHITE) IN/OUTPUT CONNECTOR

PC CARD SLOT

2MP (BLACK) IN/OUTPUT CONNECTOR

PC CARD STATUS LED (GREEN)

MICROPROCESSOR STATUS LED (GREEN)

MICROPROCESSOR

3MP (GREY) IN/OUTPUT CONNECTOR

FET LEDs

Refer to Table 5−1

QC4 (+12V OUTPUT TO RR)

(7.5A)

SPEED RELAY (SR - Board Relay K1) & LED 27

QC3 (+12V OUTPUT TO SR)

F2 (10A)

RELAY POWER QC8 (12+ VDC)

DC CURRENT SENSOR (CT1)

LED30 (GPR/IAHR)

LED31 (SSR)

6MP, IN/OUTPUT CONNECTOR

5MP, IN/OUTPUT CONNECTOR

4MP, IN/OUTPUT CONNECTOR

QC9 (FET ARC SUPPRESSION)

QC2 (GROUND FROM BATTERY)

QC1 (12+VDC FROM BATTERY)

F1 (7.5A)

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Figure 2−9 Control Module

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ALTERNATE

CONFIGURATION

+34.5 F-20.0

DEFROST

ALARM LIST

START‐STOP/

CONTINUOUS

SELECTMANUAL

ENGINE

OFF

STANDBY

MAIN POWER

891011

STANDBY

START/RUN

SWITCHES

ENGINE

OFF

1. Indicator lights

2. Keypad Door

3. Main Display

4. MessageCenter

5. Keypad

6. Up and Down Arrow Keys

7. Enter Key

8. Manual Defrost Key

9. Alarm List Key

10. Start/Stop-Continuous Key

Figure 2−10 Display And Keypad Assembly

b. Main Display, MessageCenter & Indicator Lights

(see figure Figure 2−10)

Indicator Lights

The display has six LEDs across the top to indicate operational status. These indicators are:

 Heat Indicator (Amber) - Illuminated when the unit is in

Heat Mode.

 Cool Indicator (Green) - Illuminated when the unit is in

Cool Mode.

 Defrost Indicator (Amber) - Illuminated when the unit is

in Defrost Mode.

 Alarm Indicator (Red) - Off or Flashes at a rate of 0.5

seconds.

 Start-Stop Indicator (Green) - Illuminated when

Start-Stop Operation has been selected.

 Continuous Indicator (Green) - Illuminated when

Continuous Operation has been selected.

11. Select Key

12. Switch Board MAIN POWER SWITCHES

13. Diesel/Off/Engine Standby Switch (DOES) (Note: switch is labeled ENGINE/OFF/STANDBY)

14. START/RUN - OFF Switch (SROS)

15. Diesel Electric Switch (DES) (Note: switch is labeled STANDBY/ENGINE)

NOTE

When the unit is in Null mode (fan only), the mode indicators (cool, heat and defrost) are all off.

NOTE

There is an opening between the Alarm and Start-Stop LEDs that is not used at this time.

Main Display

The microprocessor will display the refrigerated compartment set point to the left and compartment temperature to the right. Temperatures will be displayed as signed (+ or -). The microprocessor may be configured to display the set point in either whole numbers or with tenths of a degree. The compartment temperature will be followed by a letter indicating the information is in degrees Fahrenheit (F) or degrees Centigrade (C).

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Message Center

Messages generated by the microprocessor are displayed in the MessageCenter. As the main display scrolls every 5 to 10 seconds from one active compartment to another, the applicable message for that particular compartment will also be displayed. Details of the messages are described in Section 6.1 MessageCenter.

c. Switch Board Diesel/Off/Engine Standby Switch (DOES)

ENGINE

STANDBY

When placed in the ENGINE or STANDBY position, this switch provides power to the microprocessor. The

OFF

microprocessor performs a self-test (all segments of display are illuminated). Then setpoint and compartment temperatures are displayed and the unit is started in Engine Operation or Standby Operation.

To stop the unit place the DOES switch in the OFF position.

Diesel/Electric Switch (DES) - Alternate Configuration

This switch is used to select either Engine Operation or Standby Operation. When this switch is placed in standby position, the microprocessor will not energize the power source contactors until the engine oil pressure switch (ENOPS) opens.

START/RUN-OFF Switch (SROS) - Alternate Configuration

When placed in the START/RUN position, this switch provides power to the microprocessor. The microprocessor performs a self-test (all segments of display are illuminated). Then setpoint and compartment temperatures are displayed.

To stop the unit or remove power from the microprocessor, place the SROS in the OFF position.

d. Keypad

UP ARROW and DOWN ARROW Keys

These keys allow changing of the setpoints or other displayed data of the system. They also allow scrolling through the Unit Data, Function Parameters List, Alarm List, etc.

EQUAL Key (ENTER)

The EQUAL key is used for many things including entering a setpoint, changing a

Functional Parameter, clearing alarms, and locking the data menu.

MANUAL

DEFROST

MANUAL DEFROST Key

The MANUAL DEFROST key may be used to initiate a defrost cycle when the required conditions are met.

ALARM LIST

ALARM LIST Key

The ALARM LIST key allows viewing of the alarms stored in the microprocessor. The alarm list is displayed in the MessageCenter. Pressing the ALARM LIST key once displays the active alarm list. Each successive press advances through the list to the end. To view the inactive alarm list, Refer to Section 3.12.

START‐STOP/ CONTINUOUS

START-STOP/CONTINUOUS Key

Pressing this key toggles between Start-Stop and Continuous Run operation.

SELECT

SELECT Key

Press the SELECT key to scroll through the menu selections. One of the five standard menu selections will appear in the MessageCenter when the SELECT key is pressed. Repeated pressing of the SELECT key will sequence the menu through these selections. The menu wraps around. Press the SELECT key until the desired menu

selection appears in the MessageCenter. The selections are: wPRESS =O TO VIEW HOUR METERS- Displays the

hours for individual hour meters. Refer to Section 3.14.

wPRESS =O TO START PRETRIP - Used to initiate a

pretrip. Refer to Section 3.4.

wPRESS =O TO VIEW DATA - Displays Unit Data. Refer

to Section 3.13.

wPRESS =O TO VIEW (AND CHANGE) SETTINGS -

Displays unit Functional Parameter settings. Refer to Section 3.15.

wPRESS =O TO MARK TRIP START - This menu

selection is used to record a Trip Start event which is logged in the DataLink data recorder. This records the time and date of the beginning of the trip. Data can then be downloaded and reviewed by trip, making data review much easier. Refer to Section 3.10.

wPRESS =O TO VIEW PRINT MENU - Configures the

microprocessor for use with the hand-held Strip Print II printer kit P/N 12-50150-10. Refer to manual 62-90476 (Strip Print) or 62-11338 (Strip Print II).

wPRESS =O TO VIEW (AND CHANGE) INTELLISET -

Refer to Section 3.17.

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2.6 ELECTRONIC MODULES

2.6.1 Overload Ground Fault Module (OGF)

LED

Figure 2−11 OGF Module

The OGF, see Figure 2−11, is located in the control box (see Figure 2−5). The module has two electrical safety features which are active in both Engine and Standby Operation:

1. Overload protection.

2. Ground Fault (Leakage). In each case, an “A100 - “OVERLOAD GROUND

FAULT” alarm is activated and the unit shuts down. When ground leakage is detected, the red LED on the

OGF module will be on continuously.

2.6.2 Phase Reversal Module (PRM)

Figure 2−12 PRM Module

The PRM, Figure 2−12, is located in the control box (see Figure 2−5). In Standby Operation, the phase reversal module checks the electrical phase and reverses if necessary.

2.7 OPTIONS

2.7.1 Light Bar

The Light Bar is an external indicator light which can be seen in the driver’s rear view mirror from the cab of the tractor. The green LED indicates “STATUS OK”. The

amber LED indicates “CHECK UNIT”. The amber light is illuminated when the microprocessor illuminates the fault light. Alarms can be read on the microprocessor display.

AMBER

GREEN

Figure 2−13 Light Bar

2.7.2 Remote Switch(es)

The unit is provisioned to connect remote switches (DS or REMS) directly to the microprocessor.

 Two types of switches may be used:

1. A switch with contacts that are open when the switch is activated.

2. A switch with contacts that are closed when the switch is activated.

 Four Configurations are available for each switch.

1. Activate an alarm only while the switch is activated.

2. Activate an alarm and shut the unit down while the switch is activated. The unit will remain shut down for a minimum of 3 minutes under this setting.

3. Activate the alarm and bring the engine into low speed while the switch is activated.

4. Record the switch activation in the DataLink data recorder.

 If configured to shut the unit down or bring the engine

to low speed an additional choice will be available. The additional choice allows the unit to be set so that the configured action will always take place OR the configured action will only take place when the ambient temperature is below a certain temperature. For example, if the shutdown/low speed temperature choice is set to 77°F (25°C) the unit will only shutdown/go to low speed if the ambient temperature is below 77°F (25°C).

 Additionally a Functional Parameter “override” set-

ting will be available for each switch configured to shut the unit down. The Functional Parameter may be set to “YES” or “NO”. If the Parameter is set to “NO” the configured action will not be overridden. If the Parameter is set to “YES”, the alarm will be activated but the unit will not shutdown.

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2.7.3 Remote Temperature Sensors

The unit is provisioned to connect up to three remote temperature sensors directly to the microprocessor.

The microprocessor may be configured to display the sensor reading in the Unit Data and to record the sensor reading in the DataLink data recorder. A user specified name may be configured for each sensor. This name will be displayed, rather than the default Remote Sensor #1, Remote Sensor #2 or Remote Sensor #3 name, in the unit data list.

2.8 ENGINE DATA

Engine Model V2203L-DI-E3B-CTD-5 (26-00128-15) Displacement 135 in No. Cylinders 4 Rated Power 32 hp (24 KW) @1800 rpm

NOTE: Refer to Table 2-1 for engine speed settings

Weight 440 lbs (199.6 kg)

2 U.S. gallons (7.6 liters) - 50/50 mix ethylene glycol antifreeze (with inhibitors) -

2.7.4 Remote Control Panel

The unit may be fitted with, and the remote switch/door switch configurations set for, an optional remote control panel. The panel displays refrigerated compartment set point, compartment temperature and operating mode (heat, cool or defrost). The set point may be set and the unit may be started and stopped using the remote panel.

This compact panel can be mounted to suit the individual operator’s preferences - for example, flush mounted inside the trailer near the rear door. Refer to Section 3.20.2 for more information on the remote control panel.

NOTE

The remote switch/door switch configurations may be set for use as individual switches or for use with a remote panel, not both.

3 (

2.2 liters)

never to exceed 60/40

CAUTION

Coolant Capacity

Thermostat Starts to open 177 to 182F (81 to 83C). Fully open at 203F (95C).

Fuel Winter: Diesel No. 1 Summer: Diesel No. 2(Maximum 5% Bio-Diesel is also allowed) Fuel Heater

Temperature Switch Firing Order 1-3-4-2 Intake Air Heater

Amperage

Oil Pressure 40 to 62 psig (2.8 To 4.2 Bar) - Engine in high speed Oil Pressure Switch

(ENOPS) Oil Capacity with Filter 15 quarts (14.2 liters)

Lube Oil Viscosity: API CG or better OR Mobil Delvac 1

Oil Change Intervals Refer to Section 8.2 for information on service intervals.

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 antifreeze 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.

Fuel System

Close on a temperature fall @ 45F (7.2°C) Open on a temperature rise @ 75F (24°C)

42 amps at 12 VDC

Lubrication System

Closes, on pressure rise, at 18 psig (1.22 Bar)

Opens, on pressure fall, at 12 psig (0.82 Bar)

Outdoor Temperature Grade (SAE)

Below 32F (0°C) 10W30 or Mobil Delvac 1 (5W 40)

Above 32F (0C)

10W30 or Mobil Delvac 1 (5W 40)

or 15W 40

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2.9 COMPRESSOR DATA

Compressor Model 06D Number of Cylinders 6 Type Semi-hermetic Reciprocating Weight 325 lbs (1478 kg) Oil Charge 7.6 pints (3.6 liters) Approved OIl Mobil Arctic EAL 68

2.10 REFRIGERATION SYSTEM DATA

Defrost Air Switch (DAS)

Initiates Defrost: 1.40  .07 inch (35  1.8 mm) WG

Defrost Timer (micro controlled) 1.5h, 3h, 6h, or 12 hours Evaporator High Temperature Switch

(EVHTS)

Opens, on temperature rise, at: 130° 5°F (55° 2.8°C)

Closes, on temperature fall, at: 100° 7°F (37.8°  3.9°C)

Fusible Plug Melting Point 430F (221C)

High Pressure Switch (HP1)

Opens, on pressure rise, at : 465  10 psig (34  0.7 bar)

Closes, on pressure fall, at: 350  10 psig (24  0.7 bar) Unit Dry Weight, Less Battery 2045 pounds (928 KG.) Battery 50 pounds (23 KG.)

2.11 ELECTRICAL DATA

Full Load Amps (FLA) 17.5 amps @ 460 VAC

Compressor Motor

Locked Rotor Amps 99.0 amps @ 460 VAC Winding Resistance Approximately 2 ohms, phase to phase Full Load Amps (FLA) 1.9 amps @ 460 vac, 60 hz Horsepower 1.1 hp (820 watts) at 60 hz

Condenser Fan

Motors (Each)

Speed 1700 rpm @ 60 Hz Bearing lubrication Factory lubricated, additional grease not required Rotation Clockwise when viewed from shaft end Resistance 20 to 21 ohms

Heater 1

Number of heaters Three elements (1 assembly) Resistance 196 ohms $10 ohms per phase Current, Low Speed 2.6 amps nominal

Heaters

Current, High Speed 3.4 amps nominal

Heater 2

Number of heaters Four elements (1 assembly) Resistance 196 ohms $10 ohms per phase Current, Low Speed 2.6 amps nominal Current, High Speed 3.4 amps nominal

2−17

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2.11 ELECTRICAL DATA - Continued

Full Load Amps (FLA) 1.9 amps @ 460 vac, 60 hz Horsepower 1.35 hp (1007 watts) @ 60hz Speed 3500 rpm @ 60 hz

Evaporator Fan Motor

Voltage and Frequency 310 to 660 VAC 45 to 65 Hz Bearing Lubrication Factory lubricated, additional grease not required Rotation Clockwise when viewed from shaft end Resistance 34.2 to 41.8 ohms Nominal voltage & fre-

quency at High Speed Nominal voltage & fre-

Generator

quency at Low Speed Resistance 0.73 to 0.778 ohms phase to ground

Output 20.7 KVA @ 0.84 p.f @ 1800 rpm Input 360 - 460 VAC, Single Phase

Battery Charger

20 Amp

Output amps 20A (Maximum) Output voltage 14.8 VDC @ 77°F (25°C) Input 360 - 460 VAC, Three Phase

Battery Charger

40 Amp

Output amps 40A Output voltage 14.8 VDC @ 77°F (25°C)

OGF Module

Battery

Standby Power

Requirements

Standby Extension Cord

Trips - On High Current 40 Amps (Maximum) Trips - on Ground Fault 150mA Voltage 12 volt nominal - 90 amp hour capacity

Voltage Current

Gauge Length

460 VAC, 60 hz, 3 phase

345 VAC 45 hz, 3 phase

1.476 to 1.556 phase to phase

Cold cranking amps = 425 DIN, 500 IEC, 725 BCI 460/3/60 with a 30A Circuit Breaker required.

(Full Load Draw = 25A, Locked Rotor Draw = 99A) SOOW, 600V, 90°C, 10/4 (3ph + G)

50’ minimum length, 75’ Maximum length.

2.12 COMPONENT RESISTANCE & CURRENT DRAW DATA Component Ohms Amps

Unloader Solenoid Valve 9.6 ±0.8 Ohms 1.0 - 2.0 Amps 12VDC Relay (IAHR/GPR, SSR, FHR) 72 Ohms ±10% 0.14 - 0.18 Amps 12VDC Relay (PSCONR, GENCONR, CCONR,

80 Ohms ±15% 0.12 - 0.17 Amps

RCR) 12VDC Relay (HTCON1, HTCON2, CDCON,

48 Ohms ±10% 0.25 Amps ±10%

1EVCON) 12VDC Relay (PSCON1, PSCON2, GENCON,

15.5 Ohms ±10% 0.77 Amps ±10%

CCON) Fuel/Speed Actuator (FSA) 2.8 Ohms ±10% @ 68°F (20°C) 4 Amps Max Intake Air Heater Circuit 0.3 to 0.5 Ohms 38 - 46 Amps Starter Motor Less than 1 Ohm but more than 0 270 - 380 amps Fuel Heater 1.4 Ohms ±10% 10.7 amps ±10%

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2.13 SAFETY DEVICES

The system is protected from high pressure conditions which may occur when exposed to very high temperatures (such as a fire) by a fusible plug mounted in the receiver. Under very high temperature conditions (refer to Section

2.10) the plug will melt, releasing the refrigerant pressure. System components are protected from damage caused by unsafe operating conditions by automatic shut-down of

the unit when such conditions occur. This is accomplished by the safety devices listed in the following table.

Unsafe Conditions

Excessive operating pressure High Pressure Switch

Safety Device Device Setting

Refer to Section 2.10

(HPS) Excessive current draw by microprocessor Fuse (F1) Opens at 7.5 amps Excessive current draw by speed relay Fuse (F2) Opens at 10 amps Excessive current draw by run relay Fuse (F3) Opens at 7.5 amps Excessive current draw by battery output Fuse (F5) Opens at 80 amps Excessive current draw by control circuit Fuse (F6) Opens at 15 amps Excessive current draw by battery charger in-

put - 20 amp charger.

Fuse (F7, F8) Opens at 3 amps (single charger) OR

opens at 6amps (dual chargers) See note.

Excessive current draw by battery charger in-

Fuse (F7, F8, F29) Opens at 5 amps (timed) put - 40 amp charger(s).

Excessive current draw by generator/power

Fuse (F9) Opens at 10 amps supply contactors

Excessive current draw by evaporator heaters Fuse (F10/F11/12) Opens at 12 amps Excessive current draw by fuel heater circuit Fuse (F19) Opens at 20 amps Excessive current draw by fuel level sensor

Fuse (FLS) Opens at 3 amps circuit

Excessive current draw by evaporator or con-

Fuse (F26/F27/F28) Opens at 12 amps denser fan motor

Excessive condenser fan motor winding

Internal protector Auto reset temperature

Excessive compressor motor winding

Internal protector Auto reset temperature

Excessive evaporator motor winding

Internal protector Auto reset temperature

NOTE: When a second 20 amp rated charger is used to charge a lift gate battery, the higher rated fuse is installed

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2.14 REFRIGERANT CIRCUIT DURING COOLING

When cooling, (See Figure 2−14) the unit operates as a vapor compression refrigeration system. The main components of the system are: the (1) reciprocating compressor, (2) air-cooled condenser, (3) expansion valves, and (4) direct expansion evaporator.

The compressor raises the pressure and the temperature of the refrigerant and forces it into the condenser channels. The condenser fans circulate surrounding air over the outside of the channels. The channels have fins designed to improve the transfer of heat from the refrigerant gas to the air. This removal of heat causes the refrigerant to liquify. Liquid refrigerant leaves the condenser and flows to the receiver.

The receiver stores the additional charge necessary for low ambient operation. The receiver is equipped with a fusible plug which melts on occurrence of very high temperature to relieve the refrigerant pressure.

The refrigerant leaves the receiver and flows through the liquid line service valve to the subcooler. The subcooler occupies a portion of the main condensing coil surface and gives off further heat to the passing air.

The refrigerant then flows through a filter-drier where an absorbent keeps the refrigerant clean and dry.

The refrigerant flows to the suction line heat exchanger. Here the liquid is further reduced in temperature by giving off some of its heat to the suction gas.

The liquid then flows to an electronic expansion valve which reduces the pressure of the liquid and meters the

flow of liquid refrigerant to the evaporator to obtain maximum use of the evaporator heat transfer surface.

The refrigerant pressure drop caused by the expansion valve is accompanied by a drop in temperature so the low pressure, low temperature fluid that flows into the evaporator tubes is colder than the air that is circulated over the tubes by the evaporator fan. The evaporator tubes have aluminum fins to increase heat transfer; therefore heat is removed from the air circulated over the evaporator. This cold air is circulated throughout the refrigerated compartment to maintain the cargo at the desired temperature.

The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize.

This low temperature, low pressure vapor passes through the evaporator outlet. The vapor then passes through the heat exchanger where it absorbs more heat from the high pressure / high temperature liquid and then returns to the compressor through the compressor suction modulation valve (CSMV). The CSMV controls the compressor suction pressure thereby matching the compressor capacity to the load.

2.15 REFRIGERANT CIRCUIT - HEATING AND DEFROSTING

The compressor is turned off for all heating and defrost cycles. In heat, the coil mounted heaters and evaporator fan(s) are energized. Air flowing over the warm heater elements is circulated through the compartment to maintain the cargo at the desired temperature. Defrost may be accomplished using either electric heaters or return air (refer to Section 4.6).

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MICROPROCESSOR

DISCHARGE

SERVICE

VALVE

EVOP

HEAT

EXCHANGER

HP1

CDP

CDT

EVOT

CSMV

EVAPORATOR

FILTER-

DRIER

CST

EVXV

RECEIVER

FUSIBLE

PLUG

LIQUID LINE

SERVICE

VALVE

CSP

COMPRESSOR

DISCHARGE LINE LIQUID LINE SUCTION LINE

SUCTION

SERVICE

VALVE

SUBCOOLER

CONDENSER

Figure 2−14 Refrigerant Circuit

2−21

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SECTION 3 − OPERATION

PARAGRAPH NUMBER Page

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

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

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SECTION 3

OPERATION

3.1 STARTING - ENGINE OPERATION

WARNING

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

MAIN DISPLAYMODE LIGHTS

-20.0

KEYPAD DOOR

UNITS WITH A MAIN POWER SWITCH LABELED

ENGINE/OFF-STANDBY

1. Place the Main Power switch in the ENGINE position.

2. The microprocessor will perform a Self Test

+34.5 F

MessageCenter

(refer to Section 3.3) and then start the unit automatically.

SWITCH BOARD

ENGINE

STANDBY

UNITS WITH A MAIN POWER SWITCH LABELED

1. Place the Main Power switch in the ENGINE position. Then place the switch labeled START/ RUN-OFF in the START/RUN position.

2. The microprocessor will perform a Self Test

(refer to Section 3.3) and then start the unit automatically.

ALTERNATE

CONFIGURATION

STANDBY

START/RUN

OFF

Main Power Switches

START/RUN-OFF

ENGINE

OFF

3−1

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3.2 STARTING - STANDBY OPERATION

WARNING

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.

Starting units with a Main Power switch labeled ENGINE/OFF/STANDBY.

1. Ensure the switch labeled ENGINE/OFF/ STANDBY is in the OFF position.

-20.0

3. Place the switch labeled ENGINE/ OFF/STANDBY in the STANDBY position.

ENGINE

2. Ensure the external power circuit breaker is off, connect standby cable to unit and then turn the external power circuit breaker on.

+34.5 F

ENGINE

OFF

STANDBY

4. The unit will then perform a Self Test (refer to section

3.3) and start the unit automatically.

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STANDBY

3−2

Page 52

Starting units with a Main Power switch labeled START/RUN-OFF.

1. Ensure the switch labeled ENGINE/STANDBY is in the STANDBY position and the switch labeled START/RUN-OFF is in the OFF position

-20.0

3. Place the switch labeled START / RUN OFF in the START/RUN position.

2. Ensure the external power circuit breaker is off, connect standby cable to unit and then turn the external power circuit breaker on.

+34.5 F

START/RUN

OFF

4. The unit will then perform a Self Test (refer to section 3.3) and start the unit automatically.

STANDBY

ENGINE

START/RUN

OFF

NOTE

The unit is equipped with automatic phase reversal which ensures that the electric motors will run in the correct direction.

For safe, reliable operation in Standby Operation, it is important to consider the following guidelines:

• NEVER connect the unit to a high voltage power

source unless the Main Power Switch is in the OFF position.

• The power supply cable and circuit breaker must

comply with local electrical code and unit specifications. Refer to section 2.11.

• The power supply cable must be equipped with a

ground connection.

• Repairs or maintenance to the supply voltage circuit

should only be performed by licensed / authorized personnel.

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3.3 SELF TEST

MODE LIGHTS

MAIN DISPLAY

MessageCenter

DOOR

ENGINE

OFF

STANDBY

SELF TEST

When first powered up, the microprocessor will run a self test consisting of the following steps:

• All of the mode lights will illuminate.

• All of the segments on the main display will turn on.

• All of the liquid crystal diodes (LCDs) of the Messa-

geCenter will turn on to verify their operation.

• The main display will then display the set point tem-

perature in the left characters and a compartment (BOX) temperature in the right characters. The character just to the right of the box temperature indicates the temperature units as “C” Centigrade or “F” Fahrenheit.

• The MessageCenter will then display “MICRO SELF

TEST IN PROGRESS” for several seconds.

• If one or more Inactive alarms are stored, “INAC-

TIVE ALARMS IN MEMORY” will be displayed and the Alarm LED will flash for 5 seconds, then turn off. Refer to Section 3.12 for information on viewing inactive alarms.

•. If the IntelliSet option has been installed the name of

the current IntelliSet or “INTELLISET OFF” will be displayed. Refer to Section 3.17 for IntelliSet information.

• If the microprocessor has been configured to display

the hour meters, the Total Engine Hours, Standby Run Hours and/or Total Switch On Hours will be displayed.

• If there are one or more active alarms, the Mes-

sageCenter will display “UNIT SHUTDOWN - SEE ALARM LIST”. Any active alarms must be corrected and cleared before the unit can start. Refer to Section 3.11 for information on active alarms.

• The microprocessor will then display “SMV CLOS-

ING” while the CSMV and the EVXV are brought to unit starting positions.

• In engine operation, the intake air heater will ener-

gize (as required), the buzzer will sound, and the engine will start.

• In standby operation, the buzzer will sound then

the fans and compressor will start.

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3.4 PRETRIP

1. Place the switch labeled ENGINE/OFF/STANDBY in the desired position OR place the switch labeled START/RUN-OFF in the START/RUN position.

KEYPAD

HEAT CONTINUOUS

-20.0

SETPOINT BOX TEMPERATURE

TEST #1

COOL DEFROST ALARM START‐STOP

+34.5 F

XX% COMPLETE

MANUAL

DEFROST

2. Press the SELECT key until the MessageCenter displays “PRESS THE = KEY TO START PRETRIP” .

3. Press the = key to start Pretrip

ALARM LIST

START‐STOP/ CONTINUOUS

SELECT

4. Verify that during TEST#1 the complete display is turned on and that all lights on the Light Bar come on. Verify during Test #2 that the that the buzzer comes on for the first five seconds.

5. The remainder of Pretrip will take 7 to 15 minutes, and will run itself automatically.

Pretrip is a set of tests run by the microprocessor to check unit operation. It is recommended that a Pretrip be run prior to loading the trailer. It will indicate a failure when one is detected.

TIP

A Pretrip can be started at any box temperature. If Pretrip is started while the unit is in a Start-Stop off cycle the unit will start during the course of the test. If the unit is running when Pretrip is started, it will shutdown for the first three tests.

TIP

It is always a good idea to clear all alarms from both Alarm Lists before starting Pretrip. The technician will then know that any alarms present following Pretrip occurred during Pretrip, and are not old alarms that had not been cleared.

During the Pretrip test, the MessageCenter displays the current test number and description and the % of the test that has been completed. When Pretrip is complete the MessageCenter will display one of three different messages:

• “PRETRIP PASS” OR

• “PRETRIP FAIL IN TEST X” OR

• “PRETRIP FAILED & COMPLETE”. Alarm light

will be on.

Press the ALARM LIST key to review the alarms

triggered by the Pretrip tests.

TIP

The Pretrip test “PASS” of “FAIL” results message will stay displayed until any key is pressed, or until the Main Power Switch is placed in the OFF position.

Once Pretrip is started, the control panel keys are disabled until Pretrip is completed.

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PRETRIP (Continued)

TIP

If “CAN NOT START PRETRIP” is displayed in the MessageCenter, check to see if the unit is in PC Mode (Refer to Section 5.3) or Defrost mode, or check the alarm list (Section 3.11) for active shutdown alarms.

NOTE

Pretrip will run until completed, unless an alarm occurs that causes Pretrip to be aborted. Only alarms that will result in other erroneous alarms or will affect future Pretrip tests will abort Pretrip.

TIP

Pretrip may be stopped by the user by either turning the unit off then back on again, or by pressing and holding the = key for 5 seconds. “PRETRIP STOPPED BY USER” will display in the MessageCenter.

Once Pretrip is started: If the unit is running, the microprocessor will shut the unit down.

NOTE

Before completing Pretrip, the microprocessor looks at the status of alarms and if certain alarms are active (for example: Low Fuel Warning, Check Engine Oil Level, Check Coolant Level, Check Coolant Temperature, Pretrip will display “FAILED”, indicating that the unit is not ready to be sent out for a load, but that the alarm list should be checked and all present alarm situations corrected.

TIP

NOTE

The operator MUST be present and validate Test 1 by watching the microprocessor display. The microprocessor will illuminate all the Mode Lights and all segments of the Main Display. Following Test 1, the operator MUST verify that, during the first 5 seconds of Test 2, the buzzer is energized.

Test 1 - Display Test

The microprocessor activates the display, and both lights on the Light Bar. This test will last 5 seconds. All segments of the display, all LEDs on the microprocessor, both lights of the Light Bar will be on during this test. This portion of the Pretrip requires that the operator determines PASS or FAIL. A defective display is indicated if: any LCD/LED segments are not visible or any LEDs or lights do not illuminate. Anything that fails during this test should be repaired at the conclusion of the Pretrip cycle. Pretrip will continue regardless of the outcome of this test. A faulty display or light bar will not affect the operation of the unit, but will affect what is displayed during unit operation.

Test 2 - Sound and 12VDC Electrical Component

Amperage Check

At the beginning of this test the microprocessor activates the buzzer for 5 seconds, the operator is to determine if the sound test is PASS or FAIL. If the sound test fails it should be repaired at the conclusion of the Pretrip cycle. Pretrip will continue regardless of the outcome of the sound test. A faulty buzzer will not affect the operation of the unit, but will lead to operation without proper audible warning on start up.

Test 2 will continue with a check of the amperage (current) draw of the following components:

• Battery DC Current (All Components Turned Off).

• Front Unloader Solenoid (UL1).

• Rear Unloader Solenoid (UL2) .

• Intake Air Heater (IAH).

• Engine Speed Control Unit (ENSCU).

• Condenser Motor Contactor (CDCON).

• Compressor Motor Contactor (CCON).

• Generator Contactor (GENCON).

• Standby Contactor (PSCON).

• Heater Contactor (1HTCON1).

• Heater Contactor (1HTCON2).

• Evaporator Motor Contactor (1EVCON).

Each component will be individually checked for proper current draw. An alarm will be activated for any component not drawing amperage in the expected range.

Test 3 - Refrigeration System Equalization Check

With the engine and the unit off, the CSMV will open to 50% and the EVXV will open to 100% so that the pressure in the refrigeration system can equalize.

Test 4 will last approximately 5 seconds. If a problem is detected with any of the sensors, the corresponding alarm will be activated.

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PRETRIP (Continued) Test 4 - Temperature Sensor Check

Check the condition of all of the system temperature sensors.

NOTE

Tests 5, 6 an 7 are only performed when unit is in Engine Operation. When in Standby Operation, pretrip will skip to Test 8.

Test 5 - Engine Low Speed

The engine starts up in low speed with condenser fans on. The microprocessor verifies that engine speed is in low speed range. If the engine is not operating within the low speed range, the P174 -“CHECK LOW SPEED RPM” alarm will be activated.

Test 6 - Engine High Speed

The engine switches to high speed and energizes HTCON1 and HTCON2. The microprocessor verifies that engine speed is in high speed range. If the engine is not operating within the high speed range, the P175 “CHECK HIGH SPEED RPM” alarm will be activated.

Test 7 - Engine Low Speed 2

The engine switches back to low speed and heaters turn off. The microprocessor verifies that engine speed is in low speed range. If the engine is not operating within the low speed range, the P174 - “CHECK LOW SPEED RPM” alarm will be activated.

Test 8 - Electric Heater Amperage Check

Each heater will be energized individually and checked for proper current draw. An alarm will be activated for any heater not drawing amperage in the expected range.

Test 9 - Evaporator Fan Motor Amperage Check

The evaporator motor contactor will be energized and checked for proper current draw. An alarm will be activated if the evaporator fan motor is not drawing amperage in the expected range.

Test 10 - Condenser Fan Motors Amperage Check

The condenser fan motor contactor will be energized and checked for proper current draw. An alarm will be activated if the condenser fan motors are not drawing amperage in the expected range.

Test 11 - Check Compressor Suction Modulation

Valve (CSMV)

This test ensures that the CSMV is opening and closing properly. If suction pressure doesn’t change as expected with CSMV closed then the P180 - “CHECK SUCTION MOD VALVE” alarm will be activated. This test may take several minutes.

Test 12 - Electronic Expansion Valve (EVXV)

This test checks the operation of the EVXV. If valve doesn’t test properly the P177 - “CHECK EVAP SUPERHEAT” alarm will be activated.

Test 13 - Unloaders

This test checks the operation of the unloaders. If suction and discharge pressures do not change when UL1 and UL2 are energized and de-energized, the P178 “CHECK UL1” or P191 - “CHECK UL2” alarm will be activated.

Test 15 - Check For Other Alarms

The alarm list is checked for any non-pretrip alarms that may have occurred during the Pretrip test. If any operational alarms occurred, Pretrip will display FAIL, and the technician will need to review the Alarm List and take necessary and appropriate action to clear them. Test 15 will last about five seconds.

Pretrip Termination

When the Pretrip cycle is completed, the unit will return to normal temperature control operation. “PRETRIP PASS” will be displayed until the operator presses any key. In the event that the Pretrip test triggered an alarm(s), either “PRETRIP FAIL & COMPLETE” (if the entire Pretrip cycle was completed), or “PRETRIP FAIL IN TEST XX”, (if the Pretrip cycle was aborted by an alarm before it was completed) will be displayed.

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3.5 CHANGING SET POINT

HEAT CONTINUOUS

COOL DEFROST ALARM START‐STOP

-20.0

SETPOINT BOX TEMPERATURE

+34.5 F

SETPOINT CHANGED

MANUAL

DEFROST

1. Press the UP ARROW or DOWN ARROW key to change the set point to the desired value. The MessageCenter will display “↑↓ TO SCROLL, THEN = TO SAVE”.

ALARM LIST

START‐STOP/

CONTINUOUS

SELECT

2. Press the = key to save the new set point.

By default, set points of -22°F to +89°F (-30°C to +32°C) may be entered via the keypad. The microprocessor always retains the last entered set points in memory. The set points will change 1° (one full degree) OR 0.1° (one tenth of a degree - if configured to do so) for each press and release of the UP ARROW or DOWN ARROW key.

NOTES

The microprocessor may be configured with a minimum and/or maximum set point other than the default values listed above. “MAX SETPOINT HAS BEEN REACHED” or “MIN SETPOINT HAS BEEN REACHED” will display in the MessageCenter when either of these conditions is reached.

Set point may be changed any time the Main Power switch is not in the OFF position, or when the unit is in PC Mode EXCEPT when:

• Viewing the Alarm List, Data List or Functional Parameters OR

• When the unit is in Pretrip OR

• When the unit is in Sleep Mode.

Pressing the = key will cause the new displayed set point value to become active and “SETPOINT CHANGED” will be displayed. If the new value is not entered, after 5 seconds of no keypad activity, the entire display and Light Bar will flash and the buzzer will be energized for 15 seconds (with “SETPOINT NOT CHANGED” displayed) and then revert back to the last entered set point. All other keys are active at this time and if pressed while the display is flashing, will stop the flashing, and perform the requested function.

TIP

The set point may be changed quickly by pressing and holding the UP ARROW or DOWN ARROW key. The longer the key is held, the faster the setting will change.

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3.6 START-STOP OPERATION

HEAT CONTINUOUS

COOL DEFROST ALARM START‐STOP

START-STOP LIGHT

-20.0

SETPOINT BOX TEMPERATURE

+34.5 F

START-STOP MODE SELECTED

MANUAL

DEFROST

2. Verify that “START-STOP MODE SELECTED” is displayed on the MessageCenter and that the STARTSTOP light is illuminated. The unit is now in Start-Stop operation.

ALARM LIST

1. Press the START-STOP/CONTINUOUS key until the START-STOP Light on the microprocessor illuminates.

START‐STOP/ CONTINUOUS

SELECT

Start-Stop is provided to reduce fuel or power consumption. This feature allows full automatic control of the unit shutdown and restart by monitoring refrigerated compartment temperature, battery charging amps and engine coolant temperature (Engine Operation only). The main function of Start-Stop Operation is to turn off the refrigeration system near setpoint to provide an efficient temperature control system and to initiate a restart sequence after certain conditions are met. The Start-Stop/ Continuous key is pressed to select between Continuous Run and Start-Stop Operation. The corresponding LED will be iluminated.

The microprocessor may be configured with Start-Stop operation tied to the set point ranges for frozen and perishable loads. The Start-Stop/Continuous key is locked out if “START-STOP LOCKED” displays in the MessageCenter when the key is pressed and the unit is in Start-Stop Operation or “CONTINUOUS LOCKED” displays in the MessageCenter when the key is pressed and the unit is in Continuous Run Operation. Refer to Section 5.2.1 for Configuration information.

If the unit fails to start after three start attempts, the A31

- “FAILED TO START-AUTO” alarm will be activated. While running, if the unit shuts down, an internal counter keeps track of the shutdowns. Should the unit shutdown three consecutive times without running a minimum of 15 minutes between shutdowns, the A30 - “FAILED TO RUN MINIMUM TIME” alarm will be activated. The shutdown counter is cleared when the unit has run for 15 minutes.

NOTE

In Standby Operation, the unit will stop for a minimum of 5 minutes instead of 15 minutes.

Refer to Section 4.4 for more detailed information on Start-Stop Operation.

3−9

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3.7 CONTINUOUS OPERATION

HEAT CONTINUOUS

COOL DEFROST ALARM START‐STOP

CONTINUOUS OPERATION LIGHT

-20.0

SETPOINT BOX TEMPERATURE

CONTINUOUS RUN MODE SELECTED

MANUAL

DEFROST

1. Press the START-STOP/CONTINUOUS key until the CONTINUOUS OPERATION Light on the microprocessor illuminates.

+34.5 F

ALARM LIST

2. Verify that “CONTINUOUS RUN MODE SELECTED” is displayed on the MessageCenter and that the CONTINUOUS OPERATION light is illuminated. The unit is now in Continuous Operation.

START‐STOP/ CONTINUOUS

SELECT

In Continuous Operation, the unit will not shutdown except in response to a shutdown alarm. Refer to Section

4.5 for more detailed information on Continuous Operation.

The microprocessor may be configured with Start-Stop operation tied to the set point ranges for frozen and perishable loads. The START-STOP/CONTINUOUS key is locked out if “START-STOP LOCKED” displays in the MessageCenter when the key is pressed and the unit is in Start-Stop Operation or “CONTINUOUS LOCKED” displays in the MessageCenter when the key is pressed and the unit is in Continuous Operation. Refer to Table 5−2 for more information on Configurations.

If the unit fails to start after three start attempts the A 31 “FAILED TO START-AUTO” alarm will be activated. While running, if the unit shuts down, an internal counter keeps track of the shutdowns. Should the unit shutdown three consecutive times without running a minimum of 15 minutes between shutdowns the A30 - “FAILED TO RUN MINIMUM TIME” alarm will be activated. The shutdown counter is cleared when the unit has run for 15 minutes.

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3.8 SLEEP MODE

HEAT CONTINUOUS

COOL DEFROST ALARM START‐STOP

SETPOINT BOX TEMPERATURE

SLEEP MODE SETTINGS

MANUAL

DEFROST

ALARM LIST

START‐STOP/ CONTINUOUS

Entering using Functional Parameter settings:

1. Press the SELECT key until the MessageCenter displays “PRESS ↑↓ TO VIEW SETTINGS”.

SELECT

2. Press the UP ARROW key until the Functional Parameter “SLEEP MODE SETTINGS” is displayed. Press the = key. The MessageCenter will then display “↑↓ TO SCROLL, THEN = TO SAVE”.

3. Press either the UP or DOWN ARROW key until “SLEEP MODE: YES” is displayed. The MessageCenter will flash, indicating that this change has not been entered into memory. Press the = key to save the setting ti memory - the MessageCenter will stop flashing, the unit is now in sleep mode.

4. Additional Functional Parameter sub menu selections for “wake up time” and “run pretrip at wake” will now be available and may be saved to memory following the key stroke sequence in the preceding step. Refer to the following paragraphs for information on these settings.

TO EXIT SLEEP MODE

Place the Main Power switch in the OFF position, then back to the desired position.

Sleep Mode is generally used in cold ambients when the unit will be off for an extended period of time with no product inside the refrigerated compartment. Many times units are difficult to start due to a discharged battery, thickened engine oil, etc. after time in cold ambient.

There is NO TEMPERATURE CONTROL in Sleep Mode and it should never be used if the compartment contains perishable or frozen products.

In Sleep Mode and Engine Operation the unit will “Wake Up” periodically and start the engine to keep the battery charged and the engine warm.

In Sleep and Standby Mode if the unit is connected to standby power, the battery charger is energized and will keep the battery charged. The engine will not run with the switch in the STANDBY position.

ADDITIONAL SUB MENUS

1. “WAKE UP TIME” a. When “WAKE UP TIME” is set to NO the unit will

remain in Sleep Mode until it is taken out manually (refer to “TO EXIT SLEEP MODE” instruction above).

b. When “WAKE UP TIME” is set to YES the “SET WAKEUP TIME” menu will become available.

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Pressing the = key will allow the user to select the date and time the unit is to automatically wake up. The wake up time must be at least 1 hour and no more than 8 days from the time the clock is set. The following information can be entered:

 Month (1 to 12).  Day (1 to 31).  Year (1998 to 2037).  Hour (0 to 23).  Minute (0 to 59).

NOTE

The clock is a 24 hour clock. Hours 1 thru 12 are AM and hours 13 thru 24 are PM.

2.“RUN PRETRIP TEST AT WAKE” a. When “PRETRIP TEST AT WAKE” is set to NO

the unit will wake up at the designated time and control to set point.

b. When “PRETRIP TEST AT WAKE” is set to YES. the unit will wake up at the designated time, automatically run Pretrip and then control to set point. “PRETRIP PASS/FAIL” will remain in the MessageCenter until it is manually cleared.

If Sleep Mode is selected with the switch in the ENGINE position, when the unit is not running during a Start-Stop Off Cycle, any remaining Minimum Off Time will be ignored, and the engine will start. It will run for 4 minutes (minimum), until the engine coolant temperature is above 50°C (122°F), and the battery is fully charged (O.K. displays in the Data List voltage line, and charging amps are less than the configured setting). While the unit is running in Sleep Mode, “SLEEP WARNING: NO TEMP CONTROL” will flash in the MessageCenter, and the main display (set point and compartment temperatures) will be off.

If the unit is already running when Sleep Mode is selected, it will continue to run until the conditions described above are met.

While the unit is cycled off in Sleep Mode, “SLEEP MODE, OFF/ON TO WAKE” will be displayed in the MessageCenter. The display backlight will turn off after 5 minutes.

While in Sleep Mode, Unit Data and Alarm Lists may be viewed, and Functional Parameters may be viewed and changed as necessary. However, Start-Stop/Continuous Run selections and set point can not be changed. Manual Defrost and Pretrip can be initiated.

The unit will restart when engine coolant temperature drops below the configured restart temperature value or if the battery voltage drops below the configured battery restart value. (refer to Table 5−2)

NOTE (FOR ENGINE OPERATION ONLY)

In the event that the Engine Coolant Temperature sensor fails, Sleep Mode will operate as follows:

In ambients above 32°F (0°C), the unit will run as above, and will monitor battery voltage and charging amps only (according to the Configuration setting).

In ambients below 32°F (0°C), the unit will run for 20 minutes minimum run time, then restart every 60 minutes (maximum off time). Battery voltage and amperage will be monitored normally.

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3.9 MANUAL DEFROST

DEFROST LIGHT

HEAT CONTINUOUS

+34

SETPOINT BOX TEMPERATURE

COOL DEFROST ALARM START‐STOP

DEFROST CYCLE STARTED

MANUAL

DEFROST

Press the MANUAL DEFROST key. The DEFROST light will come on and the MessageCenter will display “DEFROST CYCLE STARTED” for 5 seconds, or flash “CANNOT START DEFROST CYCLE” for five seconds.

ALARM LIST

START‐STOP/ CONTINUOUS

SELECT

When defrost mode cannot be manually initiated “CANNOT START DEFROST CYCLE” is displayed in the MessageCenter. This will occur when:

• DTT is above 40°F (4°C). Defrost may be entered

any time the DTT is below 40°F (4°C) OR

• The engine has not run 15 seconds after starting OR

• The unit is in PC Mode OR

• The unit is in Pretrip OR

• There is an active shutdown Alarm.

TIP

The Manual Defrost Key can be used at any time to start a Defrost Cycle as long as the preceding conditions are met.

NOTE

Refer to Section 4.6 for more detailed information on DEFROST.

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3.10 TRIP START

HEAT CONTINUOUS

COOL DEFROST ALARM START‐STOP

-20.0

SETPOINT BOX TEMPERATURE

+34.5 F

TRIP START ENTERED

MANUAL

DEFROST

1. To mark the start of a trip in the DataLink data recorder, press the SELECT key until the MessageCenter displays “PRESS = TO MARK TRIP START”.

2. Press the = key.

ALARM LIST

START‐STOP/

CONTINUOUS

SELECT

3. If trip start is acknowledged by the DataLink data recorder, “TRIP START ENTERED” will be displayed for five seconds and then the display will revert back to the normal display. Otherwise “CANNOT ENTER TRIP START” will flash and then the display will revert back to the normal display.

Trip Start places the present time and date as a stamp in the DataLink data recorder memory to allow easy review of the data from the last trip, and to allow downloading data from a specific trip. A trip begins at a Trip Start and ends at the next Trip Start.

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3.11 VIEW ACTIVE ALARMS

ALARM LIGHT

HEAT CONTINUOUS

COOL DEFROST ALARM START‐STOP

-20.0

SETPOINT BOX TEMPERATURE

+34.5 F

NO ACTIVE ALARMS

MANUAL

DEFROST

1. Press the ALARM LIST key. If there are no active alarms, “NO ACTIVE ALARMS” will display for 5 seconds.

2. If there are active alarms, the alarm number will be displayed with the letter “A” in front and the alarm message following. The last alarm that occurred will be the first alarm displayed and so on.

ALARM LIST

START‐STOP/ CONTINUOUS

SELECT

3. Press the ALARM LIST or UP ARROW key to scroll through the list of alarms.

4. When you reach the end of the alarm list, “LIST END, = TO CLEAR ALARMS” is displayed for five seconds.

5. To clear the alarm list, press the = key while “LIST END, = TO CLEAR ALARMS” is being displayed. “ACTIVE ALARMS LIST CLEAR” is displayed. This will move all Alarms to the Inactive Alarm list.

Alarms are stored in the Alarm List in the microprocessor. Stored alarms may be viewed in the MessageCenter.

For a complete list of alarms, their meanings, and troubleshooting refer to Section 7.

Another way to clear active alarms is to turn the microprocessor OFF and then back on using the Main Power switch

“CHK WIRES FROM MICRO TO KEYPAD” indicates there is a wiring problem between the microprocessor and the display module.

TIP

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3.12 VIEW INACTIVE ALARMS

HEAT CONTINUOUS

COOL DEFROST ALARM START‐STOP

-20.0

SETPOINT BOX TEMPERATURE

+34.5 F

NO INACTIVE ALARMS

MANUAL

DEFROST

1. Press and hold both the ALARM LIST key and the UP ARROW key for six seconds. If there are no inactive alarms, the display will read “NO INACTIVE ALARMS” for five seconds.

2. If there are inactive alarms, the display will be ‘I’ in front of the alarm number and message.

ALARM LIST

START‐STOP/

CONTINUOUS

SELECT

3. Press the ALARM LIST or UP or DOWN key to scroll through the list of alarms.

4. When you reach the end of the alarm list, “LIST END, = TO CLEAR ALARMS” is displayed for 5 seconds.

5. To clear the active and inactive alarm list, press the = key while “LIST END, = TO CLEAR ALARMS” is being displayed. “ALL ALARMS CLEAR” is displayed.

The microprocessor can hold up to 16 alarms in the combined Active and Inactive Alarm lists. The lists can be read via the MessageCenter or using the ReeferManager PC Program. There are two sections in the Alarm list, an Active Alarm Section and Inactive Alarm Section. Alarms in these sections are in the order in which the alarms activate and inactivate, respectively. On startup, all alarms are marked as inactive in the entire list. If an inactive alarm becomes active, the alarm is moved from the Inactive Alarm list to the Active Alarm list.

As additional alarms occur, they will be placed first in the Active Alarm list. Each alarm can only be present in either the Active or Inactive Alarm List at any given time. As conditions change, alarms may be moved from the Active Alarm list to the Inactive alarm list and back.

Alarms are also recorded in the DataLink data recorder. They are recorded at the time they occur (become active), and the time they become inactive.

For a complete list of Alarms and troubleshooting information Refer to Section 7.

TIP

When alarms are cleared from the Inactive Alarm List, both active and inactive alarm lists are cleared.

If there is a safety shutdown “UNIT SHUTDOWN - SEE ALARM LIST” will be displayed. Pressing the Alarm List key will bring any Active Alarms into the MessageCenter. Refer to Section 7 for a complete list of Alarms and their descriptions.

NOTE

The Inactive Alarm List is also called the Technician’s List. Only qualified refrigeration technicians should access the inactive list. It is not intended for the use of drivers or operators.

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3.13 UNIT DATA

HEAT CONTINUOUS

COOL DEFROST ALARM START‐STOP

-20.0

SETPOINT BOX TEMPERATURE

+34.5 F

PRESS ↑ ↓ TO VIEW DATA

MANUAL

DEFROST

1. Press the SELECT key until the MessageCenter displays

2. Press the green UP ARROW key. The MessageCenter will display “PRESS ↑↓ TO VIEW DATA, THEN = TO LOCK” . Continue to press the green UP ARROW key to move down the Data List, or press the DOWN ARROW key to move up the Data List. (Refer to Table 3-1.)

ALARM LIST

“PRESS ↑↓ TO VIEW DATA.”

START‐STOP/ CONTINUOUS

SELECT

3. The selected Data Item will remain in the MessageCenter for ten seconds, then the default message (“STATUS OK” or other customer specified message) will display.

4. To lock an item in the MessageCenter for continuous viewing, press the = key. The Data item will flash continuously to indicate it is locked.

5. Pressing the UP or DOWN ARROW key will unlock that item and move to the next data item. Pressing the = key will unlock the item and, after ten seconds, the default message will be displayed.

Table 3-1 Unit Data

* Displays information or setting entered in the microprocessor Configurations + May or may not be displayed depending on Parameter/Configuration settings

Data readings are presented starting with “SUCTION PRESSURE” and progress-

DATA DEFINITION

SUCTION PRESSURE Compressor suction pressure DISCHARGE PRESSURE Compressor discharge pressure EVAPORATOR PRESSURE Leaving evaporator pressure ENGINE COOLANT TEMP Engine coolant temperature RETURN AIR TEMP Return (air entering evaporator) temperature

ing down the list using the green UP ARROW key.

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Table 3-1. Unit Data - Continued

* Displays information or setting entered in the microprocessor Configurations + May or may not be displayed depending on Parameter/Configuration settings

SUPPLY AIR TEMP Supply (air leaving evaporator) temperature DELTA-T Supply air temperature minus return air temperature AMBIENT AIR TEMP Ambient (air entering condenser) air temperature DEFROST TERM TEMP 1 Defrost termination temperature SUCTION LINE TEMP Suction line temperature at the compressor EVAP OUTLET TEMP Suction line temperature leaving the evaporator outlet COMP DISCHARGE TEMP Compressor discharge temperature BATTERY Battery voltage CURRENT DRAW (DC) Battery charging or discharging amps ENGINE RPM Engine speed UNIT AC CURRENT #1 High voltage current draw on circuit #1. UNIT AC CURRENT #2 High voltage current draw on circuit #2. FUEL LEVEL This is only displayed when the sensor is configured ON. % of fuel in

SUCTION MOD VALVE EXPANSION VALVE START MODE AUTO if the engine will start automatically

INSTALLED OPTIONS This is only displayed when one or more options is configured ON. Lists

SOFTWARE REVISION Revision of the software that is operating the microprocessor

tank. % open of CSMV

% open of EVXV

MANUAL if the engine must be started manually

installed options. Press “=” to access the list.

DISPLAY SOFTWARE REV Revision of the software that is operating the display CONTROL SERIAL # Serial Number of the microprocessor TRAILER ID # ID (as configured by the user)

UNIT SERIAL # Unit serial number

UNIT MODEL # Unit model number

HOURS TO ENGINE

MAINTENANCE HOURS TO S/B MOTOR

MAINTENANCE

HOURS TO UNIT

MAINTENANCE TIME LEFT TO PM (1-5) This is only displayed when one or more of the meters is configured ON.

This is only displayed when the meter is configured ON. Number of engine hours until the next programmed engine maintenance

This is only displayed when the meter is configured ON. Number of hours until the next programmed electric standby motor maintenance.

This is only displayed when the meter is configured ON. Number of switch-on hours until the next programmed general unit maintenance.

Number of hours until the next programmed maintenance. (May display user programmed identification.)

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Table 3-1. Unit Data - Continued

* Displays information or setting entered in the microprocessor Configurations + May or may not be displayed depending on Parameter/Configuration settings

PRODUCTSHIELD SETUP: Press “=” to access the list.

 PRODUCTSHIELD

ECONO:

 ECONO MIN

TEMP - XX°

 ECONO MAX

TEMP - XX°

 ECONO

DELTA-T - XX°

 PRODUCTSHIELD

HIGH AIR:

 HIGH AIR MIN

TEMP - XX°

 HIGH AIR MAX

TEMP - XX°

 HIGH AIR

DELTA-T - XX°

 PRODUCTSHIELD:

WINTER - XX°

RANGE 1 LOCK This is only displayed when Range Lock 1 is configured ON.

RANGE 1 MINIMUM TEMP Displays minimum temperature setting for Range 1. (Will only be dis-

RANGE 1 MAXIMUM TEMP Displays maximum temperature setting for Range 1. (Will only be dis-

RANGE 2 LOCK This is only displayed when Range Lock 1 is configured ON.

RANGE 2 MIN. TEMP Displays minimum temperature setting for Range 2. (Will only be dis-

RANGE 2 MAX. TEMP Displays maximum temperature setting for Range 2. (Will only be dis-

TEMPERATURE (REMOTE)

SENSOR (1, 2 or 3)

DATALOGGER (DataLink

data recorder)

Indicates if ProductShield Econo is OFF OR Go To Start-Stop OR Go

To Continuous Run

Displays minimum temperature setting for activation of ProductShield Econo. (Will only be displayed if Econo is NOT OFF)

Displays maximum temperature setting for activation of ProductShield Econo. (Will only be displayed if Econo is NOT OFF)

Displays Delta-T setting for activation of ProductShield Econo. (Will only be displayed if Econo is NOT OFF)

Indicates if ProductShield High Air is OFF OR ON

Displays minimum temperature setting for activation of ProductShield High Air. (Will only be displayed if Econo is NOT OFF)

Displays maximum temperature setting for activation of ProductShield High Air. (Will only be displayed if Econo is NOT OFF)

Displays Delta-T setting for activation of ProductShield High Air. (Will only be displayed if Econo is NOT OFF)

Indicates ProductShield Winter is OFF or the ambient temperature below which ProductShield Winter will be active.

Displays Range Lock 1 setting: OFF = Temperature Range 1 Lock is turned off. CONTINUOUS = When the set point is set between Range 1 Minimum

& Maximum Temperatures, the unit is set to operate only in Continuous. START-STOP - When the set point is set between Range 1 Minimum &

Maximum Temperatures, the unit is set to operate only in Start-Stop.

played if Range Lock 1 is ON)

Displays Range Lock 1 setting: OFF = Temperature Range 2 Lock is turned off. CONTINUOUS = When the set point is set between Range 2 Minimum

& Maximum Temperatures, the unit is set to operate only in Continuous Run.

START-STOP = When the set point is set between Range 2 Minimum & Maximum Temperatures, the unit is set to operate only in Start-Stop.

played if Range Lock 2 is ON)

Will only display when one or more of the optional sensors are configured ON. Displays temperate reading of remote Temperature Sensor 1 (2, or 3).

Displays the current Date and Time that the DataLink data recorder is using. This may be different than local time, depending on the Time Zone and Daylight Savings.

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3.14 VIEW HOUR METERS

HEAT CONTINUOUS

COOL DEFROST ALARM START‐STOP

-20.0

SETPOINT BOX TEMPERATURE

+34.5 F

TOTAL ENGINE HOURS: 0 HRS

MANUAL

DEFROST

ALARM LIST

1. Press the SELECT key until the MessageCenter dis-

START‐STOP/ CONTINUOUS

plays “PRESS ↑↓ TO VIEW HOURMETERS”.

2. Press the green UP ARROW key. The MessageCenter will display “PRESS ↑↓ TO

SCROLL, THEN = TO LOCK” . Continue to press the green UP ARROW key to move down the hour meter list, or press the DOWN ARROW key to move up the list.

SELECT

3. Displayed hour meters will depend on microprocessor configurations (refer to Table 5−2). Typical displayed meters are: “TOTAL ENGINE HOURS”, “STANDBY RUN HOURS” and “TOTAL SWITCH ON HOURS”.

4. Pressing the = key will access all other meters and display “OTHER METERS AND COUNTERS”.

5. The selected hour meter will remain in the MessageCenter for 10 seconds, then the default message (“STATUS OK” or other customer specified message) will display.

6. To lock an hour meter in the MessageCenter for continuous viewing, press the = key. The Data item will flash continuously to indicate it is locked.

7. Pressing any key on the keypad will unlock the item. Pressing the UP or DOWN ARROW key will move to the next hour meter.

Hour meters available when “OTHER METERS AND COUNTERS” is chosen are:

Meters listed in Step 3 above and, up to 5 User

Configurable meters including:

 Switch On Standby Hours  Engine Protect Hours.  Switch On Protect Hours.

 Engine Sleep Hours.  Switch On Sleep Hours.  Compressor Run Hours  High Speed Hours.  Start cycles.

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3.15 FUNCTIONAL PARAMETERS

HEAT CONTINUOUS

COOL DEFROST ALARM START‐STOP

+34.5 F

-20.0

SETPOINT BOX TEMPERATURE

+34.5 F

PRESS ↑ ↓ TO VIEW SETTINGS

MANUAL

DEFROST

1. Press the SELECT key until the MessageCenter displays

2. By pressing the UP ARROW key, you will move through the Functional Parameter list beginning at the top or by pressing the DOWN ARROW key, you will move through the list beginning at the bottom.

ALARM LIST

“PRESS ↑↓ TO VIEW SETTINGS”.

START‐STOP/

CONTINUOUS

SELECT

3. To change one of the Parameters, bring the Parameter you wish to change into the MessageCenter, and press = key. “↑ ↓ TO SCROLL, THEN = TO SAVE” will display in the MessageCenter. Pressing either UP or DOWN ARROW key will display the Parameter selections available for that Function. The MessageCenter will flash, indicating that a change to the displayed parameter selection has not been entered into memory.

4. Continue pressing UP or DOWN ARROW key until the desired Parameter selection is displayed, then press the = key. The MessageCenter will stop flashing. The new Parameter selection is now in memory. If the = key is not pressed within 10 seconds, the MessageCenter will display “FUNCTION NOT CHANGED”. This will display for 5 seconds, then return to the last Functional Parameter displayed. If no further keys are pressed, the default display will return in another 10 seconds.

NOTE

The microprocessor may be configured with all of the Parameters locked or some individual Parameters locked. Any Parameter that is displayed with a padlock symbol cannot be changed from the keypad.

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Table 3-2 Functional Parameters

FUNCTION

PARAMETER

SELECTIONS

DESCRIPTION

NOTES: Selections in BOLD are the default settings. Also, Functional Parameter marked with an asterisk (*) may

not display in the list for this unit, depending on how the microprocessor has been configured.

SILENT MODE

DEFROST INTERVAL TIMER SET FOR

OFF

1.5HRS 3HRS

6HRS

12HRS

OFF - Normal engine speed operation. On - Forced low engine speed operation. Used to disable high speed. The defrost timer will automatically put the unit into the defrost cycle at

the interval selected if DTT is below 40°F (4.4°C). Shorter times are generally used for warm, humid products like pro-

duce. Longer times can be used for dry and frozen products. NOTE: the the timer increments time toward the next defrost only

when the DTT is below 40°F and the unit is running.

Set Start-Stop Parameters

Time and Temperature values that control Start-Stop Operation are set in this section.

The microprocessor may be configured so that: 1. the same settings apply to any set point = “Together”, or 2. the settings are different, depending on whether the set point is in the perishable range or in the frozen range = “Separate”.

If “together” is configured, there will be five settings with only the fifth applicable to just frozen range. If “Separate” is configured there will be nine settings four labeled perishable and five labeled frozen.

 MIN RUN

TIME:

 MIN OFF TIME:

 RESTART TEMPERATURE

 OVERRIDE

TEMP:

 MAX OFF

TIME:

 FROZEN

SHUTDOWN OFFSET

4MINS

TO 60MINS (in 1 minute increments)

10MINS TO 90MINS

20MINS

(in 1 minute increments)

0.5°F (2°C) TO 18

°F (10°C)

°F (3°C)

5.5

(in 0.5°F or C increments)

3.6°F (2°C) TO 18

°F (10°C) °F (6°C)

(in 0.5°F or C increments)

OFF

10MINS TO 255MINS (in 1 minute increments)

05C (0°F) TO 2

°C (3.6°F)

(in 0.5°F or C increments)

This determines the minimum length of time the unit will run every time the unit starts in Start-Stop Operation.

This determines the minimum length of time the unit will remain off whenever the unit cycles off in Auto Start-Stop Operation.

Following the Minimum Off Time, should the compartment temperature drift this far above or below set point in the Perishable Range or above set point in the Frozen Range, the unit will restart.

This selects the override temperature for the Minimum Off Time portion of the Auto Start-Stop Off Cycle. During the Minimum Off Time, should the compartment temperature drift this far above or below set point in the Perishable Range, or above set point in the Frozen Range, the microprocessor will override the Minimum Off Time, and restart.

OFF = There is no maximum off time. When a minute value is selected, this is the longest amount of time the

unit will remain off during a (Perishable or Frozen or both) Auto Start-Stop Off Cycle. When this time expires, the unit will restart and run for the Minimum Run Time, regardless of any temperature change inside the compartment.

This only applies to Frozen set points in Start-Stop operation. The system generally will allow an off cycle when the RAT is 0.5°F (0.3°C) above set point. This offset is the number of degrees below the 0.5°F (0.3°C) value that the unit will run before cycling off. This will allow for a lower average compartment temperature when considering temperature rises during off cycles.

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Table 3-2 Functional Parameters - Continued

FUNCTION

PERISHABLE SENSITIVE PRODUCT

TEMP CONTROL

DISPLAY TEMPS

OFF

RETURN AIR

SUPPLY AIR

FAHRENHEIT

CELCIUS

IN ...

DISPLAY PRESSURES IN ...

PSIG

BAR

ECO MODE NO

YES

RESET PM HOURMETERS

 STANDBY

RUN HOURS

 TOTAL

ENGINE HOURS

 TOTAL

SWITCH ON HOURS

 PM 1 Thru 5

OUT OF RANGE

ALARM

Metric English OFF OFF 2°C4°F 3°C5°F

4°C7°F

PARAMETER

SELECTIONS

RESET

DESCRIPTION

OFF = Supply air temperature will be limited to the colder temperature of 32°F (0°C) or set point less the Supply Air Limit Configuration value.

ON = Supply air temperature will be limited to set point less the Supply Air Limit Configuration value.

Refer to Section 4.7.1 for complete information on Perishable Sensitive Product and Supply Air Configuration interaction.

The evaporator has both a Return Air Sensor and a Supply Air Sensor. RETURN AIR = only the return air sensor reading will be used for cal-

culating control actions. “Return Air” is generally selected for most products.

SUPPLY AIR = the microprocessor will switch to the supply air sensor when operating with a perishable set point (10.4°F [-12°C] or above). “Supply Air” will control within a narrower temperature band.

The compartment temperature will display in either English (°F) using a decimal point to display tenths of a degree OR or Metric (°C ) using a comma to display tenths of a degree.

NOTE: Temperature setting values displayed in the MessageCenter will continue to use a decimal for both °F and °C.

Pressures will display in either English (psig) or Metric (bar).

NO = When in Continuous Operation, control for maximum temperature protection.

YES = When in Continuous Operation, control for maximum fuel economy.

This Functional Parameter allows resetting of the PM maintenance alarm when an hour meter has timed out, or when over 95% of the time out value has expired. If a maintenance interval has not been configured for the alarm, this parameter will not display.

Selecting RESET and pressing the = key will de-activate the alarm, and reset the hour meter for the next maintenance interval. The amount of time added back into the meter before the next alarm trigger is determined by the maintenance interval entered in the meter Configuration.

If there are active maintenance hour meters and none have expired and turned the alarm on, or none are within 95% of the time out value, the MessageCenter will display “NO METERS TO RESET.”

NOTE: If a reset is required for a meter that has not timed out, the meter must be configured with a “0” reset value (to turn it off) and then

reconfigured with the desired reset interval. Refer to Section 5 for Configuration instructions.

The value entered here is the number of degrees away from set point the compartment temperature may drift before the compartment is considered “Out Of Range” and the configured alarm or alarm and shutdown action will be activated. Refer to Alarm A53 - “BOX TEMPERATURE OUT OF RANGE” (Section 7) for more information.

3−23

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Table 3-2 Functional Parameters - Continued

FUNCTION

PARAMETER

SELECTIONS

Allows user to set the number of minutes the unit will run in low speed every time the engine starts.

CONTINUOUS OFF

1 TO 255MINS

1 MINUTE

START-STOP OFF

1 TO 255MINS

10 MINUTES

SLEEP MODE SETTINGS

* NO S/B POWER SWITCH TO

For complete instructions on entering and setting parameters for Sleep Mode refer to Section

3.8. Press “=” to access menu.

DIESEL

SHUT UNIT DOWN

OVERRIDE

REMOTE

YES

SWITCH 1

SHUTDOWN

(REMS1)*

AND

OVERRIDE

REMOTE

SWITCH 2

SHUTDOWN

(REMS2)*

AND

OVERRIDE

DOOR SWITCH

SHUTDOWN

(DS)*

ENGLISH ENGLISH- All information displayed in the MessageCenter will be dis-

ESPAÑOL FRANÇAIS- All information displayed in the MessageCenter will be

FRANÇAIS ESPAÑOL- All information displayed in the MessageCenter will be dis-

LANGUAGE: IDIOMAS: LANGUE: LINGUAGEM:

PORTUGUÊS PORTUGUÊS - All information displayed in the MessageCenter will be

NOTE 1: This parameter can be quickly accessed by pressing and holding the Select Key for 6 seconds.

NOTE 2: If the padlock is visible when accessing language from the Functional Parameter List, the language cannot be changed. However, when accessing the language by pressing and holding the Select Key for 6 seconds the language can be changed even if the padlock is displayed.

DESCRIPTION

Low Speed Startup Minutes

Press “=” to access menu.

Allows user to set the number of minutes the unit will run in low speed every time the engine starts in Continuous operation.

Allows user to set the number of minutes the unit will run in low speed every time the engine starts in Start-Stop Operation.

*If the NO AC POWER Configuration is set to “Alarm & Shutdown” this parameter will not display

SWITCH TO DIESEL = If the NO AC POWER Configuration is set to the “Switch To Engine” (on power loss), setting this parameter to “SWITCH TO DIESEL” will confirm the Configuration and the switch will be allowed.

SHUT UNIT DOWN = If the NO AC POWER Configuration is set to the “Switch To Engine”, setting this parameter to SHUT UNIT DOWN will override the Configuration setting and shut the unit down when power is lost. The purpose of this setting is to temporarily override the Configuration setting in situations where switching to engine power is not desired.

*If the Switch is configured “Switch Not Installed”, this parameter will not display

NO = the microprocessor will respond to the switch as configured

YES = the configured action on activation of the switch will be overridden and the action will be alarm only. The purpose of this setting is to temporarily override the Configuration setting in situations where shutdown or speed change is not desired.

played in English.

displayed in French.

played in Spanish.

displayed in Portuguese.

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3.16 LANGUAGE SELECTION

HEAT CONTINUOUS

COOL DEFROST ALARM START‐STOP

-20.0

SETPOINT BOX TEMPERATURE

+34.5 F

ESPAÑOL

MANUAL

DEFROST

1. Press and hold the SELECT key for 6 seconds until MessageCenter displays the current language (ENGLISH, ESPAÑOL, FRANÇAIS or PORTUGUÊS).

ALARM LIST

START‐STOP/

CONTINUOUS

SELECT

2. Press the UP or DOWN ARROW key until the MessageCenter indicates the desired language. Press the = key. The new language will now be active. If the = key is not pressed within 10 seconds, the MessageCenter will change to “FUNCTION NOT CHANGED”. This will flash for 5 seconds, then return to the current language. If no further keys are pressed, the default display will return in another 10 seconds.

TIP

If the language is set to one that the user does not understand, press and hold the “SELECT” key for 6 seconds to bring up the Language Parameter so that it can be changed.

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3.17 INTELLISET

HEAT CONTINUOUS

+34.0

DURING START UP Observe the MessageCenter during the power up process. If an IntelliSet is running, the name of the IntelliSet

will be displayed for approximately 10 seconds before the unit starts.

DURING OPERATION Press the SELECT key to view current IntelliSet. You will be prompted to press either the “=” key or the UP or

DOWN ARROW Key to scroll through list of IntelliSets. The current IntelliSet will have either the word ACTIVE or MODIFIED after it. MODIFIED indicates that one or more of the IntelliSet settings (other than set point) have been changed. To change MODIFIED to ACTIVE, press = key while the IntelliSet is displayed in the MessageCenter.

COOL DEFROST ALARM START‐STOP

SETPOINT

APPLES

+36.5 F

BOX TEMPERATURE

MANUAL

DEFROST

ALARM LIST

ACTIVE

START‐STOP/

CONTINUOUS

SELECT

The Advance Microprocessor offers up to 31 parameters that may be set depending on the product being carried. IntelliSet allows the owner to pre-program specific product settings into the microprocessor and give the settings a name. The operator may then call up these settings by simply selecting the IntelliSet name.

For example: A load of apples may require continuous operation at 35°F (1.7°C) with a defrost every 3 hours while a load of cheese may require the same operation with set points ranging from 35°F to 42°F (1.7°C to

5.6°C) and a load of ice cream requires Start-Stop operation at -22°F (-30°C) with defrost at 12 hour intervals. The settings required for each product may be entered into the microprocessor and then locked so they cannot be changed. In the case of the cheese, the range of set points may be locked, leaving the operator the ability to change the set point within the locked range.

When a load of apples is going to be picked up, the operator simply selects “APPLES” from the IntelliSet menu; for cheese, “CHEESE” is selected ; for ice cream, “ICE

CREAM” is selected. With each selection, the microprocessor automatically re-programs the settings to provide the best temperature control, fuel economy, and performance for that particular product.

NOTE

The above settings are examples of possible settings. Factory IntelliSets are available from your authorized Carrier Transicold Truck/Trailer dealer.

NOTE

IntelliSet #32 is Range Protect, it is designed to prevent freezing or overheating of non-sensitive cargo by locking the unit is Start-Stop Operation when the compartment temperature is in the pre-set range (default range is 32 to 72°F, 0 to 32°C). Range Protect offers increased power savings over normal Start-Stop Operation.

The ONLY way to exit from Range Protect is to select a different IntelliSet.

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3.17.1 Changing IntelliSets - With the = Key Enabled.

NOTE: If pressing the = key does not

bring up the IntelliSet message the microprocessor is not configured with this feature. To view IntelliSets, refer to the following section.

HEAT CONTINUOUS

+34.0

SETPOINT

1. PRESS the = Key to display current IntelliSet.

COOL DEFROST ALARM START‐STOP

+36.5 F

BOX TEMPERATURE

APPLES

MANUAL

DEFROST

ALARM LIST

START‐STOP/ CONTINUOUS

ACTIVE

SELECT

2. Press the UP or DOWN ARROW key, to move through the IntelliSet List. The current In- telliSet will have either ACTIVE or MODIFIED to the right of the name.

3. To use a different IntelliSet, bring the desired IntelliSet into the MessageCenter and press the = Key.

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3.17.2 Changing IntelliSets - Without the = Key Enabled.

HEAT CONTINUOUS

+34.0

COOL DEFROST ALARM START‐STOP

SETPOINT

+36.5 F

BOX TEMPERATURE

PRESS ↑ ↓ TO VIEW INTELLISETS

MANUAL

DEFROST

1. Press the SELECT key until MessageCenter displays “PRESS ↑↓ TO VIEW INTELLISETS”.

2. When the UP ARROW key is pressed, the IntelliSet List will scroll up, beginning at the bottom. When the DOWN ARROW key is pressed, the IntelliSet List will scroll down, beginning at the top. The current IntelliSet will have either “ACTIVE” or “MODIFIED” to the right of the name.

ALARM LIST

START‐STOP/ CONTINUOUS

SELECT

3. Bring the IntelliSet you wish to use into the MessageCenter and then press the = key. The selected IntelliSet will now become active.

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3.18 STOPPING 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.

unit off

To stop the unit, place the Main Power switch in the OFF position.

The diesel engine or compressor will stop and the microprocessor will display “MICRO WILL STOP IN ## SECONDS”. At the end of the countdown time the Microprocessor Main Display, MessageCenter, and all indicator LEDs will then turn off.

NOTE

Due to internal processing within the microprocessor, turning the Main Power switch off then back on will result in a 4 to 50 second delay between the display going off and coming back on again.

ENGINE

OFF

STANDBY

NOTE

The microprocessor will close the Electronic Expansion Valve (EVXV) and the CSMV to 0% open before turning off.

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3.19 DataLink DATA RECORDER

The Advance microprocessor contains a built-in DataLink data recorder with 512K of memory. The recorded data can be downloaded from the DataLink data recorder using either ReeferManager or a Download PC card.

The DataLink data recorder reads the same input information as the microprocessor (Functional Parameters, Configurations, and Unit Data) at all times. The DataLink data recorder records events as they occur, such as set point changes and defrost initiation and termination, and also records all data values including temperature sensors and pressure transducers in either averaged or snapshot format.

The following intervals are available for sensor recording:

2 Minutes 30 Minutes 5 Minutes 1 Hour 10 Minutes 2 Hours 15 Minutes 4 Hours

3.19.1 Microprocessor Information

The microprocessor information that may be recorded is as follows:

 DataLink data recorder setup (Logging Intervals,

Events and Sensors)

 DataLink data recorder time clock date / time

 Set points

 ID Number

 Unit Serial Number

 Unit Model Number

 Trailer ID

 Current System Mode

 Functional Parameters

 Microprocessor Configurations

3.19.2 Data Recording

The DataLink data recorder data comes from four general categories of information:

a. Microprocessor Information as described in Section

3.19.1 above.

b. Sensor Data This information is recorded at pre-determined intervals

as a snapshot of the sensor at the time of the recording, or an averaged reading of the sensor readings since the last recording. The user can determine which sensor(s) will be recorded, at what intervals, and whether snapshot or averaged readings are preferred. (Snapshot readings of sensors are also taken at the time of a shutdown alarm.)

All of the sensors and transducers that may be read under Unit Data (refer to Table 3-1) may be included or excluded form the recordings.

c. Event Occurrences This information is any additional data that is recorded

on a “when it occurs” basis. Events are recorded by the recorder as they occur. An Event is defined as something that happens and may include:

 Set point change  Defrost cycle start  Main power on  Pretrip start  Pretrip end  Unit mode (Start-Stop or Continuous Operation)  Control mode (Heat, Cool, High/Low speed, etc)  Door and Remote switch activations.  Hour Meter readings (Hour meters are recorded at

midnight or the first time of day the Main Power switch

is toggled out of the OFF position. d. User Area Data The User or service technician may enter a Comment

into the DataLink data recorder using the ReeferManager program.

3.19.3 Data Downloading

The data within the DataLink data recorder can be downloaded using either the ReeferManager program with a download cable connected to the download port or with a Download PC card (refer to Section 5.3). If a PC card is used, the ReeferManager program is then used to extract the data from the PC card, and place it on the computer hard disk.

3.19.4 DataLink Data Recorder Power-Up

The DataLink data recorder records data the entire time the Main Power switch is not in the OFF position. A Configuration exists which allows the user to select either an additional 8 hours of sensor data be recorded after the switch is placed in the OFF position, or to stop recording at the same time the switch is placed in the OFF position. The factory setting is to stop recording at the same time the switch is placed in the OFF position. (Refer to Section 5.2.1.)

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3.20 OPTIONS

3.20.1 DataTrak

DataTrak allows remote communication with the Advance microprocessor (cellular, satellite, etc).

One way Communication providers can request data from the Advance microprocessor and transmit it via their equipment to another location. This is typically done via the Internet to any destination in the world.

WARNING

Two Way Communication providers can also send commands via their equipment to the Advance microprocessor to start or stop the unit, change settings and the way the microprocessor is operating the unit.

DataTrak is an optional feature. The DataTrak option is installed by inserting a DataTrak PC Card into the PC Card slot of the microprocessor and following the on-screen instructions on the keypad.

The DataTrak Option installation can be confirmed by scrolling through the Unit Data (refer to Section 3.13). DataTrak will be listed under the Installed Options heading if it is installed.

Once DataTrak is installed, the Advance Microprocessor must be properly configured for the provider that will be connecting to it (refer to section 5.2.1). The Satellite Com configuration can be set for “Qualcomm” or “Other”.

If the provider is Qualcomm T2 (Trailer Tracs 2) or any other provider then the “Other” setting is used. If the provider is Qualcomm Trailer Tracs then the “Qualcomm” setting is used.

Carrier Transicold has worked with approved communication providers with recommended installation locations, and wiring connections to Carrier units. Instructions for installing this equipment is supplied by each individual provider, and not by Carrier Transicold. Communications electrical harnesses and serial port splitters are available from Carrier Transicold Performance Parts Group (PPG).

Communication Providers will connect into the wiring harness at the SATCOM port. Testing the SATCOM port may be done using a serial port to PC cable (22-01690-00) and the ReeferManager program. If ReeferManager can communicate with the microprocessor the unit wiring and microprocessor are performing normally and any communication problem is with the provider’s equipment.

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3.20.2 Remote Control Panel

1 Control panel power on LED 2 System ON/OFF key 3 Reset Button

4 Manual defrost key

5 Control panel lock LED 6 HEAT mode LED 7 COOL mode LED

8 Set point display 9 Up and down arrow keys

10Temperature display

7 6

12 4 5

TEMP. DISPLAY

SET POINT DISPLAY

WAITING FOR COMMUNICATION WITH MICROPROCESSOR

UNIT WAS TURNED OFF VIA REMOTE CONTROL

UNIT IN DEFROST MODE

TEMPERATURE SENSOR MALFUNCTION

DISPLAYED WHEN SETTING PRE-SET SETPOINTS

NOTE:

1. TEMPERATURE DISPLAY (5C OR 5F) IS DEPENDENT ON MICROPROCESSOR CONFIGURATION

2. ENGINE LIGHT WILL NOT ILLUMINATE IN THIS APPLICATION.

The unit may be fitted with an optional remote control panel. The panel displays compartment set point, compartment temperature and operating modes (heat, cool or defrost). The set point may be set and the unit may be started and stopped using the remote panel.

This compact panels can be mounted to suit the individual operator’s preferences - in the cab, on the front bulkhead, or in the compartment (including in the wall itself).

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The remote control panel can be used to : Turn the unit on or off:

 Check compartment temperature

 Check and change set point

 Initiate manual defrost

 Check mode of operation

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a.Starting Unit with Remote Control Panel

NOTES

1. The unit can be shutdown using either the remote panel or the unit switch panel mounted Main Power switch. The remote panel cannot operate if the unit switch panel mounted Main Power switch is in the OFF position.

2. In order to prevent a constant drain on the battery, the remote panel will de-energize after two hours. If the panel is equipped with a RESET button, press the button to re-energize the panel. If the panel is not equipped with a RESET button, the panel may be re-energized by placing the unit switch panel mounted Main Power switch in the OFF position and then back in the desired position.

1. Place the unit switch panel

mounted Main Power switch in the desired position.

2. Press The SYSTEM ON/OFF Key. The POWER Light will illuminate.

b. Changing Set Point With Remote Control Panel

Press the UP or DOWN ARROW key to increase or decrease set point.

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c.Lock / Unlock the Remote Control Panel

LOCKING THE PANEL:

Press and hold the Carrier Logo for approximately one second and then release. The lock indicator light will illuminate.

UNLOCKING THE PANEL:

Press the Carrier Logo for 10 seconds The lock indicator light will de-energize.

CARRIER LOGO

LOCK INDICATOR LIGHT

d. Pre-setting Set Point With Remote Control Panel

The control panel allows the user to pre-set 5 different temperatures.

NOTE

Once preset set points have been chosen, only those 5 designated set points can be used.

1. Place the unit switch panel mounted Main Power switch in the desired position.

2. Press Carrier logo and the lock light will illuminate.

3. Press UP ARROW for 10 seconds. P1 will be displayed.

4. Set lowest set point required.

5. Press Carrier logo and P2 will be displayed. Set next highest temperature required.

6. Follow same procedure for the next three temperatures.

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e. Removing Pre-Set Set Points With Remote

Control Panel

1. Place the unit switch panel mounted Main Power switch in the desired position.

3. Press UP ARROW for 10 seconds. P1 will be displayed.

4. Set temperature to lowest pre-set set point and OFF will be displayed

2. Press Carrier logo and the lock light will illuminate.

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SECTION 4 − ENGINE/STANDBY/TEMPERATURE CONTROL

PARAGRAPH NUMBER Page

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

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

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

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

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

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

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

4.6.2 Defrost Modes 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.......................................................

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SECTION 4

ENGINE/STANDBY/TEMPERATURE CONTROL

NOTES

1. If the unit is in an alarm condition, the microprocessor alarm response may override the operation described herein. If an alarm is displayed in the MessageCenter, refer to the specific alarm description in Section 7 for “Unit Control” descriptions.

2. With the complex control systems in use with the Advance microprocessor there are many user selected and preprogrammed software overrides which may change the operation of the unit. Refer to Sections 4.7 & 4.8 for complete descriptions of these features.

4.1 INTRODUCTION

This section describes operation of the unit when power is supplied from an external source - Standby Operation and when power is supplied by the internal generator Engine Operation. The section also describes two additional sub-categories of operation; Start-Stop Operation (with standby or engine power) and Continuous Operation (with standby or engine power).

For descriptions of refrigerant system component interaction when cooling, with flow diagram, refer to section 2.14.

4.2 ENGINE/STANDBY OPERATION

Engine or Standby Operation is chosen by positioning of the switch labeled ENGINE/OFF/STANDBY (DOES) OR positioning of the switch labeled STANDBY/ENGINE (DES).

With the switch in the STANDBY position the power supply contactor relay (PSCONR - see wiring schematic, Section 10) is energized. Energizing PSCONR reverses its contacts to allow power from the power plug while the engine is shutdown and power from the generator is locked out.

With the switch in the ENGINE position the generator contactor relay (GENCONR) is energized. Energizing GENCONR reverses its contacts to allow the engine and generator to operate while power from the power plug is locked out.

Once the Main Power switch is toggled from the OFF position, the compressor suction modulating valve (CSMV) and evaporator expansion valve (EVXV) will both open to a predetermined position, to equalize system pressure, and then close (0% open) before the unit starts.

NOTE

The unit will not restart for at least 30 seconds following a shutdown.

4.2.1 Standby Start-Up

On command to perform a Start-Up in Standby Operation the microprocessor will energize the buzzer for five seconds. The refrigeration system or heaters will then operate in the mode(s) required for temperature control.

4.2.2 Engine Start-Up

On command to perform a Start-up in Engine Operation the microprocessor will enter the engine start sequence to start the engine and direct connected generator. Following start, the refrigeration system or heaters will then operate in the mode(s) required for temperature control.

At the beginning of the start sequence the microprocessor will close the run relay (RR) contacts to signal the engine speed control unit (ENSCU) that engine operation is required and to provide power to the optional electric fuel pump (FP - if supplied). During the start sequence the engine speed control unit (ENSCU) will hold the engine in low speed.

ENGINE RUNNING HEAT

3 to 10

Seconds

0 to 30 Seconds

15 Seconds

STOP

3 to 10

Seconds

0 to 30 Seconds

Figure 4−1 Auto Start Sequence

HEAT & CRANK

5 SEC. BUZZER

PRE CRANK HEAT

ENGINE RUNNING HEAT

HEAT & CRANK

5 SEC. BUZZER

PRE CRANK HEAT

0 - 180

Seconds

following start

ATTEMPTS

0 - 180

Seconds

following start

SECOND

AND

THIRD

FIRST

ATTEMPT

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The engine start sequence consists of periods of time with the intake air heater relay (IAHR) or glow heater relay (GPR) and starter solenoid relay (SSR) energized and de-energized for up to three start attempts. See Figure 4−1.

Energizing the heater relay closes its contacts to energize the intake air heater (IAH), the heating time will vary in duration based on engine coolant temperature (refer to Table 4−1).

Table 4−1 Intake Air Heat Time

Engine Coolant

Temperature

Heat Time

in Seconds

Preheat Post Heat

Less than 33F (1.0C) 30 180 33F to 51F (1.0C to

20 120

11C) 51F to 78F (11C to

10 60

26C) Greater than 78F (26C) 0 0

If the unit is equipped with a fuel heater, the microprocessor will monitor ambient temperature. If ambient is below 77°F (25°C) power will be supplied to the fuel heater relay (FHR). Energizing FHR closes its normally open contacts to supply power through the fuel heater temperature switch (FHTS) to the heater. Refer to Section 2.8 for FHTS settings.

4.2.3 Transition To High Speed

After a successful start, the microprocessor may call for the engine to transition to high speed. Three factors control this transition.

• First, transition may be delayed if a time value is entered in either the START-STOP HIGH SPEED DELAY or CONTINUOUS HIGH SPEED DELAY Configuration. The delay may be set to OFF or from 0 to 255 minutes. The factory default setting for Start-Stop Operation is 10 minutes while the factory default setting for Continuous Operation is OFF. If the entered value for the present mode of operation is OFF, high speed operation is not allowed for two minutes following start.

If the A129 - “CHECK ENGINE COOLANT SENSOR” alarm is active, the microprocessor assumes a temperature of less than 32F (0C) for the heat timing.

During the last five seconds of Preheat OR for 5 seconds before a start attempt, if no Preheat is required, the buzzer (B) is energized; then the starter solenoid relay (SSR) will be energized for a maximum of ten seconds while the engine condition is checked each two seconds during the cranking period. The engine is considered to be running, and the start sequence will be stopped, when engine speed is greater than 1000 rpm.

During the second and third attempts, the microprocessor will monitor additional inputs.

 When engine speed reading is less that 1000 rpm, ambient temperature is above 32°F (0°C) and the ENOPS is closed the A130 - “CHECK ENGINE RPM SENSOR” alarm will be activated and the engine will be considered running.

 When engine speed reading is less that 1000 rpm, ambient temperature is below 32°F (0°C), the ENOPS is closed and DC current is more than 2 amps the A130 “CHECK ENGINE RPM SENSOR” alarm will be activated and the engine will be considered running.

Once the engine is considered running, the microprocessor will keep the intake air heater energized for an additional 0 to 180 seconds of Post Heat, depending on engine coolant temperature (refer to Table 4−1).

During the start sequence the microprocessor monitors engine speed while cranking. If engine speed drops below 50 rpm for three seconds the starter solenoid contactor will be de-energized and the A35 - “CHECK STARTER CIRCUIT” alarm will be activated.

• Second, the engine cannot transition if the SILENT MODE functional parameter is set to YES. The value may be set to YES or NO. The factory default setting is NO. (Refer to Table 3-2).

• Third, transition will be based on the need for temperature control. Generally, the engine will operate in high speed when the unit is in Pulldown or Pull-Up Mode (full capacity required) and in low speed when the unit is in most less than full capacity required operating states.

4.3 TEMPERATURE CONTROL

4.3.1 Temperature Determination

The microprocessor monitors the temperature readings from the supply and return temperature sensors to determine the mode of operation required to maintain compartment temperature in accordance with the set point.

The sensor used for temperature control is dependent on the selection made in the “TEMP CONTROL” functional parameter.

 If the selection is “RETURN AIR” the return

air sensor (RAT) will be used, for any set point.

 If the selection is “SUPPLY AIR” the

microprocessor will switch to the supply air sensor (SAT) when operating with a perishable set point (refer to Section 4.3.2 for more information on frozen and perishable set points) and the return air sensor will continue to be used for frozen set points.

If the unit fails to start after three start attempts, the A31

- “FAILED TO START-AUTO” alarm will be activated.

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The modes of operation include Pulldown, Pull-Up, Cooling, Heating and Null.

Page 88

NOTES

1. The compressor is always started with both unloaders energized (unloaded). After 10 seconds of operation (for UL1) or 1 minute of operation (for UL2) they are allowed to transition to the unloader state required for the present mode of operation.

2. The condenser fan will operate any time the engine or compressor is operating.

3. If suction pressure is below 100 psig (6.8 bar) the evaporator fan will start 10 seconds after compressor start. If suction pressure is above 100 psig (6.8 bar) the fan start will be delayed until suction pressure is below 100 psig (6.8 bar) or until 20 seconds has elapsed.

4.3.2 Perishable And Frozen Set Point Ranges.

There are two ranges defined for set point. a. Perishable Range = set points above +10.4°F

(-12°C).

b. Frozen Range = set points of or below +10.4°F

(-12°C).

4.3.3 Pull Down/Pull-Up

When in Pulldown, the refrigeration system will operate with the compressor loaded (six cylinders), the EVXV controlling superheat to allow maximum flow, and (in Engine Operation) in high speed.

When in Pull-Up, and Engine Operation, the engine will operate in high speed.

Pulldown/Pull-Up will be entered:

• following a Start-Up.

• following a set point change.

• following an operational change (Start-Stop Opera-

tion vs Continuous Operation or Engine Operation vs Standby Operation).

• following a defrost termination.

• when in a Start-Stop ON Cycle and all other Stop

Parameters have been met except the compartment temperature Stop Parameter.

Pulldown/Pull-Up will end when one of the following occurs:

• when in Engine Operation and the microprocessor is calling for low speed due to an override or Configuration Setting.

• when in Start-Stop Operation and the compartment temperature Stop Parameter has been satisfied while one or more of the other Stop Parameters has not.

• If in Continuous Operation - perishable and the High Speed Pulldown Configuration is OFF and the temperature is in the required range Pulldown Mode ends.

• If in Continuous Operation - perishable and the High Speed Pulldown Configuration is ON: when the tem-

perature is equal to or less than 0.36F (0.2C) above set point.

4.3.4. Defrost

Refer to Section 4.6 for a description of defrost.

4.3.5. Overrides

With the complex control systems in use with the Advance microprocessor there are many user selected and preprogrammed software overrides and Configuration settings which may change the operation of the unit. Refer to Sections 4.7 & 4.8 for complete descriptions of these features.

4.4 START-STOP OPERATION

Start-Stop is provided to reduce fuel or power consumption. This feature allows full automatic control of the unit by monitoring compartment temperature, battery condition and (when in Engine Operation) engine coolant temperature.

The main function of Start-Stop Operation is to shutdown the engine or compressor after certain conditions are met (to provide an efficient temperature control system) and to initiate a restart sequence after certain conditions are met. The Start-Stop/Continuous key is pressed to select between Continuous and Start-Stop Operation. The corresponding LED will be illuminated.

NOTE

The microprocessor may be locked so that the unit will always operate in Start-Stop whenever the set point is within a specific range. Refer to Range Lock (Section 4.7.2) for additional information.

4.4.1 Start-Stop Configuration

Microprocessor control of Start-Stop Operation is dependent on both Configuration and Functional Parameter settings. The first setting to be considered is the START-STOP PARAMETERS Configuration. This setting determines control actions when in the Perishable Range or Frozen Range. The available settings are TOGETHER and SEPARATE.

• When SEPARATE is chosen the control action will be different, depending on whether the set point is in the Perishable Range or in the Frozen Range (refer to Section 4.3.2).

• When TOGETHER is chosen, the same settings apply to any set point.

If TOGETHER is selected, then the following Functional Parameter values will be available for use:

• MINIMUM RUN TIME

• MINIMUM OFF TIME

• RESTART TEMPERATURE

• OVERRIDE TEMP

• MAXIMUM OFF TIME

• FROZEN SHUTDOWN OFFSET

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If SEPARATE is selected, then the following Functional Parameter values will be available for use:

• PERISHABLE MINIMUM RUN TIME

• PERISHABLE MINIMUM OFF TIME

• PERISHABLE RESTART TEMPERATURE

• PERISHABLE OVERRIDE TEMP

• PERISHABLE MAXIMUM OFF TIME

• FROZEN MINIMUM RUN TIME

• FROZEN MINIMUM OFF TIME

• FROZEN RESTART TEMPERATURE

• FROZEN OVERRIDE TEMP

• FROZEN MAXIMUM OFF TIME

• FROZEN SHUTDOWN OFFSET

NOTE

In the event that this Configuration was set to SEPARATE and the ten Functional Parameters for Perishable and Frozen have been set and then the Configuration is changed from SEPARATE to TOGETHER. The values from the Perishable settings will be the ones that will be used.

4.4.2 Stop Parameters

Whenever the unit starts in Start-Stop Operation, it will remain in the Start-Stop ON cycle until all five of the following criteria have been satisfied:

1. It has run for the selected Minimum Run Time

The MINIMUM RUN TIME is selected in the microprocessor Functional Parameters. The purpose of this is to force the unit to run long enough to completely circulate the air inside the compartment, and to ensure that the product temperature is at set point. This value may be set from 4 to 60 minutes in 1 minute intervals. The factory default setting is 4 minutes.

If all Start-Stop parameters required to enter a Start-Stop Off cycle have been met except this parameter, the unit will operate with the compressor and heaters off and the evaporator fan running until this parameter has also been met.

2. The engine coolant temperature has warmed

Each time the unit is started in Engine Operation it must continue to run until the coolant temperature rises to 122F (50C) to ensure it has fully warmed up before shutdown is allowed.

3. The battery is fully charged - Voltage

A good battery is defined as having 13.4 VDC at 77F (25C). The microprocessor will calculate the equivalent voltage based on the ambient temperature

and shutdown will be allowed when battery voltage is at or above the calculated value.

TIP

When the microprocessor is powered up, the status of the unit battery can be readily checked by reading the Battery Voltage in the Data List. If “OK.” appears after the voltage reading, battery voltage is sufficient to allow the unit to cycle off.

If in Engine Operation and all Start-Stop parameters required to enter a Start-Stop Off cycle have been met except this parameter, the unit will operate with the compressor and heaters off and the evaporator fan running until voltage is greater than 13.4 VDC or for 20 minutes.

If in Standby Operation and the compressor has cycled off a PSCON relay will energize (to supply power to the battery charger) until battery voltage is 13.4 volts or 20 minutes has elapsed.

4. The battery is fully charged - Amperage

The microprocessor monitors the charging current. Once the charging current drops below the selected value, shutdown will be allowed. The CURRENT FOR START-STOP SHUTOFF is selected in the microprocessor Configurations The value may be set from 1 to 10 amps in 0.5 amp intervals. The factory default setting is 7 amps.

If in Engine Operation and all Start-Stop parameters required to enter a Start-Stop Off cycle have been met except this parameter, the unit will operate with the compressor and heaters off and the evaporator fan running until the charging current drops below the selected value.

If in Standby Operation and all Start-Stop parameters required to enter a Start-Stop Off cycle have been met except this parameter, the unit will enter the Off cycle. In the Off cycle, the PSCON relay remains energized, supplying power to the battery charger. The battery charger will continue to charge the battery if required.

5. The compartment temperature requirement is satisfied

In Start-Stop Operation the refrigeration system will operate in Pulldown or Pull-Up Mode in order to reach the shutdown condition as quickly as possible.

Shutdown will be allowed when the compartment temperature is within 0.5F (0.3C) of set point, for operation in the Perishable Range. In the Frozen Range, shutdown will be allowed when the compartment temperature is calculated to be within 0.5F (0.3C) minus the FROZEN shutdown OFFSET of set point.

The FROZEN shutdown OFFSET Functional Parameter may be set from 0 to 3.6F (0 to 2C) in

0.5(C or F) increments. The factory default setting is

0F (0C). If the temperature requirement has been satisfied while

one of the other shutdown requirements has not been met, the unit will remain in operation with the compressor and heaters off and the evaporator fan running until that Parameter has also been met.

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4.4.3 Re-Start Parameters

While the unit is in a Start-Stop OFF Cycle, restart will be initiated when one of the following conditions occurs:

1. Engine coolant temperature drops below selected microprocessor Configuration value

If in Engine Operation, the microprocessor will monitor coolant temperature. If coolant temperature drops below the ENGINE TEMPERATURE FOR RESTART Configuration value the engine will be started. The Configuration value may be set from 10 to 32F (-12.2 to 0C) in 0.5(C or F) increments. The factory default setting is 32F (0C).

2. Battery voltage falls below selected microprocessor Configuration value

The microprocessor will monitor battery voltage. If battery voltage is at or below the VOLTAGE FOR START-STOP RESTART Configuration value the engine will be started or, when in a Standby Operation OFF Cycle, a PSCON relay will energize (to supply power to the battery charger) . The value may be set from 12.0 to 12.8 volts. The factory default setting is

12.2 volts.

TIP

The MINUMUM OFF TIME parameter value may be set from 10 to 90 minutes in 1 minute intervals. The factory default setting is 20 minutes. The RESTART TEMPERATURE value may be set from 0.5 to 18F (2 to 10C) in 0.5 (F or C) increments. The factory default is

5.5F (3C).

5. Compartment temperature has exceeded the Override Functional Parameter value

During MINIMUM OFF TIME the microprocessor continually monitors the refrigerated compartment temperature. If the temperature should drift outside the START-STOP OVERRIDE TEMPERATURE Functional Parameter value the unit will be restarted. The value may be set from 3.6 to 18F (2 to 10C) in

0.5° increments. The factory default setting is 11F

(6C). Whenever the unit restarts, temperature control will be

in the PullDown or Pull-Up mode (refer to Section 4.3.3).

4.5 CONTINUOUS OPERATION

4.5.1. Introduction

In Continuous Operation, the unit will not shutdown except in response to a shutdown alarm. Temperature control in the compartment will operate under Pulldown, Pull-Up, Cooling, Heating or Null.

Continuous Operation is normally used for fresh produce and other sensitive product loads. The Start-Stop/Continuous key is pressed to switch between Continuous Operation and Start-Stop Operation. The corresponding LED will be illuminated.

3. The Maximum Off Time has expired

In some ambient conditions there are times when the unit may remain in a Start-Stop Off cycle for extended periods of time. To ensure that the entire load stays within the normal restart temperature range, the MAXIMUM OFF TIME Functional Parameter may be used to force the unit to restart - in low speed) with the evaporator fans operating to ensure there are no hot spots and the temperature sensor is accurately reflecting the temperature of the product. The parameter value may be set to OFF or from 10 to 225 minutes in 1 minute intervals.

If the MAXIMUM OFF TIME is OFF, there is no maximum off time for Start-Stop and the unit will remain off. The factory default setting is OFF.

4. The Minimum Off Time has expired

The MINIMUM OFF TIME Functional Parameter setting allows the unit to remain off for extended periods of time, maximizing fuel/power economy. The unit may not be restarted until the MINIMUM OFF TIME has expired and the compartment temperature is greater than the PERISHABLE RESTART value selected in the Functional Parameters away from set point. In the Frozen Range, restart is allowed when the compartment temperature is greater than the FROZEN RESTART value above set point.

NOTE

The microprocessor may be locked so that the unit will always operate in Start-Stop or in Continuous whenever the set point is within a specific range. Refer to Range Lock (Section 4.7.2) for additional information.

4.5.2. Continuous Operation

Refer to Figure 4−2 and Figure 4−3 for the Switch Point temperatures at which speed changes, unloading changes, heater operation and change to Null Mode occur while operating in Continuous Operation.

The switch points will differ depending on the setting of the microprocessor ECO MODE Functional Parameter. This value may be set to YES or NO. The factory default setting is NO. With ECO MODE set to NO, the microprocessor will control temperature closer to set point, yielding maximum product protection. With ECO MODE set to YES, the microprocessor uses the Start Stop Override Functional Parameter setting (even though the unit is in Continuous Operation) and will control temperature within a wider band, yielding improved fuel economy.

When neither heating or cooling is required the unit will enter Null Mode. In Null Mode, the electronic expansion valve (EEXV) is closed to 0% while the evaporator fan(s) continue to run.

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When Null Mode is required and the system is operating in:

• Engine Operation, the compressor will shutdown

FALLING REFRIGERATED COMPARTMENT

TEMPERATURE

SWITCH POINT

Pulldown = High Speed

6 Cylinder COOL*

while the engine, condenser fan and evaporator fan will continue to operate.

• Standby Operation, the compressor will shutdown while the evaporator fan will continue to operate.

+3.2F (+1.8C )

+1.6F (+0.9C )

+0.9F (+0.5C )

Set point

-0.4_F (-0.2_C)

-0.5F (-0.3C)

-3.6F (-2.0C )

Low Speed

6 Cylinder

COOL

Low Speed

4 Cylinder COOL

Low Speed

2 Cylinder COOL

NULL

Low Speed HEAT

HTCON1

Pull-Up = HEAT

HTCON1 & HTCON2

+3.6F ( +2.0C )

+1.8F (+1.0C )

+1.1F (+0.6C )

+0.4F (+0.2C)

Set point

-0.4F (-0.2C)

-3.2F (-1.8C )

RISING REFRIGERATED COMPARTMENT

TEMPERATURE

SWITCH POINT

Switch Point = Controlling Temperature - Set Point

+ results are above set point, - results are below set point

Switch points are the same for Perishable Range and Frozen Range except in Frozen Range heating is not allowed.

* If the HIGH SPEED PULLDOWN Configuration is set to YES, transition from pulldown is delayed from the indicated +3.2F (+1.8C ) transition temperature until the temperature is +0.36 F (+0.2C) above set point.

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

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REFRIGERATED COMPARTMENT

TEMPERATURE

SWITCH POINTS

Transition to low speed at

Start-Stop Override

Functional Parameter

Value + 1

(+5.4 to 19.85F = +3 to 115C)

FALLING

Pulldown = High Speed

6 Cylinder COOL

Enter high speed at

Start-Stop Override Func-

tional

Parameter Value + 2

(+7.2 to 23.45F = +4 to 125C)

Set point

-1.4F (-0.8C)

-3.6F (-2.0C )

Low Speed

6 Cylinder

COOL

NULL

Low Speed HEAT

HTCON1

Pull-Up = HEAT

HTCON1 & HTCON2

REFRIGERATED COMPARTMENT

TEMPERATURE

SWITCH POINTS

Enter cool at Start-Stop

Override Functional

Parameter Value

(+3.6 to 185F = +2 to 105C)

Set point

-1.3F (-0.7C)

-3.2F (-1.8C )

RISING

Switch Point = Controlling Temperature - Set Point

+ results are above set point, - results are below set point

Switch points are the same for Perishable Range and Frozen Range except

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

in Frozen Range heating is not allowed.

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4.6 DEFROST

Defrost is an independent cycle overriding cooling and heating functions in order to de-ice the evaporator. When the unit is in defrost, the DEFROST LED will be on, the MessageCenter will display DEFROST CYCLE STARTED for 5 seconds. The center of the Main Display will show “dF”. However, defrost will not be allowed when the 1DDT is above 40.0F (4.4C).

4.6.1 Defrost Initiation And Start

Defrost can be initiated by pressing the MANUAL DEFROST key or automatically by the microprocessor. Microprocessor initiation is based on coil condition or expiration of the defrost timer.

a. Defrost based on coil condition

Defrost based on coil condition will be initiated when:

• blockage is sufficient to cause an air pressure differential across the coil great enough to close the contacts of the defrost air switch (DAS).

• when the RAT - 1DTT temperature is greater than 36°F (20°C) for 15 continuous minutes. This method of defrost initiation will only be used for 3 consecutive defrosts. After three consecutive defrost initiations by this method the counter will be reset to allow this defrost initiation again only after a defrost cycle is initiated by another method (timer, air switch or manual).

TIP

Ice is not the only thing that will cause the air differential to increase across the evaporator coil. Shrink wrap, paper, plastic bags, and other such items when caught in the return air stream and pulled up against the evaporator coil or the return air grille can also cause the DAS contacts to close.

b. Defrost based on time:

Time interval between defrosts is selected in the microprocessor Functional Parameters. The parameter value may be set to 1.5, 3, 6, or 12 hours. The factory default setting is 6 hours.

NOTE

The defrost timer will not count when the unit is in defrost, the unit is in a Start/Stop off cycle or the 1DTT is greater than 40.0F (4.4C).

4.6.2 Defrost Modes

There are two defrost modes available, Normal Defrost and Natural Defrost:

NOTE

When the unit is in defrost and in Engine operation:  the condenser fan will operate to supply air

for the radiator.

 the engine will operate in high speed when

the heaters are energized (to supply power for the heaters).

 the engine will operate in low speed when

the heaters are de-energized.

a. Normal Defrost Mode

Normal Defrost Mode will be entered if RAT is less than

39.2F (4.0C) and SAT is less than 45.0F (7.2C). Defrost will be accomplished by shutting down the refrigeration system (which includes the evaporator fan) while the heaters are energized.

b. Natural Defrost Mode

Natural Defrost Mode uses a combination of the heat from the product and the electric heaters to melt any ice.

Natural defrost is available when:

 the Natural Defrost microprocessor

Configuration is set to YES and

S defrost is initiated by closing of the DAS

contacts with RAT greater than or equal to

39.2F (4.0C) and

 at least one normal defrost has been

performed since power up.

When a natural defrost is initiated, the unit will operate for the first five minutes with the evaporator fan and HTCON2 de-energized and only HTCON1 energized. After 5 minutes the evaporator fan is energized while both HTCON1 & HTCON2 are de-energized.

Only 3 consecutive natural defrosts cycles are allowed. After there have been 3 consecutive natural defrost cycles, the next defrost will be a normal deforst.

4.6.3 Defrost Termination

When in normal defrost mode, defrost will terminate when the 1DTT rises to 55F (12.8C).

When operating in natural defrost, defrost will continue for a minimum of 5 minutes, a maximum of 10 minutes, or until the SAT is equal to or higher than the RAT.

When the unit exits defrost, the engine will go to low speed. “dF” will continue to be displayed in place of compartment temperature, and the COOL LED will come on when the compressor starts.

The EVXV will open, and the evaporator coil will begin to cool down. The evaporator fan will not come on right away, so that warm air is not blown into the refrigerated compartment, but will wait for the evaporator to cool down, up to a maximum of 8 minutes. Once the evaporator fan has started, “dF” will no longer be displayed, and refrigerated compartment temperature will again be shown in the main display.

If a 1DTT sensor alarm has been activated, defrost will terminate after 10 minutes.

NOTE

Defrost uses a Defrost Duration Timer that allows for a maximum of 45 minutes in defrost. If defrost is not terminated during the 45 minutes, the microprocessor will end the defrost cycle, and activate the A54 - “DEFROST NOT COMPLETE” alarm. When this occurs, the Defrost Interval Timer is set for 1.5 hours, at which time the unit will go into defrost again.

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4.7. USER SELECTED OVERRIDE OPERATION

Three optional software override programs are available to the user. These programs include: Supply Air Limit Control, Temperature Range Lock and ProductShield. Information on how the unit operates under these programs is provided in the following sub-paragraphs.

4.7.1 Supply Air Limit Control

Supply Air Limit Control is available when the set point is at or between 32 to 65F (0 to 18.4C) and the unit is operating in cool.

Supply Air Limit is NOT a positive temperature control, drift above and below the Supply Air Limit will be seen as the system balances out.

Supply Air Temperature control will be accomplished by varying the position of the CSMV.

Supply Air Limit Configuration values can be set to allow for a different limit for Start-Stop than used in Continuous Run.

Supply Air Limit Control is set using the PERISHABLE SENSITIVE PRODUCT Functional Parameter (which can be set to OFF or ON), and the SUPPLY AIR LIMIT FOR START-STOP Operation Configuration or SUPPLY AIR LIMIT FOR CONTINUOUS Operation

Configuration (each of which can be set from 0 to

-21.6F [0 to -12C]).

NOTE

These values are all negative (except for 0), therefore, when the value is added to the set point, the result will be a temperature that is less than the set point.

When the PERISHABLE SENSITIVE PRODUCT Functional Parameter is set to OFF, the supply air temperature will be the coldest temperature of 32F (0C) OR the calculated value of Set Point minus the configured Supply Air Limit value.

When the PERISHABLE SENSITIVE PRODUCT Functional Parameter is set to ON, the supply air temperature will be the calculated value of set point minus the configured Supply Air Limit value.

Supply Air Limit controls the temperature of the supply air as it leaves the evaporator so that it does not go colder than the configured Supply Air Limit value below set point.

NOTE

The 9F value used in the following examples is not necessarily a recommend setting, but is only used to show how the Supply Air Temperature Limit is calculated.

EXAMPLE 1: Perishable Sensitive Product Functional Parameter = OFF

Supply Air coldest temperature limit is the colder temperature of:

+32F OR

Set point minus configuration value for Supply Air Limit

Sample Calculations:

Set point 50F45F40F33F Supply Air Limit Configuration Value -9F -9F -9F -9F

Set point minus Supply Air Limit 41F36F31F24F

Coldest Supply Air Temperature allowed 32F32F31F24F

EXAMPLE 2: Perish Sensitive Product Functional Parameter = ON

Supply Air will be limited to Set point minus configuration value for Supply Air Limit.

Sample Calculations:

Set point 50F40F33F Supply Air Limit Configuration Value -9F -9F -9F

Set point minus Supply Air Limit 41F31F24F

Coldest Supply Air Temperature allowed 41F31F24F

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4.7.2 Temperature Range Lock 1 & 2

Range Lock is a group of Configurations which may be set to lock the unit into Start-Stop or Continuous Operation for various set point ranges.

Two ranges are available for selection Range Lock 1 and Range lock 2. Each Range can be independently set to lock it’s set point temperatures into either Start-Stop or Continuous operation.

Each Range has it’s own selectable minimum and maximum temperature, which define the span of the range. If some set point temperatures are contained in both ranges due to range overlap, Range 1 will always have priority over Range 2.

Typically, both Range Lock 1 and Range Lock 2 are used to control different set point ranges when IntelliSet is not active. For units with IntelliSet active, because

Range Lock 1 & 2

each IntelliSet is generally programmed for a specific product, only Range Lock 1 is used to hold the unit in either the Start/Stop or Continuous Operation, and Range Lock 2 is left off.

For example (see Figure 4−4), if Continuous Operation is ALWAYS required whenever the set point is between 28°F and 55°F (-2.2°C and +12.8°C), Range 1 will be set for Continuous, with a Minimum Temperature of 28°F (-2.2°C) and a Maximum Temperature of 55°F (-12.8°C).

Should Continuous Operation ALWAYS also be required with set points between -22 and 0°F (-30 and

-17.8°C), then Range 2 will be set for Continuous, with a Minimum Temperature of -22°F (-30°C) and a Maximum Temperature of 0°F (-17.8°C). Any set point outside of Range 1 or 2 will allow changes between Start-Stop and Continuous.

Range 2 is set for 05 to -225F (-17.85 to -305C)

Range 2

The primary time that it is important to determine which range is to be Range 1 and which is to be Range 2 is when the ranges overlap each other.

In example 2 (see Figure 4−5), the ranges have been set to lock all set points into Start-Stop, except for a small range between +32° and +42°F (0° and 5.6°C) where the unit will always operate in Continuous. Range

-22 -10

-30 -23.3 -17.8 -12.2 -6.7 4.4 10.0 15.6-1.1 21.1 26.7

Figure 4−4 Range Lock Settings - Non Overlapping

10 20 40 50 6030 70

Range 1 is set for 285 to 555F (-2.25 to +12.85C)

Range 1

1 Minimum Temperature has been set for +32°F (0°C), and Maximum Temperature of +42°F (5.6°C). Range 2 has been set for a Minimum Temperature of -22°F (-30°C) and a Maximum Temperature of +89.6°F (32°C). The unit will switch to Continuous when the temperature is between +32° and +42°F (0° and 5.6°C) because, when the ranges overlap each other the Range 1 settings will take priority.

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Range 1 always has priority when Range 1 & 2 overlap

Range 1 is set for 325 to 425F (05 to 5.65C) Set for Continuous

4.7.3 ProductShield

ProductShield is a group of Configurations that work together to allow improved operating efficiency while providing customized product protection.

Each ProductShield setting allows the user to select an ambient temperature range in which to operate. The Minimum and Maximum range values can be set to OFF, or the allowed value range.

a. ProductShield: Econo

ProductShield Econo allows the microprocessor to automatically switch from Start/Stop Operation to Continuous Operation or vice versa. This allows maximum product protection while providing for power savings when ambient temperature is in the preset range.

ProductShield Econo - Go to Start-Stop Operation.

When the unit is set to Continuous Operation, ProductShield Econo allows the unit to run in Start/Stop Operation when:

• The ProductShield Econo Configuration is set to GO TO S/S AND

• The unit has run in Continuous Operation for a minimum of either 15 minutes, or the Minimum Run Time Functional Parameter setting (whichever time is longer) AND

• The ambient temperature falls within the pre-pro- grammed temperature range AND

-22 -10

-30 -23.3 -17.8 -12.2 -6.7 4.4 10.0 15.6-1.1 21.1 26.7

10 20 40 50 6030 70

Figure 4−5 Range Lock Settings - Overlapping

Range 2 is set for -225 to

89.65F (-305 to 325C) Set for Start-Stop

Range 2

Range

• The unit is not already running in ProductShield Winter. (See Section c.)

The operator can also pre-program a maximum evaporator coil temperature differential (delta-t) between the return air and supply air temperatures as an additional criteria for switching to Start/Stop Operation. The unit must bring the delta-t below this setting before going to Start/Stop Operation if this option is chosen.

NOTE

In ProductShield Econo: Go to Start/Stop, the delta-t must be lower than the value selected in order to enter Start/Stop.

Once the microprocessor detects that the above criteria have been met, the unit will switch from Continuous Operation to a Start/Stop Off Cycle for the MINIMUM OFF TIME Functional Parameter setting. During the Minimum Off Time, the RESTART OVERRIDE TEMPERATURE Functional Parameter setting can cause the unit to restart to protect the load. After the Minimum Off Time has expired the unit will return to Continuous Operation once, or if, the return air temperature is more than the configured perishable restart temperature away from setpoint in the perishable range, or the configured frozen restart temperature above set point in the frozen range.

When the unit restarts, it will return to Continuous Operation for a minimum of 15 minutes or the Minimum Run Time Functional Parameter setting, whichever time is longer. The original activation conditions must then be

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met in order for the unit to return to ProductShield Econo: Start/Stop.

ProductShield Econo: Go To Start/Stop Examples:

The following examples apply in situations where all other Start/Stop conditions have been met.

Example 1 If the Minimum is set to 30°F (-1.1°C) and the Maximum is set to 40°F (4.4°C) and the ambient air temperature falls between these temperatures, the unit operation can change to Econo Start/Stop.

Example 2 If the Minimum is set to 30°F (-1.1°C) and the Maximum is set to OFF and the ambient air temperature is above 30°F (-1.1°C), the unit operation can change to Econo Start/Stop.

Example 3 If the Minimum is set to OFF and the Maximum is set to 40°F (4.4°C) and the ambient air temperature falls below 40°F (1.7°C), the unit operation can change to Econo Start/Stop.

Example 4 If both the Min and the Max are set to OFF, unit operation can change to Econo Start/Stop at any ambient temperature.

ProductShield Econo - Go to Continuous Operation.

When the unit is set for Start/Stop, ProductShield Econo allows the unit to run in Continuous Operation when:

• ProductShield Econo configuration is set to GO TO CONTINUOUS AND

• The unit has run in Start/Stop Operation for a minimum of 15 minutes OR the Minimum Run Time, Functional Parameter setting (whichever time is longer)

AND

• The ambient temperature falls outside the pre-pro- grammed temperature range AND

• The unit is not already running in ProductShield Winter. (See Section c.)

Once the microprocessor detects that the above criteria have been met, the unit will switch from Start/Stop to Continuous Operation for a minimum of 30 minutes. After 30 minutes the unit will return to Start/Stop if the ambient temperature enters the pre-programmed temperature range.

NOTE

Delta-t logic is not used or available when ProductShield Econo - Go To Continuous is active.

ProductShield Econo: Go To Continuous Examples

Example 1 If the Minimum is set to 0°F (-17.8°C) and the Maximum is set to 90°F (32.2°C) and the ambient air temperature falls outside these temperatures, the unit operation can change to Econo Continuous Operation.

Example 2 If the Minimum is set to 0°F (-17.8°C) and the Maximum is set to OFF and the ambient air temperature falls below 0°F (-17.8°C), the unit operation can change to Econo Continuous Operation.

Example 3 If the Minimum is set to OFF and the Maximum is set to 90°F (32.2°C) and the ambient air temperature falls above 90°F (32.2°C), the unit operation can change to Econo Continuous Operation.

Example 4 If both the Minimum and Maximum are set to OFF, ProductShield Econo: Go To Continuous can not operate as there is no range for the ambient to fall outside of.

b. ProductShield: High Air

ProductShield High Air allows the microprocessor to automatically switch the engine from normal to forced high speed, and thereby provide high evaporator air flow. This allows maximum product protection when certain conditions are met while providing for power savings when High Air is not required.

Operation in High Air is controlled by four Configurations; ProductShield High Air, High air Minimum Temperature, High Air Maximum Temperature and High Air Delta-T.

• The Product Shield High Air Configuration may be set to OFF or ON. ProductShield High Air is only active when the Configuration is set to ON.

• The High Air ambient air temperature range is defined by the High Air Maximum Temperature Configuration setting and the High Air Minimum Temperature Configuration setting. When a value is entered for both of these configurations, the unit will enter High Air when ambient temperature is above the high setting or below the low setting.

• When the High Air Maximum Temperature Configuration is set for a value and High Air Minimum Temperature Configuration is set to OFF, the microprocessor will switch to high speed operation when the ambient temperature is above the setting.

• When the High Air Minimum Temperature Configuration is set for a value and High Air Maximum Temperature Configuration is set to OFF, the microprocessor will switch to high speed operation when the ambient temperature is below the setting.

• When both the High Air Minimum Temperature Configuration and the High Air Maximum Temperature Configuration are set to OFF, ProductShield is not active.

• If a value is entered in the High Air Delta-T Configuration, the delta-t must be above the value before the microprocessor may switch to High Speed

Once the microprocessor determines that the pre-programmed criteria have been met, the unit will switch to High Air. The unit will continue to operate in High Air for a minimum of 30 minutes. After 30 minutes the unit will return to normal operation if the ambient temperature falls inside the pre-programmed temperature range by ±3.6° F ( ±2° C).

If the unit shuts down in Auto Start/Stop during High Air, it will not be in High Air when it restarts and will return to normal operation for a minimum of 15 minutes. The original activation conditions must then be met in order for the unit to return to high air.

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ProductShield High Air Examples

Example 2 If the Minimum is set to 0°F (-17.8°C) and the Maximum is set to OFF and the ambient air temperature falls below 0°F (-17.8°C), the unit operation can change to High Air Operation.

Example 3 If the Minimum is set to OFF and the Maximum is set to 90°F (32.2°C) and the ambient air temperature falls above 90°F (32.2°C), the unit operation can change to High Air Operation.

Example 4 If both the Minimum and Maximum are set to OFF, ProductShield High Air can not operate as there is no range for the ambient to fall outside of.

c. ProductShield: Winter

When the unit is set for Start/Stop operation, ProductShield Winter allows it to switch to Continuous Operation when the ambient temperature falls below the pre-programmed temperature. This helps protect the unit from the possibility of cold weather issues.

Once the microprocessor detects that the ambient temperature has dropped below the pre-programmed temperature, the unit will switch into ProductShield Winter which will force the unit to operate in Continuous Operation. The unit will continue to operate in Continuous Operation for a minimum of 30 minutes. After 30 minutes, the unit will return to auto Start/Stop if the ambient temperature has risen above the pre-programmed ProductShield Winter temperature.

NOTE

All of the ProductShield settings may be viewed in the Data List (Refer to Section 3.13). For units with IntelliSets, the Data List will reflect the ProductShield settings for the IntelliSet that is currently active.

4.8. PREPROGRAMMED SOFTWARE OVERRIDES.

4.8.1 Cargo Protect Mode.

The microprocessor will activate Cargo Protect Mode when both the A122 “CHECK RETURN AIR SENSOR” and A122 “CHECK SUPPLY AIR SENSOR” alarms activate.

 If the set point is in the perishable range (refer to Sec-

tion 4.3.2), the unit will shutdown.

 If the set point is in the Frozen Range and the unit is in

Engine Operation, the compressor will operate fully loaded and the engine will go to low speed.

 If the set point is in the Frozen Range and the unit is in

Standby Operation, the compressor will operate unloaded.

The MessageCenter will display “WARNING: NO TEMPERATURE CONTROL” when the unit is operating in Cargo Protect Mode.

4.8.2 Compressor Minimum Operating Time

Each time the compressor is started it must operate for a minimum of 3 minutes before it can be de-energized.

If, during the 3 minutes, the unit is operating in the Frozen Range (refer to Section 4.3.2), it will continue to operate in cooling. If the unit is operating in the Perishable Range the unit will continue to cool with the heaters energized as required to maintain setpoint.

4.8.3 Engine Speed Overrides

This section lists the different factors that determine engine speed (high or low) in addition to the speed controls used in temperature control.

Speed Control Overrides in priority order are:

1. Forced Low Speed. The microprocessor will force the unit to run in low

speed when:  When the ambient temperature is less than 0° F

(-17.7° C) AND the unit is running in low speed heat with the AC current less than 8 Amps for 10 minutes the unit will remain in low speed until the ambient temperature is above 0° F (-17.7° C) OR the AC current is more than 8 amps for 10 minutes.

 When the ambient temperature is less than 0.°F

(-17.7°C) AND the unit is running in either cool, null, or defrost AND AC current is less than 12 Amps for10 seconds, the engine will be forced to low speed. The unit will remain in low speed until the ambient temperature is above 0.°F (-17.7°C) OR the AC current is more than 10 Amps for 10 minutes.

 When the ambient temperature is less than 77°F

(25°C) AND the unit is running in defrost AND the engine has been running less than 30 minutes since the Main Power switch was toggled from the OFF position, the unit will remain in low speed until the ambient temperature is above 77°F (25°C) OR the engine has run for a minimum of 32 minutes since the switch was toggled.

When the engine is forced to low speed under these conditions, the Message Center will display “FORCED LOW ENGINE SPEED”.

2. RAT & SAT Alarms. When both the A122 “CHECK RETURN AIR SENSOR” and A122 “CHECK SUPPLY AIR SENSOR” alarms activate microprocessor control may enter Cargo Protect Mode. Refer to Section 4.8.1.

3. High Speed To Low Speed Delay. When the engine is operating in high speed, and the microprocessor calls for low speed, the engine will remain in high speed for 40 seconds OR until the actual AC current is less than the configured Diesel or Standby Maximum Generator Amps value less the Diesel or Standby Offset Maximum Amps value.

4. Silent Mode. When the Silent Mode Functional Parameter is set to ON, the unit will operate in low speed only.

5. Engine Coolant Warm-Up. The engine will run in low speed until the coolant is above 79°F (26°C).

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6. Defrost.

When the unit is in defrost:

 the engine will operate in high speed when heaters

are energized (to supply power for the heaters).

 the engine will operate in low speed when the heat-

ers are de-energized.

7. Door/Remote Switch Configuration. If the Door/Remote Switch Configuration is set for low speed, the engine will run in low speed when the door/remote switch is open/active.

8. Start-Stop Restart.

If the engine is restarted from a Start-Stop off cycle for any reason except a Start-Stop Parameter Override Temperature the engine will operate in low speed until all conditions are met for another off cycle OR for the Minimum Run Time Functional Parameter value.

9. Low Speed To High Speed Delay.

 The compressor must operate for 2 minutes before

transition to high speed is allowed.

 The time value entered in the High Speed Delay Con-

figuration must be expired before transition to high speed is allowed.

10.Low Speed Startup.

The time value entered in the Low Speed Startup Minutes Functional Parameter (for Start-Stop or Continuous) must be expired before transition to high speed is allowed.

11.Frozen Set Point/Frozen Set Point Override.

If the set point is a frozen set point (below +10.4°F [-12°C]) and the temperature is below set point, the engine will operate in low speed.

12.Low Suction Pressure.

The microprocessor monitors the signal provided by the Suction Pressure Transducer. If the suction pressure falls below -2psig (-0.14 bar) for more than 20 seconds, the engine will operate in low speed for a minimum of 5 minutes, then remain in low speed until the suction pressure is greater than -2psig (-0.14 bar).

13.Operation With A Perishable Set Point.

If in Start-Stop Operation with a set point in the perishable range (above +10.4°F [-12°C]) and all conditions for an OFF Cycle have been met except for set point, the engine will operate in high speed to pull down to set point and cycle off quicker.

NOTE

Generally, the unit will go into an off cycle from high speed when this condition occurs. However, if one of the required conditions for shutdown is no longer met during this time, (for example, the battery voltage drops below the configured value, or the charging amps increase above the configured value, or the engine coolant temperature drops below 122°F (50°C), the engine may return to low speed operation until the shutdown condition is satisfied, then shutdown from low speed.

14.High Speed Pulldown. If in Continuous Operation with a set point in the

perishable range (above +10.4°F [-12°C]) and the High Speed Pulldown Configuration is set to YES, the engine will operate in high speed until the refrigerated compartment temperature is 0.36°F (0.2°C) above set point.

4.8.4 Unloader Control Overrides

This section lists the different factors that determine the operation (de-energizing / loading and energizing / unloading) of the unloaders in addition to the unloader control used in temperature control.

Unloaders operate in priority order for cooling ONLY (For example: Override 1 supersedes 2 and all lower overrides.):

The overrides will be allowed in Cargo Protect Mode only if the override does not use the return or supply temperature.

There is a minimum delay of 20 seconds between LOADING and UNLOADING cylinders under all operating conditions except when the engine is starting.

When the Compressor is Off the Unloaders are always de-energized.

NOTE

In all of the following instances UL1 refers to the Front Unloader and UL2 refers to the Rear Unloader.

1. Low Generator Amp Draw. When the A128 - “LOW/UNBALANCED A/C AMPS”

alarm is activated the compressor will only operate on 2 or 4 cylinders.

2. High Discharge Pressure Or High Generator Amp Draw.

The microprocessor will not allow additional cylinders to load whenever the compressor discharge pressure is above 415 psig (28.3 bar) OR when the compressor amp draw is within 1 Amp of the maximum allowable generator current (Maximum Allowable Generator Current is a Configuration Setting - Refer to 5.2.1.)

However, if the CDT is above 284°F (140°C) for more than 30 seconds at the same conditions, loading of one cylinder bank is allowed.

3. Compressor Restart.

The microprocessor will force the compressor to run in 2 cylinders for 10 minutes when the compressor restarts

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unless the compressor is restarting following a defrost cycle. If the compressor discharge temperature (CDT) becomes greater than 284°F (140°C) or the system returns to Pulldown mode 10 minute will be overridden and the unloaders will de-energize (load) as required.

4. Fan Motor Delay. Whenever any fan motor has been energized, there will

be a 3 second delay before either unloader is allowed to de-energize (load).

5. Four Cylinder Delay. When the compressor suction pressure (CSP) is great-

er than 22 psig (1.5 bar) AND the compressor is fully unloaded (operating on 2 cylinders), AND the conditions call for UL2 to be de-energized (loaded), there will be a 20 second delay while the CSMV closes down by 20% from the current setting. After UL2 loads the CSMV will go back to normal control.

6. Two-Minute Delay.

9. High Discharge Pressure.  If the compressor discharge pressure reaches 435

psig (29.6 bar) at some point soon after engine start up for more than 1 minute, UL2 will energize (unload) and remain energized until the compressor discharge pressure drops below 415 psig (29.6 bar).

 If both unloaders are energized (unloaded), and the

discharge pressure drops below 430 psig (29.3 bar), UL1 will be de-energized (loaded)

10.Low Suction Pressure.  If suction pressure falls below -2 psig or 4 inHg (0.14

bar) for more than 20 seconds, UL2 will be energized (unloaded)

 After 20 seconds: if suction pressure is still less than

-2 psig or 4 inHg (0.14 bar), UL1 will be energized (unloaded), OR

When an unloader is energized (unloaded) due to a refrigeration system pressure override (overrides #6, 7, 8 or 9), the unloader remains energized for a minimum of 2 minutes.

7. Compressor Startup.  UL1 remains energized (unloaded) for a minimum of

10 seconds when the ambient is above 100°F (37.8°C) or 5 seconds when the ambient is at or below 100°F (37.8°C) after the compressor motor contactor is energized

 UL2 remains energized (unloaded) for a minimum of

60 seconds when the ambient is above 100°F (37.8°C) or 30 seconds when the ambient is at or below 100°F (37.8°C) after the compressor motor contactor is energized

8. High Evaporator Pressure. UL2 will always be energized (unloaded) when the

suction pressure is above the value shown Figure 4−6 for 1 minute, according to the current ambient temperature. For example, at an ambient temperature of 100°F (37.8 °C), UL2 will be energized when the suction pressure rises to approximately 75 psig (5 bar). UL2 can load as soon as the pressure is 5 psig (0.3 bar) less than the value in the chart.

 Once the suction pressure rises above 5 psig (0.3

bar), UL2 will be de-energized (loaded) (after the 2-Minute Delay mentioned above)

 If both unloaders are energized (unloaded), AND 20

seconds has elapsed since energizing (unloading) UL1 AND the suction pressure rises above 5 psig (0.3 bar), UL1 will be de-energized (loaded)

11.High CDT. If the compressor is operating with both unloaders

energized (unloaded), and the CDT rises to 284°F (140°C), UL1 will be de-energized (loaded), and will remain de-energized (loaded) until the CDT drops below 266°F (130°C) for at least 2 minutes.

12.Cargo Protect Mode. Refer to Section 4.8.1

13.Start-Stop Operation. If the Off Cycle conditions have been met in Start-Stop

Mode (Refer to Section 4.4) and the minimum run time has expired, BUT compartment temperature is not at set point, both unloaders will be de-energized (loaded) and the compressor will operate on 6-cylinders until the unit cycles off.

100

PSIG

60 40 20

90 100 110 120 130 140

Ambient Temperature (5F)

Figure 4−6 Evaporator Pressure Chart

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Carrier VECTOR 6500 Operation & Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual