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Truck/Trailer Refrigeration Unit - Sunbelt Transport Refrigeration

1. 1 lice TO MICRO YD DPS Spi En FI 1 1 2 ROC m Al x 80A TY ssc SERIA PORT 2 0 SPA SPB SPC I I TO PSR 3 vi E RR De SEE Tx GND O A CR 30 HCAS ALTERNATOR 25 i WIRING BELOW n 23 3 19 11 SSR E DER GIO CAB COMMAND 7777 2 E G9 e aed 715 25 DER Om TO OL lt 62 n 1873 4 SEE NOTE 5 IRR 1DR 4 7 s ele ee AGO am Cos CH TO 3513 15A 21 gt 18 12 SPT HCD4 3 9 x 2RR AO ECOS A mO 5 ol l l uS SDR DM s o See SIO Ox 8 7719371 87 03 67 T2 85 65865 1RAS re mu Ur 30 TO IHCC4 gt 187 NOTES 7 NOTES 8 T 24 105 Beca 2 1 5 85 E DAMo gt DXC TI TETA 2015 7 A EC 22 9 85 OQO KA FH TERI m i 30 Ke CLE N 25 251 NOTES 7 NOTES 8 81 82 2 B A gt 7 205 PR 19 14 OCG 00 207 2613 01 802 1 TO MPK3 lt EBBE BHETH GI 85 er 86 8 EDI
2. LOCATION SYMBOL DESCRIPTION LOCATION IN FRAME LOCATION SYMBOL DESCRIPTION LOCATION IN FRAME P 2 R 11 12 13 ALT ALTERNATOR MID FRAME 1 8 M 8 1HGR HOT GAS RELAY 1st COMPARTMENT CONTROL BOX K 9 B BUZZER CONTROL BOX 1 8 M 10 2HGR HOT GAS RELAY 2nd COMPARTMENT CONTROL BOX N 1 BTY BATTERY 1 9 M 12 3HGR HOT GAS RELAY 3rd COMPARTMENT CONTROL BOX 0 5 CAR CAPACITOR ALTERNATOR RELAY CONTROL BOX 0 8 1HGV HOT GAS VALVE 1st COMPARTMENT EVAPORATOR B 8 CDT COMPRESSOR DISCHARGE TEMPERATURE SENSOR COMPRESSOR 0 10 2HGV HOT GAS VALVE 2 COMPARTMENT EVAPORATOR 1 9 M 8 1CR COOL RELAY 1st COMPARTMENT CONTROL BOX 0 12 3HGV HOT GAS VALVE 3rd COMPARTMENT EVAPORATOR 1 10 10 2CR COOL RELAY 2 COMPARTMENT CONTROL BOX H 5 HP1 HIGH PRESSURE CUT OUT SWITCH COMPRESSOR 1 10 12 3CR COOL RELAY 3rd COMPARTMENT CONTROL BOX 1 10 1HT HEAT THERMOSTAT 1st COMPARTMENT EVAPORATOR 1 7 N 9 N 11 N 13 DCR DEFROST COMPARTMENT RELAY CONTROL BOX 1 10 2HT HEAT THERMOSTAT 2nd COMPARTMENT EVAPORATOR H 8 Q 3 DER DIESEL ELECTRIC RELAY CONTROL BOX 1 11 3HT HEAT THERMOSTAT 3rd COMPARTMENT EVAPORATOR 1 DPS DETECTOR POWER SUPPLY CONTROL BOX L IP1 INSULATING PLUG 1 CONTROL BOX 0 9 R 5 1DR DEFROST RELAY 1st COMPARTMENT CONTROL BOX R 3 IP2 INSULATING PLUG 2 FRAME 0 11 R 5 2DR DEFROST RELAY 2nd COMPARTMENT CONTROL BOX B 2 Ji JUMPER 1 CONTROL BOX 0 13 R 6 3DR DEFROST RELAY 3rd COMPARTMENT CONTROL BOX 0 8 1LS
3. 1 8 7 Unit Diata He RUE RT EE de Eu 1 8 8 Alarm Display ses a een 18 9 Auto Start Stop Operation 19 Switches And Controls Microprocessor Controller 1 9 introduction e RS Cet en Eom eco aaa RD de 1 9 2 Electrical BOX D008 oet nM ER He E arn eed ioa 19 3 Location of Engine Safety Devices 110 Compressor Pressure Regulating Valve LII ACGUMUIAOF ee sr be LR ERR nsi uberi ue Eb NE 112 CompressorUnloaders 112 1 Unloadingin Temperature 1 12 2 Suction Pressure Operation 1123 Hot Gas Bypass 1 13 Battery Charging Alternator 113 1 Alternator 1 13 2 Integral Voltage Regulator Operation 12 volts dc 114 Refrigerant Circuit During Cooling 2 2 115 Refrigerant Circuit During Heat and Defrost 2 OPERATION i52 aan 2 1 Pre amp trip linspection 2 mm een rain nn 22 Starting And Stopping Instructions Engine Drive 221 Altomat
4. 1 Relays 4 Motor Overload MOL Model NDD 2 Fuses 5 Capacitor 3 Motor Contactor MC Model NDD Figure 1 8 High Voltage Box Trailer Unit 62 02884 1 8 6 h 6 O 1HGR 1RR D CRANE D 2HGR 5 2RR g Ss l UFR 34GR 8 3RR Bel IR 5 sr 84 DER 8 512 ARR 3CR 5 FHR 2 Q HL x Rh dle O 7 2mcomp 3 coW or OFF 3 1 Ammeter 6 Fuses 2 Manual Glow Crank Switch 7 Starter Solenoid Relay SSR and 3 Compartment On Off Switches Glow Plug Relay GPR 4 Diode Block 5 Relays Figure 1 9 Relay Box Trailer Unit 1 9 62 02884 e Evaporators The compartments of the M ulti Temp system are equipped with separate evaporators For applications single discharge and double discharge evaporators are available The evaporat
5. 4 22 4 22 Phase Sequence Module 4 24 4 23 Genesis TR 1000 Unidrive Torque Requirements 4 25 5 1 Truck Units Electrical Schematic Dwg 62 60251 5 2 5 2 Truck Units Electrical Schematic Dwg 62 60252 5 4 5 3 Genesis TR 1000 50 hz Electrical Schematic Dwg 62 03955 5 7 5 4 Genesis TR 1000 60 hz Electrical Schematic Dwg No 62 03967 5 11 LIST OF TABLES Table Page 1 1 M odel Chart res ar URP a eed 1 1 1 2 Safety DEVICES cis iss ua E LN e E s 1 14 1 3 Function ccce u hee EE 1 18 1 4 By Pass Valve 1 19 1 5 Unit Data Codes s tec Puce sauce ea eee aia 1 19 1 6 Alarni Display na trash o ara ak DA ei m tta ag aka 1 21 1 7 Battery Voltages zu s oe a a ure viera ox ed te ets p da drabo 1 24 2 1 Manual GlowTime 2 2 2 2 2 Compartment Logic Control 22 2 2 7 2 3 3 Compartment Logic Control cece eee nn 2 8 4 1 Belt Tension Truck Units 4 7 4 2 Belt Tension Trailer Units 4 7 4 3 Connection PointVoltage se ees 4 19 4 4 Sensor Resistance Micro Units CD
6. MMM S LSV2 NC A 17 15 HGV2 NC 5 5 7116 u 2 MMM T LSVEINE di 17 D gt 15 gt HGVI NC 4 4 21 18 3 ge gt NO A 2 7 116 ENTI 5 13 lt x gt TONTA Lya NG t ww 15 Y 7 HGV3 NC A j 116 s gt EMIS Ss 17 CW 15 A HGV2 7 116 a ENTI D CESVAINE pn 17040747747 15 A HGV1 NC 21 NC gt gt _ gt 5 18 3 A 20 NC gt NO ne h 5 ur D 12 II 10 N OL 11 5 lt lt lt im L gt gt TRAILER 1 Compressor 9 Subcooler 16 Evaporator 2 High Pressure Switch HP 10 Accumulator Heat Exchanger 17 Electric Heater 3 Discharge Service Valve 11 Filter Drier 18 Compressor Pressure 4 Main Heat Valve MHV 12 Quench Valve Regulating Valve CPR 5 Check Valve 13 Liquid Solenoid Valve LSV 19 Suction Service
7. If suction pressure rises to 6 psig when UFR is energized then UFR shall be de energized There isa five minute time delay set between any of the load unload steps due to suction pressure that are listed above This algorithm is turned off during defrost 62 02884 1 12 3 Hot Gas Bypass Unloader a Major Working Parts 1 Solenoid and valve system 2 Spring loaded piston type bypass control valve 3 Spring loaded discharge check valve b Unloaded Operation Pressure from the discharge manifold Figure 1 15 item 15 passesthrough the strainer 9 and bleed orifice 8 to the back of the piston bypass valve 7 U nless bled away this pressure would tend to close the piston 6 against the piston spring 5 pressure With the solenoid valve 1 energized the solenoid valve stem 2 will open the gas bypass port 3 Refrigerant pressure will be bled to the suction manifold 10 through the opened gas bypass port A reduction in pressure on the piston bypass 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 When the pressure behind the piston has been reduced sufficiently the valve spring will force the piston bypass valve back opening the gas bypass from the discharge manifold to the suction manifold Discharge pressure in the discharge manifold will dose the discharge piston check valve assembly 14 isolating the compressor
8. NOTES 7 NOTES 8 meae 305 e MEJ o B 10A E N OSGeo JUST FOR 1075 K EUROPE a n 85 86 9 253 85 o 86 RAS eton 85 O 86 d CRANK G 8 33 O 85 86 nee BRAS 2 NOTES 1 R E 85 86 it OFE u Va 1 UNIT SHOWN OFF POSITION p 10A 2 WIRE IDENTIFICATION SYSTEM LO G E CS eT ICE COLOR WHITE DC CONTROL CIRCUITS AB 97 BLACK DC GROUNDS OTO 6 GREEN AC GROUNDS 1HT 3 ADDRESS SYSTEM EXAMPLE HCD2 MPH2 1 2929 cS 78 INDICATES A WIRE BETWEEN PLUG HC PIN 02 AND MICROPROCESSOR MP AND PIN W2 9 HAO 4 VOLTAGE BELOW 12 VOLTS REFER TO OWNERS MANUAL FOR TROUBLESHODTING PROCEDURE 5 ENGINE CT2 29 2 GLOW PLUGS ENGINE CT3 44 3 GLOW PLUGS 6 IF YOU HAVE A CONTROL PANEL YOU DON T A HAVE THE J4 JUMPER 13 102585 MEMON INDICATES A SOLDERED SPLICE POINT Pins voce IS ON PIN OF DIODE stock T fh A FOR ALL DIODES SAME AS DIODE BLOCK 2 AND 3 E 7 IF YOU HAVE A CONTROL PANEL YOU DON T NEED THE 1ST 2ST 3ST SWITCH ON CAB Pin conection COMMAND THIS SWITCH ARE ON CONTROL PANEL H Lot LINES INDICATES WIRES IN THE SYSTEM COMPONENT CONNECTION NUMBER OR LETTER 19 17 TO ely 8 IF YOU DON T HAVE DOOR SWITCH YOU HAVE 10 ESE NORMALLY CLOSED CONTACTS suos SYMB0L INDICATES MOMENTARY CONTACTS JUMPER 2 HCAZ lt MA is INDICATES A WIRE GROUND 14 NORMA
9. 3 1 4 Malfunction In the Engine Starting Circuit No power to starter motor solenoid SS Run solenoid does not energize or does not remain energized Battery defective Loose electrical connections Oil pressure safety switch OP defective Run relay RR defective Water temperature safety switch open Water temperature sensor WTS defective Run Fuel solenoid defective Run Stop or Start Run Stop switch defective 3 2 ALTERNATOR AUTOMOTIVE TYPE Alternator fails to charge Limited charging system operating time Battery condition Alternator belt loose broken Loose dirty corroded terminals or broken leads Excessively worn open or defective brushes Open blocking diode Regulator faulty Open isolation diode Open rotor field coil Low or unsteady charging rate Alternator belt loose Loose dirty corroded terminals or broken leads Excessively worn sticky or intermittent brushes Faulty regulator Grounded or shorted turns in rotor Open grounded or shorted turns in stator Excessive charging rate as evidenced by battery requiring too frequent refilling or Defective regulator charge indicator shows constant charge with engine idling Regulator leads loose dirty corroded terminals or wires broken Noisy alternator Defective or badly worn V belt Worn bearing s Misaligned belt or pulley Loose pulley 62 02884 3 2 Battery defective Check Loose electrical connections Tighten Check Tighten Replace
10. Discharge Service Valve Figure 4 13 Compressor Model 05G ON 2 CYLINDER Suction Service Valve Discharge Service Valve Oil Level Sight Glass Oil Drain Plug OilFill Plug Figure 4 14 Compressor Model 05K 4 14 COMPRESSOR UNLOADER VALVE The compressor unloaders located on the compressor cylinder heads are controlled by relays UFR URR and the temperature controller refer to Section 1 12 a Checkout Procedure 1 Connect manifold gauges to the compressor suction and discharge service valves and start unit in cooling mode with the trailer temperature at least 5 F 2 8 C above set point The compressor will be fully loaded both unloader coils are de energized Note suction pressure 2 Remove wiring from the front unloader coil Place electrical tape over wire terminals 3 Set controller upscale cooler to warmer This mechanically simulates falling temperature Approximately 2 F 1 1 C below box temperature the unloader coils will energize but only the rear unloader valve will unload Note suction pressure A rise of approximately 3 psig 0 2 kg cm should be noted on the suction pressure gauge 4 Reconnect wiring on the front unloader The front unloader will retract and an additional 3 psig 0 2 kg cm rise on the suction gauge will be noted Compressor is now fully unloaded and only the top bank is loaded two cylinders 5 Reverse the above procedu
11. O Ojo O SEQ Engine Speed High High High High High High High High Micro High High High High High High High High Micro High High Micro High High High Micro High Micro High Front SEQ Fans Middel SEQ Rear SEQ Unloader S ziz z o z x o xz xz o o ojo lt lt z lt lt lt lt lt 0 S S S S one one SECTION 3 TROUBLESHOOTING CAUTION Under no circumstances should anyone attempt to service the microprocessor see section 4 21 Should a problem develop with the microprocessor contact your nearestCarrier Transicold dealer for replacement INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 3 1 DIESEL ENGINE 3 1 1 Engine Will Not Start Starter motor will not Battery insufficiently charged crank or low cranking speed Battery terminal post dirty or defective Bad electrical connections at starter Starter motor malfunctions Starter motor solenoid defective Open starting circuit Incorrect grade of lubricating oil Starter motor cranks No fuel in tank but engine fails to start Air in fuel system Water in fuel system Plugged fuel filters Plugged fuel lines to injector s Fuel control operation erratic Glow plug s defective Run solenoid defective Fuel pump FP malfunction Starter cranks engages Engine lube oil too heavy but dies after a few seconds Voltage drop in starter cable s 3 1 2 Engine Starts Then Stops Engin
12. d Service Procedure Oil Type CAUTION Always cover the engine inlettube while the air cleaner is being serviced 1 Oil Cups When to Service Remove the oil cup at regular intervals Initially inspect daily or as often as conditions require Never allow more than 1 2 inch 12 7 mm of dirt deposit in either cup M ore than 1 2 inch accumulation could result in oil and dirt carrying over into the engine causing accelerated engine wear H eavily contaminated oil will not allow the air cleaner to function properly H ow to Service Stop the engine and remove the oil cupsfrom the air cleaner Dump the oil from the oil cups Remove the inner cup from the oil cup and clean both cups of sludge Reassemble and fill both oil cupsto the indicated level with SAE 10 oil for temperatures below freezing or SA E 30 for temperatures above freezing It is generally a recommended practice to use the same oil as required in the engine crankcase CAUTION Do not underfill or overfill the cups Overfilling of cups means loss of capacity and underfilling means lack of efficiency 2 BodyAssembly When to Service The lower portion of the fixed element should be inspected each timethe oil cup isinspected or serviced If there is any sign of contaminant buildup or plugging the body assembly should be removed and back flushed At least one a year or at regular engine service periods remove the entire air cleaner and perform the following
13. 62 02884 4 18 7 Place the enclosing tube locknut over the enclosing tube Install spacer over enclosing tube making sure it is seated properly in the enclosing tube locknut Tighten enclosing tube locknut to a torque value of 20 ft Ib 2 78 mkg D o not overtighten 8 Install coil assembly nameplate and top locknut or screw 9 Dehydrate and evacuate the system Refer to Section 4 9 Charge unit with refrigerant per Section 4 10 10 Start unit and check operation 4 19 CONDENSER COIL CLEANING Remove all foreign material from the condenser coil by reversing the normal air flow air is pulled in through the front Compressed air or water may be used as a cleaning agent t may be necessary to use warm water mixed with any good commercial dishwasher detergent R inse coil with fresh water if a detergent is used 4 20 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE CPR The CPR valve isfactory pre set and should not need adjustment If it is necessary to adjust the valve for any reason proceed with the following outline When adjusting the CPR valve the unit must be runningin the high speed heat or defrost T his will ensure a suction pressure above the proper CPR setting 1 Cap 2 Jam Nut 3 Setting Screw Figure 4 19 Compressor Pressure Regulating Valve To adjust the CPR valve proceed as follows a Install a manifold gauge set b Remove cap item 1 from CPR valve c With an 8 mm Allen wrench l
14. U nidrive Torque Requirements Trailer Thermostatic Expansion Valve Replacing Evaporator Fan Evaporator Coil Cleaning Evaporator Electrical lt ELECTRICAL SCHEMATIC WIRING DIAGRAM Introduction iae T te 62 02884 LIST OF ILLUSTRATIONS Figure Page 1 1 Truck U niti Top VIEW re Bi mn BR Cer Ces N 1 2 1 2 Truck Unit Curbside View usss 1 3 1 3 Truck Unit Roadside View 1 3 1 4 Tr ck Unit Electrical Box ia aoa sera 1 4 1 5 Trailer Unit 5 5 sss Hmm 1 6 1 6 Trailer Unit Front View 1 7 1 7 Control Box Door Trailer Unit 1 8 1 8 High Voltage Box Trailer U nit 1 8 1 9 Relay Box Trailer Unit 1 9 1 10 Compartment Control BOX u dur sume eels sa ter Re Ren hen od 1 10 1 11 Evaporator sas sia a Ae RA Re tcd ae 1 11 1 12 Cab command Truck Unit sr el u kuka A MALA 1 16 1 13 M icroprocessor Control Panel Trailer Unit 1 17 1 14 Auto Start Sequence sea kku kake aS a kone eda 1 23 1 15 Compressor Cylinder Head UNLOADED 1 26 1 1
15. EE EE 2 ee 10 2 E 16 e a 26 28 30 Temperature Pressure E meo Kaleme Bar _ xL oj 725 sip sa e90 626 614 825650638 962 670 959 70 6 13037 725 7 7 1261 887 174 513 14941 1050 10 1621 140 1 Hs 1234 12 2202 1548 15 2368 16 05 16 2542 71747 17 2724 1935 18 291 6 2050 20 sie 2192 2 3329 2341 22 3550 2496 24 3782 2658 26 4023 2828 27 4276 3006 29 1540 TIMES 42 6 8 50 10 55 13 16 65 18 70 21 75 24 27 851 2911 3212 95 35 00 38 05 41 10 43 15 46 20 49 25 52 30 54 35 57 40 60 45 63 50 66 454 0 31 92 3 SECTION5 ELECTRICAL SCHEMATIC WIRING DIAGRAM 5 1 INTRODUCTION This section contains Electrical Schematic Wiring Diagrams covering the M odels listed in Table 1 1 The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual They are Isai eio precautions that must be understood and applied during operation and maintenance of the equipment covered herein WARNING Beware ofunannounced starting ofthe fans V belts and beltdriven components as the unitmay start automatically Before servicing unit make sure the Run Stop switch is in the STOP position Also disconnectthe negative battery cable WARNING Beware of unannounced starting ofthe fans a
16. a Remove oil cup Check and clean center tube DO NOT USE GASOLINE b Pump solvent through the air outlet with suf ficient force and volume to produce a hard even stream out the bottom of the body assembly R everse flush until all foreign material is removed 4 4 5 Engine Crankcase Breather Trailer Unit The engine uses a closed type breather with the breather line attached to the cylinder head cover See Figure 4 2 Thebreather assembly should be cleaned once a year or at every 3000 hours maintenance interval whichever comes first 1 Cylinder Head Cover 5 Breather Oil Shield 2 Breather Cover 6 Bolt 3 Breather Element 7 Breather Assembly 4 Plate 8 O Ring Figure 4 2 Engine Crankcase Breather Trailer 4 5 4 4 6 Servicing Fuel Pump a Mechanical Pump Trailer Unit See Figure 4 3 D ue to foreign particlesin the fuel and waxasaresult of using the wrong grade of fuel or untreated fuel in cold weather The fuel filter may become plugged or restricted and the engine will loose capacity The filter must be cleaned on a regular schedule such as unit pre trip or when the oil and fuel filters are changed refer to Section 4 1 1 Turn nut counter clockwise to loosen and remove item 1 Figure 4 3 2 Remove banjo fitting item 2 and let it hang loose making sure to keep copper rings item 4 for replacement 3 Turn filter item 3 counter clockwise and remove Check and clean 4 To re install
17. 10 Condenser 5 Electric Standby Motor 11 Radiator Overflow Reservoir 6 1 ph Alternator Under Standby Motor Figure 1 1 Truck Unit Top View 62 02884 1 2 Air Cleaner Speed amp Run Solenoid Fuel Filter Serial Model Plate Figure 1 2 Truck Unit Curbside View BONA 1 Electrical Box See Figure 1 4 Figure 1 3 Truck Unit Roadside View Change 05 10 1 3 62 02884 263 A 2 3 4 5 Run Stop Switch RS Manual Glow Crank Switch MGC Fuses Relays Diode Block Motor Overload Relay MOL Microprocessor Module Fuse F1 80 amp Capacitor Note See Figure 1 12 for Command 62 02884 Figure 1 4 Truck Unit Electrical Box 1 4 Standby Motor Contactor MC c Trailer Condensing Unit NDC NDD TheGenesisT
18. 10 Evacuate by placing a vacuum pump on the suction service valve 11 Open the receiver service valve and check the refrigerant level 12 Thevalve should befactory pre set If theunitis slow in pulling temperature or the pressures do not correspond to the relevant temperature check superheat b Checking Superheat NOTE It is not recommended to adjust the Superheat unless absolutely necessary The valve is pre set at the factory M ake sure that all other problems are diagnosed and rectified prior to adjusting the superheat Due to the time involved in setting the superheat it is recommend to replace the valve rather than adjust it 62 02884 4 26 c To Measure Superheat The three thirds dual flow evaporators and the two thirds dual flow evaporators use two expansion valves Setting the superheat on these evaporators will be dealt with separately All the other evaporators used in M ulti Temp the superheat can be measured as follows CAUTION Always make sure thatonly one evaporator is working Adjust one evaporator and then switch that evaporator off and adjust the other evaporators Theair outlet profiles must be in their widest position and no obstruction to the airflow should be present The unit should be in high speed cool The unloaders should be disconnected if fitted to make sure compressor is working at maximum efficiency The Superheat check should be carried out inside a workshop or with a mi
19. BOX V 8 F17 FUSE 2 5AMP CONTROL BOX V 9 F18 FUSE 2 5AMP CONTROL BOX V 10 F19 FUSE 2 5AMP CONTROL BOX V 10 F20 FUSE 2 5AMP CONTROL BOX F 8 F21 FUSE 2AMP CONTROL BOX 2g F22 FUSE 2AMP CONTROL BOX F 10 F23 FUSE 2AMP CONTROL BOX 0 9 FLR FLASH RELAY CONTROL BOX X 6 1HE HEATER ELEMENT 15 COMPARTMENT EVAPORATOR X 8 2HE HEATER ELEMENT 2ND COMPARTMENT EVAPORATOR X 10 3HE HEATER ELEMENT 3RD COMPARTMENT EVAPORATOR N 2 6 4 0 4 MC MOTOR CONTACTOR CONTROL BOX 1 4 P 4 L 2 OL OVERLOAD PROTECTOR CONTROL BOX E 4 N 4 PSR POWER SUPPLY RECEPTACLE J 4 R 4 SBM STANDBY MOTOR FRAME P 10 SH SHUNT CONTROL BOX Figure 5 2 Truck Units Electrical Schematic Wiring Diagram Dwg No 62 60252 Sheet 1 of 2 6 6 CIRCUITS FOR DIESEL ELECTRIC TO J2 63 2 OL DER 87 208V 220V 230V 60Hz 3PH 440V 460V 60Hz 3PH Y 380V 415V 440V 50Hz 3PH 220V 50Hz 3PH 1 gt 3 N LJ PSR gt TO DPS PH TO DPS PH PLUG Y F1 Va 2 0 get CHIO nero 1HE 2A 02 N F1 8H HS 2EHR F1 EFB 2 La
20. Check engine e engine slows down or stalls Check value of load Excessive heat over heating Ventilator holes partially blocked Dismantle and clean 4 23 62 02884 4 27 SERVICING PHASE SEQUENCE WARNING High voltage in electrical box Disconnect power before servicing unit One of the phase relays PR 1 or PR 2 must pull in when power is applied to the unit To check Phase Sequence M odule a Verify that three phase power exists on supply side and that the same voltage is present between terminalsH 4 and 46 on the phase sequence module See Figure 4 22 b Verifythat 17 to 26 vac exists between terminals 4 and X2 on module If 17 to 26 vac does not exist between either terminals5 and X 2 or 6and X2onthemodule moduleis defective and should be replaced X1 X2 Figure 4 22 Phase Sequence Module on CTC 22 02247 62 02884 4 24 4 28 TORQUE VALUES TRUCK Assembly Power Tray to Frame Tomm Ff ib RER 5 4 Engine Suppor 55 4 EngneCkh 55 4 40 26 4 29 UNIDRIVE TORQUE REQUIREMENTS TRAILER Extensive damage may occur if the proper hardware and procedures are not followed Periodic inspection of hardware and bolt torque is recommended to insure the integrity of the unidrive NOTE Thread locking sealant 5 16 flat washer and 5 16 lock washer must be used on bolts between the compressor mounting flange and the adapter spacers The recommended seal
21. Fiber dust and particles are drawn into the evaporator where they lodge between the evaporator fins If the coil is not cleaned on a regular basis sometimes as often as after each trip the accumulation can be great enough to restrict air flow cause coil icing repetitive defrosts and loss of unit capacity Due to the washing action of normal defrost the fiber dust and particles may not be visible on the face of the coil but may accumulate deep within The evaporator coil should be cleaned on a regular basis not only to remove cardboard dust but to remove any grease or oil film which sometimes coatsthe fins and prevents water from draining into the drain pan Cardboard fiber particles after being wetted and dried several times can be very hard to remove Therefore several washings may be necessary a Remove rubber check valves Kazoo from drain lines b Spray coil with a mild detergent solution such as Oakite 164 or any good commercial grade automatic dish washer detergent such as Electrosol or Cascade and let the solution stand for a few minutes Reverse flush opposite normal air flow with clean water at mild pressure A garden hose with spray nozzle is usually sufficient M ake sure drain lines are clean c Rununituntil defrost mode can be initiated to check for proper draining from drain pan 4 33 EVAPORATOR ELECTRICAL CONNECTIONS All wiring harnesses to the evaporator section are identical The only difference
22. Fuse Opens at 2 amps TRUCK evaporator fan motors Opens at 8 amps TRAILER 12 Heater over temperature High Temperature Klixon Opens 120 5F 13 Excessive current draw by Fuse Opens at 2 amps TRUCK heaters Opens at 8 amps 2 Comp Trailer Opens at 4 amps 3 Comp Trailer 62 02884 1 14 1 8 MICROPROCESSOR CONTROLLER 1 8 1 INTRODUCTION The microprocessor controller is housed in the control box Thiscontroller consists of two control boards and a relay module 1 The Procesor Board includes the microprocessor program memory and necessary input output circuitry to interface with the unit 2 The Relay M odule contains replaceable relays diodes and fuses along with the wiring harness OnGenesistruck units the Cab Command isremote mounted in the truck The Cab Command includes the LCD display keypad and keypad interface See Figure 1 12 On Genesis trailer units the Display Board is mounted in the same control box asthe processor board The display board includesthe L CD display keypad and keypad interface See Figure 1 13 CAUTION Under no circumstances should anyone attempt to repair the Logic or Display Boards See Section 4 21 Should a problem develop with these components contact your nearest Carrier Transicold dealer for replacement The Carrier Transicold microprocessor controller incorporates the following features a Controls return air temperature to tight limits by providing refrigerat
23. Malfunction Will not initiate defrost Defrost thermostats sensors defective Replace Will not initiate defrost manually Microprocessor defective Replace Loose terminal connections Tighten Defrost thermostats sensors defective Replace Glow Defrost switch defective Replace Initiates but does not defrost Solenoid valve malfunction 3 3 11 Defrost relay DR defective Replace Frequent defrost Wet load Does not terminate or Defrost thermostats sensors defective Replace Cycles on defrost Glow Defrost switch defective Replace 3 3 6 Abnormal Pressure 3 3 6 1 Cooling High discharge pressure Condenser coil dirty Condenser fan defective V belt broken or loose Discharge check valve restricted Replace Noncondensibles or refrigerant overcharge Replace Low discharge pressure Compressor valves s worn or broken Solenoid valve malfunction High suction pressure Compressor valves s worn or broken Compressor gasket s defective Low suction pressure Suction service valve partially closed King valve partially closed Filter drier partially plugged Low refrigerant charge Expansion valve malfunction No evaporator air flow or restricted air flow Excessive frost on coil Suction and discharge Compressor valves defective pressures tend to equalize when unit is operating 62 02884 3 4 INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 3 3 6 2 Heating High discharge pressure Overcharged system Condenser fan defective V belts broken or
24. Protection l Two operating modes are available Electric Standby can operate in the Start Stop mode or the Continuous Run mode In the Start Stop mode when the box temperature gets close to setpoint the controller will cycle the Standby M otor SBM OFF to conserve energy 2 Minimum ON time five minutes The unit mustrun forthe minimum run time beforeit can consider shutting off This minimum run time isto prevent short cycling and ensure adequate air flow through the load to allowthe controller to accurately sense load temperature and bringthe battery up to minimum voltage level It also prevents hot spots in a properly loaded box After the minimum run time is complete the microprocessor will look atthe remaining conditionsthat must be satisfied to allow a shutdown These are A Battery condition Battery voltage must be above 13 4 volts measured at Y 1 B The box temperature active probe must be satisfied Perishable Range Setpoints 0 5 C Frozen Range Setpoints 0 5 C If ALL of these conditions are not satisfied the motor will continue to run until they are This prevents rapid cycling of the electric drive motor 3 Minimum OFF time 5 minutes Once the motor hascycled off it will remain off for the minimum off time This prevents the motor from rapid cycling 62 02884 2 4 dueto changesin airtemperature Airtemperatureinthe box can change rapidly but it takes time for the product t
25. Replace 1 2 Replace 4 4 3 Replace Check Check 4 5 Check Repair Check Check Check Check Replace 4 5 Check Repair Check Check Check Replace Clean Repair Check 4 5 Replace 4 5 Tighten INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 3 3 REFRIGERATION 3 3 1 Unit Will Not Cool Compressor malfunction Compressor drive defective 4 11 Compressor defective 4 11 Refrigeration system Defrost cycle did not terminate Abnormal pressure Solenoid valve malfunction 3 3 2 Unit Runs But Has Insufficient Cooling Compressor Compressor valves defective 4 11 Unloader malfunction 4 14 Refrigeration system Abnormal pressure Unloader malfunction Expansion valve malfunction No or restricted evaporator airflow Engine does not Speed control linkage 4 4 3 develop full rpm Engine malfunction 3 1 3 3 3 Unit Operates Long or Continuously in Cooling Container Hot Load Allow time to pull down Defective box insulation or air leak Correct Refrigeration system Abnormal pressure 3 3 6 Temperature controller malfunction 3 3 8 3 3 4 Unit Will Not Heat or Has Insufficient Heating Refrigeration Abnormal pressure Temperature controller malfunction Solenoid valve malfunction Compressor Compressor drive defective 4 11 Compressor defective 4 11 Engine does not develop Speed control linkage Truck full rpm Engine malfunction 33 62 02884 INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 3 3 5 Defrost Cycle
26. Should be 65 to 82 C 150 to 180 F 2 Check engine speed Refer to Section 4 4 3 3 Listen for abnormal noises Refer to Section 3 3 7 4 Check compressor oil level Refer to Section 4 13 5 Observe any signs of lube or fuel oil leaks 6 Check radiator hoses for leaks 7 Check refrigerant level Refer to section 4 10 8 Feel filter drier Excessive temperature drop across drier indicates restriction Refer to section 4 15 Change 05 10 2 2 STARTING AND STOPPING INSTRUCTIONS ENGINE DRIVE WARNING Under no circumstances should ether or any other starting aids be used to start engine WARNING Beware of unannounced starting of fans and V belts caused by thermostatic cycling NOTE Whenever starting the truck unit engine in order to reduce starter cranking and engine loads the microprocessor always starts and operates in low speed unloaded cool for the first 15 seconds After first 15 seconds the microprocessor will allow the unit to operate normally providing the coolant temperature is above 26 C 79 F In order to prolong engine life the microprocessor will prevent operation in high speed until coolant temperature reaches this temperature 2 2 4 AUTOMATIC START a Starting Instructions 1 Place the Run Stop Switch in the RUN position 2 For truck units place the On Off Switch Cab Command to ON position and press the Road Key 3 The microprocessor will perform a self test all di
27. Wa DIE YER NOTES 4 m GH HED Un mo 01 LA O MO LO OO ze 18 En 02 2 2 A 5 5 2 2 22 FLR Ur ECT2 U notes 4 Sm 3EHR O9 2 1 A amp 2 KT SCH 02 SH 2A Ham Qn F23 CT 3HE VA RCIA V NOTES 4 2 TOLSRI 1 MPTI p F2 BEKO e er Bcra 2 T HIGH VOLTAGE o veles a souvenen sprice Pont RIDE moun wa gom NOTES FOR ALL DIOOES SAME AS DIODE BLOCK 2 AND 3 1 UNIT SHOWN OFF POSITION Pin Mesa APER LIES notes ues tv ne Ste conection os LETE COLOR WHITE DC CONTROL CIRCUITS I A NORMALLY CLOSED CONTACTS 5 SWITCH SYMBOL INDICATES MOMENTARY CONTACTS BLACK DC GROUNDS RED AC CIRCUITS INDICATES A WIRE GROUND GREEN AG GROUNDS __ soma open CONTACTS 3 ADDRESS SYSTEM EXAMPLE HCD2 MPW2 d INDICATES A CHASSIS GROUND NO WIRE INDICATES A WIRE BETWEEN PLUG HC PIN D2 INDICATES CONNECTION INDICATES STANDARD OPTIONS AND MICROPROCESSOR MP AND PIN W2 EFE o INDICATES A CONNECTION WIRE LUG ETC 4 THE NUMBER OF FANS DEPEND OF YOUR HEE MULTIPLE PLUG CONNECTION MEER COMPARTMENT CONFIGURATION ED INSULATING PLUG V88c0 c9 Figure 5 2 Truck Units Electrical Schematic Wiring Diagram Dwg No 62 60252 Sheet 2 of 2
28. belt tension gauge Figure 4 5 on the belt rotate idler pulley so that the gauge reads the correct tension refer to Table 4 1 4 Tighten idler and carriage bolt 5 Start unitand run for 10 minutes to allow for belt stretch 6 Turn unit off and recheck belt tension 62 02884 e Standby Motor V belts Trailer Unit NOTE The standby motor V belts are a matched set Always replace both belts 1 Remove V belt guard 2 Remove six bolts on rear face of clutch flange see Figure 4 8 3 Slide clutch flange forward inside clutch sheave until holes line up and press forward for ease of belt removal 4 Remove and replace V belt through opening 5 Adjust belt tension as indicated in Table 4 1 Install V belt guard DO NOT START UNIT UNTIL V BELT GUARD ISINSTALLED 6 Start unit and for 10 minutes to allow for belt stretch 7 Turn unit off and recheck belt tension BELT STANDBY BELTS EN J ENGINE COMPRESSOR ATTACHING SCREWS FLYWHEEL Figure A NEW BELT CLUTCH FLANGE ENGINE COMPRESSOR FLYWHEEL CLUTCH SHEAVE SLIDE CLUTCH FLANGE Figure B Figure 4 8 Removing V Belt from Clutch Trailer 4 6 SERVICING CLUTCH Trailer The clutch must be inspected if the clutch slips or grabs The clutch automatically engages clutch
29. circuitry should never require adjustment and the solid state active elements used have proved reliable enough to warrant a sealed unit The system is temperature compensated to permit the ideal charging rate at all temperatures The regulator is an electronic switching device It senses the voltage appearing at the auxiliary terminal of the alternator and supplies the necessary field current for maintaining the system voltage at the output terminal The output current is determined by the load O POS OUTPUT SRN RED i FIELD YEL o GRN OUTPUT YEL 6 O 1 D EMULATION REGULATOR D Emulation Orange 10 24 AC Terminal 10 24 Ground Screw 1 4 20 Positive Output Cable 65 AMP Figure 1 17 65 Amp Alternator and Regulator P N 30 00409 02 Trailer Unit Positive Output B Regulator 12vdc Test Lamp Terminal L Ground Terminal Tw INS 1 27 62 02884 1 14 REFRIGERANT CIRCUIT DURING COOLING See Figure 1 19 When cooling the unit operates as a vapor compression refrigeration system The main componentsof the system are the reciprocating compressor air cooled condenser thermostatic expansion valve direct expansion evaporator and liquid line solenoid valve Thecompressor raisesthetemperature and pressure of the refrigerant and it passes through a normally open M ain Heat Valve M H V through a check va
30. discharge manifold from the individual cylinder bank manifold The unloaded cylinder bank will continue to operate fully unloaded until the solenoid valve control device is de energized and the gas bypass port is closed 1 Solenoid Valve 11 Cylinder Discharge 2 Valve Stem Valve 3 Gas Bypass Port 12 Valve Plate 4 Spring Guide 13 Cylinder Suction 5 Spring Valve 6 Piston 14 Discharge Piston 7 Piston Bypass Valve Check Valve 8 Bleed Orifice Assembly 9 Strainer 15 Discharge Manifold 10 Suction Manifold Figure 1 15 Compressor Cylinder Head UNLOADED 62 02884 c Loaded Operation Discharge pressure bleeds from the discharge manifold Figure 1 16 item 15 through the strainer 9 and bleed orifice 8 to the solenoid valve stem 2 chamber and the back of the piston bypass valve 7 With the solenoid valve 1 de energized the solenoid valve stem will closethe gas bypass port 3 Refrigerant pressure will overcome the bypass valve spring 5 tension and force the piston 6 forward closing the gas bypassfrom the discharge manifold to the suction manifold 10 Cylinder discharge pressure will force open the discharge piston check valve assembly 14 Refrigerant gas will pass into the compressor discharge manifold The loaded cylinder bank will continue to operate fully loaded until the solenoid valve control device is energized and the gas bypass port is opened 1 Solenoid Valve 11 Cylinder Disch
31. light FL is turned on Engine will shut down AL12 AL13 AL1 AL AL16 AL1 DE 0 1 2 3 4 5 6 7 8 9 4 15 7 18 19 AL AL AL20 AL21 High Coolant Temperature Alarm The high coolant temperature alarm is displayed with the description ENG HOT or AL 1 This alarm is generated if the control senses a high coolant temperature over 110 C 230 F The fault light FL is turned on and the engine will shut down High Pressure Alarm The high pressure alarm is displayed with the description HI PRESSorAL2 Thisalarmis generated if the high pressure switch opens The fault light FL is turned on and the engine will shut down Start Failure Alarm The start failure alarm is displayed with the description STARTFAIL or AL3 This alarm is generated if the engine fails to start The fault light FL is turned on If function M AN OP manual start mode is selected the start failure alarm will be generated if the engine fails to start in 5 minutes Low Battery Voltage Alarm The low battery voltage alarm is displayed with the description LOW orAL4 Thisalarm is generated if the battery voltage falls below 10 vdc The fault light FL isturned on High Battery Voltage Alarm The high battery voltage alarm is displayed with the description BATT or AL5 This alarm is generated if the battery voltage is above 17 vdc Thefaultlight FL is turned on and the engine will shut down Defrost Override
32. loose Noncondensibles in system Low discharge pressure Compressor valve s worn or broken Low refrigerant charge Low suction pressure Refrigerant shortage Compressor pressure regulating valve malfunction Suction service valve partially closed 3 3 7 Abnormal Noise Compressor Loose mounting bolts Tighten Worn bearings 4 11 Worn or broken valves 4 11 Liquid slugging 3 3 10 Insufficient oil 4 13 Condenser or Loose or striking shroud evaporator fan Bearings defective Bent shaft 3 3 8 Control System Malfunction Will not control Sensor defective Relay s defective Microprocessor controller malfunction 3 3 9 No Evaporator Air Flow or Restricted Air Flow Evaporator coil blocked Froston coil Dirty coil Fan motor s malfunction No or partial evaporator Evaporator fan loose or defective air flow Evaporator fan rotating backwards Evaporator air flow blocked in trailer box Fan motor s malfunction 35 62 02884 INDIC ATION REFERENCE 3 3 10 Expansion Valve Malfunction Low suction pressure with Low refrigerant charge high superheat External equalizer line plugged Ice formation at valve seat Wax oil or dirt plugging valve or orifice Broken capillary Power assembly failure or partial Replace Loss of element bulb charge Replace Superheat setting too high 4 30 Low superheat and liquid Superheat setting too low slugging in compressor External equalizer line plugged Ice holding valve open Foreign material in valve Pin and
33. new sight glass assembly and install C Leak check receiver sight glass per Section 4 8 d After leak checking unit evacuate and dehydrate as outlined in section 4 9 e Addrefrigerant charge Refer to Section 4 10 f Check for noncondensibles 4 18 SERVICING SOLENOID VALVES 4 18 1 Solenoid Valves Alco CAUTION Do notdamage orovertighten the enclosing tube assembly Torque to 200 inch pounds 2 3 mkg Also make sure all parts are placed on the enclosing tube in proper sequence to avoid premature coil burnout a Replacing the Coil NOTE The coil may be replaced without removing the refrigerant or pumping the unit down 1 Disconnectleads Remove coil retainer and coil assembly 2 Verify coil type voltage and frequency This information appears on the coil housing 3 Place new coil over enclosingtube A dd retainer and connect wiring b Replacing Solenoid Valve Internal Parts See Figure 4 17 The liquid line solenoid valve may be serviced by pumping the unit down Refer to section 4 7 a Remove and store the refrigerant charge in an evacuated container to service hot gas solenoid valve Refer to Section 4 7 b 1 Remove coil retainer and coil assembly from valve Remove enclosing tube assembly and related items 2 Check for foreign material valve body 3 Install new parts 4 Tighten enclosing tube assembly to a torque value of 200 inch pounds 2 3 mkg and leak check the valve Ref
34. of acids resulting in metal corrosion 4 9 2 Preparation a Evacuateand dehydrateonly after pressure leak test Refer to section 4 8 b Essential tools to properly evacuate and dehydrate any system include a good vacuum pump 5 cfm 8m H volume displacement CT D P N 07 00176 01 and a good vacuum indicator such as a thermocouple vacuum gauge vacuum indicator Available through Robinair M anufacturing M ontpelier O hio Part Number 14010 NOTE It isnot recommended using a compound gauge because of its inherent inaccuracy Keeptheambienttemperature above 15 6 C 60 F to speed evaporation of moisture If ambient temperature is lower than 15 6_C 60_F ice may form before moisture removal is complete Heat lamps or alternate sources of heat may be used to raise system temperature 4 9 3 Procedure for Evacuating and Dehydrating System a Remove refrigerant using a refrigerant recovery system b There are two methods to evacuate and dehydrate the system with one or two vacuum pumps as shown in Figure 4 10 or Figure 4 11 One is to connect three evacuation hoses Do not use standard service hoses as they are not suited for evacuation purposes to the vacuum pump and refrigeration unit Also as shown connect a evacuation manifold with evacuation hoses only to the vacuum pump electronic vacuum gauge and refrigerant recovery system c With the unit service valves closed back seated and the vacuum pump
35. seat of expansion valve eroded or held open by foreign material Fluctuating suction Improper bulb location or installation 4 30 pressure Low superheat setting 4 30 High superheat Broken capillary 4 30 3 3 11 Solenoid Valve Malfunction Solenoid valve does not No power to valve function properly Improper wiring or loose connections Coil defective Valve improperly assembled Coil or coil sleeve improperly assembled Movement of plunger restricted due to a Corroded or worn parts b Foreign material lodged in valve c Bentor dented enclosing tub Solenoid valve closes but Foreign material lodged under seat Clean refrigerant continues to flow Defective seat Replace 3 4 Standby Motor Malfunction Standby motor fails to start Motor contactor MC defective Replace Motor Overload OL open Replace motor Improper power supply 1 6 Oil pressure switch OPS open Check Selector switch SSW defective Replace Standby motor starts then stops Motor Overload OL open 1 6 High amperage draw Check 62 02884 36 SECTION 4 SERVICE WARNING Beware of V belts and belt driven components as the unit may start automatically Before servicing unit make sure the Run Stop switch is in the STOP position Also disconnect the negative battery cable NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing refrigerant 4 1 MAINTENANCE SCHEDULE TRUCK UNIT REFERENCE ON OFF OPERATION SECTION a D
36. suction pressure via the unit status display While the suction pressure is being displayed press Enter Key for three seconds The display should read 0 If display reads 0 install suction pressure transducer into unit Psig Voltage Psig Voltage Psig Voltage 0 7046 40 0860 80 1253 19 0568 50 0958 90 1352 20 70463 60 Lose 100 1450 sjo peg une 4 21 62 02884 4 25 5KW GENERATOR TRAILER The5KW generator requires very little preventative maintenance to ensure good performance Belt tension should be maintained at 50 ft Ibs When trouble shooting the 5KW generator it is important to check the internal capacitor the forward reverse rotating diodes and the internal windings The forward reverse rotating diodes are located at the filter end of the generator The reverse diode is marked with a red dot on the solder terminal The forward diode is unmarked A faulty diode will give a short circuit or open circuit reading in both directions ROTOR MAIN STATOR PER SECTION 10 7 Ohms 0 89 Ohms Disconnect each lead and test resistance between U1 amp U2 and test The rotating diodes can be tested during this same operation The diode s must be removed from the U5 amp U6 Note Unit wiring must circuit to test either diode or rotor Generally premature capacitor failure can be attributed to over speeding or over heating of the generator T he maximum speed for t
37. 0 1 7 a 10 psig 10 psig 26 1 291 1 Genesis 1000 17 f Thermostatic Expansion Valve Superheat Setting at 17 8 C 0 box temperature MODEL SETTING All Units 8to 10 F 44 to 5 6 C Compressor Discharge Temperature Sensor U nit shut down at 154 C 310 F for 3 minutes or 177 C 350 F Bypass Pressure Switch If Used Opens at 1 4 kg cm 20 psig Closes at 1 9 kg cm 28 psig 1 6 ELECTRICAL DATA a Evaporator Fan Motors Bearing Lubrication Factory lubricated additional grease not required Horsepower 15 kw 1 5 hp Operating Amps 1 5 amps Speed 2250 rpm Voltage 230 vdc e 1 13 b Generator 1 phase alternator Generator 1 phase alternator TRUCK 1 5 kva R70 Wattage 2 kva R90 Volts Speed rpm 1800 2200 c Standby Motors Bearing Lubrication Factory lubricated additional grease not required STANDBY MOTOR TRUCK Power Type of Ex EEG Genesis R70 122007 r Aes a ENS P A E s PI E se aj 0 n _____ oo Y ___ Genesis R90 pao 3 12 24 3 A u ur 386 Y __ 29 Rotation Speed 1760 rpm 9 6012 1500 rpm 5017 STANDBY MOTOR TRAILER FULL LOAD AMPS d Alternator 65 amps North amp South America 70 amps Europe e Standby Motor Overload STANDBY MOTOR OVERLOAD MODEL SETTING Genesis R70 R90 f Evaporator Heaters PartNo Wattage Volt
38. 15 Hot Gas Valve HGV 2 High Pressure Switch HP 9 Subcooler 16 Evaporator 3 Discharge Service Valve 10 Accumulator Heat Exchanger 17 Electric Heater 4 Main Heat Valve MHV 11 Filter Drier 18 Compressor Pressure 5 Check Valve 12 Sight Glass Regulating Valve CPR 6 Condenser 13 Liquid Solenoid Valve LSV 19 Suction Service Valve 7 Receiver 14 Expansion Valve 20 Receiver Pressure Valve RPV Figure 1 19 Truck Units Refrigeration Circuit Cooling 1 29 62 02884 E IIIII IIZ QII ICIIIIOIIOOI lt 17 AAA O 15 A lu lt lt KUU VO UAD DET TATT 5 III S IIIIIIIIIIIIIIIIIL lt DOD 15 i HGV2 A 5 KUNI cM 17 GVVVVVVVVO 15 A HGV1 A 20 5 f gi ly Km 9 Ur 5 2 fb 7 gt 1 Compressor 8 Receiver King Valve 15 Hot Gas Valve HGV 2 High Pressure Switch HP 9 Subcooler 16 Evaporator 3 Discharge Service Valve 10 Accumulator Heat Exchanger 17 Electric Heater 4 Main Heat Valve MHV 11 Filter Drier 18 Com
39. 4 23 Genesis 1000 Unidrive Torque Requirements 4 25 62 02884 4 30 THERMOSTATIC EXPANSION VALVE The thermal expansion valve is an automatic device that maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure The valve functions are a automatic response of refrigerant flow to match the evaporator load and b prevention of liquid refrigerant entering the compressor U nless the valve is defective it seldom requires any maintenance a Replacing Expansion Valve 1 Pump down the unit by closing the receiver service valve king valve Refer to section 4 7 a 2 Remove insulation from expansion valve bulb Note position of bulb in relation to the suction line Remove bulb from suction line 3 LoosentheOR Sfittingnutontheliquid lineand remove O Ring 4 Wrap valve in wet rags to act as a heat sink itis imperative that no moisture enter the system U nsolder the equalizer line and distributor pipe from the valve and remove the valve 5 Clean the suction line where the bulb is located 6 Solder the equalizer line and distributor pipe into the valve 7 Install the new valve after smearing the ORS fitting with clean refrigerant oil Tighten the liquid line nut CAUTION Overheating the expansion valve body can cause the valve to malfunction 8 Install the thermal bulb in the correct position Tighten the clamp and re insulate 9 Install new drier
40. 6 Compressor Cylinder Head LOADED 1 26 1 17 65 Amp Alternator and Regulator P N 30 00409 00 Trailer Unit 1 27 1 18 70 Amp Alternator and Regulator for Units Built In Europe 1 27 1 19 Truck Units Refrigeration Circuit Cooling 1 29 1 20 Truck Units Refrigeration Circuit Heating 1 30 1 21 Trailer Unit Refrigeration Circuit Cooling 1 31 1 22 Trailer Unit Refrigeration Circuit Heating 1 32 2 1 Compartment Control 2 2 2 2 Temperature Controller perating Sequence Perishable R ange Controller Set Point Above 12 C 410 2 5 2 3 Temperature Controller O perating Sequence L ead E vaporator Perishable Range Controller Set Point Above 12 C 10 F 2 5 2 4 Temperature Controller O perating Sequence Frozen R ange Controller Set Point Below 12 10 2 6 2 5 Temperature Controller perating Sequence L ead E vaporator Frozen Range Controller Set Point Below 12 C 10 F 2 6 4 1 Speed and Run Control Solenoids Truck 4 4 4 2 Engine Crankcase Breather Trailer 4 5 4 3 Mechanical Fuel Pump Trailer Unit 4 5 4 4 Elect
41. 820 29 8 7 Operating Mode Front Cool Cool Cool Cool Cool Cool Cool Cool Cool Heat Heat Heat Heat Heat Heat Heat Heat Heat Null Null Null Null Null Null Null Null Null Defrost Middle Cool Cool Cool Heat Heat Heat Null Null Null Cool Cool Cool Heat Heat Heat Null Null Null Cool Cool Cool Heat Heat Heat Null Null Null Defrost Rear Cool Heat Null Cool Heat Null Cool Heat Null Cool Heat Null Cool Heat Null Cool Heat Null Cool Heat Null Cool Heat Null Cool Heat Null Defrost 1CR O O O O O O O O gt 2 SEQ 1HGR O O O O O O O O 2 SEQ Table 2 3 3 Compartment Logic Control 1EHR SEQ 2CR PRI SEQ 2HGR o o o o o o o 2 2 o o o o o o o oO O O O O O O O PRI SEQ 2EHR O O O O SEQ Engine speed is for truck units only Trailer unit is one speed Output is ON O Output is OFF PRI Hot gas priority logic Refer to Section 2 7 SEQ Defrost logic Refer to Section 2 8 Micro Micro control on temperature demand M Control both suction pressure and temperature demand one one unloader energized unloaded 3CR Ojo o o PRI SEQ 3HGR PRI SEQ 3EHR
42. AY or AL 17 Maintenance Hour Meter 1 Alarm The M aintenance H our M eter Alarm 1 is displayed with the description SERVICE lor AL18 This alarm is generated when the designated hour meter is greater than maintenance hour meter 1 Maintenance Hour Meter 2 Alarm The M aintenance H our M eter Alarm 2 is displayed with the description SERVICE 20r AL19 This alarm is generated when the designated hour meter is greater than maintenance hour meter 2 Compartment 1 Out of Range Alarm The out of range alarm is displayed with the description IRA OUT or AL20 This alarm is generated when compartment 1 is out of range refer to section 1 8 6 The fault light FL isturned on 62 02884 Compartment 2 Out of range Alarm The out of range alarm is displayed with the description OUT or AL21 Thisalarm is generated when Compartment 2 is out of range refer to section 1 8 6 The fault light FL isturned on Compartment 3 Out of range Alarm The out of range alarm is displayed with the description 3RA OUT or AL22 This alarm isgenerated when Compartment 3 is out of range refer to section 1 8 6 The fault light FL isturned on No Power for Standby Alarm Truck Unit NO POWER will be displayed if truck unit is switched to standby and power plug is not plugged in 1 8 9 AUTO START STOP OPERATION Automatic start stop is provided to permit starting restarting of the diesel driven compressor as required Thisfeature fully enables aut
43. Alarm The defrost override alarm is displayed with the description DEFR FAIL or AL6 Thisalarm is generated if the unit is in a defrost override mode T he fault light FL isturned on Alternator Auxiliary Alarm The alternator auxiliary alarm is displayed with the description ALT AU X orAL7 Thisalarmis generated if the alternator auxiliary signal is not present with the engine running See Section 1 8 9 Thefault light FL is turned on Starter Motor Alarm The starter motor alarm is displayed with the description STARTER orAL8 Thisalarm is generated if the starter motor input signal is not present with starter solenoid energized The fault light FL is turned on Compartment 1 Return Air Sensor Alarm The Compartment 1 return air sensor alarm is displayed with the description IRA SENSOR or AL9 This alarm is generated if the return air sensor is open shorted fault light FL isturned on because there 15 no controlling probe Compartment 2 Return Air Sensor Alarm The Compartment 2 return air sensor alarm is displayed with the description 2RA SENSOR or AL10 This alarm is generated if the return air sensor is open shorted fault light FL isturned on because there 15 no controlling probe 62 02884 Coolant Temperature Sensor Alarm The coolant temperature sensor alarm is displayed with the description WT SENSOR orAL11 Thisalarmis generated if the coolant temperature sensor is open or shorted
44. CONTROL BOX D 1 K F2 F FUSE 5A CONTROL BOX 5 10 0 6 2RR RUN RELAY 2nd COMPARTMENT CONTROL BOX M B M 10 M 12 F9 F10 F1FUSE CONTROL BOX 5 11 0 6 3RR RUN RELAY 2rd COMPARTMENT CONTROL BOX E F F C 1 RS RUN SWITCH CONTROL BOX 0 9 EGR FUEL HEATER OPTION ENO Ne Box 0 4 SCS SPEED CONTROL SOLENOID ENGINE R 2 L 8 FHR FUEL HEATER RELAY OPTION CONTROL BOX 9 2 SM STARTER MOTOR ENGINE 5 2 FHTH FUEL HEATER THERMOSTAT OPTION ENGINE F 2 SP SERIAL PORT CONTROL BOX H 9 H 8 FAULT RELAY CONTROL BOX B 5 SPT SUCTION PRESSURE TRANSDUCER CONPRESSOR 5 3 FP FUEL PUMP FUEL TANK L 4 H 9 SR SPEED RELAY CONTROL BOX 0 4 GP GLOW PLUG ENGINE 0 3 55 STARTER SOLENOID STARTER L 4 H 6 GPR GLOW PLUG RELAY CONTROL BOX P 2 ssc STARTER SOLENOID CONTACTOR STARTER L 3 H 6 SSR STARTER SOLENOID RELAY CONTROL BOX B 5 WTS WATER TEMPERATURE SENSOR ENGINE 9 9 1ST START STOP SWITCH 1st COMPARTMENT COMMAND 9 9 257 START STOP SWITCH 2nd COMPARTMENT CAB COMMAND 9 9 3ST START STOP SWITCH 3RD COMPARTMENT CAB COMMAND Figure 5 1 Truck Units Electrical Schematic Wiring Diagram Dwg No 62 60251 Sheet 1 of 2 S 788 0 9
45. Compressor Discharge Temperature Alarm The compressor discharge temperature alarm is displayed with the description HIGH 12 This alarm is generated if the temperature is sensed above 155 C 310 F for three minutes If the discharge temperature exceeds 177 C 350 F the three minute timer is overridden and the unit shut down immediately The fault light FL is turned on Compressor Discharge Temperature Sensor Alarm The compressor discharge temperature sensor alarm is displayed with the description CD SENSOR orAL 13 This alarm is generated if the sensor is open or shorted Standby Motor Overload Alarm The standby motor overload alarm is displayed with the description SBY MOTOR or AL 14 This alarm is generated when the M OL input is sensed open with the Run Relay energized in electric mode Diesel E lectric Relay energized Fuse Alarm The fuse alarm is displayed with the description FUSE BAD or AL 15 This alarm is generated when the FUSE input is sensed low The fault light FL isturned on Compartment 3 Return Air Sensor Alarm The Compartment 3 return air sensor alarm is displayed with the description 3RA SENSOR or AL 16 Thisalarm is generated if the return air sensor is open or shorted Thefault light FL isturned on becausethereis no controlling probe Display Alarm When no communications exist between the main board display board for eight seconds the display alarm description is DISPL
46. DEF for 20 seconds The last temperature setpoint and current compartment temperature will then be displayed 5 Set required temperature by pressing up or down arrow keys as required 6 Turn compartment evaporator is not required button OFF when Figure 2 1 Compartment Control Box b To SetPre set Setpoint 1 Switch main on off switch on the unitto ON Press system on off button to ON position see Figure 2 1 2 Switch OFF each compartment unit will stop 3 Press manual defrost button for 10 seconds Pl will be displayed in all compartments 4 Setlowest setpoint temperature required 5 Press compartment on off button P2 will be displayed Set next lowest temperature required up to five pre set setpoints are available 6 Switch system on off switch on the unit to OFF This stores the pre set setpoints in memory c To Remove a Pre set Setpoint 1 Start unit and press system on off button to ON position see Figure 2 1 2 Switch OFF each compartment unit will stop 3 Press manual defrost button for 10 seconds 1 will be displayed in all compartments 4 Settemperature to lowest possible and OF will be displayed 5 Switch system on off switch on the unit to OFF This erases the pre set setpoints in memory 2 5 CONTROL CIRCUIT OPERATION ENGINE DRIVE 2 5 1 Introduction NOTE To make it easier to locate the schematic components referred to in the written text the
47. LLY OPEN CONTACTS j js CR INDICATES A CHASSIS GROUND NO WIRE Ge ear mo GEO WIRING FOR ALTERNATOR WIRING FOR ALTERNATOR o INDICATES A CONNECTION WIRE LUG ETC 30 00363 00 00393 E 30 00393 00 HCF2 MULTIPLE PLUG CONNECTION NUMBER Figure 5 1 Truck Units Electrical Schematic Wiring Diagram Dwg 62 60251 Sheet 2 of 2 VG LOCATION SYMBOL DESCRIPTION LOCATION IN FRAME B 8 ALT ALTERNATEUR SINGLE PHASE FRAME C 10 CAR CAPACITOR ALTERNATOR RELAY CONTROL BOX R 6 C1 CAPACITOR CHEATERS CONTROL BOX R 7 c2 CAPACITOR HEATERS CONTROL BOX Q 6 C3 CAPACITOR HEATERS CONTROL BOX B 10 C4 CAPACITOR ALTERNATOR CONTROL BOX B 11 C5 CAPACITOR ALTERNATOR CONTROL BOX D 8 EFB ELECTRIC FAN BOARD CONTROL BOX H 8 1EM ELECTRIC MOTOR 15 COMPARTMENT EVAPORATOR H 9 2EM ELECTRIC MOTOR 2ND COMPARTMENT EVAPORATOR ELECTRIC MOTOR 3RD COMPARTMENT EVAPORATOR E 8 1EMR ELECTRIC MOTOR RELAY 15T COMPARTMENT CONTROL BOX Eg 2EMR ELECTRIC MOTOR RELAY 2ND COMPARTMENT CONTROL BOX E 10 3EMR ELECTRIC MOTOR RELAY 3RD COMPARTMENT CONTROL BOX T 6 1EHR ELECTRIC HEATER 15 COMPARTMENT CONTROL BOX T 8 2EHR ELECTRIC HEATER 2ND COMPARTMENT CONTROL BOX T 10 3EHR ELECTRIC HEATER 3RD COMPARTMENT CONTROL BOX V 6 F12 FUSE 2 5AMP CONTROL BOX V 6 F13 FUSE 2 5AMP CONTROL BOX V 7 F14 FUSE 2 5AMP CONTROL BOX V 7 F15 FUSE 2 5AMP CONTROL BOX V 8 F16 FUSE 2 5AMP CONTROL
48. M an OP the Auto S S Continuous Key can be used to toggle between Auto Start Stop and M anual Start Continuous Run Table 2 1 Manual Glow Time Glow Time in Seconds 49 10 Greaterthan 26 10 o b Stopping Instructions Place the On Off Switch Cab Command if used to OFF position or place Run Stop Switch in the STOP position to stop unit Ambient Temperature 2 3 STARTING AND STOPPING INSTRUCTIONS STANDBY MOTOR DRIVE WARNING Beware of unannounced starting of fans and V belts caused by thermostatic cycling 1 Plugin the power plug 2 a For Truck Units place the On Off Switch Cab Command to ON position and press the Standby Key 2 b For Trailer Units place the Engine Standby Switch in the STANDBY position and place the Run Stop Switch in the RUN 1 position 62 02884 2 2 3 The microprocessor will perform a self test all display messages will appear in display window Next setpoint and box temperature will be displayed NO POWER will be displayed if truck unit is switched to standby and power plug is not plugged in 2 4 COMPARTMENT OPERATION a Starting Compartment l Switch unit Engine Start run switch ON For starting instructions on the nosemount unit refer to section 2 2 2 Press system on off button to ON position see Figure 2 1 3 Press required compartment on off button to ON position see Figure 2 1 4 The unit will start and display
49. OMPARTMENT 1 COMPARTMENT 2 COMPARTMENT 3 11 Figure 1 12 Cab Command Truck Unit 1 8 4 KEYPAD Cab Command Truck Unit The keypad has 12 keys which will allow the operator to initiate various functions display operating data and change operating parameters The keypad has up and down arrow keys which are used to modify increment or decrement the displayed data If theunitis in the default display then these keys will modify the setpoint selection Enter Key gt 3 o The enter key is used to accept a change in unit parameters or a change in setpoint Manual Defrost Key The manual defrost key is used to initiate a defrost cycle given that the proper conditions are met Pretrip Check Key This key is inactive and not applicable for this application via Auto Start Stop Continuous Key The autostart stop continuous key is used to change the operating mode from auto start continuous run to auto start stop E ach push of the key will alternate the operating modes The operating status will be stored in memory and is retained through power outages The digital display will indicate when stop start is enabled refer to Section 1 8 9 To start the unit in manual start mode the autostart stop continuous selection must bein continuous run mode 62 02884 Function Change Key The function change key is used to display the operating parameters Each time this k
50. OR CONTROLLER 1 9 1 Introduction Components required for monitoring and controlling the diesel engine refrigeration system are located in the electrical box The water temperature sensor is located on top of the engine 1 9 2 Electrical Box Door See Figure 1 4 a Gauges 1 Ammeter Gauge A Trailer Unit The DC ammeter indicates the rate of charge or discharge of the battery charging system including batteries battery charging alternator and the voltage regulator b Switches 1 Run Stop Switch R S When placed in the RUN position this switch provides power to the microprocessor To stop the unit or remove power from the microprocessor move the Run Stop switch to the STOP position 2 Manual Glow Crank Switch M GC The manual glow crank switch when held in the GLOW position energizes approximately 7 5 amps per plugat 12 vdc the glow plugsinthe engineto pre heatthe combustion chamber The CRANK position of the switch is used to manually engage the engine starter 3 Selector Switch SSW Trailer Unit This switch is used to select mode of operation either engine drive or standby electric motor drive W hen this switch is placed in standby position the electric motor will not start until the oil pressure safety switch OP opens 1 9 3 Location of Engine Safety Devices a Oil Pressure Safety Switch OP Thisswitch to open below 1 0 0 2 15 3 psig will automatically stop the engin
51. OR a Checking Capacitor GENERATOR TRUCK 1 Unscrew top plastic cover The single phase alternator is mounted under the 2 Di t it C t it compressor The belt drive arrangement ensures that when the diesel engine is in high speed the alternator to a main voltage with a switch and an ammeter to read delivers 240 vac 60H z and when the diesel engine isin low current see table below speed the generator delivers 240 vac 50H z Capacitor MF 220 50 Hz lA 240 60 Hz lA The alternator has a brushless compound excitation using an auxiliary phase capacitor to provide the self excitation The alternator has only one rotating component no electronic controls and sealed for life bearings combining simplicity with reliability b Fault Finding Parts to be Checked Without Load Action to take No voltage with no load when starting Loss of residual magnetism Apply a battery 4 5 V to capacitor termi nals Load alternator and run engine above nominal speed for a few seconds Defective capacitor Change capacitor Rotor diode out of order or shortcircuit Change 2 diodes on rotor Winding short circuit or loose Check resistance of coils connections Voltage win no load less than 80 of nominal voltage c FaultFinding Parts to be Checked With Load ak Case Action to take Correct voltage with no load low voltage Rotor diode out of order or short circuit Change 2 diodes on rotor with load 1
52. R 1000 ND C NDD isafully charged pre wired refrigeration heating nosemount diesel powered condensing unit for use on insulated trailers to maintain cargo temperatures within very close limits T he model serial number plate is located inside of the unit as shown in Figure 1 5 The condensing unit consists of engine compressor drive package condenser fan condenser radiator coil control panels relay module refrigerant controls piping wiring and associated components H eatingisaccomplished either by circulating hot gas directly from the compressor to the evaporator coil or by electric heaters run by a 5 kilowatt induction generator Two electric solenoid valves in each evaporator control the refrigerant circuit to operate the heating cooling system E vaporator coil defrosting is initiated by the defrost timer in the microprocessor or by the manual defrost keys The control door and relay module include manual switches microprocessor ammeter fuses and associated wiring Thetemperature controller isa microprocessor solid state controller Refer to section 1 8 Once the controller is set at the desired temperatures the unit will operate automatically to maintain the desired temperatures within very close limits T he control system automatically selects cooling null or heating as necessary to maintain the desired temperatures within the trailer The 05G compressor is equipped with Varipowr as standard equipme
53. T 2 amp WTS 4 21 4 5 Suction Pressure Transducer 4 21 4 6 Generator Voltage Output llel nn 4 22 4 7 R 404A Pressure Temperature Chart 4 28 T 62 02884 SECTION 1 DESCRIPTION 1 1 INTRODUCTION b Truck Condensing Units a System The Genesis R70 R90 models are one piece This manual contains Operating Data Electrical Data and Service Instructions for the refrigeration units listed in Table 1 1 Also Table 1 1 charts some significant differences between these models The Genesis Multi Iemp multiple compartment refrigeration systems offer the versatility of two or three compartment temperature control in truck or trailer The Multi Temp allows the shipper to ship frozen and condensing units designed for truck applications They are equipped with an electric standby motor The model serial number plate is located inside of the unit on the frame as shown in Figure 1 2 The control system is a microprocessor controller Refer to section 1 8 Once the controller remote Cab Command within the cab ofthe truck 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 perishable commod
54. TRANSICOLD Truck Trailer Refrigeration Unit Genesis R70 Genesis R90 Genesis TR1000 Multi Temp 62 02884 Change 05 10 OPERATION AND SERVICE TRANSICOLD ___ OPERATION AND SERVICE MANUAL TRUCK TRAILER REFRIGERATION UNITS Genesis R70 R90 and Genesis TR1000 Multi Temp LZ Carrier Carrier Transicold E T O Boite Postale Nr 16 Franqueville Saint Pierre 76520 Boos FRANCE A United Technologi Carrier Transicold Division Carrier Corporation Box 4805 Syracuse N Y 13221 U S A Carrier Corporation 1997 D Printed in U S A 0297 Section 1 DESCRIPTION Rh ll Introduction sa esen pa a amo Eaton taste sea i na 12 Engine Data acte kan e a Ink ating utate es 1 3 SENGINSAITGIEANER oos om pe en e Ra a tete Pahoa idee 14 Compressor Reference 15 Refrigeration System Data 1 6 Electrical Data tecum D e Re ER ER acr a MER AO ER Lade He 17 Safety Devices E I IC 18 Microprocessor Controller 1 8 1 Introduction vro Ret el Rr ddr te eee eds 1 8 2 coss eoe nes ein See eigenen 1 8 3 D igital Displdy 2 2 2 te eere e yas inkuba 1 8 4 Keypad Cab Command Truck Unit 185 Keypad Trailer Unit 18 6 Functional lt
55. V LIQUID SOLENOID VALVE 1st COMPARTMENT EVAPORATOR 5 7 105 DOOR SWITCH Ist COMPARTMENT EVAPORATOR 0 10 2LSV LIQUID SOLENOID VALVE 2nd COMPARTMENT EVAPORATOR 5 7 205 DOOR SWITCH C2nd COMPARTMENT EVAPORATOR 0 12 SLV LIQUID SOLENOID VALVE 3rd COMPARTMENT EVAPORATOR 5 8 305 DOOR SWITCH 3rd COMPARTMENT EVAPORATOR L B 8 1DTS DEFROST THERMISTOR SENSOR 1st COMPARTMENT EVAPORATOR H 8 M 6 MHR MAIN HEAT RELAY CONTROL BOX B 7 2DTS DEFROST THERMISTOR SENSOR 2nd COMPARTMENT EVAPORATOR 9 6 MHV MAIN HEAT VALVE FRAME B 7 3DTS DEFROST THERMISTOR SENSOR 3rd COMPARTMENT EVAPORATOR D 11 D 2 M MICROPROCESSOR BOARD CONTROL BOX P 9 P 10 P 12 1 2 3DWR DRAIN WATER RESISTANCE 1st 2nd 3rd EVAPORATOR 6 OP OIL PRESSURE SAFETY SMITCH NO ENGINE T 5 EFB ELECTRIC FAN BOARD CONTROL BOX B 3 P1 CAB COMMAND PLUG CONNECTOR CONTROL BOX 1 10 ELECTRIC HEAT RELAY 1st COMPARTMENT CONTROL BOX D 3 P2 MICROPROCESSOR CAB COMMAND PLUG CONNECTOR CONTROL BOX I 10 2EHR ELECTRIC HEAT RELAY 2nd COMPARTMENT CONTROL BOX B 6 RAS RETURN AIR SENSOR 1st COMPARTMENT EVAPORATOR I 11 3EHR ELECTRIC HEAT RELAY 3rd COMPARTMENT CONTROL BOX B 9 2RAS RETURN AIR SENSOR 2nd COMPARTMENT EVAPORATOR K 2 F FUSE MAXI FUSE 80A CONTROL BOX B 10 3RAS RETURN AIR SENSOR 3rd COMPARTMENT EVAPORATOR K 3 K 8 F3 F8 FUSE 25A CONTROL BOX C 2 D 1 RCR RUN CONTROL RELAY CONTROL BOX K 4 F FUSE 15A CONTROL BOX 5 3 RC RUN COIL ENGINE K 5 5 FUSE 7 5 CONTROL BOX 5 9 0 5 1RR RUN RELAY 1st COMPARTMENT
56. Valve 6 Condenser 14 Expansion Valve 20 Receiver Pressure Valve RPV 7 Receiver 15 Hot Gas Valve HGV 21 By Pass Valve BPV 8 Receiver King Valve Figure 1 22 Trailer Unit Refrigeration Circuit Heating 62 02884 1 32 SECTION 2 OPERATION 2 1 PRE TRIP INSPECTION a Before Starting Engine 1 Drain water and sediment from fuel tank sump Fill tank with diesel fuel 2 Check radiator coolant level Add pre mixed 50 50 permanent antifreeze water as required USE ETHYLENE GLYCOL ONLY Refer to Section 1 2 3 Check evaporator and condenser coil for cleanliness 4 Checkengine lubrication and fuel filter oil lines and connections for leaks Tighten connections and or replace gaskets 5 Check engine oil level Refer to Section 1 2 6 Check V belts for proper tension fraying or cracks Adjust belts or replace WARNING Inspect battery cables for signs of wear ab rasion or damage at every Pre Trip inspec tion and replace if necessary Also check battery cable routing to ensure that clamps are secure and that cables are not pinched or chafing against any components 7 Check battery terminals for cleanliness and tightness Clean and coat with a mineraltype grease such as Vaseline 8 Check engine air cleaner for cleanliness and condition of air cleaner hose 9 Check defrost drain pan hoses Should be clear of debris b After Starting Refrigeration Unit 1 Check water temperature
57. age OHM Horsepower Voltage Full Load Amps Lock Rotor Amps RPMS 2880 62 02884 1 7 SAFETY DEVICES System components are protected from damage caused by unsafe operating conditions by automatically shutting down the unit when such conditions occur This is accomplished by the safety devices listed in Table 1 2 Table 1 2 Safety Devices Unsafe Conditions Safety Device Device Setting 1 Low engine lubricating oil Oil pressure safety switch OP Opens below 1 0 2 kg cm Pressure automatic reset 15 3 psig 2 High engine cooling water Water temperature sensor Opens above 110 3 C temperature microprocessor 230 5 F 3 Excessive current draw by glow Fuse F1 Opens at 80 amps plug circuit control circuit or starter solenoid SS 4 Excessive current draw by Fuse F2 Opens at 5 amps microprocessor 5 Excessive current draw by Fuse F3 Opens at 25 amps control circuit 6 Excessive current draw by Fuse F4 Opens at 15 amps speed control solenoid 7 Excessive current draw by Fuse F5 Opens at 7 1 2 amps auto restart 8 Excessive compressor High pressure cutout switch HP Cutout 32 7 0 7 kg cm 9 discharge pressure automatic reset 469 10 psig 9 Excessive compressor Compressor discharge Shuts unit down above 154 C discharge temperature temperature sensor CDT 310 F for 3 minutes or 177 350 F 10 Excessive current draw by Fuse Opens at 10 amps compartment 11 Excessive current draw by
58. aged with replacement gaskets for this purpose The tightening sequence shown below should be adhered to when tightening the retaining bolts or nuts The recommended torque for securing nuts or bolts 15 15 inch Ibs Over tightening the nuts or bolts or using a tightening sequence other than the one shown may cause warping of the K ey Board Figure 4 20 Tightening Sequence for Microprocessor Trailer Unit b Hour Meter The hour meter can be set to any value via the serial port ifthe meter haslessthen five hoursonit Thisallows areplacement microprocessor to be set to the same hours as the microprocessor it is replacing The microprocessor has two programmable registers which are set via the serial port These registers are compared to one of the hour meters diesel standby or switch on If the hour meter is greater than the register then the proper alarm is set 62 02884 4 22 CONFIGURATION OF MICROPROCESSOR When replacing a microprocessor it is important to check that the configurations are compatible for the unit into which it will be installed This same board fits both trailer and truck model units All configuration fields should be viewed before starting the unit To reach the configuration fields 1 TurntheRun Stop switch to the Stop position 2a Trailer units only With the unit off locate the serial port plug located below the control panel Remove the protective plug to gain access to the wire termin
59. aily Inspection Perform daily inspection 4 1 Check wire harness for chafing and loose terminals Replace Tighten Check unit mounting bolts for tightness 4 28 Check standby motor bearings for end play None Change engine lube oil and filter 4 4 2 Perform daily inspection Tighten all electrical connections Check that evaporator drain lines are clear Replace fuel filter Check engine speeds d Oil Change Intervals Without With MODEL Bypass Oil Filter Bypass Oil Filter Truck Units 750 Hours 1000 Hours 4 1 62 02884 4 2 MAINTENANCE SCHEDULE TRAILER UNIT REFERENCE ON OFF OPERATION SECTION a Daily Maintenance 1 Pre Trip Inspection before starting La 2 Pre Trip Inspection after starting 1 b 3 Check engine hours un 10 min Pre Trip Inspection before starting l a Change lube oil and filter 4 2 Pre Trip Inspection after starting l b Check engine hours un 10 min Complete 400 Hour Maintenance Refer to paragraph 1 2 for oil change intervals 4 1 b Tighten engine compressor and unit mounting bolts None Tighten all electrical connection in control box Tighten Clean air cleaner check hose and connections 4 4 4 Check water pump bearing end play None Check alternator brushes None Clean evaporator and condenser coils 4 32 4 19 Check fuel pump FP filter 4 4 6 Replace fuel filters 4 4 6 Complete a 1500 Hour Maintenance 4 1 c Clean crankcase breather 4 4 5 Replace all V belts 4 5 C
60. als Place an insulated jumper wire between wires SPA and SPB at the serial port plug 2b Truck units only Place an insulated jumper wire between plugterminalsL SPA and M SPB inthe CC plug see plug drawing below for terminal locations CAUTION Do not allow jumper wire to touch any ground CIRCULAR CONNECTOR VIEWED FROM OUTSIDE THE ELEC TRI CIRCULAR CONNECTOR VIEWED FROM INSIDE THE ELECTRICAL 3 Turn the Run Stop switch to the Run position The FAULT light will come on and the micro display will read CNF1 TV or CNF1 DI Remove the jumper wire from the serial port and reinstall the protective plug The configuration screen will now remain available for 5 minute Scroll through the configuration list using the Function Key and compare the settings with those shown on the table in the next column If any of the configurationsneed to be changed continue with step 4 below 4 change the configuration selection a Bringthe configuration to be changed onto the display Press the Enter Key to allow change access to the displayed configuration b Press either the Up or Down Keys to display available selections for that configuration Leave the correct selection on the screen T selection display will flash warning the operator that the displayed value has not been entered Press the Enter Key to enter the new selection into memory The display will revert to the original selection if no fur
61. and electronic vacuum gauge valves open start the pump and draw a deep vacuum Shut off the pump and check to see if the vacuum holds This operation isto test the evacuation setup for leaks Repair any leaks if necessary d Midseat the refrigerant system service valves e Open the vacuum pump and electronic vacuum gauge valves if they are not already open Start the vac uum pump Evacuate unit until the electronic vacuum gauge indicates 2000 microns Close the electronic vac uum gauge and vacuum pump valves Shut off the vacuum pump Wait a few minutes to be sure the vacuum holds E 9 l f Break the vacuum with clean dry refrigerant U se refrigerant called for in the unit specifications Raise system pressure to approximately 2 psig g Remove refrigerant using a refrigerant recovery system h Repeat steps e through g once i Evacuate unit to 500 microns Close off vacuum pump valve and stop pump Wait five minutes to see if vacuum holds This checks for residual moisture and or leaks j With a vacuum still in the unit the refrigerant charge may be drawn into the system from a refrigerant container on weight scales The correct amount of refrigerant may be added by observingthe scales R efer to section 4 10 Refrigerant Recovery Unit Refrigerant Cylinder Evacuation Manifold Valve Vac
62. ant is Loctite screw lock no 262 Figure 4 23 showsthe torque value size and grade of hardware to be used when reassembling the unidrive assembly M8 x 1 25 x 20 mm lg 4 Req d 28 ft Ibs 3 87 mkg 5 16 18 x 3 4 lg Grade 8 4 Req d 22 ft lbs 3 04 mkg 3 8 24 x 1 00 lg Grade 8 28 ft Ibs 3 87 mkg DIRECT DRIVE 3 8 24 x 1 00 lg Grade 8 28 ft Ibs 3 87 mkg Install snap ring with color coded side away from bearing 90 ft Ibs 12 45 mkg J TI M8 x 1 25 x 20 mm lg 6 Req d 28 ft lbs 3 87 STANDBY CLUTCH 3 8 16 x 1 19 Grade 5 10 Req d 28 ft Ibs 3 87 mkg 5 25 65 ft Ibs 8 99 mkg SEIT X M12 x 1 2 3 Req d Figure
63. arge 2 Valve Stem Valve 3 Gas Bypass Port 12 Valve Plate 4 Spring Guide 13 Cylinder Suction 5 Spring Valve 6 Piston 14 Discharge Piston 7 Piston Bypass Valve Check Valve 8 Bleed Orifice Assembly 9 Strainer 15 Discharge Manifold 10 Suction Manifold Figure 1 16 Compressor Cylinder Head LOADED 1 26 1 13BATTERY CHARGING ALTERNATOR 1 13 1 Alternator Operation CAUTION Observe proper polarity when installing battery Negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precautionary measure disconnect positive battery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator The alternator converts mechanical and magnetic energy to alternating current AC and voltage by the rotation of an electromagneticfield rotor inside athree phase stator assembly The alternating current and voltage is changed to direct current and voltage by passing AC energy through a three phase full wave BD rectifier system Six silicon rectifier diodesare used See Figure 1 17 or Figure 1 18 1 13 2 Integral Voltage Regulator Operation 12 volts DC The regulator is an all electronic transistorized device No mechanical contacts or relays are used to perform the voltage regulation of the alternator system The electronic
64. ator whereit isdrawn back through the compressor pressure regulating valve C PR to begin the process again When temperature is achieved in all evaporators they will go into null mode The compartment with the highest set point will then take the lead and revert back to cool heat cycles b Principle Of Induction Heating Electric Heat A control box recuperates the self indicated current from the electric motor when the unit is driven by the diesel engine This current energizes electrical heaters mounted inside the evaporator On standby operation the heaters are directly energized by the main electrical supply The system includes a control box connected with electrical cables to the refrigeration unit and to the heaters inside the evaporator 1 28 17 15 jum lr gt 13 5 INI S SP DOWD 15 HGV2 eo lt lt 13 5 LSV1 A Y lt 17 AWWW 15 HGV1 20 5 gt 6 f N m Cl m 9 eui z lt gt 2 fb 7 gt gt gt 1 Compressor 8 Receiver King Valve
65. blies compressor discharge temperature sensor CDT suction pressure transducer and the wiring to the high pressure cutout switch H P 1 g RemovelOboltsfromthe engine compressor spacer h Disconnect ground strap from frame i Disconnect suction pressure transducer from compressor j Attach sling or other device to the compressor 62 02884 Slidecompressor enoughto clear clutch housing and remove compressor from unit l Drainoilfromdefective compressor before shipping m The original unloader valves must be transferred to the replacement compressor The plug arrangement removed from the replacement is installed in the original compressor asa seal If piston isstuck it may be extracted by threading socket head cap screw into top of piston A small teflon seat ring at bottom of piston must be removed NOTES The service replacement compressor is sold without shutoff valves but with valve pads Customer should retain the original capacity control valves for use on replacement compressor Check oil level in service replacement compressor Refer to sections 1 3 and 4 13 n Removethe complete high pressure switch assembly HP 1 and install on new compressor after checking switch setting Remove compressor discharge temperature sensor CDT and suction pressure transducer and install on new compressor Install compressor frame to new compressor if removed with defective compressor o Install compressor in u
66. cator Generator 5 kw Figure 1 6 Trailer Unit Front View 1 7 62 02884 2 1 2 3 a x A 6 5 4 1 Fault Light 4 Selector Switch SSW 2 Standby Power Light PL 5 Keypad Door 3 Run Stop Switch 6 Microprocessor Control Panel See Figure 1 12 Figure 1 7 Control Box Door Trailer Unit Fr 9 FEES P F me 9 2EHR 3EHR E T EE 1 7 sesso 25228 22208 Bi ke 2 er 9 1EMR e o FLR e e amm Tej 9 2EMR amp CFR E Lo d ELI ne iL MIT 3EMR S p nel ELI 18 umm E TI H gun LIS 2 JEL 7 N P In SUB Pela e lt gt f OVERLOAD HM
67. cing Engine Related Components 4 3 441 CoolingSystem 4 3 4 4 2 Changing Lube Oil and Lube Oil 4 3 4 4 3 Replacing the Speed and Run Control Solenoids Truck Unit 4 3 444 Engine Adr Cleaner i ou cete tx en I Re E 4 4 4 4 5 Engine Crankcase Breather Trailer Unit 4 5 446 Servicing 4 5 447 ServicingGlowPlugs sssssssss ee 4 6 62 02884 ii TABLE OF CONTENTS CONT D Section 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 14 4 15 4 16 4 17 4 18 4 19 4 20 4 21 4 22 4 23 4 24 4 25 4 26 4 27 4 28 4 29 4 30 4 31 4 32 4 33 5 1 SERVICE CONT D uu yu ae nee Servicing And Adjusting 45 1 Belt Tension Gauge 4 5 2 Servicing and Adjusting V belts Truck Units 45 3 Servicing and Adjusting V belts Trailer Unit Servicing Clutch Pumping The U nit D own Or Removing The Refrigerant Charge Refrigerant Leak Checking Evacuation And Dehydration 4 91 General ha x tege re elek 4 9 2 4 9 3 Procedure for Evacua
68. compartment 2 8 Defrost Logic D efrost will be handled sequentially starting with the rear most highest number active compartment in which the DTS reads low enough to allow defrost 2 7 To energize defrost DCR is energized along with the and EHR associated with that compartment D uring defrost all other compartments will run in null mode CR EHR and HGR off In order to start a defrost the DTS reading must be 1 C 34 F or below D efrost shall terminate when the DTS reading exceeds 10 C 50 F When defrost terminates in each compartment there will be a recovery period under normal control until all compartments read within 2 C of set point or for 15 minutes whichever comes first Following this the next lowest numbered compartment will defrost within the constraints of DTS At the end of the entire defrost period all compartments the defrost timer shall be reset to 0 and restarted D efrost can be initiated via internal timer manually via the microprocessor keypad cab command and by R S232 from the remote panel If defrostisinitiated manually either through the panel or cab command or the R S232 there will be no recovery period between compartments If any DTS reads open or shorted defrost will not occur in that compartment the alarm shall light and defrost fail shall be displayed on the panel Other functions shall remain normal for that compartment 62 02884 78
69. cription OFF T or FN2 The off timesare 10 20 30 45 or 90 minutes Thedataforthe off time is displayed with two digits and then the letter M for minutes i e OFF T 20M On Time The on time selection for the auto start mode is displayed with the description ON T or FN3 The on times are four or seven minutes The data for the on time is displayed with two digits and then the letter M for minutes i e ON 4 1 18 Standard Units Select The standard units select will control how all parameters are displayed The two choices areDEGREES F and DEGREES C This parameter also controls units that data is displayed in psig or bars i e Degrees F or D egrees C The code display is FN4 The selections are F or C Maximum Off Time The description for the maximum off time is STRT or TIME STRT The code display is FN5 and the selections are ON or OFF ON corresponds to TIM E STRT With the unit in time start the control will force the engine to restart 30 minutes after shutoff MOP By Pass Valve The description for B y Pass Valve setup isM OP The code display is FN6 Once By Pass Valve is de energized it will be held off for a minimum of 2 minutes Table 1 4 By Pass Valve Setup PSIG E TRUCK TRAILER Energized De Ener Energized De Ener Open Open 17 20 gized gized Bor a 22951 Close Close Auto Manual Start Operation Theselection for startingthe unitisdisplaye
70. d without shutoff valves but with valve pads Customer should retain the original capacity control valves for use on replacement compressor Check oil level in service replacement compressor Refer to Sections 1 3 and 4 13 2 Attach two lines with hand valves near vacuum pump to the suction and discharge service valves Dehydrate and evacuate compressor to 500 microns 29 90 Hg vacuum 75 9 cm Hg vacuum Turn off valves on both linesto pump 3 Fullybackseat open both suction and discharge service valves 4 Removevacuum pump linesand install manifold gauges 5 Checkrefrigerantlevel efer to section 4 10 1 NOTE Itisimportant to check the compressor oil level of the new compressor and fill if necessary 6 Check compressor oil level Refer to Section 4 13 A dd oil if necessary 7 Check refrigerant cycles 4 12 REPLACING THE COMPRESSOR TRAILER If compressor is inoperative and unit still has refrigerant pressure frontseat suction and discharge service valves to trap most of the refrigerant in the unit If compressor runs pump down the unit Refer to Section 4 7 a a Removethe two rear compressor bracket mounting bolts compressor shockmount end b Block up engine Slowly release compressor pressure to a recovery system d Remove bolts from suction and discharge service valve flanges e Removeoilfilter and bracket from 05G compressor f Disconnect wiring to unloader valve assem
71. d from the air circulated through the evaporator This cold air is circulated throughout the box 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 into the accumulator tank The compressor draws the vapor out of the accumulator through a pick up tube which is equipped with a metering orifice This orifice preventsthe accumulation of oil in the accumulator tank The metering orifice iscalibrated to control the rate of oil flowing back to the compressor The vapor refrigerant then enters the compressor pressure regulating valve CPR which regulates refrigerant pressure entering the compressor where the cycle starts over The quench valve opens as required to maintain a 116 C 240 F maximum discharge temperature 62 02884 1 15 REFRIGERANT CIRCUIT DURING HEAT AND DEFROST See Figure 1 20 In heat mode two technologies can be used H ot gas heating through the hot gas solenoid valves HGV 1 HGV2 amp HGV3 or heating by electric heaters in the evaporator H eating by hot gasisallowed only if no evaporator is in cooling mode If two or three evaporators are in heat mode one evaporator only will be in hot gas heating The other evaporators will be given inductive heating using the electric heaters in the evaporator Both hot gas and electric heat are used for defrost a Ho
72. dAUTO OP codeFN7ON for auto start operation or MAN OP code FN7 OFF for manual start operation To start the unit in manual start mode the START STOP CONTINUOUS selection must be in Continuous Run mode Out of Range Tolerance The out of range temperature tolerance selection is displayed with the description T RANGE or code FN8 The selection are A B and C A 2 C 3 6 F B 3 C 5 4 and C 4 7 2 The controller indicates out of range when the temperature has been within the tolerance band at least once and then goes outside the tolerance band for 15 minutes For set points at or below 12 2 C 10 F frozen range the unit is only considered out of range for temperatures above set point 1 8 7 UNIT DATA The unit data key can be used to display the unit operating data values The data values are displayed for five seconds then the display will revert back to the default display if no further action istaken T hefollowing sections describe the list of data which can be displayed via the keypad The description of the data is displayed on the left side with the actual data on the right side The unit data list can be scrolled through by pressing the unit data key With each successive key push the list is advanced one item If the unit data up or down arrow key isheld for one second the list will change at a rate of one item every 0 5 seconds T hislist iscircular meaning once the end of the list is reached
73. dby Motor Engine Compressor Single Phase Alternator Generator Engine to Compressor V Belt Alternator V Belt Standby Motor to Compressor V Belt Standby Motor to Single Phase Alternator Generator V Belt Figure 4 6 V Belt Arrangement Truck Units Alternator V Belt Truck Units 1 Make disconnected sure negative battery terminal is 2 Place V belt on alternator sheave and driving pulley 3 Pivot alternator to place tension on belt using hand force only Do not use pry bar or excessive force as it may cause bearing failure For correct belt tension see Table 4 1 Tighten pivot and adjustment bolts b Water Pump Belt Tensioner Truck Units Water pump belt is driven by the diesel engine crankshaft pulley The automatic belt tensioner ensures the correct tension To change the water pump belt proceed as follows 1 To compress the tensioner spring place a threaded bolt or rod into hole and turn clockwise This will draw the spring up and slacken V belt for easy removal 2 After replacing V belt remove the bolt to release the spring to return the idler to the correct tension c Standby Motor Compressor V Belt Truck Units 1 Remove alternator V belt Change 09 95 2 Loosen the V belt idler securing bolt 22mm 3 Replace V belt and alternator V belt Position the idler to correct belt tension Tighten the idler retaining bolt d Single phase Alternator gene
74. dicates that the correct charge has been added close liquid line valve on cylinder and backseat the king valve 4 10 1 Checking the Refrigerant Charge a Start unit in cooling mode Run approximately ten minutes Partially block off air flow to condenser coil so discharge pressure rises to 14 8 kg cm 210 psig The unit is correctly charged when the middle receiver sight glass is full and no refrigerant is in the upper receiver sight glass 4 11 REPLACING THE COMPRESSOR TRUCK a Removing If compressor is inoperative and unit still has refrigerant pressure frontseat suction and discharge service valves to trap most of the refrigerant in the unit If compressor runs pump down the unit Refer to Section 4 7 a 1 Slowlyrelease compressor pressure to a recovery system 2 Remove boltsfrom suction and discharge service valve flanges 3 Disconnect wiring to compressor discharge temperature sensor CDT suction pressure transducer and the wiring to the high pressure switch HP 4 Release idler pulleys and remove belts 5 Removethe four bolts holdingthe compressor to the power tray Remove the compressor from chassis 6 Remove the pulley from the compressor 7 Drain oil from defective compressor before shipping b Installing 1 To install the compressor reverse the procedure outlined when removing the compressor Refer to Section 4 28 for torque values NOTE The service replacement compressor is sol
75. e hour meter an alarm will be generated Switch On Hour Meter Thenumber of Switch OnH oursisdisplayed with the description SON or CD20 i e SON 2347H or CD20 2347H The display range is 0 to 99999 1 20 1 8 8 ALARM DISPLAY The fault light FL isturned on only for alarms that specify it The default display will be overridden if an alarm is generated When an alarm is generated the display will alternate the default display setpoint air temperature and the active alarm s Each item will be displayed for 3to 10 seconds and will continue to scroll through the list See Section 1 8 6 for the procedure on resetting alarms Table 1 6 Alarm Display ENGLISH ALARM DESCRIPTION ENG OIL VY Low Oil Pressure y High Coolant HI PRESS High Pressure STARTFAI v Start Failure C L v Return Air Sensor 1 SENSOR Compartment 1 v Return Air Sensor 2RA SENSOR Compartment 2 AL AL AL AL AL AL AL AL AL AL AL10 AL11 Coolant Temperature WT SENSOR Sensor v High Discharge HIGH CDT Temperature Discharge Temperature CD SENSOR Sensor vw Compartment 1 IRA OUT Out of range Y Compartment 2 2RA OUT Out of range 3RA OUT Compartment 22 Out of range NO POWER No Power for Standby v FAULT LIGHT ON Low Oil Pressure Alarm The low oil pressure alarm is displayed with the description ENG OIL or ALO Thisalarm is generated if the control senses low oil pressure under the proper conditions The fault
76. e up down arrow key is pressed the five second display timer will be reset D epressingthe enter key will cause the new displayed setpoint value to become active If the display isflashing and the new value is not entered after five seconds of no keypad activity the display will revert back to the active setpoint 1 8 3 DIGITAL DISPLAY The digital display has9 digits The default display is compartment number C1 C2 or C3 left setpoint in the middle and controlled air temperature on the right The readout is keypad selectable for Degrees C or Degrees F For Truck U nits the display also has symbol indicators for the following modes COOL HEAT DEFROST OUT OF RANGE CITY SPEED AUTOSTART STOP STAND BY and ROAD diesel operation See Figure 1 12 For Trailer Units digital displays are provided to indicate the following modes COOL HEAT DEFROST IN RANGE HI AIR START STOP See Figure 1 13 Oneach power up the unit will display a D isplay Test for five seconds then display the default reading 62 02884 E a 2 20 158 Lc SETPOINT FUNCTION ENTER on BOX TEMPERATURE Main ON OFF Switch Cool Mode Heat Mode Defrost Mode Road Mode Autostart Stop Mode Stand by Mode City Speed Mode Out of range Fault Light Compartment On Off Switches AUTO START ST o veon o C esuo MAN DE BUZZER STANDBY o I o 1 o C
77. e Starting Circuit 3 2 32 Alternator Automotive 3 2 3 3 Refrigeration is sa kea ean e AN ste ee ate eie 3 3 3 31 Url WIEN oUC 01 IDE Renta 3 3 3 343 UnitRunsButHasinsufficient Cooling 3 3 3 3 8 Unit Operates Long or Continuously in Cooling 3 3 334 UnitWillNotHeatorHaslnsufficientHeating 3 3 3 35 Defrost CycleMalfunction 3 4 3 3 6 Abnormal Pressure co okar a eee hingen 3 4 3 3 6 11 Cooling ss et PETI nennen 3 4 3 2 62 Mae eat 3 5 3 3 7 Abnormal Noise ats en ah er da EG kalor elas 3 5 3 3 8 Control System Malfunction 3 5 3 3 9 Evaporator Air Flow or Restricted Air Flow 3 5 3 3 10 Expansion Valve Malfunction 3 6 3 3 11 Solenoid Valve Malfunction 3 6 34 Standby Motor Malfunction 3 6 4 SERVICE s ee Cx eO EN KO 4 1 4 1 Maintenance Schedule Truck 4 1 4 2 Maintenance Schedule Trailer 4 2 43 Priming The Fuel System Trailer 4 3 44 Servi
78. e stops after Fuel supply restricted several rotations No fuel in tank Leak in fuel system Faulty fuel control operation Fuel filter restricted Injector nozzle s defective Injection pump defective Air cleaner or hose restricted Safety device open Open wiring circuit to run solenoid Fuel pump FP malfunction 3 1 3 Starter Motor Malfunction Starter motor will not crank or turns slowly Battery insufficiently charged Battery cable connections loose or oxidized Battery cables defective Starter brushes shorted out Starter brushes hang up or have no contact Starter solenoid damaged Run Stop or Start Run Stop switch defective Engine lube oil too heavy 31 Check Check Check 3 1 3 Engine Manual 3 1 4 1 2 Check Check Drain Sump Replace Check Engine 4 4 7 4 4 3 4 4 6 Check Check Check Engine Replace Engine Manual Engine Manual Check Replace Engine Manual Engine Manual Engine Manual Replace 1 2 62 02884 3 1 3 Starter Motor Malfunction CONTINUED INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION Starter motor turns but pinion does not engage Pinion or ring gear obstructed or worn Starter motor does not disen Run Stop or Start Run Stop switch defective gage after switch was depressed Starter motor solenoid defective Clean both remove burrs or replace apply grease Replace Engine Manual Pinion does not disengage Defective starter Engine Manual after engine is running
79. e to energize the speed control solenoid SCS The engine will be in high speed For truck units as the box temperature falls toward set point the microprocessor will place the unit in low speed cool The speed relay SR de energizes to open 2 3 the circuit to the speed control solenoid SCS Engine speed decreases from high speed to low speed With decreasing temperature the unit will shift to Null and then to low speed heat Theunit will remain in various stagesof heatinguntil the boxtemperature increases enough to placethe unitin the null mode A sthe boxtemperature increases the unit will shift to cool mode 2 5 3 Heating Refer to Section 1 15 for a description of the heating cyde The controller automatically selects the mode necessary to maintain box temperature at set point The heating modes are as follows with descending temperatures a Low Speed H eating b High Speed H eating The controller will shift the unit into low speed unloaded heat when the box temperature falls below set point The microprocessor pulls terminal X1 low to complete the ground paths for the heat relay HR 1 If moreheatingcapacityisrequired theunit will shift to high speed heating The microprocessor energizes HR land speed relay SR coils Terminals X Land N 3 will be pulled low SR contacts close to energize the speed control solenoid SCS The engine will bein high speed 2 5 4 Defrost Referto Sections 1 15 and 2 8fo
80. e upon loss of oil pressure See Figure 1 1 for location b Water Temperature Sensor WTS This sensor senses engine water temperature The microprocessor will stop the unit when this temperature exceeds110 3_C 230 5 F The sensor islocated near the thermostat housing in the cylinder head 1 10 COMPRESSOR PRESSURE REGULATING VALVE CPR This adjustable regulating valve is installed on the suction line of the compressor to regulate the amount of suction pressure enteringthe compressor T he CPR valve is adjusted to maintain a maximum suction pressure For CPR settings refer to Section 1 5 The suction pressure is controlled to avoid overloadingthe electric motor or engine during high box temperature operation To adjust the CPR valve refer to Section 4 20 1 11 ACCUMULATOR The accumulator is a refrigerant holding tank located in the suction line between the evaporator and compressor The purpose of the accumulator is to prevent or minimize entry of any liquid refrigerant that may be entrained in the suction line into the compressor causing internal damage This is accomplished by the compressor drawing the refrigerant vapor through the outlet pipe of the accumulator which is equipped with an orifice T hisorifice controls the oil return to the compressor and prevents the accumulation of oil within the accumulator tank 1 12 COMPRESSOR UNLOADERS 1 12 1 Unloading in Temperature Mode The compressor is equipped with unl
81. em is opened it must be evacuated and dehydrated Refer to section 4 9 Removing the Refrigerant C harge Connect a refrigerant recovery system to the unit to remove refrigerant charge R efer to instruction provided by the manufacture of the refrigerant recovery system b 62 02884 4 10 4 8 REFRIGERANT LEAK CHECKING If system was opened and repairs completed leak check the unit a The recommended procedure for finding leaks in a system is with a electronic leak detector for HFC b If system is without refrigerant charge system with refrigerant to build up pressure between 2 1 to 3 5 kg cm o 30 to 50 psig Remove refrigerant cylinder and leak check all connections NOTE It must be emphasized that only the correct refrigerant cylinder be connected to pressurize the system Any other gas or vapor will contaminate the system which will require additional purging and evacuation of the high side discharge of the system c Remove refrigerant using a refrigerant recovery system and repair any leaks E vacuate and dehydrate the unit Refer to section 4 9 Charge unit with refrigerant Refer to section 4 10 4 9 EVACUATION AND DEHYDRATION 4 9 1 General M oisture is the deadly enemy of refrigerant systems The presence of moisture in a refrigeration system can have many undesirable effects The most common are copper plating acid sludge formation freezing up of metering devices by free water and formation
82. emperature to change 4 Low battery voltage protection The microprocessor will restartthe unit ifthe battery voltage drops below 11 0 volts to recharge the battery after the minimum off time delay NOTE When in ContinuousRun Perishable range the unit will cycle between Cool and Heat to maintain boxtemperature at setpoint In Frozen rangethe unit will run in Cool only Continuous Run is normally used for perishable products that require constant air flow 2 6 2 Standby Cool When in standby cool Start Stop microprocessor will energize the following circuits After a five second delay the Diesel Electric Relay DER will be energized this will open the N C DER contacts to prevent the Fuel H eater Relay FHR Fuel Pump FP and the Fuel Solenoid FS from being energized during standby operation At the same time theN O DER contactswill close Thiswill energizethe Motor Contactor MC With the motor contactor energized the N O M C contacts will close supplying voltage to energize the standby motor Atthe sametime RR will be energized closingthe N O RR contactssupplying voltageto therefrigeration control circuitry the 2 6 3 Standby OFF In the start stop mode after the standby motor has run at least five minutes and the controller is ready to switch from cool to heat boxtemperature near setpoint the microprocessor will de energizethe R R causingthe standby motor to cycle off The unit will
83. engagement 550 50 rpm during starting cycle of the engine as the engine accelerates to low speed T he clutch does not engage during standby motor operation a Removethe two rear compressor bracket mounting bolts compressor shockmount end b Block up engine Remove clutch V belts Pump down the unit Remove suction and discharge service valve Attach sling or other device to the compressor Slide compressor enough to remove clutch Remove six 6 5 16 18 capscrews from rotor assembly Item 2 Figure 4 9 i Using three of the capscrews as jacking screws remove the center section of the clutch housing This will exposethe snap ringholdingthe housingto the drive hub Remove snap ring and housing j After replacing necessary parts reassemble by reversing above steps k Startunit and check operation mn PE O OY Ul gt QO N Housing Assembly Rotor Plate 9 Friction Shoe 10 Delta Bridge 11 Spring Leaf 12 Screw 13 Washer 14 Coupling Adapter 15 Housing Screw Washer Ball Bearing Assembly Snap Ring Retaining Plate Snap Ring External Figure 4 9 Clutch Assembly Trailer 4 9 62 02884 4 7 PUMPING THE UNIT DOWN OR REMOVING THE REFRIGERANT CHARGE NOTE To avoid damage to the earth sozone layer use a refrigerant recovery system whenever removing refrigerant Pumping the Unit Down To service t
84. er to Section 4 8 5 Install coil assembly and retainer 6 Start unit and check refrigerant charge per Section 4 10 1 7 Check refrigeration cycles Refer to Section 2 paj 5 Gasket 6 Piston Assembly 7 Body 8 Bracket Adapter 1 Retainer 2 Coil Assembly 3 Enclosing Tube Assembly 4 Plunger Assembly Figure 4 17 Solenoid Valve Alco 62 02884 4 18 2 Solenoid Valve Sporlan a Replacing the Coil NOTE The coil may be replaced without removing the refrigerant or pumping the unit down 1 Remove top locknut spacer cup and nameplate 2 Disconnect wiring and remove coil 3 Replace coil by reversing steps 1 and 2 Replacing Internal Components See Figure 4 18 1 Locknut Screw 6 Locknut 2 Spacer Cup 7 Enclosing Tube 3 Nameplate 8 Gasket 4 Coil 9 Seat Disc 5 Spacer 10 Body Figure 4 18 Solenoid Valve MHV Sporlan 1 Remove and store the refrigerant charge in an evacuated container Refer to Section 4 7 b 2 Removethetop locknut spacer cup nameplate coil assembly and spacer 3 Using 12 point 1 3 8 inch box wrench loosen the enclosing tube locknut and bleed off remaining refrigerant 4 Remove enclosing tube and locknut assembly The gasket is inside the enclosing tube 5 Remove seat disc from inside of body and check for obstructions and foreign material 6 Place the seat disc into the valve body with the smaller diameter end facing up
85. es tester shown in Figure 4 5 whenever V beltsare adjusted or replaced A belt tension gauge provides an accurate and easy method of adjusting belts to their proper tension Properly adjusted belts give long lasting and efficient service Too much tension shortens belt and bearing life and too little tension causes slippage and excessive belt wear It is also important to keep belts and sheaves free of any foreign material which may cause the belts to slip The belt tension gauge can be used to adjust all belts The readings specified for Carrier Transicold units are applicable only for our belts and applications as the tension is dependent on the size of the belt and distance between sheaves When using this gauge it should be placed as close as possible to the midpoint between two sheaves See Figure 4 6 The V belts must be kept in good condition with the proper tension to provide adequate air movement across the coils When installing a new V belt the tension should be somewhat higher than specified and readjusted after allowing the unit to run for some time Part No 07 00253 Figure 4 5 Belt Tension Gauge 4 5 2 Servicing and Adjusting V belts Truck Units Table 4 1 Belt Tension Truck Units See Figure 4 5 BELTS Tension CT3 44TV engine D722 Water pump 30 to 40 Engine to Compressor 30 to 50 Alternator 30 to 50 Standby Motor to Compressor 30 to 50 Standby Motor to 1ph Alternator Gen 30 to 50 Stan
86. ey The unit data keyis used to display the unit operating data This key in conjunction with the up down arrow keys will allow the user to display the unit s operating data values i e coolant temperature battery voltage etc See Section 1 8 7 62 02884 1 8 6 FUNCTIONAL PARAMETERS The functional parameters will control selected operating features of the unit These parameters can be displayed by pressing the function change key All functional parameters are retained in memory The following sections describe the list of functions which can be modified viathe keypad description of the function is displayed on the left side with the corresponding data on the right side The function parameter list can be scrolled through by pressing the function change key or by using the up down arrow keys With each function change key push the list isadvanced oneitem If the function key is pressed and held for one second the list will advance one item at a time This listis circular meaning once the end of the list is reached the list will go to the first entry Whilethefunctional parameter is displayed the data can be changed by pressing enter then pressing either the up or down arrow keys If the value is changed the displayed data will then flash to indicatethatthe value has not been entered If the new value is not entered in five seconds the display will revert back to the last entered value If the enter key is pressed the di
87. ey is pressed the display will advance to the next parameter This key in conjunction with the up down arrow and enter keys will allow the user to change the parameters Refer to Section 1 8 6 Unit Data Key The unit data key is used to display the unit operating data T his key in conjunction with the up down arrow keys will allow the user to display the unit s operating data values i e coolant temperature battery voltage etc Referto Section 1 8 7 City Speed Key The city speed key enables the city speed low speed Each push of the key toggles the operating mode The operating status will be stored in memory T he display will indicate when city speed is activated Pio Buzzer Off Key buzzer off key will turn off the cab 19 command buzzer The buzzer isturned on when the fault light is energized and off when the fault light is de energized Road Key The road key selects the diesel engine operating mode The operating status will be stored in memory Stand by Key The stand by key selects the electric motor operating mode The operating status will be stored in memory NO POWER will be displayed if unitis switched to standby and power plug is not plugged in LMJ 1 16 COOL HEAT DEFROST START STOP UNIT PRE AUTO 5 4 MANU DATA TRIP CONTINUO AL Figure 1 13 Microprocessor Control Panel Trailer Unit 1 8 5 KEYPAD Trailer Unit See Figure 1 13 The keypad has eight ke
88. eyond 2 0 C 3 6 of setpoint for the Perishable range or above 2 0 43 6 of setpoint for the Frozen range i Battery Voltage Provision is made to sense when the battery is good A good battery is defined ashaving 13 4vat 24C 75 F This condition is used to allow shut off of the diesel engine If battery voltage falls below 10v during glow cycle the starter will not engage and the start sequence will continue it is considered a failed start The start sequence is repeated until the unit starts or three consecutive start attempts have failed Table 1 7 Battery Table1 7 Battery Voltages Message LOW BATT Unit will shut down ex AL4 or e cept during cranking 11 to 13 4 If the unit has cycled off in auto start stop mode and battery voltage drops below 11 0 volts the unit is automatically started to charge battery Unit will operate until a battery voltage of 13 4 voltsis obtained at which level unit will stop if tempera tures are satisfied HI BATT Unit will shut down AL5 or j Oil Pressure Signal W hen the oil pressure switch is closed it shows that the engine is running and prevents engagement of the starter motor when operating in auto mode 62 02884 k Maximum Off Time A keypad selectable feature is provided which will cause the engine to be started 30 minutes after the engine has stopped regardless of the box temperature 1 9 SWITCHES AND CONTROLS MICROPROCESS
89. filter reverse steps 1 through 3 1 Nut 2 Banjo 3 Filter 4 Copper Rings Figure 4 3 Mechanical Fuel Pump Trailer Unit 62 02884 b Electrical Pump See Figure 4 4 To Check or Replace Filter 1 Remove three screws from cover Figure 4 4 2 Remove cover gasket and filter 3 Wash filter in cleaning solvent and blow out with air pressure Clean cover 4 re install reverse above steps bi 2 item 1 1 2 Gasket Figure 4 4 Electric Fuel Pump 4 4 7 Servicing Glow Plugs The glow plugs when energized draw a nominal 7 0 amps at 10 5 vdc When servicing the glow plug isto be fitted carefully into the cylinder head to prevent damage to glow plug Torque value for the glow plug is 0 8 to 1 5 mkg 6 to 11 ft Ib Checking for a D efective Glow Plug a One method is to place an ammeter or clip on ammeter in series with each glow plug and energize the plugs E ach plug if good should show amperage draw b A second method is to disconnect the wire connection to the plug and test the resistance from the plugto a ground on the engine block reading should be 0 7 to 1 2 ohms if the plug is good 62 02884 4 6 4 5 SERVICING AND USTING V BELTS WARNING Beware of V belts and belt driven components as the unit may start automatically 4 5 1 Belt Tension Gauge It is recommended using one of the belt tension gaug
90. g item 7 from the engine run lever 2 Disconnect wiringto solenoid Remove clip item 5 from linkage rod item 8 Remove mountinghardware and solenoid 3 Attach linkage to new solenoid and install the clip to the linkage rod Install the replacement solenoid and mounting hardware loosely Connect the ground wire and spring 4 Energize the solenoid with a jumper wire connected to a battery Slide the solenoid far enough back on the bracket to set the engine run lever item 9 against the stop Tighten solenoid mounting hardware 5 De energize the solenoid If the engine does not shut off repeat step 4 and adjust the solenoid forward slightly When operating correctly tighten solenoid mounting hardware and reconnect the positive wire 62 02884 6 Run Solenoid 7 Spring Run Control 8 Linkage Rod Run 3 Engine Speed Lever 9 Engine Run Lever 4 Linkage Rod Speed 10 Boot 5 Clip Speed Solenoid Spring Speed Control Nr Figure 4 1 Speed and Run Control Solenoids Truck b Speed Control Solenoid see Figure 4 1 1 Remove spring item 2 from the engine speed lever item 3 2 Disconnect wiringto solenoid Disconnect linkage rod item 4 from solenoid Remove mounting hardware and solenoid 3 Attach linkage to new solenoid and install the clip item 5 to the linkage rod Install the replacement solenoid and mounting hardware loosely Connect the ground wire and spring 4 Energize the
91. he filter drier expansion valve liquid line solenoid valve CPR valve or evaporator coil pump most of refrigerant into condenser coil and receiver asfollows 1 Backseat suction and discharge service valve turn counterclockwise to close off gauge connection and attach manifold gauges to valves a 2 Open valves two turns clockwise Purge gauge line 3 Closethe receiver outlet king valve by turning clockwise Start unit and run in high speed cooling Place Run Stop switch in the STOP position when unit reaches 0 1 kg cm 1 psig 4 Frontseat close suction service valve and the refrigerant will be trapped between the compressor suction service valve and the manual shutoff king valve 5 Before opening up any part of the system a slight positive pressure should be indicated on the pressure gauge 6 Whenopeninguptherefrigerant system certain parts may frost Allow the part to warm to ambient temperature before dismantling This avoids internal condensation which puts moisture in the system 7 Open backseat king valve and midseat suction service valve 8 Leak check connections with a leak detector Refer to section 4 8 9 Start the unit in cooling and check for noncondensibles 10 Check the refrigerant charge Refer to section 4 10 1 NOTE Store the refrigerant charge in an evacuated container if the system must be opened between the compressor discharge valve and receiver Whenever the syst
92. he generator is 3600 rpm Setting engine speed on multi temp units is critical to proper operation of the generator The engine speed should be set to 1500 rpm with unit operating in fully loaded high speed cool mode with all compartments turned on Refer to Table4 6 for corresponding generator voltage output Table 4 6 Generator Voltage Output Engine RPM Generator RPM Volts HZ 1530 3600 240 60 A generator fault finding guide is shown in Figure 4 21 This should be used whenever troubleshooting a problem with a 5KW generator AUXILIARY WINDING 1 18 Ohms Remove the wires from capacitor to be disconnected from generator for winding resistance this test FAULT Off Load On Load No Output Incorrect Voltage No Output Incorrect Voltage Over Voltage Voltage Unstable Voltage Voltage Unstable heating Check Check Check Check Load Check Check Over Residual Speed Engine for Short Speed Engine Load Voltage Governing Circuit Governing Inlet or Check all Check Outlet Stator Connections Opening Resistances Obstructed Check Hot Engine i or Generator Air Circulating Check Rotor Resistances Check Rotating Diodes Figure 4 21 Generator Fault Finding Guide 62 02884 4 22 4 26 SINGLE PHASE ALTERNAT
93. he glow time for the first start attempt will vary in duration based on engine coolant temperature and the unit type as follows Glow Time in Seconds m Thesecond andthird start attempts have a glowtime that is five seconds greater than the table amount The glow time can be manually overridden through the function parameters If the coolant temperature sensor is defective the control assumes a temperature of lessthan 0 C 32 F for the glow timing Ambient Temperature Less than 0 C 32 1 Cto 10 C 33 F to 50 F 4 11_C to 25_C 51_F to 77_F Greater than 26 C 78 62 02884 g Minimum On Time The engine is allowed to turn off only after a minimum of four or seven minutes of run time After the minimum on time the unit will go to fully loaded for setpointsgreaterthan 12 C 10 F and high speed loaded for setpoints of 12 C 10 F or less The unit will not cycle off if the engine coolant temperature is less than 50 C 122 F or the battery is less than 13 4 volts If the unit can not cycle off it will operate normally in continuous mode If all temperature probes fail and the setpoint is 12 C 10 or less the unit will not shut down The unit will shut down when the box temperature is within x0 5 C of setpoint h Minimum Off Time The unit is designed to select the minimum off time of 10 20 30 45 or 90 minutes After the minimum off time the unit will restart for temperatures b
94. heck starter condition Engine Manual Check and adjust injector nozzles Engine Manual 1 Check and adjust injector nozzles Engine Manual 2 Check engine compression Engine Manual 3 Adjustengine valves Engine Manual 4 Drain and flush cooling system 44 1 f Oil Change Intervals API MOBIL MODEL Class CD DELVAC 1 Trailer Unit 1500 Hours 3000 Hours Oil change intervals are First 400 hours thereafter as listed above CAUTION The maximum oil change interval is one year for either approved oil The only approved synthetic lube oil is Mobil Delvac 1 The normal oil change intervals listed above should be reduced if the equipment is operated under extreme conditions such as in dirty environments 62 02884 4 2 4 3 PRIMING THE FUEL SYSTEM Trailer a Mechanical Fuel Pump The trailer unit is equipped with a mechanical fuel lift pump which is mounted on the engine next to the injection pump also see section 4 4 6 This pump has a manual plunger for bleeding fuel when the fuel tank has been run dry Since the unit employs a closed fuel circuit the following steps are recommended 1 Turn bleed valve Red counter clockwise until fully opened see Figure 1 6 2 Turn the top of the manual plunger counter clockwise to unlock it see Figure 1 6 Next rapidly hand pump the manual plunger until a positive pressure resistance isfelt which will indicate fuel flow 3 Depressand turn the top of the manual plunger c
95. icStart esse ne tie die ha S hrs 2 2 2 Mi nual St rtind ae GEL RUSAN T ER RC 23 Starting And Stopping Instructions Standby Motor Drive 24 Compartment Operation 2222 25 Control Circuit Operation 2 5 introduction sa ero Ape TU ta Wehe nich 2 527 ioi a KRA A an bias a kl AN 2 0030 it area erlernt elle a aa 2 5 4 Defrost casse ar pai e oni TABLE OF CONTENTS 62 02884 TABLE OF CONTENTS CONT D Section Page 2 OPERATION 2 1 26 Control Circuit Operation Standby Motor 2 4 2 6 1 Electric Standby Features sss nn 2 4 2 0 2 Standby a RE RE MED 2 4 263 Standby OFF u hen 2 4 2 6 4 Standby Defrost iiis cake Ren nn en okra DEN CR 2 4 24 oHotGasHeating Logic unten o nei el 2 7 2 9 Defrost E oglC ueni are ne Helene 2 7 3 TROUBLESHOOTING 3 1 3b pu SE eni Uca 3 1 3 1 1 Engine Will NotStart c UR aa X ERR RR 3 1 312 EngineStartsThenStops 3 1 3 1 3 Starter Motor Malfunction 31 3 14 Malfunction In the Engin
96. ion control heat and defrost to ensure conditioned air delivery to the load b Dual independent readouts of set point and return air temperature C Digital readout and ability to select data Refer to Table 1 3 for Function Codes and Table 1 5 for U nit D ata d Alarm digital display identification Refer to Table 1 6 e A self test check on program memory and data memory T he self test is executed each time the system is switched from Stop to Start Errors if any shall be indicated onthedisplayasa ERR X where X isa number corresponding to the number of the test The unit shall display this error for five seconds and then reset the microprocessor ERROR CAUSE ERR 1 Processor failure ERR 2 Check chip installation or Replace ERR 3 microprocessor Display board to logic board communication failure This can be caused by a defective AN cable or ribbon cable not ERR 4 1 8 2 SETPOINT Setpointsof 30 C to 30 C 22 F to 86 may be entered via keypad The controller always retains the last entered setpoint in memory If no setpointisin memory i e on initial startup the controller shall lock out the run relay and flash SP on the left hand display until a valid setpoint is entered The setpoint may be changed up or down in whole numbers until the desired setpoint is displayed T he display will flash to indicate that the setpoint reading currently being displayed is a non entered value Each time th
97. is phase sequence sensing system provides a safe method of automatically providing correctly phased three phase power to the unit This feature allows the user to connect the unit to any three phase power source of correct voltage and frequency without regard to the phase sequence of the power source This module contains two electrically identical sections of circuitry each connected to a different pair of phases D epending on the phase sequence occurring at the module inputs X 1 X2 H4 and 46 relay PR 1 or PR 2 will be energized as required to effect correct phasing of power to unit 62 02884 1 Main Heat Valve MHV 11 2 Receiver 12 3 Filter Drier 13 4 Compressor Pressure Regulating Valve 14 5 Accumulator Heat Exchanger 15 6 Pressure Switch If Used for BPV 16 7 King Valve 17 8 Receiver Pressure Valve RPV 18 9 Quench Valve 19 10 By Pass Valve BPV High Voltage Box See Figure 1 8 Battery Radiator Fill Neck Condenser Motor Muffler Model Serial No Location Radiator Overflow Reservoir Relay Box See Figure 1 9 Control Box Door See Figure 1 7 Figure 1 5 Trailer Unit Side Views 62 02884 1 6 1 2 3 4 5 6 7 Alternator and Regulator 8 Standby Motor 9 Compressor 056 10 Fuel Filter 11 Bypass Oil Filter 12 Oil Drain 13 Lube Oil Fill Lube Oil Filter Engine Air Cleaner Mechanical Fuel Pump Fuel Bleed Valve Air Cleaner Service Indi
98. is the length WARNING For safety when disconnecting the harness at the condensing section end for testing purposes always leave the separate earth cable connected A seventeen core cable is provided with a multi pin connector on one end to connect directly to the condensing section The other end of the cable is color coded to allow easy connection in the evaporator When there are two wires of the same color they will be numbered i e yellow 1 yellow 2 brown 1 brown 2 Yellow 1 Re Heater element Color Red Red Earth Live from alternator Brown Neutral alternator Green Yello Green Blue 62 02884 Table 4 7 R 404A Pressure Temperature Chart To determine superheat use dew point vapor values To determine subcooling use bubble point liquid values shaded numbers Based on Du Pont publication T HP62 ENG dated 12 93 C Ps end 5 o 5 135 w sr 41759 32 129 29 163 28 177 27 192 3239 22 256 1 273 192 2 291 205 ost art gt 32 8 231 2 22 16 368 14 389 13 411 12 433 11 45 6 101 480 SEY 581 609 3 63 7 2 665 1 69 5 alu JI N Ww N J N gt co ULI O CO O w e FI 40 35 30 25 20 18 12 10 ELE
99. ities in the same load under separate refrigeration control WARNING Beware of unannounced starting of the fans V belts and belt driven components as the unit may start automatically Before servicing unit make sure the Run Stop switch is in the STOP position Also disconnect the negative battery cable The microprocessor controller has an auto start stop feature 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 A remote standby receptacle is standard with all units except trailer model NDC Table 1 1 Model Chart Refrigerant Standby Motor IB KG 3ph 50hz 3ph 60hz TRUCK UNITS TRAILER UNIT Genesis TR1000 NDD 26 118 osGeCyinde 14h Genesis TA1000 NDC 26 11 8 CTa1a41V 056 6oyinder Heat Only EVAPORATORS Evaporator Models MTD 700 1 MTD 700 2 MTD 1100 2 MTD 1450 2 MTD 1450 3 MTD 2200 3 MTD 2200 4 MTS 700 1 MTS 700 2 MTS 1100 2 MTS 1450 2 MTS 1450 3 MTS 2200 3 MTS 2200 4 Number of Fans 25 25 28 25 go a gt Change 05 10 1 1 62 02884 WARNING 1 Muffler 7 Accumulator Heat Exchanger 2 Engine Refer toTable 1 1 8 Filter Drier 3 Compressor Refer toTable 1 1 9 Receiver 4 Alternator
100. izingthe run relay and after five secondsenergizethe glow plugrelay G PR to supply power to the glow plugs and five seconds later the starter is energized On initial power up the control will delay five seconds before the starting sequence begins If the required glow time is zero the control will energize the starter after a five second delay After a period of time the starter solenoid SS isenergized to crank the engine The engine will crank for 10 seconds or until engine operation is sensed by the alternator signal The glow relay is de energized after the auxiliary input is sensed 15 second null cycle will elapse before subsequent start attempts The run relay will remain energized until the next starting sequence Before the next starting sequence the oil pressure alternator auxiliary output is checked to insure that the engine is not running For the second and third start attempts the glow time is increased by five seconds over the glow time of the first attempt listed below The control allowsthree consecutive start attempts before the startingis locked out and the start failure alarm is activated REPEAT A 5 Seconds GLOW THIRD AT 15 Seconds TEMPT STOP REPEAT A 5 Seconds GLOW SECOND AT 15 Seconds STOP MAXIMU 10 Seconds Checked at 2 Seconds FIRST VARIABLE ATTEMPT Oto 30 SE A CONDS Figure 1 14 Auto Start Sequence f Variable Glow Time T
101. layed with the description WT or CD3 The data is displayed with the proper unit designator Degree C or Degree F i e WT 185F or CD 3185F Thedisplayrangeis 12 C to 130 10 F to 266 F Compartment 1 Return Air Temperature Compartment 1 Return Air Temperature is displayed with the description IRA or CD4 The data is displayed with one decimal place and the proper unit designator Degree C or Degree F i e RAS 85 0F The display range is 38 C to 70 C 36 F to 158 Compartment 2 Defrost Thermistor Sensor Compartment 2 Defrost Thermistor Sensor is displayed with the description 2DT or CD6 The data is displayed with one decimal place and the proper unit designator Degree C or Degree F i e 2DT 85 0F The display range is 38 C to 70 C 36 F to 158 Compartment 3 Defrost Thermistor Sensor Compartment 3 Defrost Thermistor Sensor is displayed with the description or CD 7 The data is displayed with one decimal place and the proper unit designator Degree C or Degree F i e 85 0F The display range is 38 C to 70 C 36 F to 158 Compartment 1 Defrost Thermistor Sensor Compartment 1 Defrost Thermistor Sensor is displayed with the description IDT or CD8 The data is displayed with one decimal place and the proper unit designator Degree C Degree F i e IDT 85 0F The display range is 38 C to 70 C 36 F to 158 Compressor Discharge Temperature Compressor Discha
102. lockwise to lock in place 4 Start engine 5 When engine is running properly turn bleed valve clockwise until fully closed b Electrical Fuel Pump If the unit is equipped with electrical fuel pumps they are mounted on thefuel tank mounting bracket also see section 4 4 6 Followthese stepsto primethe system 1 Open bleed valve located on top of the injection pump see Figure 1 6 2 Start engine 3 When engine is running properly turn bleed valve clockwise until fully closed 4 4 SERVICING ENGINE RELATED COMPONENTS 4 4 1 Cooling System The condenser and radiator assembly is designed with the radiator circuits located behind the condenser coil circuits The condenser fans draw the air through the condenser and radiator coil To provide maximum air flow the condenser fan belt should be checked periodically and adjusted if necessary to prevent slippage The condenser and radiator can be cleaned at the same time The radiator must be cleaned internally as well as externally to maintain adequate cooling CAUTION 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 5096 concentration of anti freeze Use a low silicate anti freeze 4 3 a Remove all foreign material from the radiator condenser coil by reversing the normal air flow air is pulled in thr
103. lve into the condenser The condenser fan circulates surrounding air over the outside of the condenser tubes H eat transfer is then established from the refrigerant gas inside the tubes to the condenser air flowing over the tubes The condenser tubes have fins designed to improve the transfer of heat This removal of heat causes the refrigerant to liquefy Liquid refrigerant flows from the condenser and through a check valve to the receiver The receiver storesthe additional charge necessary for low ambient operation and for heating and defrost modes The refrigerant leaves the receiver and flows through a manual receiver shutoff valve king valve The refrigerant then flows through the subcooler Thesubcooler occupies a portion ofthe 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 Therefrigerantthen flowsthrough the accumulator heat exchanger and then to the liquid solenoid valves LSV These solenoids are electrically energized when in cooling mode and allow the liquid refrigerant to flow through the externally equalized thermostatic expansion valve T XV which reducesthe pressure ofthe liquid and metersthe flow of liquid refrigerant to the evaporator to obtain maximum use of the evaporator heat transfer surface The evaporator tubeshave aluminumfinsto increase heat transfer heat is remove
104. ment will create excess belt wear and limit alternator bearing life The center line of the alternator sheave and the driving sheave must be in line 5 Pivot alternator to place tension on belt using hand force only Do not use pry bar or excessive force as it may cause bearing failure For correct belt tension see Table 4 1 Tighten pivot and adjustment bolts 6 Replace generator V belt b Water Pump V Belt Trailer Unit The water pump V belt is driven by a sheave on the engine crankshaft Frayed cracked or worn belts must be replaced A djustment is achieved by alteringthe position of the front side idler When replacing V belt avoid excessive force when applying tension to the V belt to prevent damage to the water pump bearings Refer to Table 4 1 c Condenser Fan V Belt Trailer Unit 1 Disconnect negative battery cable 2 Through top of the unit loosen condenser fan idler pulley 3 Removeold belt and replace with new belt See Figure 4 7 4 Using a belt tension gauge Figure 4 5 on the belt rotate idler pulley so thatthe gauge readsthe correct tension refer to Table 4 1 5 Tighten idler and carriage bolt 6 Operate unit for 5 to 10 minutes Repeat steps 4 and 5 d Generator V Belt Trailer Unit 1 Disconnect negative battery cable and remove V belt guard Loosen idler bolt 2 To remove generator V belt from drive shaft follow instructions for standby motor V belt 3 Replace belt using a
105. mum ight un Minimum 05K 05G Figure 4 12 Oil Level in Sight Glass b Adding Oil with Compressor in System Two methods for adding oil are the oil pump method and closed system method 1 OilPump M ethod One compressor oil pump that may be purchased isa Robinair part no 14388 This oil pump adapts to a one 0 5 gallon 3 785 liters metal refrigeration oil container and pumps 2 1 2 ounces 0 0725 liters per stroke when connected to the suction service valve port Also there is no need to remove pump from can after each use W hen the compressor isin operation the pump check valve prevents the loss of refrigerant while allowing servicemen to develop sufficient pressure to overcome the operating suction pressure to add oil as necessary Backseat suction service valve and connect oil charging hose to port Crack the service valve and purge the oil hose at oil pump Add oil as necessary 2 Closed System M ethod In an emergency where an oil pump is not available oil may be drawn into the compressor through the suction service valve CAUTION Extreme care must be taken to ensure the manifold common connection remains immersed in oil at all times otherwise air and moisture will be drawn into the compressor Connect the suction connection of the gauge manifold to the compressor suction service valve port and immerse the common connection of the gauge manifold in an open container of refrigeration oil Crack the s
106. nd V belts caused by the thermostatand the start stop cycling of the unit WARNING Under no circumstances should ether or any other starting aids be used to startengine CAUTION Under no circumstances should anyone attemptto repair the Logic or Display Boards see section 4 21 Should a problem develop with these components contact your nearest Carrier Transicold dealer for replacement CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precautionary measure disconnectpositive battery terminal when charging batteryin unit Connecting chargerin reverse will destroy the rectifier diodes in alternator CAUTION Underno circumstances should a technician electrically probe the processor atany point otherthan the connector terminals where the harness attaches Microprocessor components operate at differentvoltage levels and atextremely low currentlevels Improperuse ofvoltmeters jumper wires continuity testers etc could permanently damage the processor CAUTION Mostelectronic components are susceptible to damage caused by electrical static discharge ESD In certain cases the human body can have enough static electricity to cause resultantdamage to the components by touch This is especially true of the integrated circuits found on the truck trailer microprocessor 5 1 62 02884 8870 79 CS
107. nimum air ambient of 5 C The coil should be clean and free of ice 1 RemovePresstite from expansion valve bulb and suction line 2 LoosenoneTXV bulbclamp and make sure area under clamp above TXV bulb is clean 3 Place thermocouple above parallel TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line 4 Connect an accurate gauge to the 1 4 port on the suction service valve 5 Open the CPR valve fully by turning the adjusting screw clockwise until valve is fully open 6 Run unit until stabilized C 7 From the temperature pressure chart determine the saturation temperature corresponding to the evaporator outlet pressure 8 Note the temperature of the suction gas at the expansion valve bulb 9 Subtract the saturation temperature determined in Step 7 from the average temperature measured in Step 8 The difference is the superheat of the suction gas e Adjusting Superheat One thirds Dual flow and three thirds Dual flow evaporators have two expansion valves per evaporator CAUTION Make sure only one evaporator is operating and thatthe air outlet profiles are fully open No obstruction to the airflow should be present The unit should be in high speed cool The unloaders should be disconnected if fitted to make sure compressor is working at maximum efficiency The Superheat check should be carried out inside a workshop or with a minimum air ambien
108. nit by reversing steps 4 12 c through Itisrecommended using new locknuts when replacing compressor Torque bolts to a value of 46 ft Ib 6 4 mkg Install new gaskets on service valves and tighten bolts uniformly p Attach two lines with hand valves near vacuum pump to the suction and discharge service valves Dehydrate and evacuate compressor to 500 microns 29 90 Hg vacuum 75 9 cm Hg vacuum Turn off valves on both linesto pump q Fully backseat open both suction and discharge service valves r Remove vacuum pump lines and install manifold gauges s Start unit and check for noncondensibles t Check refrigerant level Refer to Section 4 10 1 u Check compressor oil level Refer to Section 4 13 A dd oil if necessary v Check compressor unloader operation refer to Section 4 14 w Check refrigerant cycles refer to Section 2 62 02884 4 14 4 13 CHECKING COMPRESSOR OIL LEVEL a To Check Oil Level in Compressor l Operate the unit in high speed cooling for at least 20 minutes 2 Check the oil sight glass the compressor to ensure that no foaming of the oil is present after 20 minutes of operation If the oil is foaming excessively after 20 minutes of operation check the refrigerant system for flood back of liquid refrigerant Correct this situation before performing step 3 3 Check the level of the oil in the sight glass with the compressor operating See Figure 4 12 1 4 Maxi
109. nt Varipowr is used as a compressor capacity control to unload the compressor during periods of reduced loads This provides closer temperature control reduces potential for top freezing and reduces power required to operate the compressor thusreducing fuel consumption 1 5 The engine refer to Table 1 1 gives excellent fuel economy and has easy starting characteristics The engineisequipped with spin on lube oil and fuel oil filters for easier filter changes NOTE Throughout this manual whenever the left or right hand side of the engine is referred to itis the side as viewed from the flywheel end of the engine Electrical power for the control system and for charging the batteries is provided by the 12 vdc alternator The auto start stop feature is standard equipment 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 diesel engine drives the compressor directly through a centrifugal clutch except during standby operation During standby operation the centrifugal clutch is disengaged from the compressor sheave The compressor is then belt driven by the standby motor d Model with Phase Sequence Module Some units have a Phase Sequence M odule see Figure 1 8 amp Figure 4 22 Th
110. oaders electronically controlled by the microprocessor for capacity control The capacity controlled cylinders are easily identified by the solenoid which extends from the side of the cylinder head When the solenoid is energized the cylinders unload The unloaded cylinders operate with little or no pressure differential consuming very little power A de energized solenoid reloads the cylinders NOTES 1 The unloader relay is locked in for a minimum of five minutes once it is energized due to suction pressure 2 There is a delay of 30 seconds between de energizing one set of unloaders to de energizing the other set of unloaders There are two modes of unloader operation temperature control and suction pressure control a Temperature Control 1 Cool light CL or heat light HL illuminated depending on mode of operation 2 Inlow speed cooling or heating unloader relays UFR or UFR amp URR may energize to unload compressor banks Refer to Table 2 2 or Table 2 3 1 12 2 Suction Pressure Operation Suction pressure is used for controlling the compressor unloaders to reduce capacity in the compressor at low suction pressures If suction pressure falls to 0 psig or below and no unloaders are energized then U FR will energize If suction pressurefallsto 0 psigor below and UFR is energized URR shall also be energized If suction pressure rises to 6 psig when URR and UFR are energized then URR is de energized
111. omatic control of the diesel engine starting and stopping The main function of automatic engine cycling is to turn off the refrigeration system near setpoint to provide a fuel efficient temperature control system and to initiate a restart sequence after conditions are met System shut off is allowed only if the battery condition signal is good The engine coolant temperature shall override the minimum off time and out of range condition to force engine restart when the engine coolant temperature drops below 1 C 34 F A restart will also be initiated if the battery voltage falls below 11 0 V dc a Autostart Stop Continuous A keyis provided to select between continuous run and auto start stop operating mode In the continuous run mode the diesel engine will not shut down except for safeties or if the engine stalls This function also applyto the operation of the electric motor b Auto Mode Indicator The Auto start stop indicator islit and will be on to indicate the autostart stop mode has been selected c Auto Start Failure If theunit for three consecutive times failsto start shuts down on a safety or fails to run for the minimum run time the Start Fail alarm is activated d Continuous Run Mode In continuous run mode the engine is started but not allowed to shut off except for safeties or if the engine stalls e Auto Start Sequence When the starting conditions are met the start sequence will begin by energ
112. oosen the jam nut Figure 4 19 item 2 d Using the 8 mm Allen wrench adjust the setting screw To raisethe suction pressure turn the setting screw item 3 clockwise to lower the suction pressure turn the setting screw counterclockwise Refer to Section 1 5 for CPR valve setting e Whenthe setting has been adjusted tighten the jam nut securely against the setting screw item 3 This will prevent any movement of the setting screw due to vibration in the unit Replace the cap 4 21 MICROPROCESSOR NOTE The erasable programmable read only memory EPROM chip component U3 on the microprocessor logic board has a window on it which is covered with a label listing the revision level of the software The window isused to erase the chip s memory with the use of ultraviolet light The label prevents light from entering the chip and erasing the memory Under NO circumstances should this label be removed CAUTION Under no circumstances should a technician electrically probe the processor at any point other than the connector terminals where the harness attaches Microprocessor components operate at differentvoltage levels and atextremely low current levels Improper use of voltmeters jumper wires continuity testers etc could permanently damage the processor As mentioned above some microprocessor inputs operate at voltage levels other than the conventional 12 vdc Connector points and the associated approximate voltage le
113. or is totally disconnected from the unit it cannot monitor the engine s safety switches for oil pressure and coolant temperature Sincetheengineis runningunprotected when the test board is used it is imperative that should a problem develop with the microprocessor it be replaced immediately The test board is intended to be a trouble shooting tool only When using the test board to troubleshoot the unit should be started in low speed unloaded cool in the same way as when the processor startsthe unit G ood judgment should also be used when cycling any unit with the test board Rapid cycling should be avoided When weldingisrequired on theunit frame or onthe front area of the trailer ALL wiring to the microprocessor M U ST bedisconnected When weldingis performed on other areas of the trailer the welder ground connection M UST be in close proximity to the area being welded It isalso good practice to remove both battery cables before welding on either the unit frame or the truck to prevent possible damage to other components such asthe alternator and voltage regulator a Replacing Key Board Trailer Unit Should damage to the Key Board of the microprocessor occur it is possible to replace only the Key Board It is absolutely imperative that whenever a microprocessor is removed from a unit for any reason thatthe old K ey Board gasket be removed and a new one be installed All replacement microprocessors and Key Boards are pack
114. or truck units only Trailer unit is one speed 2 Outputis ON Output is OFF PRI Hot gas priority logic Refer to Section 2 7 SEQ Defrost logic Refer to Section 2 8 Micro Micro control on temperature demand M Control both suction pressure and temperature demand one one unloader energized unloaded 2 7 Hot Gas Heating Logic Ifhotgas heatingis available no compartment requires cooling the hot gas will be sent to the compartment which is the furthest below set point This check is made every time that hot gas becomes available H ot gaswill stay with this evaporator now known asthe lead evaporator until another compartment generates a cooling demand or this compartment reaches the cooling mode itself To initiate hot gas heat the main heat relay MHR is activated along with CR and HGR for that compartment and EHR for that compartment is de energized If two compartments are exactly the same temperature away from set point then hot gas shall go to the compartment with the highest set point If everythingisthe same hot gas should go to the lowest number active compartment If all compartments call for null mode then one compartment must become the lead compartment and always accept hot gas heating and cooling This compartment will bethe one with the highest set point or if there are two or three compartments running the same set point then the lowest numbered compartment will become the lead
115. ors are different in size capacity and number of fans but all work on the same principle and use the same single phase 50H 2 60 2 fan assembly The electrical heaters vary according to the type of condensing unit used and number of compartments see Figure 1 11 The evaporator is constructed with aluminium profilesdesigned to meetthe specificrequirements of the transport industry T he bottom section of the evaporator is hinged to allow easy access to both the electrical and refrigeration hardware The air outlet profiles are designed to adjust to allow different airspeeds and velocity Insidethe evaporator housingareone or more of the following 240 Volt Single phase backward curved impeller which supplies high air volumes at low noise levels expansion valve check valve 12V hot gas solenoid 12V liquid line solenoid 12V water drain heater electrical heater element sensor defrost termination sensor safety heating thermostat f Compartment Control Box Optional The compartments of the M ulti Temp system maybe equipped with remote mounted control box see Figure 1 10 Thiscontrol boxhasa system on off button compartment on off buttons and a manual defrost button T heremote mounted control box displays current compartment temperature and setpoint Set setpoint by pressing the up or down arrows as required The control box can be locked no buttons active by pushingthe Carrier oval once T his will activate the LED ne
116. ough the front Compressed air or water may be used as a cleaning agent It may be necessary to use warm water mixed with any good commercial dishwasher detergent Rinse coil with fresh water if a detergent is used b Drain coolant by removing lower radiator hose and radiator cap c Install hose and fill system with clean untreated water to which 3 to 5 of an akaline based radiator cleaner should be added six ounces dry 151 gramsto one gallon 3 78 liters of water d Run engine 6 to 12 hours and drain system while warm R inse system three times after it has cooled down Refill system with water e Runengine to operating temperature D rain system again and fill with treated water anti freeze see Caution and refer to section 1 2 NEVER POUR COLD WATER INTO A HOT ENGINE Hot water can always be added to a cold engine 4 4 2 Changing Lube Oil and Lube Oil Filters After warming up the engine stop engine remove drain plug from oil reservoir and drain engine lube oil CAUTION When changing oil filters the new filters should be primed with clean oil if the filters are notprimed the engine may operate fora period with no oil supplied to the bearings Replace filter s lightly oil gasket on filter before installing and add lube oil Refer to section 1 2 Warm up engine and check for leaks 4 4 3 Replacing the Speed and Run Control Solenoids Truck Unit a Run Solenoid see Figure 4 1 1 Remove sprin
117. per The upper serial number of the unit is displayed with the description SERU or CD 15 The data is the upper three digits of the serial number burned in to the E prom i e SERH 001 or CD 15 001 Compartment 2 Return Air Temperature The return air temperature for Compartment 2 will be displayed with the abbreviated description 2RA onthe left side of display The code display is CD 16 The data will be displayed with one decimal place and the proper unit designator Degree C or Degree F i e 85 0F Compartment 3 Return Air Temperature The return air temperature for Compartment 3 will be displayed with the abbreviated description 3RA onthe left side of display The code display is CD 17 The data will be displayed with one decimal place and the proper unit designator Degree C or Degree F i e 85 0F Maintenance Hour Meter 1 The M aintenance H our M eter 1 setting is displayed with the description M HR 10r CD 18 The maintenance hour meter iscompared to one of the hour meters diesel standby or switch on determined by its mode If the hour meter is greater than the maintenance hour meter an alarm will be generated Maintenance Hour Meter 2 The M aintenance H our M eter 2 setting is displayed with the description M HR 2on the left side or CD 19 The maintenance hour meter is compared to one of the hour meters diesel standby or switch on determined by its mode If the hour meter is greater than the maintenanc
118. pressor Pressure 5 Check Valve 12 Sight Glass Regulating Valve CPR 6 Condenser 13 Liquid Solenoid Valve LSV 19 Suction Service Valve 7 Receiver 14 Expansion Valve 20 Receiver Pressure Valve RPV Figure 1 20 Truck Units Refrigeration Circuit Heating 62 02884 1 30 Te I OY OT TOU o Receiver King Valve h 5 in HL 7 2 lman 10 A 11 5 lt lt lt fp gt TRAILER Compressor 9 Subcooler 16 Evaporator High Pressure Switch HP 10 Accumulator Heat Exchanger 17 Electric Heater Discharge Service Valve 11 Filter Drier 18 Compressor Pressure Main Heat Valve MHV 12 Quench Valve Regulating Valve CPR Check Valve 13 Liquid Solenoid Valve LSV 19 Suction Service Valve Condenser 14 Expansion Valve 20 Receiver Pressure Valve RPV Receiver 15 Hot Gas Valve HGV 21 By Pass Valve BPV Figure 1 21 Trailer Unit Refrigeration Circuit Cooling 1 31 62 02884 577116 x OD 13 S ESY3 NO A ITA 15 5 HGV3 NC e lt
119. r the heat and defrost cyde NOTE The unit will be in high speed in the defrost mode The defrost mode may be initiated two different methods if the evaporator coil is below 1 7 C 35 F Refer to Section 1 5 M ethod one to initiate defrost press the Manual D efrost Key Method two is that defrost may be initiated automatically at preset intervals by the defrost timer in the microprocessor R efer to Section 1 8 4 The manual defrost key and defrost timer are part of the microprocessor and are not shown on the schematic In defrost the microprocessor pulls terminals X1 and N3 low to shift the unit into high speed heat The processor also pulls terminal W2 low to energize the defrost relay coil The defrost and heat display will also be illuminated Normally closed defrost relay contacts open to to stop the evaporator fans 62 02884 2 6 CONTROL CIRCUIT OPERATION STANDBY MOTOR DRIVE NOTE To make it easier to locate the schematic components referred to in the written text the schematic in this manual has map coordinates added to the margins These locations have also been added to the legend The relay module which contains plug in interchangeable relays provides the controller with a means for switching the unit components to achieve a desired operating mode 2 6 1 Electric Standby Features 1 Two O perating M odes 2 Minimum ON Time 5 Minutes 3 Minimum OFF Time 5 M inutes 4 Low Battery
120. rator V Belts Truck Units 1 Loosen single phase alternator bolts 2 Replace V belt and check belt tension Tighten the alternator bolt e Engine Compressor V Belts Truck Units 1 To allow for easy removal installation and adjustment of the V belts it is recommended that the muffler be disconnected from the muffler bracket and moved 2 Remove alternator V belt 3 Remove the standby motor compressor V belt 4 Loosen belt idler bolt 24 mm Move idler to remove V belts 5 Replace V belts Position the idler to the correct belt tension Tighten the idler retaining bolt 4 5 3 Servicing and Adjusting V belts Trailer Unit See Figure 4 5 BELTS Tension 35 to 40 35 to 40 50 to 55 Water pump Condenser Fan Generator Alternator Standby Motor Condenser Motor Generator 4 Alternator Standby Motor 1 Condenser Fan V Belt 2 Standby Motor V Belt Set 3 Generator V Belt 4 Alternator V Belt Figure 4 7 V Belt Arrangement Trailer Unit 62 02884 a Alternator V Belts Trailer Unit 1 Make sure negative battery terminal is disconnected 2 Remove generator V belt and then alternator V belt see Figure 4 7 3 Place V belt on alternator sheave and then install alternator with two bolts loosely in position 4 Check the center alignment of the generator driving pulley and alternator pulley to ensure proper drive Pulley misalign
121. re to check compressor loading Suction pressure will drop with this test p DO S NOTE If either unloader coil energizes and the suction pressure doesnot change the unloader assembly must be checked 62 02884 b Solenoid Coil Replacement NOTE The coil may be removed without pumping the unit down 1 Disconnect leads Removeretainer L ift off coil see Figure 4 15 2 Verify coil type voltage and frequency of old and new coil This information appears on the coil housing 3 Place new coil over enclosingtube A dd retainer and connect wiring 1 Retainer 8 Plunger Assembly 2 Coil Assembly 9 Gasket 3 Installation Removal 10 Valve Body Tool 11 Gasket 4 Enclosing Tube 12 Bolt Collar 13 Gasket Bolt 5 O Ring 14 Piston Ring 6 Enclosing Tube 7 Plunger Spring Figure 4 15 Unloader Solenoid Valve c Replacing Solenoid Valve Internal Parts See Figure 4 15 1 Pump down the unit Frontseat both service valves to isolate the compressor 2 Remove coil retainer and coil 3 Remove enclosing tube collar item 4 Figure 4 15 using installation removal tool supplied with repair kit item 3 4 Check plunger for restriction due to a Corroded or worn parts b Foreign material lodged in valve c Bent or dented enclosing tube 5 Install new parts Do not overtighten enclosing tube assembly Torque to a value of 100 inch pounds 1 15 mkg 6 Remove supplied installation removal tool In
122. reading Two preferred methods of determining the actual test temperature at the sensor arean ice bath at 0_C 32 F oracalibrated temperature tester Table 4 4 Sensor Resistance Micro Units CDT 1 RA 2RA 3RA amp WTS RAS amp WTS CDT Resistance Resistance In Ohms In Ohms 1 653 000 1 178 000 o 1 8 85500 855000 10 122 62400 624 000 20 67 4630 463000 3o i1 3450 345 000 of 3270 327000 44 262 000 199 000 153 000 119 000 100 000 93 000 73 000 58 000 47 000 38 000 so 100 1990 ol iss 1530 o zii noo 80 2657 930 o 312 73 I aj o 95 915 6 800 66 130 3 010 302 150 1 860 4 24 SUCTION PRESSURE TRANSDUCER A new suction pressure transducer must be calibrated before it is installed The calibration will not be performed if the run relay is energized T his prevents the operator from calibrating the unit with the sensor in the system T he reading of the sensor must be at atmospheric pressure 0 psig or 14 7 psi If the sensor readingisgreater than 20 psig 34 7 psi or lessthan 6 7 psig 8 psi it cannot be calibrated nce the microprocessor is calibrated the display will readout the actual value a Turn power off and remove starter solenoid wire then let unit fail to start This will de energize run relay b Connect wiring to new suction pressure transducer B efore installing suction pressuretransducer into unit display the
123. remain off for at least five minutes before restarting If after five minutes the battery voltage drops below 11 0 volts or the box temperature drifts out of range 2 0 C 3 6 from setpoint for perishable range and 2 0 C 3 6 above setpoint for frozen range the standby motor will restart 2 6 4 Standby Defrost Standby defrost operates the same as engine drive defrost Refer to Section 2 5 4 FALLING TEMPERATURE RISING TEMPERATURE HIGH SPEED HIGH SPEED 2 0_C 3 6_F or COOL 1 5_C 2 7_F 1 3_C LOW SPEED COOL LOW SPEED COOL 1 0 1 8 0 8 0 5 1 4 0 5 1 4 LOW SPEED 0 3 C HEAT LO EAT gt 10 C 18 15 C 2 HIGH SPEED HIGH SPEED LU HEAT 2 0 C 3 6 NOTE Trailer units are single speed Figure 2 2 Temperature Controller Operating Sequence Perishable Range Controller Set Point Above 12 C 10 FALLING TEMPERATURE RISING TEMPERATURE 12 0 6 3 6 HIGH SPEED 1 5 2 7_F HIGH SPEED COOL 13 C 1 0 1 8 LOW SPEED COOL LOW SPEED cooL 0 5 1 4 SET POIN LOW SPEED 0 5_ 1 4_F HEAT 1 0 1 8 0 2 LOW SPEED HEAT 15 2 7_F HIGH SPEED HEAT HIGH SPEED HEAT 2 0 C 3 6_F NOTE Trailer units are single speed Figure 2 3 Temperature Controller Operating Sequence Lead Evaporator Perishable Range Controller Set Poin
124. rge Temperature is displayed with the description CDT or CD9 The data is displayed with the proper unit designator D egree C or Degree F i e 85F The display range is 40 C to 200 C 40 F to 392 F If the sensor is absent then the display will read for the data Battery Voltage The battery voltage is displayed with the description BATT or CD 10 The data is displayed with one decimal place and then the letter V for volts i e BATT 12 2V or CD 10 12 2V The voltage reading is displayed with a plus sign if the battery status is good Standby Hours The number of electric motor hours are displayed with the description SBY or CD 11 The data is displayed in hours and units designator H i e SBY 5040H or CD 11 5040H The display range is 0 to 99999 Mod V Future Expansion This unit data is not used at this time The Code display is CD 12 62 02884 Software Revision The Eprom software revision number is displayed with the description REV or CD 13ontheleftand E prom software revision number on the right side Pressing the ENTER key for 3 seconds will display CD 13 U 2 on the left and the board mounted software revision number on the right side Serial Number Low The low serial number of the unit is displayed with the description SERL or CD 14 The data is the lower three digits of the serial number burned in to the E prom i e SERL 504 or CD 14 504 Serial Number Up
125. ric Flel PUMP sss eee meet nts et oe me E qe Ret dne 4 6 4 5 Belt Tension tet server pre Ee Ub uere bete tee pni 4 6 4 6 V Belt Arrangement Truck Units 4 7 4 7 V Belt Arrangement Trailer Unit 4 7 4 8 Removing V Belt from Clutch 4 8 4 9 Clutch Assembly Trailer 4 9 4 10 One Vacuum Pump Connections 4 11 4 11 Dual Vacuum Pumps lt 4 12 4 12 Oil Level in Sight 55 4 14 4 13 Compressor Model 056 4 15 4 14 Compressor Model 05K 4 15 4 15 U nloader Solenoid Valve 4 16 4 16 Typical Setup for Testing High Pressure Switch 4 16 4 17 Solenoid Valve A GO ua a ee aap ARABIA o De Re ee 4 17 62 02884 iv LIST OF ILLUSTRATIONS Figure Page 4 18 Solenoid Valve MHV 5 4 18 4 19 Compressor Pressure Regulating Valve 4 18 4 20 Tightening Sequence for icroprocessor Trailer U nit 4 19 4 21 Generator Fault Finding Guide
126. schematic in this manual has map coordinates added to the margins These locations have also been added to the legend The controller boards shown on the electrical schematic Figure 5 1 that interface with unit components are analog interface or processor board on the left and the relay module on the right Connectionsto these boardsare madethrough three multiple pin plug connectors HC HC2 amp MP The address system i e HCD2 MPW2 indicates a wire between plug H C pin D2 and microprocessor M P amp pin W 2 The processor board connections are mainly inputs and outputs for control switches temperature sensors safety and auto start functionsthat control theoperation of the unit The processor board also controls the operation of the relay board through plug connections The relay module which contains plug in interchangeable relays providesthe microprocessor with a means for switching the unit components to achieve a desired operating mode 2 5 2 Cooling Therearetwo control ranges Frozen and Perishable The Frozen range is active with set points at or below 12 10_F and the Perishable range is active at set points above 12 C 10_F The controller automatically selects the mode necessary to maintain box temperature at set point see Figure 2 2 or Figure 2 4 If the unit isin high speed cool the microprocessor will pull terminal N3lowto energize the speed relay A set of normally open contacts SR clos
127. sly affect the performance and life of the engine The air cleaner is designed to effectively remove contaminants from the air stream entering the engine An excessive accumulation of these contaminants in the air cleaner will impair its operation therefore a service schedule must be set up and followed Remember that the air cleaner cleans the air but the air cleaner requires cleaning The following simple service steps are easily made while the engine is being serviced in the field The simple inspection steps are as follows 1 Check all connections for mechanical tightness Be sure cleaner outlet pipe is not fractured 2 In case of leakage and if adjustment does not correct the trouble replace necessary parts or gaskets Swelled or distorted gaskets must always be replaced b Air Cleaner Service Indicator The air cleaner service indicator is connected to the engine air intake manifold Its function is to indicate when the air cleaner requires replacing In operation When a plugged air cleaner decreases intake manifold pressure to 20 500 mm WG the indicator moves to the red line The air cleaner should be replaced and the indicator reset by pressing the reset button c Service Procedure Dry Type The air cleaner has a primary and secondary element The secondary inner element should be changed every 374 or 4th primary element change 1 Stop the engine remove air cleaner element Install new air cleaner element
128. solenoid with a jumper wire connected to a battery Slide the solenoid far enough back on the bracket to set the engine speed lever against the stop Tighten solenoid mounting hardware 5 With the engine stopped place a mark on the crankshaft sheave white paint for example Check engine speed Speed may be verified Strobette model 964 strobe tachometer Carrier Transicold P N 07 00206 6 Disconnect the jumper wire and start the engine Theengineisin low speed R efer to Section 1 2 for engine speed Reconnect the jumper wire to energize the solenoid The engine should increase to high speed If engine speed is not correct engine lever against stop stop engine and move the solenoid forward slightly Repeat procedure if adjustments need to be made 7 When operating correctly tighten solenoid mounting hardware and reconnect the positive wire 8 Ifadjustmentisnot achieved by performing step 6 stop engine and remove linkage from solenoid Remove boot item 10 from solenoid and pull solenoid shaft out far enough to loosen jam nut on solenoid 62 02884 4 4 shaft Energize solenoid for maximum force pull and then turn shaft clockwise to shorten 9 De energize solenoid tighten shaft jam nut and replace boot Connect linkage and repeat steps 5 and 6 4 4 4 Engine Air Cleaner a Inspection The dry type or oil bath air cleaner should be inspected regularly for leaks A damaged air cleaner or hose can seriou
129. splay messages will appear in display window Next setpoint and box temperature will be displayed The microprocessor will energize glow cycle length of time depends on engine temperature and start the engine 4 To change the setpoint press the Up Or Down Arrow Key and then the Enter Key 5 Pressing the Auto S S Continuous Key changes the operation of the unit between automatic start stop unit will automatically start and stop in response to changing box temperature or automatic start continuous run unit will operate continuously after starting b Stopping Instructions Place the On Off Switch Cab Command if used to OFF position or place Run Stop Switch in the STOP position to stop unit 62 02884 2 2 2 MANUAL STARTING a Starting Instructions Manual Starting 1 Tostartthe unit manually place Run Stop Switch to RUN position and the On Off Switch Cab Command if used to ON position 2 Press the Auto S S Continuous Key if necessary to erase AUTOSTART STOP Symbol from the display 3 Press the Function Change Key until AUTO OP or MAN OP appears on the display a If AUTO OP appears Press the Enter Key Press the Up Or Down Arrow Keyto make OP appear on the display Press the Enter Key The unit is in MANUAL START mode b If MAN OP appears the unit 15 MANUAL START mode 4 Usethe Manual Glow Crank Switch to start the unit refer to Table 2 1 NOTE Once the unit is programmed for
130. splay will stop flashing to indicate that the value has been entered T he new value will continue to be display for five seconds before reverting back to the default display E ach time a key is pressed the five second delay will reset To select a different functional parameter the function change key must be pressed first Table 1 3 Function Codes ENGLISH DATA FNO DEFR Defrost Interval FN1 ON SPD Low Speed FN1 OFF HIGH SPD High Speed FN2 OFFT Minimum Off time Degrees Temperature Unit ForC F TIME 4 STRT Maximum Off time 30 Min CODE FN4 FN5 ON Out of Range Tolerance Alarm RST Alarm Reset Required FN6 FN7 ON FN7 OFF FN8 Alarm CLR No Alarm Active FN1 is NOT APPLICABLE for Genesis TR1000 62 02884 Code Vs English Messages The description messages of the functional parameters unit status and alarms can be displayed in English or Codes using this function selection The two choices displayed NGLISH or CODES With this parameter set to CODES all display descriptions are set to their code display T his parameter will not change due to this selection Refer to each section for the alternate display description Manual Glow Override The auto start glow time can be manually overridden through this function The messages are displayed as NORM GLOW or ADD GLOW If the ADD GLOW selection is entered the control will add 30 seconds of glow to the glow times li
131. stall coil voltage plate and retainer 7 Evacuate and dehydrate the compressor R efer to Section 4 11 p through 4 11 w 62 02884 8 Start unit and check unloader operation refer to section 4 14 a 4 15 CHECKING AND REPLACING FILTER DRIER To Check Filter Drier Check for a restricted or plugged filter drier by feeling the liquid line inlet and outlet connections of the drier cartridge If the outlet side feels cooler than the inlet side then the filter drier should be changed To Replace Filter D rier a Pump down the unit per Section 4 7 Remove bracket then replace drier b Check refrigerant level Refer to section 4 10 1 4 16 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCH 4 16 1 Replacing High Pressure Switch a Pump down the unit Refer to Section 4 7 a Frontseat both suction and discharge service valves to isolate compressor b Slowly release compressor pressure through the service valve gauge ports c Disconnect wiring from defective switch The high pressure switch islocated near the top of the compressor See Figure 4 14 d Install new cutout switch after verifying switch settings Refer to Section 4 16 2 e Evacuate and dehydrate the compressor Refer to Section 4 11 4 16 2 Checking High Pressure Switch WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 165 kg cm 2350 psi Do not use oxygen in or near a refrigerant sys
132. sted in Section 1 8 9 his feature must be selected before the three start attempts have been completed At higher ambients this override will only affect the second or third start attempt The ADD GLOW time is deselected when the engine starts or fails to start This parameter will not change due to the Code vs English selection Alarm Reset Alarms can be reset through this function The messages are displayed as ALARM RST or ALARM CLR If the ALARM RST is displayed then there is at least one alarm present Pressing enter key will clear all the alarms present Ifthe ALARM CLR isdisplayed then there are no alarms present See Section 1 8 8 This parameter will not change due to the code vs English selection Defrost Interval The defrost interval is displayed with the description DEFR or FNO data for the interval is displayed with one decimal place then the letter H for hours i e DEFR 12 0H The defrost intervals are 1 15 3 6 or 12 hours Airflow For Genesis TR 1000 this function is not applicable because Genesis TR 1000 is a single speed unit For Truck Units the status of the speed control solenoid override is displayed as CITY SPD or HIGH SPD The code display is FN 1 The city speed setting is ON and the high speed settingis OFF If the display shows CITY SPD the unit is locked into low speed Minimum Off Time The off time selection for the auto start mode is displayed with the des
133. t Above 12 10 2 5 62 02884 FALLING TEMPERATURE HIGH SPEED COOL LOW SPEED COOL LOW SPEED HEAT HIGH SPEED HEAT 5 9 RISING TEMPERATURE HIGH SPEED COOL LOW SPEED COOL 40 5 C LOW SPEED HEAT HIGH SPEED HEAT 6 10 8_ NOTE Trailer units are single speed Figure 2 4 Temperature Controller Operating Sequence Frozen Range Controller Set Point Below 12 10 F FALLING TEMPERATURE HIGH SPEED COOL LOW SPEED COOL 1 5 LOW SPEED HEAT HIGH SPEED HEAT RISING TEMPERATURE HIGH SPEED COOL 2_C 3 6_F LOW SPEED 1_C 1 8_F _ _ COOL 0 5 C LOW SPEED HEAT 5 9 HIGH SPEED u 6_C 10 8_ NOTE Trailer units are single speed Figure 2 5 Temperature Controller Operating Sequence Lead Evaporator Frozen Range Controller Set Point Below 12_ 10 62 02884 2 6 Table 2 2 2 Compartment Logic Control out l rear Mode Engine Fans ERE RN o High m or amela EN sms Het Col o o 1 o o Hin 1 i M Heat Heat PRI PRI PRI PRI PRI PRI High ore Het 1 1 o o o oO Meo 1 I M 0 056 0 Mieres 1 Moon Null Heat O O Meo 1 I M Nul Nul PRI PRI PRI PRI Micro I oe Engine speed is f
134. t Gas Heating When refrigerant vapor is compressed to a high pressure and temperature in a reciprocating compressor the mechanical energy necessary to operate the compressor is transferred to the gas as it is being compressed This energy is referred to as the heat of compression and can be used as the source of heat during the heating cycle When in the heat mode with no evaporators calling for cooling the hot gas solenoid valves H G SV 1 HG SV 2 and HGSV3 could be energized The main heat valve MHV will close diverting the refrigerant to H GSV 1 HGSV2 and HGSV3 The normally closed liquid solenoid valves LSV 1 LSV 2 LSV3 will energize and open The normally closed receiver pressure valve RPV situated in the hot gas line to the receiver will open This allows the receiver to be pressurized and liquid refrigerantto flowthrough the drier and sight glass and pass through any liquid line solenoid valves which would be energized The refrigerant passes through the expansion valve into the evaporator At the same time high temperature high pressure gas enters the evaporator via the solenoid valves H GSV 1 2 and 3 to give the required heating The extra liquid purged from the receiver ensures maximum heating capacity in low ambient conditions The evaporator fan passes the air over the hot refrigerant pipes and distributes heated air into the cargo space The hot gas travels through the suction line check valve into the accumul
135. t of 5 C The valve should be fully open The coil should be clean and free of ice Remove the Presstolite from both bulbs and loosen the clamps Put a thermocouple above parallel TXV bulb next to each bulb R etighten clamp and re insulate with Presstolite M ake the standard adjustment to both expansion valves which is unscrew completely the superheat setting screw in the counter clockwise direction Then tighten three turns 3X 360 in the clockwise direction Allowtheunitto stabilize at O C makingsure thatthe unit is in high speed cool Note the temperature of the suction gas at the expansion valve bulb Subtract the saturation temperature taken from the suction gauge to determine superheat Adjust each valve a turn ata time allowing the unit to stabilize between adjustments Always adjust both valves equally to avoid priority of refrigerant to any evaporator coil 4 31 REPLACING EVAPORATOR FAN MOTOR Remove two retaining screws which hold the door assembly in position The complete hinged assembly drops down allowing access to the fan Disconnect wiresin terminal box relative to fan being removed Remove four bolts and fan assembly Fit new fan to mounting plate Install fan assembly into evaporator 4 32 EVAPORATOR COIL CLEANING The use of recycled cardboard cartons is increasing across the country The recycled cardboard cartons create much more fiber dust duringtransport than new cartons
136. tem as an explosion may occur See Figure 4 16 1 Cylinder Valve and Gauge Pressure Regulator Nitrogen Cylinder Pressure Gauge 0 to 400 psig 0 to 28 kg cm Bleed Off Valve 1 4 inch Connection TUO De o vl Figure 4 16 Typical Setup for Testing High Pressure Switch a Remove switch as outlined in Section 4 16 1 b Connect ohmmeter or continuity light across switch terminals Ohmmeter will indicate resistance and continuity light will be lighted if switch closed after relieving pressure Connect switch to a cylinder of dry nitrogen See Figure 4 16 d Set nitrogen pressure regulator higher than cutout point on switch being tested Pressure switch cutout and cut in points are shown in Section 1 3 e Close valve on cylinder and open bleed off valve f Open cylinder valve Slowly close bleed off valve and increase pressure until the switch opens If light is used light will go out If an ohmmeter is used the meter will indicate open Open pressure on gauge Slowly open bleed off valve to decrease pressure until switch closes light will light or ohmmeter will move 4 17 REPLACING RECEIVER SIGHT GLASS ASSEMBLY NOTE There are two types of receiver sight glasses the floating ball type and the prism type both are interchangeable a Store the refrigerant in an evacuated container Refer to Section 4 7 b b Unscrew the sight glass assembly Spread some sealing compound on pipe threads of
137. the list will go to the first entry Each time the unit data key or the up down arrow key is pressed the display time will be reset to five seconds If the enter keyis pressed the displaytime will be set to 30 seconds The position in the unit data list will remain at the last selected value except if power is removed If the display wereto time out and revert to the default display the operator would only haveto pressthe unit data key to display the same data again Table 1 5 Unit Data Codes CODE ENGLISH DATA SUCI Engine Temperature Return Air Temperature C1 3 CD6 Compartment 2 Defrost Thermistor Sensor Compartment 2 COI Air Temperature CD17 Compartment 3 Air Temperature CD18 MHR1 Maintenance Hour Meter 1 CD19 MHR2 Maintenance Hour Meter 2 CD20 Switch On Hour Meter Suction Pressure The suction pressure is displayed with the description SU CT or CD 1 The data is displayed with the proper unit designator P psig or B Bars i e SU CT 25P The display is in inches of mercury for readings below 0 psig The display range is 0 7 Bars to 29 4 Bars 20 HG to 420 psig T RA DT Compartment 3 Defrost Thermistor Sensor T EV RA RA 62 02884 Engine Hours The number of diesel engine hours are displayed with the description ENG or CD2 The data is displayed with units designator H i e ENG 5040H OR CD2 5040 The display range is 0 to 99999 Engine Temperature The coolant temperature is disp
138. ther action istaken for the next five seconds 62 02884 4 20 c Continue to scroll through the configuration list by pressing the Function Key Change any other configurations as required d When finished turn the Run Stop switch to the Stop position then back to the Run position to start the unit ewe Fo vage 3 ewe Fon ems ON 90 Setpoint CNF4 CNF5 NotUsed E ON Truckunit Ener High speed start Truck unit Low speed start Trailer unit NUM CNF8 ON Outofrange alarm and unit shut down NotUsed CHITI ON Funcions _________ cute Fon CNF9 CNF10 0 0 0 0 F F Electric fan motors F F 4 23 CONTROLLER SENSOR CHECKOUT An accurate ohmmeter must be used to check resistance values shown in Table 4 4 Due to variations and inaccuracies in ohmmeters thermometers or other test equipment a reading within 296 of the chart value would indicate a good sensor If a sensor is bad the resistance reading will usually be much higher or lower than the resistance values given in Table 4 4 Atleast one lead from the sensor IRA terminalsD 1 or E1 must be disconnected from the unit electrical system before any reading is taken Not doing so will result in a false
139. tion and D ehydrating System Charging The Refrigeration System 4 10 1 CheckingtheRefrigerantCharge Replacing The Compressor Truck Replacing The Compressor Trailer Checking Compressor Oil Level Compressor Unloader Valve Checking And Replacing Filter Drier Checking And Replacing High Pressure Cutout Switch 4 16 1 Replacing High Pressure Switch 4 16 2 Checking High Pressure Switch Replacing Receiver Sight Glass Assembly Servicing Solenoid Valves 4 18 1 Solenoid Valves 4 18 2 Solenoid Valve Sporlan Condenser Coil 0 Adjusting The Compressor Pressure Regulating Valve Microprocessor 2 Configuration Of Microprocessor Controller Sensor Checkout Suction Pressure Transducer 5KW Generator 1 5KW Single Phase Alternator Generator Truck Servicing Phase Sequence Torque Values Truck
140. uction service valve and gauge valve to vent a small amount of refrigerant through the common connection and the oil to purge the lines of air Close the gauge manifold valve With the unit running frontseat the suction service valve and pull a vacuum in the compressor crankcase SLOWLY crack the suction gauge manifold valve and oil will flow through the suction service valve into the compressor Add oil as necessary c Adding Oil to Service Replacement Compressor Service replacement compressors may or may not be shipped with oil If compressor is without oil Add correct oil charge Refer to section 1 3 by removing the oil fill plug See Figure 4 14 d To remove oil from the compressor l Closesuction service valve frontseat and pump unit down to 0 1 to 0 3 kg cm 2 to 4 psig Frontseat discharge service valve and slowly bleed remaining refrigerant 2 Removethe oil drain plug from compressor and drain the proper amount of oil from the compressor Replace the plug securely back into the compressor 3 Open service valves and run unit to check oil level Repeat as required to ensure proper oil level UD UU UU UU UD High Pressure Switch Connection Suction Pressure Transducer Connection Suction Service Valve Oil Fill Plug Bottom Plate Oil Drain Plug Oil Level Sight Glass Oil Pump Unloader Solenoid Discharge Thermistor Connection
141. uum Pump Electronic Vacuum Gauge Evaporator Coil Receiver Outlet King Valve Condenser Coil Suction Service Valve Discharge Service Valve FON PUO NJ ES T Figure 4 10 Single Vacuum Pump Connections 4 11 62 02884 1 Suction Line 2 Equalizer Line 3 Tee on Suction Line 4 Schrader Valve 5 Discharge Service Valve 6 Suction Service Valve 7 Manometer 8 Vacuum Pump Figure 4 11 Dual Vacuum Pumps Connections 4 12 62 02884 4 10 CHARGING THE REFRIGERATION SYSTEM CAUTION Do not vapor charge R 404A Only liquid charging through the liquid line king valve is acceptable a Dehydrate unit and leave in deep vacuum Refer to section 4 9 b Place refrigerant cylinder on scale and connect charging linefrom cylinder to receiver outlet king valve Purge charging line at outlet valve Note weight of refrigerant cylinder d Open liquid valve on refrigerant cylinder Open king valve half way and allowthe liquid refrigerantto flow into the unit until the correct weight of refrigerant has been added asindicated by scales Correct charge will befound in Section 1 3 NOTE Itis possible that all liquid may not be pulled into the receiver as outlined in step d In this case frontseat the receiver outlet valve king valve and the liquid will be pulled into the system U nit must be operating in the cooling mode e When refrigerant cylinder weight scale in
142. vels are listed below for reference only U nder no circumstances should 12 vdc be applied at these connection points Grounded wrist cuffs are available at most radio computer and electronic supply stores It is recommended that these be worn whenever handling a microprocessor Table 4 3 Connection Point Voltage Connection Point Approximate Voltage CDT RAS WTS 2 5 vdc Variable 1 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 truck trailer microprocessor Although there is less danger of electrical static discharge ESD damage in the outdoor environment where the processor islikelyto be handled proper board handling techniques should always be stressed Boards should always be handled by their edges in much the same way one would handle a photograph This not only precludes the possibility of ESD damage but also lowers the possibility of physical damage to the electronic components Although the microprocessor boards are fairly rugged when assembled they are more fragile when separated and should always be handled carefully D uring emergency situations the test board may be used to keep a unit running and prevent a critical load from spoiling Since the microprocess
143. xcessive wear on all operating parts However it is the responsibility of the operator to give the air cleaner equipment regular and constant attention in accordance with the instructions Refer to section 4 4 4 Clean air is supplied to the engine through the air cleaner see Figure 1 5 This air supply is necessary for complete combustion and scavenging of the exhaust gases As the engine piston goes through the intake stroke the piston draws clean fresh air down into the cylinder for the compression and power strokes Asthe engine goes through its exhaust stroke the upward movement of the piston forcesthe hot exhaust gases out of the cylinders through the exhaust valves and the exhaust manifold If the air filter is allowed to become dirty operation of the engine will be impaired 62 02884 1 12 1 4 COMPRESSOR REFERENCE DATA 200 cc 12 2 in 2 Displacement No Cylinders 3 o 52 kg 137 bs 38 L 6 pin APPROVED COMPRESSOR OIL Refrigerant 056 R 404A Mobil Arctic EAL 68 1 5 REFRIGERATION SYSTEM DATA Defrost Timer 1 1 2 3 6 or 12 hours Defrost Temperature Sensor Opensat 10 3 C 50 5F Closesat 7 3 C 45 5F High Pressure Cutout Switch HP Cutout at 32 7 0 7 kg cm 469 Cut inat 24 6 0 7 kg cm 350 Refrigerant R 404A Charge Refer to Table 1 1 e Compressor Pressure Regulating Valve CPR CPR Setting MODEL kg cm Genesis R70 R9
144. xt to the lock picture To unlock the control box press the Carrier oval for 10 seconds When the compartment control box is locked the temperature setting and manual defrost can still be altered with microprocessor panel 62 02884 1 10 Figure 1 10 Compartment Control Box SINGLE DISCHARGE DOUBLE DISCHARGE 1 Capacitor 6 Evaporator Fan amp Motor 2 Defrost Terminal Sensor 7 Expansion Valve 3 High Temperature Klixon 8 Liquid Solenoid Valve LSV 4 Heaters 9 Hot Gas Solenoid Valve HGV 5 Thermostat Sensor 10 Check Valve Figure 1 11 Evaporator 1 11 62 02884 1 2 ENGINE DATA Engine Model CT4 134TV V2203TV CT3 69TV 1105 CT3 44TV D722 Used on Genesis TR1000 Genesis R90 Genesis R70 Displacement 2 2 liters 134 in3 1105 cc 68 5 in3 719 cc 43 9 in 20 8 kw 28 hp 13 8 kw 18 5 hp 10 3 kw 13 4 hp Horsepower 1500 rpm 2300rpm 2200rpm O __ om 140 to 150 kg cm2 1991 to 2133 psi a Water Temperature Sensor WTS Closesat 110 3 C 230_ 5_F b Lubrication System Lube Oil Viscosity A PI Classification CD Outdoor Temperature Centigrade Below 32_ 10W or 15W40 32_to 77_F 0_to25_C 20W or 15W40 Over 77_F Over 25 30W 15W40 c Oil Pressure Safety Switch Closes at 1 05 0 2 kg cm 15 3 psig 1 3 ENGINE AIR CLEANER The air cleaner isdesigned to prolongengine life and performance by preventing dirt and grit from gettinginto the engine causing e
145. ys which will allow the operator to initiate various functions display operating data and change operating parameters Arrow Keys The keypad has up and down arrow keys which are used to modify increment or decrement the setpoint selection or modify the displayed data Enter Key The enter key is used to accept a change in unit parameters or a change in setpoint Manual Defrost Key The manual defrost key is used to initiate a defrost cycle given that the proper conditions are met Pretrip Check Key This key is inactive and not applicable for this application Auto Start Stop Continuous Key The start stop continuous key is used to change the operating mode from auto start continuous run to auto start stop E ach push of the key will alternate the operating modes The operating status will be stored in memory and will be retained through power outages T he digital display will indicate when stop start is enabled also see Section 1 8 9 To start the unit in manual start mode the Start Stop Continuous selection must be in continuous run mode HI AIR mm a 1124 21 BOX TEMPERATURE IN RANGE ENTER Function Change Key The function change key is used to display the operating parameters E ach time this key is pressed the display will advance to the next parameter This key in conjunction with the up down arrow and enter keys will allow the user to change the parameters see Section 1 8 6 Unit Data K

Truck/Trailer Refrigeration Unit - Sunbelt Transport Refrigeration

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