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caution - Sunbelt Transport Refrigeration

1. NOTES T INDICATES A SOLDERED SPLICE POINT 1 UNIT SHOWN O POSITION SP 2 WIRE IDENTIFICATION SYSTEM G CONNECTION COLOR WHITE DC CONIROL CIRCUITS IGHT LINES INDICATES WIRES IN THE SYSTEM GREEN DC GROUNDS CIRCUITS uu RED POSITIVE BATTERY CIRCUITS E m 70 5004 BLACK NEGATIVE BATTERY CIRCUITS 3 ADDRESS SYSTEM EXAMPLE CN2 8 CFM A INDICATES WIRE BETWEEN CONNECTOR CN2 HC F2 MULTIPLE PLUG CONNECTION NUMBER PIN 8 AND PLUG CFM PIN AD JUNCTION BLOCK CONNECTION LOCATION SYMBOL DESCRIPTION B 9 LP LOW PRESSURE SWITCH B 8 BPT QUENCH THERMOSTAT P 9 BPV QUENCH VALVE A 5 CC CAB COMMAND P 7 CFM CONDENSER FAN MOTOR P 4 CLHR CLUTCH P5 EFM EVAPORATOR FAN MOTOR C 3 F1 MAIN ROAD FUSE B 10 FI IGNITION FUSE D 3 FUSE ROAD SUPPLY FUSE B 9 HP1 HIGH PRESSURE SWITCH B 7 HP2 CONDENSER PRESSURE SWITCH P 8 HGS1 HOT GAS SOLENOID VALVE P 9 HGS2 CONDENSER PRESSURE CONTROL VALVE B 7 RAS RETURN AIR SENSOR Fe yko C0 TCH SYMBOL INDICATES MOMENTARY CONTACTS DICATES A WIRE GROUND INDICATES A CHASSIS GROUND NO WIRED T DICATES INDICATES STANDARD OPTIONS A CONNECTION WIRE UG E
2. 2 4 FS FORRINGER EON MM 2 4 2 8 MICROPROCESSOR 2 5 2 8 1 Funcional Sellllgs veo o ne Nee erbe xe e o e ee da ele te 2 5 TEMPERATURE CONTROL 2525 22 023 e robe PC oo Era CGU GAIA NEG bec 3 1 94 SEQUENCE OF OPERATION eet don e dein ubt tee Geb ire abe 3 1 Salad Penshable IMOGOG e br hot ae eto dae edge dus ach ager ela ee 3 1 3 2 us uia ach tor EC a tcd rad o Ma dee SU EAD 3 1 ou S as turbant EM 3 2 TIMES nilo ett acp ce a tiem Umane e sci 3 2 SERVICE S Rob Or ard app quint are appe Muro dn 4 1 AA IMAINTENANGE SCHEDULE ise reden a CE ete eet deae eee 4 1 42 INSTALLING R 404a MANIFOLD GUAGE 6 4 2 4 2 1 Preparing Manifold Gauge Hose Set For Use 4 2 4 2 2 Connecting Manifold Gauge Hose 4 2 4 2 3 Removing the Manifold Gauge Set 4 2 43 REMOVING THE REFRIGERANT CHARGE 4 3
3. 1 2 Figure 1 2 NIIGKOPIOCCSSOM ame ode ee ta Abd awed doh e po Caine 1 3 FOUG SEVADOLAION s ayy dope Mn E 1 4 Figuire t 4 GCabsGOmimaids 1 6 Figure 1 5 Refrigeration Circuit Cooling Cycle 1 10 Figure 1 6 Refrigeration Circuit Heating And Defrost Cycle 1 11 Figure 2 1 Gab Gommand de ena dep dete e o aou dera A seed ire 2 1 Figure 2 2 Green Eight Slats ro ob odo e UA tu o nbus 2 2 Figure 3 1 Operating Sequence Perishable Mode 3 1 Figure 3 2 Operating Sequence Frozen Mode 3 1 Figure 4 1 Manifold Gauge Set 404 4 2 Figure 4 2 Vacuum Pump Connection 4 3 Figure 4 3 Procedure for Adding A Complete Charge 4 5 Figure 4 4 Procedure For Adding A Partial Charge 4 6 Figure 4 5 Typical Setup For Testing Pressure Switches HP1 And 2 4 7 Figure 4 6 Hot Gas Valve Condenser Pressure Control Valve or Quench Valve 4 8 Figure 4 7
4. Compressor oil type Compressors are supplied with CARRIER POLYESTER POE oil Oils of PAG type are strictly incompatible with the operation of this unit never use an oil other than that approved by CARRIER Table 4 2 Service Category Descriptions Service A Service B Service C 1 Check that the vehicle engine idles correctly with unit operating Check compressor mounting hardware 2 Check the tightness of bolts and screws and that the unit is correctly fastened onto the box 1 Clean evaporator amp condenser Paragraphs 4 15 amp 4 16 2 Check and if required replace the filter drier Paragraph 4 8 3 Check the operation of cab com mand 4 Check the defrost DCut in DFan shut down DCut out DDefrost water drain 1 Check the operation of the evapora tor and condenser fans 2 Check the shockmounts if any installed on the road compressor mounting kit 3 Change the compressor oil Use polyester oil POE approved by CAR HIER Refer to paragraph 1 6 1 62 10891 4 2 INSTALLING R 404a MANIFOLD GUAGE SET An R 404a manifold gauge hose set with self sealing hoses is required for service of models covered within this manual The manifold gauge hose set is available from Carrier Transicold Carrier Transicold P N 07 00294 00 which includes items 1 through 6 Figure 4 1 To perform service using the manifold gauge hose set do the following 4 2 1 Preparing Manifold Gauge Hose Set For Use
5. 4 6 1 Checking The Refrigerant Charge a Start unit in cooling mode and run approximately ten minutes b Partially block off air flow to condenser coil so dis charge pressure rises to 325 psig 22 Bar c The unit is correctly charged when there are no bubbles in the sight glass 4 6 2 Installing A Complete Charge NOTE The ambient air entering the condenser air temperature should be above 40 F 4 4 C a Evacuate the refrigeration circuit leave in a deep vac uum Refer to section 4 5 b Place refrigerant 404a cylinder on scale Connect the discharge gauge field coupler of the manifold test set to the king valve or liquid line charging port Connect the suction pressure hose of the manifold gauge set to the manifold dead head port Connect a charging line between the center tap of the second gauge set and the refrigerant drum Midseat discharge knob Open the liquid valve on the drum and purge all hoses Frontseat discharge knob See Figure 4 3 c Note weight of refrigerant cylinder d Open liquid valve on refrigerant cylinder Open king valve or field coupling attached to liquid line charging port half way and allow the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added as indicated by scale See Table 1 1 for correct charge NOTE It may be necessary to finish charging the unit using the partial charge method due to pres sure rise in the high side of the syste
6. d eode ea ten em a ea on ee asl de 5 2 52 1 oor x VR clan e bs EN Uam s x Ronee Yi EE 5 2 5 2 2 Unit Runs But Has Insufficient Cooling 5 2 5 2 3 Unit Operates Long or Continuously in Cooling 5 2 5 2 4 Unit Will Not Heat or Heating Insufficient 5 2 9 2 0 se tee oot rec ae tr tee a ie wh aie de pos be C e Manto S beca onis 5 2 320 JAADhOLTali P ressllG s od satia ga iie do eae ou Fatum See 5 3 5 2 7 FOMOMMal NOISE ndisse ek enn ah 5 3 5 2 0 Gab Command MalunctiOn e CHR DE Do alee ee ea CR as 5 3 5 2 9 Evaporator Air Flow or Restricted Air 5 3 5 2210 EXPANSION des din hk dle d 5 4 5 2 11 Malfunction Hot Gas Solenoid Condenser Pressure Regulating Valve or Quench Valve 5 4 SCHEMATIC DIAGRAMS ek Ee ae eee oe dedero tacts 6 1 INTRODUCTION Ee HP de ee et a e E e de ue ans 6 1 iii 62 10848 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 1 1 Condenser Cab Command
7. high amp draw Condenser Pressure Control Current draw of coil high or Tow approx 176 amp Valve HGS2 high amp draw 210 SION Hot Gas Solenoid Valve Current draw of coil high or low approx 1 33 amp A09 HGS1 5 1 62 10891 Table 5 1 Alarm Indications Continued Reference Setpoint adjusted out of the range 20 2 to 86 F 29 C 30 C or below the 10 setpoint programmed low threshold Return Air Sensor Return air sensor defective Vehicle battery voltage low eck alternator system o Setpoint error Programming error Reset Table 5 2 Mechanical Indications REFERENCE INDICATION TROUBLE POSSIBLE CAUSES SECTION 5 2 REFRIGERATION 5 2 1 Unit Will Not Cool Compressor drive clutch defective Replace Compressor defective Defrost cycle has not terminated 5 2 5 Refrigeration system Abnormal pressure 5 2 6 Hot gas solenoid malfunction HGS1 4 10 5 2 2 Unit Runs But Has Insufficient Cooling Compressor Compressor defective Abnormal pressure 5 2 6 Refrigeration system Expansion valve malfunction 5 2 10 Non existent or restricted evaporator airflow 5 2 9 5 2 3 Unit Operates Long or Continuously in Cooling Hot Load Insufficient pull Box down time Defective box insulation or air leak Correct Refrigeration system Abnormal pressure 5 2 6 Temperature controller malfunction 5 2 8 5 2 4 Unit Will Not Heat or Heating Insufficient Abnormal pressure 5 2 6 Refrig
8. Truck Refrigeration OPERATION amp SERVICE for 20X Truck Refrigeration Units 62 10891 Rev TRANSICOLD OPERATION AND SERVICE MANUAL 20X TRUCK REFRIGERATION UNITS TABLE OF CONTENTS PARAGRAPH NUMBER Page GENERAL SAFELY NOUIGES cut tarira Aven de RU et Rit rece es oafety 1 RIRS TAID dhe d ad tase dated ds oafety 1 OPERATING PRECAUTIONS 49 3 atat ba teda E nee RE eed oafety 1 MAINTENANGE PREGAUTIONS 52 5 T EE ES eee Coe duende cone oafety 1 SPECIFIC WARNING AND CAUTION STATEMENTS oafety 1 DESCRIPTION diera Sod ome dra es ES dus am Ete 1 1 MINDER UG oi iode odia nt ec eee cde is 1 1 1 2 GENERAL DESQGRIPTION RESUME IA dad doe omn 1 1 1 2 GONDENSING SEGTION edad ae oet od ao eod aiti aaa eich anette ash ace eames 1 1 1327 re 1 1 TE FILED ASER PD rr 1 1 1 53 Hot Gas Solenoid Valve HOS1 o ete za iE ea ict a 1 5 1 3 4 Condenser Pressure Control Valve HGS2 1 5 COMPNCSSON ach o e TR e Eo tester d ped e ani dad red 1 5 12220 TCC CIV RECENSITO rrr 1 5 1 9 7 High Pressur
9. a If the manifold gauge hose set is new or was exposed to the atmosphere it will need to be eva cuated to remove contaminants and air as follows b Back seat turn counterclockwise both field service couplers see Figure 4 1 and midseat both hand valves c Connect the yellow hose to a vacuum pump and an R 404a cylinder d Evacuate to 10 inHg 254mmHg and then charge with R 404a to a slightly positive pressure of 1 0 psig 0 07 Bar e Front seat both manifold gauge set hand valves and disconnect from cylinder The gauge set is now ready for use 4 2 2 Connecting Manifold Gauge Hose Set To connect the manifold gauge hose set for reading pressures do the following a Connect low side field service coupler to the suction access valve See Figure 4 1 b Turnthe field service coupling knob clockwise which will open the system to the gauge set c Read system pressures d Repeat the procedure to connect the other side of the gauge set to the discharge access valve 4 2 3 Removing the Manifold Gauge Set 1 While the compressor is still ON turn the high side field service coupler knob counter clockwise to close the system to the gauge set 2 Midseat both hand valves on the manifold gauge set and allow the pressure in the manifold gauge set to be drawn down to low side pressure This returns any liquid that may be in the high side hose to the system 62 10891 4 2 CAUTION To prevent t
10. 4 3 1 Removing Complete Charge 4 3 4 4 REFRIGERANT LEAK CHECKING 4 3 45 EVACUATION AND DEHYDRATION 4 4 er Rm 4 4 4 59 27 1 net ee e nie dae aed o cR 4 4 4 5 3 Procedure For Evacuation And Dehydrating System 4 4 4 6 CHARGING THE REFRIGERATION SYSTEM 4 5 4 6 1 Checking The Refrigerant Charge 4 5 4 6 2 Installing A Complete Charge 4 5 46 9 Adairg A Partlal Charge xaxd ste boe zs t RS DA ER RARE IE RAS RR weet ated ahead aes 4 6 47 CHECKING FOR NON CONDENSABLES 4 7 62 10848 ii TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page SERVICE cont d 48 CHECKING AND REPLACING FILTER DRIER 4 7 498 GHECKING Fiter DNE a do otn ta tc he dot eua dob rte 4 7 4 9 2 Replacing The Filter Drier 4 7 49 HIGH PRESSURE 1 AND CONDENSER PRESSURE HP2 SWITCHES 4 7 4 9 T REMOVING S
11. No evaporator air flow or restricted air flow Excessive frost on coll Suction and discharge pressures Compressor defective Replace tend to equalize when unit is Hot gas solenoid malfunction 4 10 operating 5 2 6 2 Heating High discharge pressure Overcharged system 4 6 1 High discharge pressure Condenser fan or HP2 pressure switch defective Hs Noncondensables in system Condenser motor fan defective Nd motor Compressor defective rU Low discharge pressure Hot gas solenoid valve malfunction Low refrigerant charge 4 6 1 Low suction pressure Compressor pressure regulating valve misadjusted CPR 4 11 Condenser Pressure Regulating valve fault HGS2 4 10 5 2 7 Abnormal Noise Loose mounting bolts Worn bearings Compressor Worn or broken valves Liquid slugging Insufficient oil Loose shroud Bearings defective Fan loose on shaft Bent shaft 5 2 8 Cab Command Malfunction Fuse open Replace Cab Command non operational Microprocessor malfunction Replace Microprocessor Cab command cable 4 14 5 2 9 No Evaporator Air Flow or Restricted Air Flow Evaporator coil blocked anneal EL Evaporator fan loose or defective Check Evaporator fan rotating backwards Check Evaporator air flow blocked in box Check Fan motor malfunction Replace Condenser or evaporator fan No or partial evaporator air flow 5 3 62 10891 Table 5 2 Mechanical Indications Continued REFERENCE INDICATION TROUBLE POSSIBLE
12. Replace the cap 4 12 THERMOSTATIC EXPANSION VALVE MOP expansion valve characteristics Rule in order to avoid compressor overcharge a MOP expansion valve expansion valve with limited flow is used SOperating the expansion valve will not open more than the MOP setpoint Any temperature increase at the bulb should not open the expansion valve further The thermal expansion valve is an automatic device which maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure The valve functions are automatic response of refrigerant flow to match the evaporator load and b prevention of liquid refrigerant entering the compressor Unless the valve is defective it seldom requires any maintenance NOTE Due to the time involved in adjusting the super heat it is more economical to replace the valve rather than to adjust it 4 12 1 Replacing expansion valve a Remove refrigerant charge See section 4 3 b Remove insulation from expansion valve bulb and then remove bulb from suction line c Loosen flare nut and disconnect equalizer line from expansion valve d The txv bulb is located below the center of the suction line This area must be clean to ensure positive bulb contact Strap bulb to suction line and insulate both e Braze the equalizer tubes to expansion valve f Evacuate dehydrate and recharge unit See Sec tions 4 5 and 4 6 g Check superheat See S
13. cuc 1 8 1 8 REFRIGERATION CIRCUM 2 2 1 9 LoT Goong 1 9 1 82 ARAL ANG HID CI OS Coat hap senso acia dosha aaa Ecos 1 9 i 62 10848 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page OPERATION Tr 2 1 21 OONTIROLSYSTEN db tend els 2 1 211 MOGUCOM wat bs ih de RE dot eat ao Shed os 2 1 21 2 Microprocessor NOTUS ii natia nexu ty Rr NER ree Saee T heec eatin cae 2 1 2 1 9 Commande eiiean Gaia at eae dal hata an 2 1 Do UIE A arbre E eee 2 2 2 2 1 2 61 a Re ee 2 2 22 2 Ola qas au etiem 2 3 22092 SETPOINT ADJUSTMENT e etri et UD ao ed 2 3 24 MANUALCDEFROS T 2 3 25 mae ee eve 2 3 2 5 1 Accessing Alarmi Messages 2 21 04 4 AC Hi ee ae ee 2 3 2 5 2 LOW Battery Voltage Alarms i 2 3 26 CHECKING THE EEPROM VERSION 2 2320
14. fore installing 62 10891 CAUTION Do not damage or over tighten the enclos ing tube assembly Place all parts in the en closing tube in proper sequence in order to avoid premature coil burn out e Tighten enclosing tube f Install coil assembly voltage cover and snap cap g Evacuate dehydrate and recharge unit See Sec tions 4 5 and 4 6 h Start unit and check operation k ST meme 222 EEE 7 IE pE 1 Cap 2 Jam Nut 3 Set Screw Figure 4 7 Compressor Pressure Regulating Valve 4 11 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE CPR The CPR valve is not factory pre set and needs adjustment When adjusting the compressor pressure regulating valve CPR see Figure 4 7 the unit must be running in heating or defrost mode and at 2400 rom compressor speed This will ensure a suction pressure above the proper CPR setting To adjust the CPR valve proceed as follows a Install a gauge on the suction line b Remove cap from CPR valve c With an 8 mm Allen wrench loosen the jam nut d Using the 8 mm Allen wrench adjust the set screw To raise the suction pressure turn the set screw clock wise to lower the suction pressure turn counter clockwise Refer to paragraph 1 6 2 for CPR valve setting e When the setting has been adjusted tighten the jam nut securely against the set screw This will prevent any movement of the set screw due to vibrations in the unit
15. Compressor Pressure Regulating 4 8 Figure 4 8 Thermostatic Expansion Valve Bulb And Thermocouple 4 9 Figure 4 9 Cab Command Diagnostic Tool 4 9 Figure 6 1 Electrical Schematic Wiring Diagram Based On Dwg No 62 61350 RevE 6 2 Figure 6 2 Electrical Schematic Wiring Diagram Based On Dwg No 62 61350 Rev E 6 3 LIST OF TABLES TABLE NUMBER Page Table det Moder CMAN Fait uhh teeth HE uic USE A shee ee eR d 1 1 Table 1 2 Additional Support Manuals 2 5 e eo e deed RC e oce t oo 1 1 Table 2 1 Alarm Messages or ido OL Re ace eor aded ed NAUES POESIE TRES 2 4 Table 41 Maintenance Schedules 7 4 1 Table 42 Service Category Descriptions 4 1 Table 4 3 R 404a Temperature Pressure Chart 4 11 Table 5 1 AIAN INGICATIONS gt 5 42 re eae ed ad c do oce a 5 1 Table 5 1 Alarm Indications Continued 5 2 Table 5 2 fre RU 5 2 62 10848 iv SAFETY SUMMARY GENERAL SAFETY NOTICES The followin
16. Evaporator Air Flow or Restricted Air Flow 5 4 O Oil Separator 1 3 OPERATION 2 1 P Partial Charge 4 5 Perishable Mode 3 1 Q Quench Valve 1 4 1 10 Quench Valve BPV 1 9 R Receiver 1 3 Refrigerant Leak Checking 4 3 Refrigerant Removal From Compressor 4 3 Refrigeration System 1 9 Replacing The Compressor 4 6 Road Compressor Clutch 1 10 5 Safety Devices 1 11 Sequence Of Operation 3 1 62 10891 INDEX Service 4 1 Set point 2 3 Standby Compressor Malfunction 5 4 Standby Compressor Speed 1 10 Standby Motor 1 3 Standby Motor Contactor 1 10 Standby Motor Ratings 1 10 Standby Motor Compressor V Belt 4 2 Start up 2 2 Starting 2 3 Stopping 2 5 T Temperature Control 3 1 Thermal Expansion Valve 1 4 Thermostatic Expansion Valve 4 8 Thermostatic Expansion Valve 1 9 Torque Values 1 10 Troubleshooting 5 1 U Unit Operates Long or Continuously in Cooling 5 3 Unit Will Not Cool 5 2 Unit Will Not Heat or Heating Insufficient 5 3 W Wiring Diagram 6 2 6 3 6 5 6 6 6 7 6 9 Index 2 TRANSICOLD North America Central America Carrier Transicold and Mexico 700 Olympic Drive Ejercito Nacional No 418 Athens GA 30601 USA Piso 9 Torre Yumal Tel 1 706 357 7223 Col Chapultepec Morales Fax 1 706 355 5435 11570 Mexico D F Tel 5255 9126 0300 Fax 5255 9126 0373 A member of the United Technologies Corporation family Stock symbol UTX 2005 Carr
17. VOLTAGE i F1 TRANSCIENT ae BESUEATOR m 40A FUSE SUPRESSOR Hi 1 ji Bz 25A REF E 7 WATCHDOG TIMER VBAT SUPERVISOR amm B TY te POWER FAIL J gt WD INPUT gt 2 AA WRITE PROTECT rp CONTROL a E2PROM SENSE A CN2 3 CLHR ZL TOPFET ai g HIGH SIDE 2 12C BUS MICROCONTROLLER COMMAND SP CONNECTOR Lr Q 311 2 EFM 3 4 POWER CN4 3 TOPFET TUDAT L LOW SIDE CN2 5 RAG x FILTERS DATA C C c 226 gt CN2 4 VBAT lL 4 1 Eu VBAT 1 TOPFET FILTER LOW SIDE CN2 8 A CN3 9 I gt HP 2 VBAT 5 CN2 7 B B CN3 8 E cl EMI T VBAT FILTER TOPFET 1 CN3 4 i T LOW SIDE CN2 2 H6S1 BPT CN3 7 9 n 7 CN3 E 1 1 a ae LOW SIDE A CN2 11 es rm 5 CN3 5 n em CN2 10 A CN3 2 VBAT E TOPFET E B CN3 3 n E LOW SIDE 2 3 ES MI BPV FILTER gt CN2 12 Ta TO IGNITION ET CN3 1 TE lt gt S KEY eC F STAGE CONFIG 8 1A JUMPERS Bul Figure 6 2 Electrical Schematic Wiring Diagram Based On Dwg No 62 61350 Rev E A Abnormal Noise 5 4 Abnormal Pressure 5 3 Accessing Alarm Messages 2 4 Alarm Display 2 4 Alarm Indications 5 1 B Belt Adjustment 4 2 Belt Tension 4 2 C Cab Command 2 1
18. and b below Validate modified settings NOTE If no buttons are depressed within 5 seconds of pressing the Defrost and On Keys Step 2 of the above procedure or modifying parameters the Cab Command reverts to box temperature dis play and the configuration procedure is aborted a The defrost duration parameter is displayed This set ting determines the length of time in minutes the unit will remain in defrost once defrost is initiated The de frost duration can be selected by scrolling through available options 10 20 25 30 or 45 minutes using the or keys Selection MUST be validated by pressing the SET key The defrost interval parameter is displayed next This setting determines the time between defrosts in hours The defrost interval can be selected by scroll ing through available options 0 1 1 5 2 2 5 3 4 5 2 5 6 hours using the or keys Selection MUST be validated by pressing the SET key 3 The next steps must be performed with the unit ON Unit start up Press the then then DEFROST keys All gio THEN keys should be held momentarily after pressing in the correct sequence Modify parameters See a b andc below NOTE If no buttons are depressed within 5 seconds of pressing the ON key or modifying parameters the Cab Command reverts to box temperature display and the configuration procedure is aborted a The minimum setpoint parameter is disp
19. causes the liquid to vaporize The vapor at low temperature and pressure enters the heat exchanger then enters the compressor pressure regu lating valve CPR which regulates refrigerant pressure entering the compressor where the cycle starts over The discharge pressure is regulated with HP2 The quench valve opens as required to maintain a maxi mum discharge temperature Refer to section 1 6 3 for settings 1 8 2 Heat And Defrost See Figure 1 6 When refrigerant vapor is compressed to a high pressure and temperature in a 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 is used as the source of heat during the heating or defrost cycle When the microprocessor activates heating or defrost the hot gas solenoid valve energizes and the condenser pressure control valve energizes closing the port to the condenser and opening a port which allows heated refrigerant vapor to flow directly to the evaporator coil The main difference between heating and defrosting is that when in heating mode the evaporator fans continue to run thus circulating the air throughout the compartment to heat the product When in defrost the evaporator fans stop thus allowing the heated vapor to defrost any ice build up on the coil When the pressure is above the setting of the condenser pressure control switch HP2 the
20. condenser pressure control valve HGS2 is closed to prevent additional pressure rise in the system When pressure is below the setting of the condenser pressure control switch the valve is opened to pressurize the receiver and force additional refrigerant into the system and increase heating capacity 62 10891 IF FITTED QUENCH VALVE HEAT CHECK BPV VALVE FILTER DRIER SIGHT GLASS CONDENSER RECEIVER GAS SOLENOID VALVE HGS1 SERVICE SE FITTING CONTROL IF VALVE FITTED HGS2 UCTION DISCHARGE MUFFLER gt m 4 o HP2 DISCHARGE DISCHARGE Y ACCESS VALVE CHECK M VALVE QUENCH THERMOSTAT ee HIGH PRESSURE VAPOR ROAD HIGH PRESSURE LIQUID COMPRESSOR c LIQUID INJECTION LINE mF LOW PRESSURE VAPOR LOW PRESSURE LIQUID Figure 1 5 Refrigeration Circuit Cooling Cycle 62 10891 1 10 IF FITTED CHECK QUENCH VALVE vere VALVE BPV CCHANGER OPTION A FILTER DRIER SIGHTGLASS CONDENSER RECEIVER HOT GAS SOLENOID SERVICE COND VALVE HGS1 id FITTING PRESS CONTROL FITTED HANE HGS2 SUCTION DISCHARGE MUFFLER ER H HP2 He DISCHARGE DISCHARGE ACCESS VALVE CHECK VALVE QUENCH THERMO STAT BPT ou HIGH PRESSURE VAPOR ROAD c LIQUID INJECTION LINE C
21. covered herein WARNING Beware of unannounced starting of the unit The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate Press OFF key on the cab command and disconnect power plug 4A WARNING Under no circumstances should anyone attempt to repair the microprocessor components or Cab Command 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 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 different voltage levels and at extremely low current levels Improper use of voltmeters jumper Wires continuity testers etc could permanently damage the processor CAUTION Most electronic components are susceptible to damage caused by electrical static discharge ESD In certain cases the human body can have enough static electricity to cause resultant damage to the components by touch This is especially true of the integrated circuits found on the microprocessor Use proper board handling techniques See Section 4 14 6 1 62 10891 6801 29 0 9
22. lamps or al ternate sources of heat may be used to raise system temperature d Additional time may be saved during a complete sys tem evacuation by replacing the filter drier with a section of copper tubing and the appropriate fittings Installation of a new filter drier may be performed during the charging procedure 62 10891 4 5 3 Procedure For Evacuation And Dehydrating System a Remove refrigerant using a refrigerant recovery sys tem b The recommended method to evacuate and dehy drate the system is to connect three evacuation hoses to the vacuum pump and refrigeration unit as shown in Figure 4 2 Do not use standard service hoses as they are not suited for evacuation pur poses as shown in to the vacuum pump and refrig eration unit Connect an evacuation manifold with special evacuation hoses to the vacuum pump elec tronic vacuum gauge and to the refrigerant recovery system c Make sure vacuum gauge valve is closed and vacuum pump valve is open d Test the evacuation system for leaks by backseating the king valve or closing the field coupler connected to the liquid line charging port turning suction and discharge access valves counter clockwise to close and drawing a deep vacuum with the vacuum pump and gauge valves open Shut off the pump and check to see if the vacuum holds Repair leaks if necessary e Midseat king valve or field couple connected to the liq uid line charging port Turn suction a
23. may occur 44 WARNING Ensure vehicle engine is OFF and negative battery cable is disconnected before replacing compres sor CAUTION Under no circumstances should anyone attempt to repair the microprocessor components or Cab Command Should a problem develop with these components contact your nearest Carrier Tran sicold dealer for replacement 62 10891 Safety 2 CAUTION If starting unit for the first time after installation the compressor pressure regulating valve will need to be reset CAUTION If starting unit for the first time after installation or starting after adding removing an optional feature or if Owners operating parameters have changed the Configuration will need to be reset CAUTION Compressor failure will occur if inert gas brazing procedures are not used on units with R404A and POE oil For more information see Technical Procedure 98 50553 00 Inert Gas Brazing CAUTION To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before disconnecting CAUTION When working with refrigerant use safety glasses and gloves to avoid burns Hoses and copper tub ing can be hot when unit is running CAUTION Refrigerant R404a is a blend Charging as a vapor will change the properties of the refrigerant Only liquid charging through the king valve is acceptable CAUTION Do not damage or over tighten the e
24. will oper ate under the control of the condenser pressure con trol switch HP2 If the engine coolant option is installed the optional heaters will also be energized See Section 1 8 2 for a description of the refrigera tion circuit during heat and defrost 3 1 5 4 F 3 C or43 6 F 2 C or 41 8 F 1 C UNIT STOPPED SETPOINT 1 8 F 1 C or 3 6 2 C or 5 4 3 C setting Figure 3 1 Operating Sequence Perishable Mode 3 1 2 Frozen Mode The unit operates in the frozen mode with setpoints at or below 10 F 12 C Operation in the frozen mode is the same as in the perishable mode except no heating takes place 5 4 F 3 C or43 6 2 C or 41 8 F 1 C SETPOINT 1 8 F 1 C or 3 6 2 C or 5 4 3 C setting UNIT STOPPED Figure 3 2 Operating Sequence Frozen Mode 62 10891 3 2 DEFROST CYCLE Defrost is an independent cycle overriding cooling and heating functions in order to melt frost and ice from the evaporator when necessary Defrost may be initiated by the microprocessor or manually by the operator In defrost mode the microprocessor displays dF on the cab command and setpoint is no longer displayed 62 10891 3 2 During defrost the evaporator fans shut down and operation of the condenser fan is controlled by the microprocessor See Section 1 8 2 for a description of the refrigeration circuit during heat and defrost 3 3 MINIMUM OF
25. CAUSES SECTION 5 2 10 Expansion Valve Low refrigerant charge External equalizer line plugged Low suction pressure with high Broken capillary superheat Superheat setting too high ouperheat setting too low Low superheat and liquids lug External equalizer line plugged ging in compressor Pin and seat of expansion valve eroded or held open by foreign material Improper bulb location or installation 4 12 Fluctuating suction pressure Insulation missing from sensing bulb Replace Low superheat setting 4 12 2 High superheat Expansion valve setting 4 12 2 5 2 11 Malfunction Hot Gas Solenoid Condenser Pressure Regulating Valve or Quench Valve No power to valve Improper wiring or loose connections SAG Dn exc eat T oil or coil sleeve improperly assemble Valve does not function properly Movement of plunger restricted due to a Corroded or worn parts b Foreign material lodged in valve c Bent or dented enclosing tube Valve shifts but refrigerant Foreign material lodged under seat continues to flow Defective seat 62 10891 5 4 SECTION 6 ELECTRICAL SCHEMATIC WIRING DIAGRAM 6 1 INTRODUCTION This section contains Electrical Schematic Wiring Diagram covering the Models listed in Table 1 1 The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual They are recommended precautions that must be understood and applied during operation and maintenance of the equipment
26. CAUTIONS Beware of unannounced starting of the unit This unit is equipped with Auto Start The unit may start at any time When performing any check of the system make the unit is turned off and the battery power supply is disconnected Be sure unit is turned off before working on motors controllers solenoid valves and electrical control switches Tag vehicle ignition to prevent accidental energizing of circuit Do not bypass any electrical safety devices e g bridging an overload or using any sort of jumper wires Problems with the system should be diagnosed and any necessary repairs performed by qualified service personnel When performing any arc welding on the unit or container disconnect all wire harness connectors from the microprocessor Do not remove wire harness from the modules unless you are grounded to the unit frame with a static safe wrist strap In case of electrical fire turn unit off and extinguish with CO never use water REFRIGERANTS The refrigerant contained in your unit can cause frostbite severe burns or blindness when in direct contact with the skin or eyes For this reason and because of legislation regarding the handling of refrigerants during system service we recommend that you contact your nearest Carrier Transicold authorized repair facility whenever your unit requires refrigeration system service Safety 1 62 10891 SPECIFIC WARNING AND CAUTION STATEMENTS To help identify the label hazards on
27. Cab Command Malfunction 5 4 Checking The Eeprom Version 2 5 Checking the Refrigerant Charge 4 5 Clearing Alarm Messages 2 5 Compressor 1 3 Compressor Pressure Regulating Valve 4 8 Compressor Pressure Regulating Valve 1 4 Condenser Coil Cleaning 4 9 Condenser Fan Motor 1 10 Condenser Fan Motor Brushes 4 7 Condenser Pressure Control Solenoid 4 7 Condenser Pressure Control Valve 1 10 Condenser Pressure Control Valve 1 3 Condenser Pressure Switch 4 6 Condenser Pressure Switch 1 4 Condenser Pressure Switch HP2 1 9 Condenser Subcooler 1 1 Connect Power 2 3 Control System 2 1 Cooling 1 12 D Defrost Cycle 2 3 3 2 Defrost Malfunction 5 3 Defrost Termination Thermostat 1 9 Defrost Timer 1 9 INDEX Description 1 1 Diagnostic Tool 4 9 E Electrical Data 1 10 Evacuation and Dehydrating System 4 4 Evacuation And Dehydration 4 4 Evaporator 1 4 Evaporator Coil Cleaning 4 9 Evaporator Fan Motor 1 10 Expansion Valve 5 4 Filter Drier 1 1 FILTER DRIER 4 6 Frozen Mode 3 1 H Heat And Defrost 1 12 High Pressure Safety Switch 1 4 High Pressure Switch 4 6 Hot Gas Solenoid 4 7 Hot Gas Valve 1 10 Hot Gas Valve 1 1 3 Inspection 2 2 Installing a Complete Charge 4 5 Insufficient Cooling 5 2 L Low Battery Alarm 2 5 Low Pressure Switch 1 4 Maintenance Schedule 4 1 Manual Defrost 2 3 Microprocessor 4 9 Minimum Off Time 3 2 Index 1 62 10891 N No
28. F TIME Once the unit has cycled off it will remain off for the minimum off time of 5 minutes This prevents rapid cycling due to changes in air temperature Air temperature in the box changes rapidly but it takes time for the product temperature to change SECTION 4 SERVICE 4A WARNING Beware of unannounced starting of the unit The unit may cycle the fans and compressor unexpect edly as control requirements dictate Press OFF key on the cab command CAUTION Compressor failure will occur if inert gas brazing procedures are not used on units with R404a and POE oil For more information see Technical Procedure 98 50553 00 Inert Gas Brazing NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing refrigerant When working with refrigerants you must comply with all local government environmental laws U S A EPA section 608 4 1 MAINTENANCE SCHEDULE Regular servicing is required in order to optimize the life and reliability of your unit The recommended scheduled maintenance intervals and categories are provided in Table 4 1 while descriptions of the service procedures to be carried out under each category are provided in Table 4 2 Table 4 1 Maintenance Schedules 100000005 3 18 36 54 72 90 108 126 oin on so oo ooo ooo aoo ono eee 8 eee SevieD P Pi I Refrigerant Type R404a
29. HOOTING WARNING Beware of unannounced starting of the unit The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate Press OFF key on the cab command and turn vehicle engine off CAUTION Under no circumstances should anyone attempt to service the microprocessor module and cab com mand Should a problem develop with the control system contact your nearest Carrier Transicold dealer for replacement components 5 1 INTRODUCTION Under normal circumstances unit problems will be indicated by an active alarm in the alarm list Suggested troubleshooting actions for each alarm indication are provided in Table 5 1 Suggested corrective actions for mechanical type problems are listed under subject headings in Table 5 2 Table 5 1 Alarm Indications m Reference ALARM CORRECTIVE ACTION Paragraph No Wicomponensiuionngnomaly i aor 9 A02 A Verify operation of evaporator fans 2 780077 Alternating Alarm High Pressure Switch HP1 Verify operation of condenser fan Open Compressor Clutch CLHR Current draw of road clutch coil either high or low Malfunction Verity motor rotates rey high amp draw Repacemoor Evaporator Fan Motor EFM Verify motorrotates trey Replacemotor pee E MEME 2 Condenser Fan Motor CFM Quench Valve BPV Current draw of coil high or Tow approx 1 2
30. OMPRESSOR om LOW PRESSURE VAPOR Figure 1 6 Refrigeration Circuit Heating And Defrost Cycle 1 11 62 10891 SECTION 2 OPERATION 2 1 2 1 1 CONTROL SYSTEM Introduction CAUTION Under no circumstances should anyone at tempt to service the microprocessor com ponents or Cab Command Should a prob lem develop with the control system contact your nearest Carrier Transicold dealer for replacement components The Control System consists of the microprocessor Figure 1 2 Cab Command Figure 2 1 and intercon necting wiring a The Microprocessor includes the temperature control software and necessary input output circuitry to inter face with the unit controls b The Cab Command is remotely mounted in the truck The Cab Command includes the LCD display and keypad The keypad and display serve to provide user access and readouts of microprocessor infor mation The information is accessed by keypad selections and viewed on the display 2 1 2 Microprocessor Module The microprocessor controls the following functions a Maintains the box temperature at setpoint by regu lating the cooling heat off mode and automatic de frost cycles b Permanently displays the return air temperature and on request the setpoint temperature c Digital display and selection of data For further details on digital message display see section 2 5 2 1 3 Cab Command The Cab Command is mounted in the cab and allows the dr
31. OOL Figure 4 9 Cab Command Diagnostic Tool CTD P N 07 00440 00 a lesting a cab command cable that is already installed on the unit and routed into the truck cab re quires the use of both pieces of the diagnostic tool b Unplug the cab command cable from the micropro cessor and also from the back of the cab command module c Plug one end of the cable into the primary tool and the other end into the remote tool d Begin the test by turning on the power switch and ob serving the sequence of green lights As each circuit is tested the corresponding light is illuminated If a fault is found in the cable the light that corresponds to that particular circuit is not illuminated e To test a cable that is not installed on a unit simply plug each end of the cable into the primary tool and perform the test as above 62 10891 4 14 MICROPROCESSOR 4X WARNING Under no circumstances should anyone at tempt to repair the microprocessor module or Cab Command Should a problem devel op with these components contact your nearest Carrier Transicold dealer for re placement Although there is less danger of electrical static discharge ESD damage in the outdoor environment where the processor is likely to be handled proper board handling techniques should 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 b
32. Refrigerant charge Refer to Table 1 1 e Compressor Pressure Regulating Valve CPR At end of defrost 28 1 psig 1 91 Bar f Thermostatic Expansion Valve TXV Superheat setting at commissioning 8 C at box temperature of 0 C 4 C at box temperature of 20 C g Low Pressure switch LP Cutout at 5 7 inHG 3psig 0 19 bar Cut in at 414 5 psig 3 psig 1 bar h Quench Thermostat BPT Opens at 260 F 127 C Closes at 212 F 105 C 1 6 3 Electrical Data a Fan Motors Evaporator Fan Motor EFM Condenser Fan Motor CFM Bearing Lubrication Factory Lubricated Bearing Lubrication Factory Lubricated OMM Operating Amps ioSamps Operating Amps 2100 rpm rated 3300 rpm b Compressor Clutch CLHR Amp Draw 3 75A Resistance 3 29 c Hot Gas Solenoid Valve HGS1 Coil Amp Draw 1 33 Amp Resistance 9 29 d Condenser Pressure Control Valve HGS2 Coil Amp Draw 1 65 Amp Resistance 7 3Q e Quench Valve BPV Coil Amp Draw 1 16 Amp Resistance 10 3Q 1 6 4 Torque Values Assembly fib gm Mounting Bolts 44 to 60 i7 62 10891 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 following fuses and safety devices Automatic re restart Unsafe Conditions Safety Device with fault Device setting cleared 1 Excessive dro
33. TC INSULATING PLUG COMPONENT CONNECTION NUMBER OR LETTER LOCATION IN UNIT EVAPORATOR ROAD COMPRESSOR EVAPORATOR CAB CONDENSER ENGINE COMPARTMENT EVAPORATOR VEHICLE BATTERY ENGINE COMPARTMENT CONDENSER CONDENSER CONDENSER CONDENSER CONDENSER EVAPORATOR Figure 6 1 Electrical Schematic Wiring Diagram Based On Dwg No 62 61350 Rev E 6 9 6801 29 VBAT ue 16V COMP 20V COMP VOLTAGE
34. WIC IM a ut tech Be Peed elk eee tira la ut ee 4 7 4 9 2 Checking Pressure 1 4 7 4 10 HOT GAS SOLENOID VALVE HGS1 CONDENSER PRESSURE CONTROL VALVE HGS2 AND QUENCH VALVE BPV 2 6546 tino ate edad cs Bed wander big 4 8 4 10 1 Replacing Solenoid Ade 4 8 4 10 2 Replacing Valve Internal Parts kc ain 4 8 4 11 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE CPR 4 8 4 12 THERMOSTATIG EXPANSION VALVE 54 255 e ute et a IUIS iR s 4 9 4 12 1 REDIACING expansion ValVe 43 x on eee em eene e ec ee elas 4 9 4 122 Measuring SUDEINCAL 5 aq t o dot on On s e Pen D Rat Rem Som ra 4 9 4d3 DIAGNOSTIC TOOL 5 2 gatur ael 4 9 214 MIGROPROGESSOR ario eiie eb tosta e d pe oh Eee tei 4 10 4 15 EVAPORATOR COIL CLEANING 4 10 4 16 CONDENSER COIL CLEANING bI HERE een ote de cR Ec eee t oct s 4 10 TROUBLESHOOTING 2255 RUSSE DSi ve Ic 5 1 On INTRODUCTION a unter des tcc dide bene do ien d opti red 5 1 52 RERRIGERATION
35. ardboard dust but to remove any grease oil film which sometimes coats the 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 Spray coil with a mild detergent solution such as any good commercial grade automatic dish washer de tergent 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 Make sure drain lines are clean Run unit until defrost mode be initiated to check for proper draining from drain pan 4 16 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 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 Table 4 3 R 404a Temperature Pressure Chart Temperature Pressure 15 T 45 99 129 163 Psg Bar 12 7599 702 96 947 0 8 60 m 48 7105 105 428 420 150 66 4540 3192 3130 4 11 62 10891 SECTION 5 TROUBLES
36. d 2 clamps Carrier Transicold P N 34 60019 02 in liquid line before continuing with leak check ing or charging instructions Refer to Figure 4 2 1 3 7 High Pressure Switch HP1 HP1 is a normally closed switch which monitors the system for high pressure and shuts down the unit when pressure rises above predetermined setting For HP1 settings see Section 1 6 2 1 3 8 Condenser Pressure Control Switch HP2 HP2 is a normally open switch which closes to signal the microprocessor to activate the condenser fan HP2 also cycles the condenser pressure control valve HGS2 and the quench valve BPV in addition to the condenser fan in order to maintain discharge pressure for heating capacity For HP2 settings see Section 1 6 2 1 5 1 4 EVAPORATOR SECTION The evaporator assembly consists of an evaporator fan evaporator coil thermostatic expansion valve defrost termination thermostat low pressure switch a compressor pressure regulating valve and a quench valve 1 4 1 Thermostatic Expansion Valve The thermostatic expansion valve is an automatic de vice which controls the flow of liquid to the evaporator according to changes in superheat of the refrigerant leaving the evaporator The thermal expansion valve maintains a relatively constant degree of superheat in the gas leaving the evaporator regardless of suction pressure Thus the valve has a dual function automatic expansion control and preventing liquid from returning
37. e Switch HP 5 oid oOx E Ee ERI RR RENS 1 5 1 3 8 Condenser Pressure Control Switch 2 1 5 14 EVAPORATOR SECTION 33 51 32 25 2 9 2 Mich ety aeuo tut 1 5 1 4 1 Thermostatic Expansion Valve da m edd EE Ed vec RR DEOR 1 5 1 4 2 Compressor Pressure Regulating Valve CPR 1 5 1 43 Quench Valve BPV ica tris dot bia abren e x a T ENS ARE KR 1 5 TAA Evaporator Oll so o d o oct Aeon del dd ae Ae cet ar etta o a 1 5 1 4 5 Low Pressure Switch LP siue ng e Ru ce x aee rece po Se 1 5 L G Teal ua eaae ed DU ad e au AO nd 1 5 1 5 SYSTEM OPERATING CONTROLS AND COMPONENTS 1 6 e AUINVT SPECIFICATIONS utm ES pa EX Ep EIE pias ee vidis eed ee soe as 1 6 Ld Compressor Bald tne Sabor aet dedo na denim ef Medrano autos dh dtes tiat o nef 1 6 1 6 2 Refrigeration System REED Reo ee ek tet du scu s 1 6 JEICCIIGAID OI de cio tha En tu RAS X end acne ah 1 7 164 ban dedere shed e ciet aD be hades mek ded 1 7 3
38. e reciprocating compressor air cooled con denser thermostatic expansion valve direct expansion evaporator and hot gas solenoid two way The compressor raises the pressure and temperature of the refrigerant and forces it into the condenser tubes The condenser fan circulates surrounding air over the outside of the condenser tubes Heat transfer is thus established from the refrigerant gas inside the tubes to the air ambient 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 to the receiver The refrigerant then flows through the filter drier where an absorbent keeps it dry and clean The refrigerant then flows through a sight glass with moisture indication to the check valve and then to the liquid gas heat exchanger The liquid then flows to the thermostatic expansion valve with external pressure equalizer which regulates the flow rate of refrigerant in the evaporator in order to obtain maximum use of the evaporator heat transfer surface The evaporator tubes have aluminium fins to increase heat transfer therefore heat is removed from the air cir culated through the evaporator This cold air is circu lated throughout the refrigerated compartment to main tain the box at the desired temperature 1 9 The transfer of heat from the air to the low temperature liquid refrigerant
39. ection 1 6 2 f 4 12 2 Measuring Superheat a Remove insulation from expansion valve bulb and suction line See Figure 4 8 b Loosen one T XV bulb clamp and make sure area un der clamp above bulb is clean c Place thermocouple above parallel to the TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in Figure 4 8 d Connect an accurate gauge to the 7 port on the suc tion service valve e Run unit until stabilized at 4 F 20 C box tempera ture f From the temperature pressure chart Table 4 3 de termine the saturation temperature corresponding to the evaporator outlet pressure g Note the temperature of the suction gas at the expan sion valve bulb h Subtract the saturation temperature determined in otep f from the average temperature measured in otep g The difference is the superheat of the suction gas Refer to paragraph 1 6 2 for superheat setting 4 9 i If required adjust superheat by turning the adjusting screw located under the cap on the side of the valve 1 Nut and Bolt Clamp 4 TXV Bulb 2 Suction Line 5 Thermocouple end view 3 TXV Bulb Clamp Figure 4 8 Thermostatic Expansion Valve Bulb And Thermocouple 4 13 DIAGNOSTIC TOOL NOTE The Cab Command diagnostic tool comes with two jumpers These are not applicable to the 20X system and should not be used in this ap plication REMOTE TOOL PRIMARY T
40. eration Temperature controller malfunction 5 2 8 Hot gas solenoid malfunction HGS1 4 10 Compressor Compressor drive clutch defective Check Compressor defective Replace Compressor malfunction 5 2 5 Defrost Malfunction Defrost thermostat DTT open or defective Replace Automatic defrost will not initiate gas solenoid valve malfunction 4 10 Defrost disabled through cab command 2 8 1 Microprocessor defective Replace Defrost thermostat DTT open or defective Replace Defrost cycle initiates but does Hot gas solenoid malfunction HGS1 4 10 not defrost Condenser Pressure Control valve malfunction HGS2 4 10 Wet load FE reen Defrost settings set to low Does not terminate or cycles on Defrost thermostats DTT shorted closed ADIGE defrost Manual defrost will not initiate 62 10891 5 2 Table 5 2 Mechanical Indications Continued REFERENCE INDICATION TROUBLE POSSIBLE CAUSES SECTION 5 2 6 Abnormal Pressure 5 2 6 1 Cooling Condenser coil dirty Noncondensables in system Refrigerant overcharge Condenser fan motor defective Replace motor Compressor defective Replace Low discharge pressure Hot gas solenoid malfunction 4 10 Low refrigerant charge 4 6 1 Compressor defective Replace High suction pressure Hot gas solenoid malfunction 4 10 Compressor pressure regulator misadjusted CPR 4 11 4 8 Filter drier partially plugged Low refrigerant charge Low suction pressure Expansion valve malfunction
41. g clip then replace the filter drier Following drier replacement evacuate and recharge unit refer to sections 4 5 amp 4 6 4 9 HIGH PRESSURE HP1 AND CONDENSER PRESSURE HP2 SWITCHES 4 9 1 Removing Switch a ASCHRAEDER valve is located under each switch to allow removal and installation without removing the refrigerant charge b Remove switch and test in accordance with para graph 4 9 2 c Replace or reinstall switch 4 9 2 Checking Pressure Switch 4X WARNING Do not use a nitrogen cylinder without a pressure regulator See Figure 4 5 Cylin der pressure is approximately 2350 psig 160 bars Do not use oxygen in or near a refrigerant system as an explosion may oc cur Remove switch as outlined in paragraph 4 9 1 Connect ohmmeter across switch terminals Ohm meter will indicate resistance if switch is closed HP 1 or open HP2 after relieving pressure Connect switch to a cylinder of dry nitrogen see Figure 4 5 Set nitrogen pressure regulator higher than switch over point on switch being tested Pressure switch settings points are provided in paragraph 1 6 2 d Close valve on cylinder and open bleed off valve e Open cylinder valve While observing meter slowly Co Tes close bleed off valve and increase pressure until the switch opens HP1 or closes HP2 Slowly open bleed off valve to decrease pressure until switch re verts to normal position If switch d
42. g general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein The general safety notices are presented in the following three sections labeled First Aid Operating Precautions and Maintenance Precautions A listing of the specific warnings and cautions appearing elsewhere in the manual follows the general safety notices Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind During normal operation all moving parts are fully enclosed to help prevent injury During all pre trip inspections daily inspections and problem troubleshooting you may be exposed to moving parts Stay clear of all moving parts when the unit is in operation and when the ON OFF switch is in the ON position FIRST AID No injury no matter how slight should go unattended Always obtain first aid or medical attention immediately OPERATING PRECAUTIONS Always wear safety glasses Wear hearing protection as required Keep hands clothing and tools clear of the evaporator and condenser fans No work should be performed on the unit until the unit is turned off and the battery power supply is disconnected Always work in pairs Never work on the equipment alone In case of severe vibration or unusual noise stop the unit and investigate MAINTENANCE PRE
43. ht flashes at 1 Hz The light will continue to flash at 1 Hz until the alarm is cleared At that point the steady green indicator light will light and the alarm will become inactive 62 10891 2 2 b Keypad The keypad consists of six keys that enable the operator to activate various functions display operating data and modify operating parameters Unit shut down key The unit can also be shut down with the ignition key The SET key together with the and keys enables display and modification of unit operating data The display scrolls through parameters each time the SET key is pressed Decrease key for selected data Increase key for selected data 2 2 START UP 2 2 1 Inspection Before starting the truck engine check the following a Check condenser coil for cleanliness b Check condition of refrigerant hoses c Check condition and tension of compressor belt s d e f Check condition of condenser fan blades and motor Check truck battery fluid level Check truck battery and terminal connections clean and tighten as necessary Check defrost water drains from evaporator Check evaporator coil for cleanliness i Check condition of evaporator fan blades and motor 2 2 2 2 Starting CAUTION If starting unit for the first time after installa tion the compressor pressure regulating valve will need to be reset refer to para graph 4 11 CAUTION If starting unit f
44. ier Corporation D Printed in U S A 0405 Carrier A United Technologies Company Carrier Transicold Division Carrier Corporation Truck Trailer Products Group P O Box 4805 Syracuse N Y 13221 U S A www carrier transicold com
45. ipment Covered Type of Manual 62 10890 20X Parts List 62 10892 Direct Drive Truck Units With Cab Command Operator s Manual 62 10893 Direct Drive Truck Units With Cab Command Easy To Run T 62 10891 CAB COMMAND 9 10 11 12 I 2 Y i 1 i 1 Condenser Fan 7 Condenser Coil 2 Nameplate 8 Receiver 3 Hot Gas Solenoid Valve HGS1 9 Condenser Pressure Control Valve HGS2 4 Sight Glass 10 High Pressure Switch HP1 5 Control Box 11 Condenser Pressure Control Switch HP2 6 Frame 12 Filter Drier Figure 1 1 Condenser And Cab Command 62 10891 1 2 FAHRENHEIT CELSIUS JUMPER MICROPROCESSOR ROAD SUPPLY FUSE POSITIVE BATTERY CONNECTION NEGATIVE BATTERY CONNECTION Figure 1 2 Microprocessor 1 3 62 10891 1 Evaporator coil 12 Defrost Termination connector 2 Defrost Termination Thermostat DTT 13 Fan connector 3 Quench Valve BPV 14 Liquid Line Check Valve 4 Quench Valve Thermostat BPT 15 Liquid Line 5 Low Pressure Switch LP 16 Suction Line 6 Evaporator Fan Blower 17 Hot gas line 7 Heat Exchanger 18 Return Air Sensor 8 Defrost Element 19 Compressor Pressure Regulating Valve 9 Frame CPR 10 RAS sensor connector 20 TXV Schraeder 11 Quench Valve connector 21 Expansion Valve TXV Figure 1 3 Evaporator 62 10891 1 4 1 3 3 Hot Gas Solenoid Valve HGS1 HGS1 is normally closed and prevents discharge gas from entering the evaporator The
46. iver to carry out the control operations e manual start up and shut down of the unit e automatic start up of the unit e adjust the setpoint initiate manual defrost 2 1 The driver can display the box temperature and see whether the setpoint is being maintained by checking the green indicator The indicator lights up red in the event of a malfunction When the battery voltage is too low a fail safe system shuts down the unit Unit restart is automatic and time delayed if the voltage rises to the normal level TRANSICOCD Figure 2 1 Cab Command a Display The digital display consists of 3 alphanumeric characters The default value displayed is the box temperature The microprocessor enables selection of the display in degrees Celsius or Fahrenheit The display also includes settings for defrost operation dF The display also includes three LEDs Digital Display ef Standby operation LED Not applicable for units covered by this manual Road operation LED Unit operating LED D Green cycling left hand side D Red malfunction right hand side 62 10891 Unit operating LEDs Green Light Status Under normal operation the green LED will indicate the temperature control status as follows Steady green COOLING Green LED is SETPOINT Green LED flashing 1 Hz HEATING Figure 2 2 Green Light Status Red Light Status When an alarm has been detected the red unit indicating lig
47. l the warm liquid refrigerant This results in greater system efficiency and helps to prevent liquid refrigerant return to the compressor 62 10891 1 5 SYSTEM OPERATING CONTROLS AND COMPONENTS The unit is furnished with a microprocessor control sys tem Once the setpoint is entered at the Cab Command the unit will operate automatically to maintain the de sired temperature within very close limits See 2 1 1 4X WARNING Beware of unannounced starting of the evaporator or condenser fans The unit may cycle fans unexpectedly as control require ments dictate CAUTION Under no circumstances should anyone at tempt to repair the microprocessor module or Cab Command Should a problem devel op with these components contact your nearest Carrier Transicold dealer for re placement IRANSICOLD Figure 1 4 Cab Command 62 10891 1 6 1 6 UNIT SPECIFICATIONS 1 6 1 Compressor Data 022 TMIB _ Displacement Gere un 4 8 lbs 6 7 k Oil Charge 0 422 pint 200 ml Approved Oil Carrier POE 46 60002 02 1 6 2 Refrigeration System Data a Defrost Timer Automatic triggering or at preset intervals 0 Disabled auto 1h 2h 3h 4h 5h 6h b High Pressure Switch HP1 Cutout at 465 psig 10 psig 32 bars Cut in at 360 psig 10 psig 25 bars c Condenser Pressure Control Switch HP2 Cutout at 245 psig 10 psig 17 bars Cut in at 329 psig 10 psig 22 bars d
48. layed The minimum setpoint can be selected by Sup through available options 20 F 28 9 C 20 C 32 F 0 C using the or keys Piu setting is 20 F Selection MUST be validated by pressing the SET key b The null mode differential temperature is displayed next This setting determines the temperature differ ence between box temperature and setpoint that con trols compressor cycling The differential can be se lected by scrolling through available options 1 8 F 1 C 3 6 F 2 C or 5 4 F 3 C using the or keys Factory setting is 3 6 F 2 C Selection MUST be validated by pressing the SET key c The ON OFF Continuous airflow parameter for the evaporator fan is displayed next This feature deter mines whether the evaporator fan is on or off when the unit cycles off upon reaching setpoint The AR setting is OFF Change setting by using the or Ao ENS Selection MUST be validated by pressing the key d The return air temperature will be displayed after the above sequence 62 10891 SECTION 3 TEMPERATURE CONTROL 3 1 SEQUENCE OF OPERATION General operation sequences for cooling null and heating are provided in the following paragraphs The microprocessor automatically selects the mode necessary to maintain box temperature at setpoint 3 1 1 Perishable Mode Theunit operates in the perishable mode with set points above 10 F 12 C a With return air temperature above
49. linder King Valve Access Port King Valve Liquid Line Charging Port Figure 4 4 Procedure For Adding A Partial Charge 1 Suction Valve Low Side 2 Manifold Gauge Set 3 Discharge Valve High Side 4 Dead Head Port 62 10891 4 6 4 7 CHECKING FOR NON CONDENSABLES To check for non condensables proceed as follows a Stabilize system to equalize pressure between the suction and discharge side of the system b Check temperature at the condenser and receiver c Check pressure at the king valve access port or the liquid line charging port d Check saturation pressure as it corresponds to the condenser receiver temperature using the Tempera ture Pressure Chart Table 4 3 e If gauge reading is 3 psig 0 2 Bar or more than the calculated P T pressure in step d non condens ables are present f Remove refrigerant using a refrigerant recovery sys tem Refer to section 4 3 g Evacuate and dehydrate the system Refer to sec tion 4 5 h Charge the unit Refer to section 4 6 4 8 CHECKING AND REPLACING FILTER DRIER 4 8 1 Checking Filter Drier Check for any obstruction of the filter drier by feeling the inlet and outlet connections of the liquid line on the filter cartridge If the temperature of the outlet connection seems lower than the temperature of the inlet connection replace the filter drier 4 8 2 Replacing The Filter Drier Remove refrigerant charge See section 4 3 Remove the drier mountin
50. m Leave gauges and hoses in place and refer to para graph 4 6 3 e If scale indicates the correct charge has been added close liquid line valve on drum and manifold valves f Backseat the king valve or field coupler attached to liquid line charging port Remove charging hoses and check charge in accordance with paragraph 4 6 1 g Start unit and check for non condensables See 4 7 Suction Valve Low Side Manifold Gauge Set Discharge Valve High Side Dead Head Port Refrigerant Cylinder King Valve Access Port King Valve Liquid Line Charging Port N O Figure 4 3 Procedure for Adding A Complete Charge 62 10891 4 6 3 Adding A Partial Charge a Check sight glass to determine charge See 4 6 1 If undercharged proceed with step b CAUTION Refrigerant R404a is a blend Charging asa vapor will change the properties of the re frigerant Only liquid charging through the king valve is acceptable NOTE If receiver king valve is not equipped with a ser vice access port install the charging connec tion kit Carrier Transicold P N 76 61188 00 in liquid line before continuing with leak check ing or charging instructions Refer to Figure 4 2 NOTE The ambient air entering the condenser air temperature should be above 40 F 4 4 C Place drum of refrigerant on scale and note weight Backseat suction and discharge access valves and install a manifold gauge set i
51. n order to monitor sys tem Purge lines Connect the field coupler of the dis charge gauge of a second manifold test set to the king valve access port or liquid line charging port Connect the suction pressure hose to the manifold dead head port Connect a charging line between the center tap of the second gauge set and the refrigerant drum Midseat discharge knob Open the liquid valve on the drum and purge all hoses Frontseat discharge knob See Figure 4 4 otart unit with compressor turning at 2400 rpm Frontseat the king valve Monitor the second set of manifold gauges When the king valve pressure drops below the pressure in the refrigerant drum mid seat the manifold gauge set discharge valve and al low liquid refrigerant to flow into the system While monitoring the sight glass carefully weigh re frigerant into the system It is not possible to accu rately determine when the system is full because unit is in discharge state therefore never allow more than 0 5 Ib 0 23 kg of refrigerant into system at a time f After monitoring 0 5 Ib 0 23 kg of refrigerant into the system close the valve of the manifold gauge set connected to the king valve Open the king valve and allow the system to balance out to determine charge Follow the procedures of Section 4 6 1 and repeat above procedure as required to clear the sight glass Start unit and check for non condensables N O Refrigerant Cy
52. nclosing tube assembly Place all parts in the enclosing tube in proper sequence in order to avoid premature coil burn out CAUTION Observe proper polarity when installing battery Negative battery terminal must be grounded Safety 3 62 10891 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 differ ent voltage levels and at extremely low current levels Improper use of voltmeters jumper wires con tinuity testers etc could permanently damage the processor CAUTION Most electronic components are susceptible to damage caused by electrical static discharge ESD In certain cases the human body can have enough static electricity to cause resultant damage to the components by touch This is especially true of the integrated circuits found on the microprocessor Use proper board handling techniques See Section 4 14 62 10891 Safety 4 SECTION 1 DESCRIPTION 1 1 INTRODUCTION WARNING Beware of unannounced starting of the unit The unit may cycle the fans and com pressor unexpectedly as control require ments dictate Press OFF key on the Cab Command This manual contains Operating Data Electrical Data and Service Instructions for the Carrier Transicold Model 20X truck refrigeration units listed in Table 1 1 Additional suppo
53. nd discharge ac cess valves clockwise to open f Open the vacuum pump and electronic vacuum gauge valves if they are not already open Start the vacuum pump Evacuate unit until the electronic vac uum gauge indicates 2000 microns Close the elec tronic vacuum gauge and vacuum pump valves Shut off the vacuum pump Wait a few minutes to be sure the vacuum holds g Break the vacuum with 404a Raise system pressure to approximately 2 psig 0 14 Bar 2 Remove refrigerant using a refrigerant recovery sys tem Repeat steps f through h j If required remove the copper tubing and install a new filter drier Evacuate unit to 500 microns Close off vacuum pump valve and stop pump Wait five min utes to see if vacuum holds This checks for residual moisture and or leaks x With a vacuum still in the unit the refrigerant charge may be drawn into the system from a refrigerant con tainer on a scale See Table 1 1 for correct charge Continue to Section 4 6 2 46 CHARGING THE REFRIGERATION SYSTEM CAUTION Refrigerant R404a is a blend Charging as a vapor will change the properties of the re frigerant Only liquid charging through the king valve is acceptable NOTE If receiver king valve is not equipped with a ser vice access port install the charging connec tion kit Carrier Transicold P N 76 61188 00 in liquid line before continuing with leak check ing or charging instructions Refer to Figure 4 2
54. ne alarm press the or keys to list them 2 5 2 Low Battery Voltage Alarms There is a 40 second time delay during start up After this delay if the battery voltage drops below 10 5V 0 5V the microprocessor will react 20 seconds later and the unit will go out of temperature control mode The microprocessor will check the voltage after another 20 seconds If battery voltage still has not risen the unit will remain out of temperature control mode for another 10 minutes the battery alarm will be activated and the Cab Command will display the message Unit will return to temperature control mode if battery voltage has risen after 10 minutes If the battery voltage has not risen after this 10 minute period the unit will remain out of temperature control mode another 2 minutes and the microprocessor will check the battery voltage every 2 minutes Unit will return to temperature control mode in its current configuration when battery voltage rises to 10 5V 0 5V 62 10891 Table 2 1 Alarm Messages Malfunction ALARM ALARM AND UNIT SHUT Red LED flashes No malfunction Unit in operation Condenser fan motore x Evaporator tan motore x Ai Condenser pressure contol vave 4050 x o o o Setpoint adjusted out of the range 20 2 to A15 86 F 29 C 30 C or below the programmed X low threshold EE Probe malfunction or evaporator temperature X out of limits 49 to 174 F 45 to 79 C Set
55. oes not activate within tolerances provided replace switch Test new switch before installation Cylinder valve and gauge Pressure regulator Nitrogen cylinder Pressure gauge 0 to 400 psig 0 to 28 bars Bleed off valve 1 4 inch connection Figure 4 5 Typical Setup For Testing Pressure Switches HP1 And HP2 62 10891 4 10 HOT GAS SOLENOID VALVE HGS1 CONDENSER PRESSURE CONTROL VALVE HGS2 AND QUENCH VALVE BPV 4 10 1 Replacing Solenoid Coil It is not necessary to remove the refrigerant charge to replace the coil see Figure 4 6 a Remove coil snap cap voltage plate and coil assem bly Disconnect leads and remove coil junction box if necessary b Verify coil type voltage and frequency This informa tion appears on the coil voltage plate and the coil housing c Place new coil over enclosing tube and then install voltage plate and snap cap Snap cap Voltage plate Coil assembly Enclosing tube Plunger assembly Valve body assembly Direction of flow RON gt oo Figure 4 6 Hot Gas Valve Condenser Pressure Control Valve or Quench Valve Hot Gas Valve Shown 4 10 2 Replacing Valve Internal Parts a Remove the refrigerant charge See Section 4 3 b Remove coil snap cap voltage cover and coil assem bly Remove the enclosing tube c Check for foreign material in valve body d Check for damaged plunger and o ring If o ring is to be replaced always put refrigerant oil on o rings be
56. or the first time after installa tion or starting after adding removing an optional feature or if Owners operating pa rameters have changed the Configuration will need to be reset refer to paragraph 2 8 Start the vehicle engine Press the ON key to start the unit Start up is time delayed for 40 seconds The digital display of the Cab Command displays the box tem perature Check that temperature setpoint is correct by pressing the SET key The setpoint temperature is highlighted on the digital display 2 3 SETPOINT ADJUSTMENT T Displays the setpoint temperature Decrease the setpoint Increase the setpoint Validate setpoint temperature and return to display of box temperature NOTE If no key is pressed within 5 seconds of adjusting settings the system reverts to dis playing the box temperature Only validated changes are recorded 2 3 2 4 MANUAL DEFROST Check that box temperature is 40 F 4 4 C or lower Press manual defrost key to initiate manual defrost 2 5 ALARM DISPLAY In the event of a malfunction the unit will shut down and the Cab Command will display an error message or alarm message The message will remain displayed until the malfunction is corrected A listing of the error messages and alarm codes is provided in Table 2 1 2 5 1 Accessing Alarm Messages To access the alarm messages Press SET for 5 seconds ena bles access to alarm messages In the event of more than o
57. p in pressure Automatic reset of low Cutout 5 7 inHG 3psig pressure switch LP YES 0 19 bar Timer 5 min 2 Excessive current draw on all mi Electronic relay Self protected opening croprocessor outputs evaporator and condenser fan 3 Excessive current draw control Fuse on electronic board Self protected opening circuit 4 Excessive current draw motor Overload relay See electrical wiring diagram compressor 5 Excessive current draw evapora Electronic relay Self protected opening tor and condenser fan motors 6 Opens at 25 A 12 V Opens at 40 A 12 V Self protected openin Opens 311 F 155 C 7 Excessive current draw unit in Road Supply Fuse road operation 8 Excessive current draw unit in Main Road Fuse F1 2 road operation 9 Clutch malfunction road exces Electronic relay sive current draw 10 Clutch malfunction road insuffi Electronic relay Detection of min threshold cient current draw at 750 mA 11 Low battery voltage Cutout cut in at 10 V 12 Excessive current draw igni Fuse FI Opens 1 tion circuit Neiman a This fuse is located close to the vehicle battery 12 v Excessive compressor discharge Automatic reset of High T YES NO YES YES YES NO NO YES YES YES NO 62 10891 1 8 1 8 REFRIGERATION CIRCUIT 1 8 1 Cooling See Figure 1 5 When cooling the unit operates as a vapor compression refrigeration system The main components of the sys tem are th
58. point lower than maximum setpoint but in X the range of 20 F to 86 F 2 6 CHECKING THE EEPROM VERSION 2 7 STOPPING THE UNIT Start up unit P Press the OFF key or turn the ignition key to off position Press the SET key for 5 seconds Press again to display eeprom version number 00 01 02 04 06 07 09 temperature 62 10891 2 4 2 8 MICROPROCESSOR CONFIGURATION CAUTION If starting unit for the first time after installa tion or starting after adding removing an optional feature or if Owners operating pa rameters have changed the Configuration will need to be reset 2 8 1 FUNCTIONAL SETTINGS The procedure for adjusting the functional parameters is as follows 1 The temperature display is selectable between Fahr enheit and Celsius Units are configured for Celsius from the factory To set the display to Fahrenheit the selection jumper must be removed and discarded See Figure 1 2 NOTE The board contains another set of pins similar to the Degrees C Degrees F selection jumper marked as J1 This jumper is not used for unit operation but it is used during the microproces sor controller manufacturing process DO NOT CONNECT THE J1 PINS TOGETHER The following steps must be performed with the unit OFF Shut down unit Hold both keys momentarily in order to display parameters Modify parameters See a
59. rapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before disconnecting 3 Turn the low side valve counter clockwise Remove the couplers from the access valves 4 Install both access valve caps Finger tight only Low Pressure High Pressure Gauge d Opened Frontseated Valve To High Side 1 Valve RED 1 Valve To Low Side E Valve BLUE p 4 YELLOW 4 5 Blue Knob Red Knob 1 Manifold Gauge Set 2 Hose Fitting 0 5 16 Acme 3 Refrigeration and or Evacuation Hose SAE J2196 R 134a 4 Hose Fitting w O ring M14 x 1 5 5 High Side Field Service Coupler 6 Low Side Field Service Coupler Figure 4 1 Manifold Gauge Set R 404a 4 3 REMOVING THE REFRIGERANT CHARGE Connect a refrigerant recovery system Carrier P N MVS 115 F L CT 115V or MVS 240 F L CT 240V to the unit to remove refrigerant charge See Figure 4 2 Refer to instructions provided by the CAUTION When working with refrigerant use safety glasses and gloves to avoid burns Hoses and copper tubing can be hot when unit is running NOTE Once the system is open it must be evacuated and dehydrated See section 4 5 NOTE To avoid damage the earth s ozone layer use a refrigerant recovery system whenever remov ing refrigerant manufacturer of the refrigerant recovery system Refrigerant Recovery Unit Suction Valve Lo
60. rt manuals are listed in Table 1 2 Remove the skins and look on the roadside of the unit to locate the model serial nameplate See Figure 1 1 1 2 GENERAL DESCRIPTION The unit Figure 1 1 is of the split system type with the condenser mounted outside the truck body evaporator mounted in the body and a Cab Command control center mounted in the driver s compartment One type of compressor drive is available D Road operation the road compressor is located in the engine compartment and is driven by the engine of the vehicle when in operation over the road 1 3 CONDENSING SECTION The condensing section see Figure 1 1 contains the condenser fan amp coil filter drier hot gas solenoid valve receiver and a condenser pressure control valve 1 3 4 Condenser Coil The condenser is of the tube and fin type and acts as a heat exchanger in which the compressed refrigerant gas is condensed into a liquid and lowered in tempera ture Air movement over the condenser is provided by a fan mounted in the condensing section 1 3 2 Filter Drier The drier is a cylindrical shell containing a drying agent and screen It is installed in the liquid line and functions to keep the system clean and remove moisture from the refrigerant Table 1 1 Model Chart Model No R404a cer Condenser Weight Evap Wt TRC120R03D Road Onl 13 66 2 Ib 30 kg 66 Ib 30 Kg Table 1 2 Additional Support Manuals Manual Number Equ
61. s in a system is with an electronic leak detector Carrier P N 07 00295 00 Testing joints with soap suds is only satisfactory for locating large leaks b Charge system with refrigerant to build up pressure between 30 to 50 psig 2 1 to 3 5 Bar Remove refrig erant cylinder and leak check all connections c Remove refrigerant using a refrigerant recovery sys tem See 4 3 and repair any leaks Evacuate and de hydrate the unit Refer to section 4 5 4 5 EVACUATION AND DEHYDRATION 4 5 1 General Moisture can seriously damage 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 of acids resulting in metal corrosion 4 5 2 Preparation a Evacuate and dehydrate only after pressure leak test Refer to section 4 4 b Essential tools to properly evacuate and dehydrate any system include a good vacuum pump 5 cfm 8m H volume displacement P N 07 001 76 01 anda good vacuum indicator such as a thermocouple vacu um gauge vacuum indicator Carrier P N 0700414 00 NOTE Use of acompound gauge is not recommended because of its inherent inaccuracy c Keep the ambient temperature above 60 15 6 C to speed evaporation of moisture If ambient temper ature is lower than 60 F 15 6 C ice might form be fore moisture removal is complete Heat
62. setpoint and de creasing the unit will be cooling with the compressor and evaporator fans operating See Section 1 8 1 for a description of the refrigeration circuit during cool ing The condenser fan will operate for the first three minutes after start up then operate under the control of the condenser pressure control switch HP2 The green unit operating LED will operate in accordance with Figure 2 2 b If discharge temperature increases to the setpoint of the quench thermostat BPT the thermostat will close energizing the quench valve BPV This will al low liquid into the suction line in order to cool com pressor Once the discharge temperature decreases to the setpoint of the BPT the thermostat will open DE energizing the BPV c Once temperature decreases to the setpoint the unit will enter the null mode If the continuous air flow pa rameter is set to ON the evaporator fans will continue to operate with all other components OFF If the con tinuous air flow parameter is OFF the evaporator fans and all other components will be OFF A 5 min ute delay is required before restart is allowed d If temperature increases during the null mode the unit will restart in cooling e If temperature continues to decrease the unit will en ter the heating mode with the compressor and evapo rator fans operating and the hot gas solenoid valve HGS1 energized open The condenser fan and condenser pressure control valve HGS2
63. the unit and explain the level of awareness each one carries an explanation is given with the appropriate consequences DANGER means an immediate hazard which WILL result in severe personal injury or death WARNING means to warn against hazards or unsafe conditions which COULD result in severe personal injury or death CAUTION means to warn against potential hazard or unsafe practice which could result in minor personal injury product or property damage The statements listed below are applicable to the refrigeration unit and appear elsewhere in this manual These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein 4 amp WARNING Beware of unannounced starting of the unit The unit may cycle the fans and compressor unexpect edly as control requirements dictate Press OFF key on the cab command WARNING Beware of V belt and belt driven components as the unit may start automatically 4A WARNING Ensure power to the unit is OFF and vehicle engine is OFF and negative battery cable is connected before replacing compressor 4A WARNING Slowly open the plug on the suction and discharge valves of the new compressor to vent the nitrogen holding charge 4X WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 psig 160 bars Do not use oxygen in or near a refrigerant system as an explosion
64. to the compressor For TXV superheat settings see Section 1 6 2 To adjust the TXV refer to Section 4 12 2 1 4 2 Compressor Pressure Regulating Valve CPR The CPR valve is installed on the suction line to regulate the suction pressure entering the compressor The CPR valve is set to limit the maximum suction pressure For CPR settings refer to section 1 6 2 1 4 3 Quench Valve BPV The quench valve is a normally closed solenoid valve controlled by the quench thermostat BPT mounted on the compressor discharge line The valve allows me tered liquid refrigerant to enter the suction line in the evaporator in order to provide compressor cooling For BPT settings refer to section 1 6 2 1 4 4 Evaporator Coil The evaporator is of the tube and fin type The operation of the compressor maintains a reduced pressure within the coil At this reduced pressure the liquid refrigerant evaporates at a temperature sufficiently low enough to absorb heat from the air Air movement over the evapo rator is provided by an electric fan 1 4 5 Low Pressure Switch LP The low pressure switch is a normally closed switch which signals the microprocessor to shut down the unit when the system is outside the low pressure limit For LP settings refer to section 1 6 2 1 4 6 Heat Exchanger The heat exchanger is of the tube in tube type connected in the main suction line and liquid line Within the heat exchanger the cold suction gas is used to coo
65. ut 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 When welding is required on the unit frame or on the front area of the truck ALL wiring to the microprocessor MUST be disconnected When welding is performed on other areas of the truck and van the welder ground connection MUST in close proximity to the area being welded It is also a 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 as the alternator and voltage regulator 62 10891 4 10 4 15 EVAPORATOR COIL CLEANING The use of recycled cardboard cartons is increasing The recycled cardboard cartons create much more fiber dust during transport than new cartons The 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 It is recommended to clean an the evaporator coil on a regular basis not only to remove c
66. valve opens to allow hot gas refrigerant to be delivered from the compressor to the evaporator during heat or defrost modes 1 3 4 Condenser Pressure Control Valve HGS2 The condenser pressure control valve or condenser closing valve is a normally open valve that is powered when the condenser pressure control switch HP2 is closed With the solenoid coil de energized the valve is in the cool mode and the compressor discharge gas is delivered to the condenser In the cool mode heat is removed from the air inside the truck body and rejected to the surrounding air With the solenoid coil energized the valve is in the heat mode and the compressor dis charge gas is diverted to the evaporator and rejected to the air inside the truck body 1 3 5 Compressor The compressor withdraws refrigerant gas from the evaporator and delivers it to the condenser at an in creased pressure The pressure is such that refrigerant heat can be absorbed by the surrounding air at ordinary temperatures 1 3 6 Receiver Liquid refrigerant from the condenser is delivered to the receiver The receiver serves as a liquid reservoir when there are surges due to load changes in the system as a storage space when pumping down the system and as a liquid seal against the entrance of refrigerant gas into the liquid line NOTE If receiver king valve is not equipped with a ser Vice access port install a charging connection Carrier Transicold P N 40 60059 02 an
67. w Side Evacuation Manifold Discharge Valve High Side Refrigerant Cylinder Electronic Vacuum Gauge 4 3 1 Removing Complete Charge Connect a refrigerant recovery system to the suction and discharge access valves to remove refrigerant charge Refer to instructions provided by the manufac turer of the refrigerant recovery system 4 4 REFRIGERANT LEAK CHECKING CAUTION Refrigerant R404a is a blend Charging asa vapor will change the properties of the re frigerant Only liquid charging through the king valve is acceptable NOTE If receiver king valve is not equipped with a ser vice access port install the charging connec tion kit Carrier Transicold P N 76 61188 00 in liquid line before continuing with leak check ing or charging instructions Refer to Figure 4 2 uma Vacuum Pump Vacuum Pump Valve King Valve Access Port 0 King Valve 1 Liquid Line Charging Port ON Figure 4 2 Vacuum Pump Connection 62 10891 A refrigerant leak check should always be performed after the system has been opened to replace or repair a component To check for leaks in the refrigeration system perform the following procedure NOTE Use only R404a to pressurize the system Any other gas or vapor will contaminate the system which will require additional purging and evacu ation of the high side discharge of the system The recommended procedure for finding leak

caution - Sunbelt Transport Refrigeration

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