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OPERATION & SERVICE MANUAL VECTOR 6600MT

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4. GENCON GEN OGF SP ZONE ACRONYM DESCRIPTION SPX C13 AAT AMBIENT AIR TEMP SENSOR G C m BROW SPY SPY SPY e 1 K7 B BUZZER U A H mH He c L3 BTY BATTERY 1 R SP54 SPZ SPZ SPZ BTYC BATTERY CHARGER E FAJAS 34 C6 ce 2CPT RUN STUP SWITCH COMPRESSOR PSR C SEN 1 z JE An x Sr 2 2 TIMED En a COMPRESSOR CONTACTOR RI 72 u v 14 27 12AMP TIMED 010 CoP COMPRESSOR DISCHARGE PRESSURE SENSOR cl Gi SP53 2 CDT COMPRESSOR DISCHARGE TEMPERATURE SENSOR 68 2 TIMED 2954 CDCUN CONDENSOR MOTOR CONTACTOR 2 t BUDE 4 CONDENSOR MOTOR 1 lu 55 come CONDENSOR MOTOR 2 H CONDENSATE HEATER EVAP 2 C T VIEW FROM INLET 5 COMPRESSOR SUCTION MODULATION VALVE sez L3 BROWN Dio CSP COMPRESSOR SUCTION PRESSURE SENSOR W Le BLACK NB E 1 cu esr COM
5. GEN B GENCON G Ls U A W M H T DGF R 4 SPX P Aik THREE SR BROW PHASE CHARGERS 5 2 CT3 SPY ONLY cw LY T T 5 54 SP Eat a 2 d 25 e SPX 013 SA TIMED Ly ma Mi Y Mov Jk 2 2 2ND BATTERY CHARGER SPY o 2 90 Ld Hi Gy w m low 3T T ENE ACRONYM 2 1 F26 12 ON B TIMED LH SES L1 SB 8 A Ji 2ND COMPARTMENT RU BTYC TIMED ERAT CUMPARTMENT RUN SWITCH FS E PARTMENT RI H A BAT TEMP Bg 28 1 14 3RD CO ETURN gt meae 2 eae en e cc EM ET EUM CS B BIENT AIR PLY AIR 57 1 5 5 5 8045 5 2 L3 BTY BUZZER TEMP SENSOR NSOR OPTIONAL 900 H li GND 2 777 ne Bryce BATTERY CHARGER ipe ACT 1 mes 1EVCIN RAIN IET
6. F G H I J K L M N 0 Q R T U V X Y GENCON GEN CT4 SPX THREE PHASE CHARGERS ONLY N SP SPX G BH BROW CT3 SPY Ser Ht ZONE ACRONYM DESCRIPTION c T OH SP54 SPZ Ez a ZND COMPARTMENT RUN SWITCH SPZ COMPARTMENT RUN SWITCH m iz F7 5A TIMED 8ND BATTERY CHARGER OPTION e 3 T3 14 2RAT 2ND COMPARTMENT RETURN AIR SENSOR PSR Is 12AMP TIMED 14 25 2ND COMPARTMENT SUPPLY AIR SENSOR OPTIONAL B 5 o Bryce AMBIENT AIR TEMP SENSOR Gv i 2 F8 SA TIMED ivice A 12AMP TIMED 52 BUZZER Hav je S 5 53 A BUT ak Me BTYC BATTERY CHARGER 3 BIVC un M A Y ng Eo 12 TIMED Ne BTYCe BATTERY CHARGER OPTION 21 1206 Wie EUN COMPRESSOR 3 y COMPRESSOR CONTACTOR 2 PSCUN z TEMP VOLT r A FSA 2 FAN ROTATION 18 816 COMPRESSOR CUNTACTDR RELAY L3 BROWN i VN ee Be COMPRESSOR DISCHARGE PRESSURE TRANSDUCER DA MPRESSUR DISCHARGE TEMPERATURE SENSOR L2 m 59 54 CDCON CONDENSER MOTOR CO
7. ON ENGINE OFF N SF STANDBY 4 The microprocessor will then perform a Self Test 3 Place the switch labeled ENGINE ENGINE refer to section 3 3 and start the unit automatically OFF STANDBY in the STANDBY po sition 5 Ensure the 2nd Compartment Run C2 and or the ZF 3RD Compartment Run C3 switch is in the ON posi STANDBY tion if operation is desired 62 11524 3 2 Starting units with a Main Power switch labeled START RUN OFF 1 Ensure the switch labeled ENGINE STANDBY is in the STANDBY position and the switch labeled START RUN OFF is in the OFF 2 Ensure the external power circuit breaker is off connect standby cable to unit and then turn the ex ternal power circuit breaker on O O HEAT COOL DEFROST SNR ENOP CON TINUOU SETPOINT BOX TEMPERATURE SERERE 3 Place the switch labeled START RUN OFF in the START RUN position NOTE START RUN The unit is equipped with automatic phase re versal w
8. ede ROLE RR 2 13 252 Line Solenoid valve I2LSV or 3bSV 22 22 5252 Rr acea 2 13 coo Thermal Expansion Valve 2 13 2 5 4 Remote Evaporator Switches Transducers and Sensors 2 13 2 6 SYSTEM OPERATING CONTROLS AND COMPONENTS 2 13 2 13 202 SNS 2 13 2 13 2 6 4 Component Description And Location 2 14 27 ELECTRONIC MODULES 2 18 27 1 Overload Ground Fault Module OGF 2 18 27 2 Phase Reversal Module PRM 2 18 CP 2 18 cod ei ed oe uad o Up 2 18 282 etd PER 2 18 283 Remote Temperature Sensors Peg 2 19 204 Remo Conka Panel RH EIER ARE REY DR Ra b C OR 2 19 29 ENGINE DAD 2 20 210 COMPRESSOR 2 20 211 REFRIGERATION SYSTEM 2 21 212 EBECIBIGAL DATA 54 2 21 2 13 COMPONENT RESISTANCE amp CURRENT DRAW DATA 2 23 2 14 ered DEVICES 2 23 215 REFRIGERANT CIRCU
9. 2 22 2 15 REFRIGERANT CIRCUIT DURING COOLING dents eee px PRA 2 23 2 16 REFRIGERANT CIRCUIT HEATING AND DEFROSTING 2 23 OPERATION mE 3 1 a STAHING ENGINE OPERATION 3 1 32 STARTING STANDBY OPERATION 2 nnn mre RR REESE UR Ra 3 2 RECHTE EE 3 4 m3 3 5 eo CHANGING SETPOINT 549 1 Fo E EE b A Bricks ebd E de e dece ed b EE 3 8 am STB SP OFERATON 3 9 CONTINUOUS OPERATION 22 Seinen S eum ded 3 10 BLEEP bb 3 11 62 11524 ii TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 39 RI OO 3 13 TEE INE o123 hig edn cones Rd 3 14 mi 3 15 129 WIEW INAC TIVE ALARMS ius 3 16 Ove DATA 3 17 VIEN MOUR METERS croire epee ee ee 3 20 445 FUNCTIONALE PARAMETERS SUE A ae E UA ea E RE SUE A Ma DR UP CR e ced 3 21 116 LANGUAGE SELECTION uei dat do ed a SUE A EORR RE UR e nae Svp Re RE UP C 3 25 217 Ire LL 3 26 ore DATA REGORDER da oae lecta usta Redi Used 3 27 peers minis PC EE EE 3 27 De
10. CONFIGURATION SIMILAR FOR ALL EVAPORATORS MODEL MHD1100 SHOWN 1 Coil 6 Supply Air Temperature Sensor 2 Fan amp Motor Assembly 25 Optional 2EVM1 2 3 or 4 amp 2EVMIP1 2 3 or 4 7 Heaters 2HTR1 amp 2HTR2 3 Return Air Temperature Sensor 2RAT 8 Liquid Line Solenoid Valve 2LSV Located on return air grille 9 Thermal Expansion Valve 4 Defrost Termination Temperature 10 Equalizer Line Sensor 2DTT 11 Thermal Expansion Valve Bulb 5 Evaporator High Temperature Switch 2EVHTS 12 Suction Connection 13 Liquid Connection Figure 2 5 Remote Evaporator Cover Removed 2 7 62 11524 THREE COMPARTMENT ONLY w 43 5157 M CHENE i elle zie 9 e i 1 Fuse F13 23 Display Keypad and Switch Board 2 Fuse F28 24 Control Module See Figure 2 10 3 Fuse F27 25 Fuse Standby Contactor
11. NO engine amp inspect FSA should Remove new ENSCU and re install old ENSCU back into unit move freely without binding and shaft should be straight Is Review results FSA functioning properly System of above tests OK Replace the FSA Did you find and correct the condition NO Remove new FSA and re install old FSA back into unit FSA is not the fault Review results of above YES Review results of above tests with your super visor If necessary go to the beginning of the tree amp test again ENSCU is not the fault Review results of above tests with your supervisor If necessary go to the beginning of the tree amp test again with your super visor If necessary go to the beginning of the tree amp test again tests with your supervisor If necessary go to the beginning of the tree amp test again Figure 9 3 ENSCU Diagnostic Tree 2 Long 3 Short LED Code 9 11 62 11524 Replace ENSCU Did you find and correct the condition START HERE With the Main Power switch ON and the ENSCU wire 13 removed from the connector connector plugged in check voltage at ENSCU terminal 13 Is voltage 26 VDC or higher NOTE With connector unplugged unit will not start but will crank Check voltage while unit is cr
12. 7 91 P149 C2 HEATER T CIBGUIT enar 7 92 Pia G2 CHECK HEATER 2 GIRGUIT tinea 7 94 P151 CHECK GLOW PLUG CIRCUIT This applies to the Intake Air Heater 7 95 P1528 CHECK FUEL SOLENOID CIRO 7 96 P153 CHECK RETURN AIR SENSOR panii ieie 7 97 Pine CHECK SUPPLY AIR SENSOR 5 qd dddad agas riant iaiia Yd asad 7 97 P155 CHECK COOLANT TEMP SENSOR e Ree s iE 7 97 CHECK BATIERY VOLIS p e p co E db d Ge ica a CR eg OEC 7 97 Fis CHECK BATTERY CURRENT 2 54 7 98 P158 CHECK AMBIENT AIR SENSOR east OE OR Re 9 7 98 P159 CHECK DEFROST TEAM 1 SENSOR Oda e RUE 7 99 P160 CHECK DISCHARGE TEMP SENSOR big a 7 99 P161 CHECK SUCTION TEMP SENSOR CST 9424049 93004 64 7 99 P163 C3 CHECK HEATER 1 CIRCUIT PERSE 7 100 Pict CHECK DES 7 101 P168 C2 CHECK SUPPLY AIR SENSOR ita ER S RUN 7 101 Piaf C3 CHECK HEATER 2 CIPOGUIT 7 102 P168 C2 CHECK LSY VALVE
13. 8 36 B ODE E ee ee eee RUE eee ee ee UR A 8 36 b OGF Checkout PIODQUUNS 8 36 Bus cass 8 37 8 9 6 Compartment 1 Evaporator Blower amp Motor 8 37 847 Condenser Assembles 8 38 So8 Charger 8 39 S90 enero GEN inca ak a SERE Re Up Rr dp epi 8 39 a Preventive Maintenance and Operating Precautions 8 39 D Gencrat r Removal 8 40 222222255545 ede kal ORA dada 8 42 88210 Sensor Checkout nep P Mle E dde P II RP da PR 8 43 UNIT TROUBLESHOOTING 9 1 OA ENGINE ERG DA ord ei 9 1 Engine NOt c Er 9 1 9 2 9 13 Engine Not Shut Om E UM E Up Ai ot dupl 9 2 914 Statler Motor PER b PEE FE ERA DR wads 9 2 9 1 5 Malfunction In The Engine Starting Circuit 9 2 9 1 6 Miscellaneous Engine Troubleshooting eee em eoe e eoe ere nee 9 3 PATER CHARGER
14. 8 14 8 6 1 Refrigerant System Service Connections 8 14 8 6 2 Servicing The Refrigerant Charge 8 15 a Checking Change Lowell 8 15 b Checking For 8 15 ep uc cn 8 15 d Pumping Down The LOW SIOE 2 cia uel mic m sed REA Ge uli 8 16 B Pumping Down The Compressor 8 16 L UID CU The Charge Level METTE 8 16 g Adding a Complete Charge cn spa SC CE ERR IUS TERT ES Re ERS 8 17 ix 62 11524 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page sagas Pid Dd udo qoe doe E AO dos 8 17 Leak Checking a Charged eres en eI ure b RR eran Yee 8 17 b Leak Checking a System Without Charg 8 17 Leak Checking With Low Side Pumped 8 18 d Leak Checking CompfressDf 8 18 8 6 4 Evacuation And Denyaration cs ehe Reb 8 19 a Evacuation of the Complete System 8 19 lh Evacuation o ihe Wow SII Ri 3ud3a 8 20 Evacuation ofthe Compressor sisse eie een P Rd xe need mew pr 8 20 87 COMPRESSOR AND
15. 7 1 INIRODUCTION tierce DRE E RR 7 1 E 7 2 23 DRIVER OPERATOR ALARMS SOR d edd Rua deg dg d 7 3 1 LOW FUEL LEVEL WISRNING 353545422544 led died tangas 7 3 SHUTDOWN ALARMS Red 7 4 11 LOW ENGINE QOIL PRESSURE hr 7 4 12 JRA COOLANT TEMPERATURE onde ies Gas 7 5 13 HIGH DISCHARGE PRESSURE ALARM 75 WILL ALSO ACTIVATE 7 7 TE HGRA CAMPS abd dies bike Ad Pi 7 8 18 BAMERY VOLTAGE DOO HIGH c sb cents 7 9 18 VOLTAGE TOQ LOY cipe OR Sep x Dn 7 10 7 HIGH GOMP DISCHARGE TEMP EE 7 11 16 LOW REFRIGERANT PRESSURE x24 3p E dre rp ERES SUE ea ERO SUE EHE UC Rd edo 7 12 19 DOW FUEL poni E Ere PH pP Pe 7 14 20 MAXIMUM COMPRESSOR ALARMS cic ice cide ecco kam mtb deo and sae RU Go A 7 15 21 TECHNICIAN RESET REQUIRED 7 15 22 SUCTION SUPERHEAT n s 7 16 22 OVER AMIT mE 7 18 er Reda 7 20 28 CHECK REFRIGERATION SYSTEM 7 21 To STARI UF ENGINE ALARMS
16. che 7 104 GBHEORLOW SPEED APM 7 105 vii 62 11524 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page Pigs CHECK HIGH SPEED RPM CR VI ada 7 106 7 107 P177 CHECK EVYAP 7 108 CHECK UET MM 7 109 P180 CHECK SUCTION MOD VALVE ea Rae 7 110 184 C2 CHECK EVAP FAN MOTOR 7 111 P185 CHECK EVAP MOTOR 7 113 P186 CHECK OUTLET TEMP 5455 E UE 7 115 P187 GHEGK T GIPIGLIT 424 kai Ya der Dco 7 115 P180 CHECK HEATER 2 CIRCUIT 7 117 P188 CHECK EVAPORATOR FAN MOTOR 1 enar ht der ee 7 119 P190 CHECK CONDENSER MOTOR o 7 121 CI EE and E RU I RUE 7 122 P199 C2 CHECK RETURN AIR SENSOR 7 123 P206 CHECK CONDENSER FAN GIRCUIT a hok area CR e BOR GR 7 124 P207 GHECK COMPRESSOR CONTACT cnt doce eie 7 124 P208 CHECK GENERATOR CONT CIRC 44493 4 HOA
17. 62 11524 8 44 Table 8 6 Sensor Resistance CDT F Ohms F Ohms F Ohms F Ohms 40 40 3 360 000 0 32 325 860 40 0 104 53 330 101 7 215 6 510 38 9 38 3 121 020 1 1 34 307 970 41 1 106 51 010 104 4 220 6 000 37 8 36 2 900 710 2 2 36 291 180 42 2 108 48 800 107 2 225 5 540 36 7 34 2 697 500 3 3 38 275 410 43 3 110 46 710 110 0 230 5 130 35 6 32 2 509 940 44 40 260 590 444 112 44 710 112 8 235 4 760 34 4 30 2 336 720 5 5 42 246 670 45 5 114 42 820 115 6 240 4 410 33 3 28 2 186 670 6 6 44 233 570 46 7 116 41 010 118 3 245 4 090 32 2 26 2 028 680 7 7 46 221 260 47 8 118 39 290 121 1 250 3 800 31 1 24 1 891 780 89 48 209 670 48 9 120 37 660 126 7 260 3 290 30 22 1 765 060 10 50 198 760 50 0 122 36 100 132 2 270 2 850 28 9 20 1 647 700 11 1 52 188 490 51 1 124 34610 137 8 280 2 490 27 8 18 1 538 950 12 2 54 178 820 522 126 33 200 143 3 290 2 170 26 7 16 1 438 120 13 3 56 169 700 53 3 128 31 850 148 9 300 1 910 25 6 14 1 344 580 144 58 161 100 544 130 30 560 154 4 310 1 680 24 4 12 1 257 770 15 5 60 152 990 55 6 132 29 330 160 0 320 1 480 23 3 10 1 177 150 16 6 62 145 340 56 7 134 28 160 165 5 330 1 310 22 2 8 1 102 240 17 7 64 138 120 57 8 136 27 040 171 1 340 1 160 21 1 6 1 032 600 189 66 131 310 589 138 25 970 176 7 350 1 040 20 4 967 830 20 0 68 124 870 60 0 140 24 960 182 2 360 920 18 9 2 907 560 21 1 70 118 790 61 1 142 23 980 187 8 370 830 17 8 0 851
18. 9 3 GENERATOR 9 4 9 4 REFRIGERATION TEMPERATURE CONTROL bk Re RR REIR 9 4 c MP 9 4 9 4 3 Unit Operates Long Or Continuously In Cooling 9 4 9 4 4 Unit Will Not Terminate Goong 9 5 Unt Wil Not Terminate Heating oca 9 5 Beret Cycle E 9 5 AMAMA ROO eee 9 6 mao ADOMAN O T 9 6 9 4 10 No Evaporator Air Flow Or Restricted Air 9 6 9 4 11 Evaporator Expansion Valve EVXV Malfunction 9 7 9 4 12 Evaporator Expansion Valve TAV Malfunction 9 7 9 4 13 Compressor Suction Modulation Valve CSMV Malfunction 9 7 95 Speed Control System 9 8 96 Microprocessor 9 13 62 11524 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page dicm cmm 10 1 10 14 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED ENDGINEIOFFISTANDBY oe 10 1 10 2 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED STARTIBUN OPE i942 06154440
19. 8 9 8 10 SB Engine Oil Apnd Ol PSP 8 10 SUCHE UT ICE DET EDUCHUEX FECIMUS 8 11 do M prp 8 12 Spes CON ol SSO ouis nid pc DR ARR 8 12 STO DCG 2 usd pape ER EAE bd 8 13 0 5 19 Viale usos cod E Ope e ped esa Rd Rc ae 8 14 GRON 8 14 REFRIGERANT SYSTEM SERVICE 8 14 8 6 1 Refrigerant System Service Connections 8 14 Servicing the Meigerant Charge 8 15 toa Me NN TE 8 17 864 Evacuation And Dehydration cia doc QE 8 19 87 COMPRESSOR AND UNLOADER SERVICE 8 20 8 7 1 Repair or Replacement Determinat cadet Rx EERTECRI 8 20 8 7 2 Removal and Replacement of 8 21 8 7 3 Cylinder Head and Valve Plate Service 8 22 S74 Ol Pomp And Bearing ERE 8 23 8 24 BID MINGUS Co 8 25 8 8 REFRIGERANT SYSTEM COMPONENT SERVICE 8 26 COMME roo
20. With A Perishable Setpoint If in Start Stop Operation with a setpoint in the per ishable range above 10 4 F 12 C and all condi tions for an OFF Cycle have been met except for set point the engine will operate in high speed to pull down to setpoint and cycle off quicker NOTE Generally the unit will go into an off cycle from high speed when this condition occurs Howev er if one of the required conditions for shutdown is no longer met during this time for example the battery voltage drops below the configured value or the charging amps increase above the configured value or the engine coolant temper ature drops below 122 F 50 C the engine may return to low speed operation until the shutdown condition is satisfied then shutdown from low speed 14 High Speed Pulldown If in Continuous Operation with a setpoint in the perishable range above 10 4 F 12 C and the High Speed Pulldown Configuration is set to YES the engine will operate in high speed until the refrigerated compartment temperature is 0 36 F 0 2 C above setpoint 4 8 4 Unloader Control Overrides This section lists the different factors that determine the operation de energizing loading and energizing un loading of the unloaders in addition to the unloader con trol used in temperature control Unloaders operate in priority order for cooling ONLY For example Override a supersedes b and all lower override
21. 8 26 foe Converse Cell 8 27 Bug Willer Diner SERA CIR Ded dd edd 8 28 8 8 4 Replacing Receiver Sight Glass Or Fusible Plug 8 28 8 8 5 Compressor Suction Modulation Valve CSMV 8 28 Bob Pe doppi 8 29 Boc JD bid 8 31 SB aia ead ei said 8 31 8 31 8 8 10 Liquid Line Solenoid Valve PLSVISLSV ci sirisa ciriciri bisa diss 8 32 6 0 17 Thermal Expansion VANG lade dee ROC GEO edd 8 33 8 9 ELECTRICAL SYSTEM COMPONENT SERVICE 8 34 6 9 1 Megohmme et r Test Procedure Ren 8 34 3 9 2 PhassHMeversal Module PRM 8 35 Rc 8 36 0 04 Overload Ground Faut OGF 25 cccuscke 8 36 8 37 8 9 6 Compartment 1 Evaporator Blower amp Motor 8 37 Condenser Fan ASSOmBIIGR 8 38 5908 Battery Charger BIG 2565 ctae SEDE EL RUE 8 39 519 9 Generator GENI orsa
22. e d bud ES eR tens 7 22 30 FAILED TO RUN MINIMUM TIME inert ERE he UR IR SERRE DER IDEE 7 22 FAILED TO START AUTO MODE etai Rech as 7 23 ENGINE FAILED TO STOP 7 25 SPARTER CIRCUIT 7 26 38 CHECK COOLANT TEMPERATURE giaa dia sten i Roe Rea eniin Sota 7 27 Sr LOW SPEED RPM x p aos ns 7 28 oe CHECK HIGH SPEED RPM EX ORARE ERE 7 29 ad ieii RR SUCRE dat Sup ra E EE RU eat up 7 31 40 CHECK GLOW PLUGS This alarm applies to the Intake Air Heater 7 33 41 ENGINE STALLED Sih nin e 7 34 62 11524 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 7 5 WARNING STATUS ALARMS 7 36 51 ALTERNATOR NOT CHARGING This alarm applies to the Battery Charger 7 36 53 BOX TEMP OUT OF RANGE Comparimant 1 7 37 54 DEFROST NOT COMPLETE apu 7 39 55 CHECK DEFROST AIR SWITCH EEn E 7 40 57 CHECGKREMOTE SWITCH 1 7 41 58 CHECK REMOTE SWITCH 2 REMS2 7 42 59 DATALOGGER DataLink data recorder NOT RECORDING
23. gil3 9 SP5 SP16 1 15 1155 2EVC E HC2 INLET 18 516 COMPRESSOR 4MP8 I Ge TV po CONPRESSOR CENTACTDR le 2 7 5 1515 2 CDT Bee Sel DIESEL 4 gt 9 1 dx 26 u EVM CDCON PRESSURE TRANSDUCE 5 ENSER EMPERATURI R ise lume 7 X ae 1 CONDENSER wore p N ACTOR 25952 spse SMP2 6 1 BLK 5 5557 CDCDN CONDENSATE HEATER J SMP HC SPV SMV DMPARTMENT EVAP 2 3 FT 4 Tm 6MP2 WHT T 15 C CSP COMPRESSOR MEE SMP1 6MP3 RED La gt SPT 4 531 SUCTION MODULATION VALVE Hcg lt De R SUCTION TEMP TRANSDUCER TH HO H HE me SENSIR ERATURE SENSOR SP5 B 6MPS BRN 4 W3 GND 1 L B bd DOES DEFROST AIR SWIT OWER COIL Die 12 DIESEL OFF ENGI CH 2 N pem 6MP6 2 794 KO 4 Bie ENCT DEFRUST TEMPERATURE SENSOR EVAP 5 6MP7 gt lt 03 LANT TEMP VAPS L2 3 ORG 6 p DRIP 1H ENSCU NGINE OIL P ERATURE 2 DRAI 03 RESSURE DAS i 6MP8 NEC MEER come 9 83 ENGINE SPEED UNIT 1 2 SP15 2MP6 2 8 D 1 EVAPORATOR TARTU 2 2 CE
24. iR OV dc C OA 7 125 P209 CHECK STANDBY CONT CIRCUIT wee RE RR tatem ER ee 7 126 P210 C3 CHECK RETURN AIR SENSOR ERREUR RR RUE e 7 127 GHEGR DEFROST SENSOR COM EE 7 127 P212 DHEGKBEFROST SENSOR SDI 7 128 7 10 MAINTENANCE ALARMS o EE SR RR Ee RO Ron 7 129 223 ENGINE MAINTENANCE DUE 7 129 994 STANDBY MAINTENANCE DUE SOROR Race XUI RU C 7 129 225 GENERAL MAINTENANCE DUE 7 130 298 SERVICE SOON PM BI DUE erissa ni machine waa 7 130 227 SERVICE SOON PM 2 DUE 7 131 206 SERVICE SOON PM AS BUE eed VERE Oc 7 131 229 SERVICE SOON PM 4 DUE 7 132 230 SERVICE SOON PM 85 DUE 7 132 ZO MICHOBBOUESSUBM ALBBBNIS 7 133 232 ERROR 7 133 234 MODEL ERROR 4004 7 133 237 FUNCTION PARAMETERS ERROR addo rt dh OR ck ae eh ap oe 7 1
25. INTERNAL PROTECTOR EVAPORATOR FAN MOTOR DC eed g Hees FET 7 AUTI RESTART LIGHT PHTCOIN 7 TE GUIDE e LIGHT CUPTIDNAL MOTORS sil DPI6 P 1MP17 FE 8 EE e XI JVC ih 2ND COMPARTMENT LIQUID SOLENOID VALVE 20 stis Sum ET 9 ADM LS c Du MANIFOLD ATMOSPHERIC PRESSURE SENSOR OPTIONAL NEM 3 18 F 10 1HTCON1 3MP18 ZEVC e 2EW2 4 All DC OPTIONAL CONTROL PANEL CONNECTOR 1MP7 Er WP 2 5 45 8EVMI 2 3 4 42 DPTIDNAL CONTROL PANEL CONNECTOR JUMPER ENCT FET 12 2 2 0 2EVC F die CONNECTOR 2 9 1 18 FET 13 AT A2 hoe Ge DGF DVERLDAD GR UND FAULT MODULE IMPIU F 2MP5 22 8 4 PWR MICRO POWER E eee 03714 PSCUN PIVER SOURDE CONTACT FE CONTACTOR m 1MP09 ES P DEFR 2 2 514 PSCON2 POWER SOURCE 2 12 1 20 OST LIGHT 015 PSCUNR POWER SOURCE CONTACTOR RELAY am 1MP34 ET 17 Na 4 REMS 1 2 RE MOTE SWITCH Here 014 REMSNL2 REMOTE SENSOR 0 16 IMP21 SP42 FET 19 8 HIS RR RUN RELAY 2EVC K 1MP8 FET 20 44 RUN CONTROL RELAY 1 21 SP42 1EVCON 2 PSR STANDBY POWER PLUG AEE 1 FET 21 1HTCON2 2EVM4 tis SAT RETURN AIR TEMPERATURE REMSNI SUPPLY AIR TEMPERATURE REMF 1 14 spi
26. 62 11524 Locate and inspect 10 position con nector for optional sensors and switches see wiring schematic Sec tion 10 Connector must have cap on No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the con nector may be removed and each individual wire sep arated from the others terminated and insulated with heat shrink um Alarm Cause Corrective Action 59 DATALOGGER DataLink data recorder NOT RECORDING e TRIGGER ON No data is being recorded by the DataLink data recorder e UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Alarm may be manually reset via keypad NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Clear Alarm a Clear Active Alarm s Alarms Clear b Check for Active Alarm If Inactive download all data amp retain re occurrence If Active go to next step Microprocessor Defective a Download previous data using Data retrieval OK Download PC Card or ReeferManager Program b Replace microprocessor amp set New microprocessor in place Configurations Functional Parameters Enter hours from removed microprocessor set Maintenance H
27. 7 62 95 CHEDKODGON RELAY COIL mes MEH RE 7 63 506 CHECK GENUONE RELAY deka oe 7 64 08 DHEGONHBIGH TEMP THERMOSTAT 633 UA 7 65 99 CHECK STANDBY CONTACTOR PERIERE RI CR pss edd uos 7 66 100 OVERLOADISROUND FAULT cia ipid xat doe b ao OE Up Race S RUE A Ce e rat Sup dre 7 67 101 C2EVAP MOTOR QVERHEATED erriari ase batte 7 68 102 UOSEVAPMOTOHRH OVERHEATED R4 7 69 109 CHECK 2ATCONT RELAY COIL 7 70 108 EHECROSBICONZ RELAY COIL 7 70 105 CHEGKJHTCONI RELAY GOIL 3 444 21 3033 ce ARE RE ds 7 71 108 GHECK SHTGON2 RELAY COLL oe ee oe oe 7 71 107 DHEDRCLSY CIRCUIT 95 rac e Sup ARCH oA sod o ERE 7 72 D Ee Is Fees Gon 7 72 109 IEVOON RELAY COIL 7 73 CHECK 2EVCON RELAY COIG iet m omm 7 73 Tt CHECK SEVCON RELAY COIL 7 74 62 11524 vi TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page SENSOR ALARMO OR dell d e cae ua C 7 75 jal CHECK AIR SENSOR 7 75 122 CHECK RETURN AIR SENSOR 7 76 123 CHECK SUPPL
28. 7 43 60 DATALOGGER DataLink data recorder TIME 7 44 61 BOOR OPEN IOSD EOE da 7 45 62 C2BOX TEMP OUT OF RANGE Compartment 2 7 46 63 BOX TEMP OUT OF RANGE Compartment 3 7 48 TJ ELEC RIG 7 50 71 BAD Fe OF Fo FUSE 21255494 E GOES ELA e ELE eae 7 50 73 POWER CHECK POWER CORD see aes 7 51 GOMP MOTOR OVERLOAD mereka 7 52 76 CONDENSER MOTOR OVERHEAIED Rea Ie UR AE URGE 7 53 27 7 55 84 CHECK REMOTE ALARM LIGPIT PRG 7 57 7 58 UE CIRCUIT 22 7 59 80 CHECK REMOTE AUTO LIGHT Right Bar lt gt ee aie 7 60 91 CHECK RELAY COIL 7 60 DS o QHECK DATGLNZ RELAY 7 61 Mo SISA UP BUZZER 7 62 CHECK COMP CONTACTOR 2 2552
29. NO Remove new ENSSN and re in stall old ENSSN back into unit ENSSN is not the fault Review results of above tests with your supervisor If neces sary go to the beginning of the tree amp test again Figure 9 1 ENSCU Diagnostic Tree 1 Long 1 Short LED Code 9 9 62 11524 START HERE Verify unit starts go into high speed and stall after running for a few seconds Using jumper wire verify there is at least 11 VDC at ENSCU terminal 25 Check for high resistance or an Verify there is at least 11 open in the VDC going into the ENSSN ground ENSSN 12 V terminal circuit Did you find and correct the condition Check for high resistance or an open between No ENSCU terminal Using jumper wire check for U 5 VDC at ENSCU terminal Did you find and correct 10 Do you have 5 VDC at terminal 10 the condition Replace ENSCU Did you find and correct the condition i Remove new ENSCU Check for open or high and re install old resistance on circuit ENSCU back into between ENSSN and ENSCU unit ENSCU is not Did you find and correct the condition the fault Review results of above tests with your supervisor If necessary go to the beginning of the tree
30. 5 10 via bw ER 5 11 5 7 5 Functional Parameters via Keypad 5 11 5 7 6 DataLink Data Recorder Via ReeferManager 5 11 mu Miroprocessor Final CHOCKDEUT 5 11 62 11524 SECTION 5 MICROPROCESSOR INTERFACE 5 1 INTERFACE METHODS There are five methods for interfacing with the Advance microprocessor 1 Operator Interface using the keypad 2 Technician Interface using the configuration jump er 3 Mode using the PC Mode jumper 4 PC Card Transferring data using PC Card 5 ReeferManager amp Reports Access using a com puter Operator Interface such as start stop Pretrip reading alarms reading data and changing Functional Parameters may all be performed using the Keypad refer to Section 3 Technician Interface and PC Mode require the use of an additional connector before any actions may be performed and each allows increased interaction including operations that may be performed with the microprocessor powered while the unit is shutdown Insulated Jumper Download Port WHITE WIRE CONFIGURATION JUMPER P N 22 50180 00 Figure 5 1 Technicians Interface Connection 5 2 TECHNICIAN INTERFACE REMOVE JUMPER MODE The Technician Interface Mode allows the technician to change Configurations test the unit components and or service the refrigeration system
31. 9 3 GENERATOR beagle ie 9 4 94 REFRIGERATION TEMPERATURE CONTROL 9 4 24 1 UAWN hed E SUO D D d uA 9 4 9 4 3 Unit Operates Long Or Continuously In Cooling 9 4 944 Unit Will Not Terminale Cooling 9 5 946 Unit Will Not Teminat Healing E E UR ER 9 5 947 Gycls MANCON 9 5 9 6 9 4 9 Abnoriidl NOSES 9 6 9 4 10 No Evaporator Air Flow Or Restricted Air Flow 9 6 9 4 11 Evaporator Expansion Valve EVXV Malfunction 9 7 9 4 12 Evaporator Expansion Valve TXV Malfunction 9 7 9 4 13 Compressor Suction Modulation Valve CSMV Malfunction 9 7 Speed Control System DISOnoSUDS cesses dade e Ro RR OE des 9 8 95 Microprocessor DIBIDUBDGS 9 13 62 11524 SECTION 9 UNIT TROUBLESHOOTING CAUTION Under no circumstances should anyone attempt to repair the keypad display or internal control module components Should a problem develop with these components contact your nearest Carri er Transicold dealer for replacement Run a Pretrip and check all active alarms before continuing with tr
32. Fuel Speed Actuator FSA Control Box Refer to Figure 2 6 Engine Speed Sensor ENSSN Engine Oil Pressure Switch ENOPS Display a te Switch Board Keypad Door Serial Download Port SLP Lube Oil Filter Lube Oil Fill amp Dipstick Lube Oil Drain Starter Motor SM Generator GEN Battery Tray OR Lift Gate Charger Mounting Battery Changer BTYC Fuel Heater FH Location Fuel Filter Figure 2 3 Front View Engine Components 2 5 62 11524 7 1 Defrost Termination Temperature Sensor 10 Evaporator Outlet Pressure Transducer EVOP DTT Located on curbside tube sheet 11 Evaporator Outlet Temperature Sensor EVOT 2 Evaporator Air Nozzle On suction line under insulation 3 Evaporator Fan Motor Assembly EVM 12 Evaporator High Temperature Switch 1EVHTS 4 Evaporator Fan Motor Wiring Located on roadside tube sheet 5 Supply Air Temperature Sensor 1SAT 13 Evaporator Coil 6 Remote Evaporator Wiring 14 Return Air Temperature Sensor 1 RAT 7 Remote Evaporator Suction Line 15 Heat Exchanger 8 Remote Evaporator Liquid Line 16 Electric Heaters HTR1 HTR2 9 Electronic Expansion Valve EVXV Figure 2 4 Evaporator Section Grille Removed 62 11524 2 6 HARNESS WIRING NOTE FUSE F16 REMOTE EVAPORATOR DRAIN HEATERS 2CH
33. Microprocessor Defective 62 11524 a Download previous data using Download PC Card or ReeferManager Program Data retrieval OK b Replace microprocessor amp set Configurations Functional Parameters Enter hours from removed microprocessor set Maintenance Hour Meters and DataLink data recorder Setup New microprocessor in place Alarm Cause Corrective Action 61 DOOR OPEN 051 TRIGGER ON 051 is set to activate an alarm if the switch is activated opened or closed depend ing on switch type for more than five seconds UNIT CONTROL May be configured as alarm only alarm and force low engine speed or alarm and shutdown RESET CONDITION Alarm Only Auto Reset after the switch has de activated for more than five seconds Shutdown Auto Reset after three minutes minimum off time for door open condition and the switch has de activated for more than five seconds NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary IF A SWITCH IS INSTALLED Determine what DS1 is controlled by DS1 may be connected to a com partment door or some other device and used to remotely control the unit Locate the device used as DS1 Check
34. Uae phe I d e PPP Se RR Cc 8 2 anos oua etus cma Ond te MLR dota b datu 8 4 Table 8 3 OODDbIOII AUR BH SUR RERO RU ER 8 28 Tablo 8 4 EVYXV 2 RE CURRERE E Ee E CD READ AC 8 30 mm 8 44 Table 8 6 Sensor Resistance CDT breue ac E UG RR dadas d d de deu 8 45 Table 5 7 Tomperature Pressure Chall ys si died gags ied ease GR 8 46 Table 9 1 ENSOU LED Fault Chall ERE T REESE ERROR RRM T eR 9 8 Table 9 2 Microprocessor DIagnostiGS tot DER EERE REAR es 9 13 XV 62 11524 SECTION 1 SAFETY PRECAUTIONS PARAGRAPH NUMBER Page 13 SAFETY PRECAUTIONS dore Re Rx 1 1 12 SPECIFIC WARNING AND CAUTION STATEMENTS 1 2 118 SAFETY DECALS 1 6 62 11524 SECTION 1 SAFETY PRECAUTIONS 11 SAFETY PRECAUTIONS Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind During normal operation all moving parts are fully enclosed to help prevent injury During all pre trip inspections daily inspections and problem troubleshooting you may be exposed to moving parts Please stay clear of all moving parts when the unit is in operation and whe
35. eI Rd EE I REPE NIS EAR 8 7 8 5 ENGINE AND ENGINE RELATED SYSTEMS SERVICE 8 7 8 7 B Priming The Fuel SUBDIBIM 8 8 853 Mechanical Fuel Pump Screen La uiuere ck e wr EROR Re HUP Shea Seed epp deme 8 8 554 Elecite Fuel PUMP SCG ER GU Re Rau S or ori 8 9 85 9 8 9 Level 8 9 257 IJFUB HGB 8 10 858 Engine Oil And OU ARS 8 10 ID Check The Engine DII Levet 8 10 b To Change Engine OVE us setas nes BER PERDER 8 11 TO Change 8 11 Soe 8 11 20 10 Make E Te PP BERI D REPRE Ed ER ee 8 12 Troubleshooting The Intake Air Heater IAH 8 12 b Replacing The Intake Air Heater i irs 99956 RE 8 12 85 11 Speed Control 8 12 85 12 Cooling SYE HH 8 13 m pan and FISO 8 13 b ERE OE E 8 13 95213 Water Fump V Bell 8 14 23504 Grankcase BeSITISI di 8 14 86 REFRIGERANT SYSTEM SERVICE tres
36. ret ever sre RSCRE 8 39 5 9 10 Sensor cosa eps ROSTER VI ER ULRIKE ue S E SUE Ed 8 43 62 11524 SECTION 8 SERVICE WARNING Advance microprocessor equipped units may start automatically at any time the Main Power Switch is not in the OFF position Also the unit may be fitted with two way communication equipment that will allow starting of the unit from a remote location even though the switch is in the OFF posi tion WARNING Be aware of HIGH VOLTAGE supplied at the power plug or from the generator When performing service or maintenance proced ures ensure any two way communication is disabled in accordance with the manufac turer s instructions ensure the Main Power switch is in the OFF position and whenever practical disconnect the high voltage source lockout tagout the receptacle and disconnect the negative battery connec tion NEVER dis assemble the generator HIGH MAGNETIC FIELD INSIDE This field can interfere with cardiac implants such as pacemakers and defibrillators WARNING Disconnect batteries before doing elec trical welding on unit or chassis to which unit is attached trailer container rail car metal building etc CAUTION Unit uses R404A and POE The use of in ert gas brazing procedures is mandatory for all Carrier Transicold refrigeration units otherwise compressor failure will occur For more information Refer to Technical
37. 5 6 nod HOD 5 6 PODON ne eRe 5 7 D ea t dupli d dup 5 7 Connecting Computer and Microprocessor 5 7 55 MICROPROCESSOR DISPLAY DIAGNOSTICS atem e 5 8 57 MICROPROCESSOR REPLACEMENT amp SETUP 5 8 E Pre Replacenicnt SIBDE dices see 5 9 572 assuseseddsesste CEP EERIUPQERTEBS ERES 5 9 62 11524 iv TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page a 5 10 S74 Conngaradons Via Keypad 5 11 525 Funchonal Parameters Keypad comb eben rene erences 5 11 5 7 6 Datalink Data Recorder Via ReeferManager issus scel uuu xxx x nnd ARR RR Rn 5 11 5g Microprocessor Final Checkout ER Rp ka So Go ER Rope let due o 5 11 MESSAGECENTER 6 1 MESSAGEVENTERM MESSAGES dol a dene 6 1 ALARM TROUBLESHOOTING
38. Check for defective communication from Main Power switch Is the unit and install 1 Switch defective Jumper This will elim inate remote commu nication from the sys tem Replace defective switch Did you find YES and correct the condi tion NO Y Check wiring to the Main Power Switch for an open or short Did you find and correct the condition NO System OK re install remote communication disconnected earlier A NO Verify the Run Relay de energ izes when the Main Power switch is placed in the OFF position Replace Run Relay Did you find and correct the condition Unplug fuel speed actuator Does the unit stop Is the relay defective YES NO NO Y n Check wiring for fuel speed Y actuator for a short Did you Ch eck wiring to Run Relay correct the condi for an open or short Did you ny find and correct the condition Verify correct fuel speed actuator operation amp replace if needed Operate system in order to verify defective or mechanically repair Did you find and correct YES seized the condition Did the loading Load current version of R emove new fuel speed of the software gore rom nios MW actuator amp re install old correct the
39. 62 11524 1 8 A WARNING THIS UNIT CHARGED WITH R 404A CAUTION COMPRESSOR MUST BE CHARGED WITH P O E OIL ONLY CTD P N 07 00317 00 UNIT MAY MOBIL ARCTIC P N EAL63 START CTD 62 03797 11 AUTOMATICALLY 62 02146 00 REV_A SI RIMING M RED FUEL WHEN CHANGI ENING THE FUEL BLEED VALVE LINES FOR A STEM HAS BEEN RUN 0 F L S TO RIME THE Ls AJ H Mmm JST 2 UDV LOC D OP JM ROUG ES Eee THIS E ENG SARY TO CONT TO PU TARTS TO PREVENT POSSI 0 O Ol ES ART T gt zz m m m 2 Sun Ft lt MANUAL FUEL PUMP PLUNGER FAILURE DO NOT ATTEMPT TIVE STARTS WITHOUT A T LAY BETWEEN EACH START AT CAUTION RUNNING THE ENGINE DOES NOT START AFTER 3 1 FOR EXTENDED PERIODS OF TIME TEP 3 WITH THE MANUAL FUEL PUMP AND TURN THE TOP OF THE PLUNGER UP CA CAUSE A INGER CLOCKWISE TO LOCK I PRIMING PUMP FAILURE THE UNIT 15 RUNNING CLOSE T FED VALVE CTD P N 62 11416 00 REV A m 2 m OG Mc pm x St 1 1 C0 CO T SH 27 970 10 20 gt l
40. Check System Pressures Install manifold gauge set and check system pressures Suction amp Discharge Pressures must be in the nor mal range Suction amp Discharge Pressures must have the same reading on gauges amp on micro dis play Check Evaporator Airflow Alarm Check for alarm 56 Must be corrected and cleared to continue Perform Pretrip Check Clear Active Alarm list then run Pretrip amp check for any new alarms Any active alarms must be corrected and cleared betore proceeding Check For Low Delta T Read Delta T from Unit Data 7 49 In Cool the Delta T must be greater than cooling more than 1 F 0 56 In Heat the Delta T must be greater than 0 1SAT must be higher than 1RAT 62 11524 Alarm Cause Corrective Action 7 7 ELECTRICAL ALARMS 71 BAD F2 OR F3 FUSE TRIGGER ON One or more of the following fuse circuits have been open for more than 2 seconds F2 F3 e UNIT CONTROL Engine Operation Alarm Only If the engine shut off see troubleshooting steps below to correct Standby Operation Additional verification required if the NO A C POWER configuration is set for Installed and shutdown the refrigeration system will shutdown with the alarm on and PSCON still energized RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a probl
41. 4 15 62 11524 SECTION 4 ENGINE STANDBY TEMPERATURE CONTROL NOTES 1 If the unit is in an alarm condition the microprocessor alarm response may override the operation described herein If an alarm is displayed in the MessageCenter refer to the specific alarm description in Section 7 for Unit Control descriptions 2 With the complex control systems in use with the Advance microprocessor there are many user selected and preprogrammed software overrides which may change the operation of the unit Refer to Sections 4 7 amp 4 8 for complete descriptions of these features 41 INTRODUCTION This section describes operation of the unit when power is supplied from an external source Standby Operation and when power is supplied by the internal generator Engine Operation The section also describes two additional sub categories of operation Start Stop Operation with standby or engine power and Continuous Operation with standby or engine power For descriptions of refrigerant system component interaction when cooling with flow diagram refer to section 2 15 4 2 ENGINE STANDBY OPERATION Engine or Standby Operation is chosen by positioning of the switch labeled ENGINE OFF STANDBY DOES OR positioning of switch labeled STANDBY ENGINE DES With the switch in the STANDBY position the power supply contactor relay PSCONR see wiring schematic Section 10 is energized Energizing PSCONR reverses its c
42. 9 There should be 12 VDC from MPQC9 to Ground b Use Component Test Mode to ener gize CDCON circuit Refer to Sec tion 5 2 2 FET 1 will be on Unplug the connector to condenser fan motor 1 CDM1 and check voltage on pins 4 5 in the engine harness connector 12 VDC between pin 4 and pin 5 indicates the open circuit is in the IP for CDM1 d Test continuity through CDM1 IP at pins 4 5 in the fan motor harness connector Should be 0 Ohms If condenser fan motor 1 is extremely warm allow it to cool off then recheck IP continuity Test continuity through IPC Should be 0 Ohms If either condenser fan motor is extremely warm allow it to cool off then recheck IPC continuity f Test IP circuit from condenser fan motor wires to microprocessor 12 VDC at 4MP2 Check Condenser Fan Motor Conta ctor a Inspect the wire connections to the contactor See wiring schem atic Section 10 No signs of overheating of the contactor Wiring is routed correctly to the contactor b Check tightness of the contactor wire connections Tighten with screwdriver and check for discoloration of wires Perform Pretrip Clear Active Alarm list then run Pre trip amp check for any new alarms Any active alarms must be corrected and cleared be fore proceeding Additional steps on the next page 7 53 62 11524 Steps Alarm Cause Corrective Action
43. RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 3HTCON2 a Inspect heater contactor coil and terminals No damage to coil No damage or corrosion b Check contactor coil resistance Cannot be opened infinite ohms Shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check 2HTCON 2 Current Draw Use Component Test Mode Refer to Section 5 2 2 to test actual current draw of the circuit Refer to Section 2 13 for correct electrical values View current draw in Data List Check 2HTCON 2 Wiring Inspect harness amp control box con nector pins amp terminals See wiring schematic Section 10 7 71 No physical damage to harness No damage moisture or corrosion in connectors 62 11524 Alarm Cause Corrective Action 107 CHECK 2LSV CIRCUIT TRIGGER ON Compartment 2 Liquid Solenoid Valve 2LSV circuit is shorted The 2LSV output from the microprocessor 8MP 18 is negative so the circuit will not be shorted to groun
44. 16 2 35 2 1 SP62 2 10 4 T1 L1 K9 IPCDM1 2 INTERNAL PROTECTORS CONDENSOR FAN MOTORS RS J J EVXV 6 2MP11 5 4MP2 CDCUN 5 CDM 4 gCDMe K9 IPEVM INTERNAL PROTECTOR EVAPORATOR FAN MOTORS 1D5 13 m 30 8 uit 2 INTERNAL PROTECTORS 2 COMPARTMENT EVAP MOTOR TO 2 6 G G Al na EVAP 2 2HTR2 2 L2 J13 LB LIGHT BAR OPTIONAL JE E DPIE N Anes EN IP EVAR 25 ZND COMPARTMENT LIQUID SOLENDID VALVE Evi MANIFOLD ABSOLUTE PRESSURE SENSOR 9 2 6 54 5 59 2c10 6 1 cj 3 15 MICROPROCESSOR 2MP13 D 2 1MP30 lt SP7 gt AMETS Oe all OPTIONAL CONTROL PANEL CONNECTOR CW VIEW FROM IN CDP 3 1 05 FET LEGEND AMPIA 1HTCON2 En D7 OPTIONAL CONTROL PANEL CONNECTOR JUMPER Af Pas CIE 2EVCON Ge DGF DVERLDAD GRDUND FAULT MODULE SP6 5 44 BIB 3 FET 1 CDCUN SP55 6 EVHTS A 701027 3 E4 PWR MICRO POWER 256 ip 5 lt 7 gt 2 CCDN 4MP13 5 am UN 43 014 PRM PHASE REVERSAL MODULE fc 1MP29 e 210 1016 03 814 POWER SOURCE CONTACTOR Na 3 1 IMPIS lt 16 3 4 4 10 10 2 10 8 12 POWER SOURCE CONTACTOR 2 io DPR 1MP30 3MP06 ATE ILK PSCON INTERLOCK 3 7916 5 1MP06 FET 7 AUTO RESTART LIGHT af W LS 015 PSCDNR
45. Check System Pressures Install manifold gauge set and check and compare compressor discharge amp suction pressures with those shown on the microprocessor dis play Suction pressure must be above 3 psig 0 2 bar Suction amp Discharge Pressures must have the same reading on gauges amp on microprocessor display NOTE Microprocessor suction CSP and evaporator EVOP pressure readings have a maximum value of 100 psig 7 5 bar The actual suction pressure must be lower than 100 psig in order to perform this test Manually Defrost Unit Defrost unit and terminate automati cally Typical defrost cycle time is 5 20 minutes Visually verify that all ice is cleared from evaporator coils in all compartments Perform Pretrip Check Clear Active Alarm list then run Pre trip amp check for any new alarms Any active alarms must be corrected and cleared before proceeding Check Unloader Operation Check Front UL1 and Rear UL2 Unloaders Refer to Alarms 85 and 86 Check CSMV a Check compressor suction modulation valve Refer to Section 8 8 5 b Check airflow with unit running Even airflow through the entire coil No dead spots 62 11524 Additional steps on the next page Steps Alarm Cause Corrective Action LOW REFRIGERANT PRESSURE Continued 7 Check Evaporator Sections a Check evaporator section in all compartm
46. Check for voltage at switch plug between pins A and B ground Energize circuit See Note 2 page 7 2 Voltage should be approximately 12 VDC If OK skip to step 4 if not continue with step 3 Check Engine Oil Switch Harness a Inspect harness amp control box connector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors b Check for shorted circuit in harness and continuity through the harness Check for voltage from 2MP17 to plug terminal A Check for ground at plug terminal B Check Switch Remove switch connect to an external pressure source and test Contacts closes on a pressure rise at 15 psig 1 02 bar Contacts open on a pressure fall at 12 psig 0 82 bar Check Engine Oil Pressure 62 11524 Connect mechanical oil gauge 7 4 Oil pressure must be greater than 15 psig 1 02 bar um Alarm Cause Corrective Action 12 HIGH COOLANT TEMPERATURE e TRIGGER ON When in Engine Operation for ambient temperatures below 120 F 48 9 C Engine coolant temperature is above 230 F 110 C or Ambient temperatures above 120 F 48 9 C engine coolant temp is over 241 F 116 C or Engine coolant temperature is between 230 and 241 F 110 and 116 C for more than 5 minutes UNIT CONTROL Engine Operation Engine and unit shutdown and alarm Standby Operation Will not activate in stan
47. Sample Calculations Setpoint Supply Air Limit Configuration Value Setpoint minus Supply Air Limit Coldest Supply Air Temperature allowed EXAMPLE 2 Perish Sensitive Product Functional Parameter ON Supply Air will be limited to Setpoint minus configuration value for Supply Air Limit Sample Calculations Setpoint Supply Air Limit Configuration Value Setpoint minus Supply Air Limit Coldest Supply Air Temperature allowed 4 7 3 Temperature Range Lock 1 amp 2 Range Lock is a group of Configurations which may be set to lock the unit into Start Stop or Continuous Operation for various setpoint ranges NOTE Range Lock is applicable to Compartment 1 only When Compartment 1 is operating under Range Lock all compartments will operate in Start Stop Operation or Continuous Operation according to the setting for Compartment 1 For that reason Range Lock is not recommended for use when another compartment s is en abled Two ranges are available for selection Each Range can be independently set to lock it s setpoint temperatures into either Start Stop or Continuous operation Each Range has it s own selectable minimum and maximum temperature which define the span of the range If some setpoint temperatures are contained in both ranges due to range overlap Range 1 will always have priority over Range 2 For example see Figure 4 4 if Continuous Operation is ALWAYS required whenever the setpoint is b
48. Tighten and check for discoloration of wires Check Motor Operation Turn the unit ON Check current on each phase Refer to Section 2 12 for correct electrical values Check voltage on each phase must be at least 440VAC Check Compartment 3 Evaporator Motors Disconnect power plug at motor Test IP circuit for continuity using ohmmeter If open remove and replace motor If closed then an intermittent IP circuit is suspect Check phase to phase and phase to ground for short or open circuits If motor tests good check the DC IP circuit to microprocessor Perform Pretrip Check Run Pretrip amp check for alarms 7 69 Any active alarms must be corrected and cleared before proceeding 62 11524 Alarm Cause 103 CHECK 2 1 RELAY COIL TRIGGER ON Remote heater contactor 1 2HTCON1 circuit is shorted The contactor output from the microprocessor 3MP34 is negative so the circuit will not be shorted to ground but is shorted either within the contactor coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again Corrective Action NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appro
49. Timing must be correct b Check engine valve adjustment Rocker arm clearance must be correct c Check engine compression Compression must be above 400 psig 27 2 bar Check refrigeration system Check discharge amp suction pressures 7 35 Must be within normal operating range for conditions 62 11524 AOT Alarm Cause Corrective Action 7 6 WARNING STATUS ALARMS 51 ALTERNATOR NOT CHARGING This alarm applies to the Battery Charger TRIGGER ON Unit is running in either Engine or Standby Operation and the current flow is more than 1 0 amps discharge between the battery charger and the battery for 3 continuous minutes e UNIT CONTROL is set to YES configure alarm Engine Operation alarm only or if Alternator Check Shutdown configuration d for shutdown engine and unit shutdown and Standby Operation alarm only regardless of configuration setting RESET CONDITION Auto Reset if not shutdown when alternator is charging if not shutdown change unit to standby Operation or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Microprocessor Curr
50. c Check compressor amp draw on all 3 legs CCON high voltage circuits d Check heater amp draw 1 1HTCON2 2HTCON1 2 2 1 3HTCON if applicable Verify that all three actual amperage readings for each component are within 1096 of each other and are within the values shown in Section 2 12 Check Generator Voltage If Used When Alarm Occurred Check voltage at GENCON L1 L2 L1 L3 L2 L3 Must be within voltage limits shown in Section 2 12 Check Power Source Voltage If Used When Alarm Occurred Check voltage at PSCON L1 L2 L1 L3 L2 L3 Must be within voltage limits shown in Section 2 12 Check Voltage Output From Contactors a Check voltage at GENCON T1 T2 T1 T3 T2 T3 Must be within voltage limits shown in Section 2 12 b Check voltage at CCON with com pressor operating T1 T2 T1 T3 T2 T3 Must be within voltage limits shown in Section 2 12 Verify AC Current Sensor Accuracy CT2 amp CT3 Power the microprocessor by tog gling the Main Power switch out of the OFF position Unit AC Current 1 and 2 reading in Data List must be 0 0 1 0 amp Defective Overload Ground Fault OGF Detector Opens prematurely Remove and replace 62 11524 Alarm NO Corrective Action Alarm Cause 27 HIGH SUCTION PRESSURE e TRIGGER ON The refrigeration system is running and the suction pressur
51. card into computer and re install the correct bex file NO Y Software has finished YES Is the card status LED on solid loading NO Y There is a problem loading Has the card status the software Turn unit Is the card status LED ashing 1 2 LED been illuminated for Main Power switch second on and 1 2 second off more than 5 minutes off Remove the Program card and try again NO NO y Y Micro does not recognize the card Try another Wait at least 5 minutes program card or use MicroProgrammer Figure 9 12 Micro Diagnostic Tree Cond 8 Programming Problems With PC Cards 9 21 62 11524 SECTION 10 WIRING PARAGRAPH NUMBER Page 10 1 HARNESS PLUG WIRING FOR UNITS WITH MAIN POWER SWITCH LABELED ENGINE ta tl nadine CM SCA 10 1 10 2 HARNESS PLUG WIRING FOR UNITS WITH MAIN POWER SWITCH LABELED IIIA sl M Ceu 10 7 10 3 CONTROL BOX INTERIOR SPLICE POINTS FOR UNITS WITH MAIN POWER SWITCH LABELED ENGINE OFF STANDBY cici adesioni aiiai xh ok ann ka 10 13 10 4 CONTROL BOX INTERIOR SPLICE POINTS FOR UNITS WITH A MAIN POWER SWITEH LABELED S PAHTIBUN QEE 5255 esa Rcs Ioa m cR races ADR a codename 10 14 hs DISPLAY TEST POINTS Ed AGERE da ROGA dee OL 10 15 106 WANG SCH
52. e UNIT CONTROL Engine Operation engine and unit shutdown and alarm Standby Operation refrigeration system shutdown and alarm with PSCON still energized e RESET CONDITION Auto reset after 15 minutes or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check System Pressures Install manifold gauge set and check Suction amp Discharge Pressures must have the same and compare compressor discharge reading on gauges amp on microprocessor display amp suction pressures and evaporator NOTE Microprocessor suction CSP and evaporator outlet pressure with those shown on EVOP pressure readings have a maximum value of the microprocessor display 100 psig 7 5 bar The actual suction pressure must be lower than 100 psig in order to perform this test Check Refrigerant Charge Check for undercharged system Refer to Section 8 6 2 Check For Restricted Evaporator Airflow Check for restricted evaporator air Check for proper Evaporator Fan operation in all flow in all enabled compartments compartments Refer to Section 8 9 6 Check for correct Evaporator Fan rotation in all com
53. 0 3 to 0 7 bar with refrigerant from the high side by turning the liquid line service valve off frontseat for a few seconds and then returning to frontseat WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 psig 159 9 bar Do not use oxygen in or near a refrigerant system as an explosion occur See Figure 8 30 5 Connect a cylinder of dry nitrogen Use the nitrogen to increase the low side pressure to 20 to 150 psig 1 4 to 10 2 bar to detect the leak The larger the leak the less pressure is required The smaller the leak the greater the pressure required 6 The recommended procedure for finding leaks from a system is with an electronic leak detector Checking joints with soapsuds is satisfactory only for locating large leaks or pinpointing small leaks once a general area has been located Once leak checking is complete remove the refriger ant nitrogen vapor from the low side of the system 8 If no leaks are found the low side of the system is ready for evacuation Skip to Step 11 9 If any leaks are found they must be repaired before proceeding 10 Repeat steps 4 thru 9 as necessary 11 Disconnect the nitrogen cylinder Evacuate the low side of the system after all leaks are repaired Refer to Section 8 6 4 d Leak Checking Compressor The compressor and its associated switches transducers etc must be leak checked once the compr
54. A United Technologies Company Carrier Transicold Division Carrier Corporation Truck Trailer Products Group P O Box 4805 Syracuse N Y 13221 U S www carrier transicold com
55. AULA RO dad AE PAOLO ROLE RR 2 9 a NOE NOUIS CK E DESEE dE A 2 9 2 10 2 11 2 3 7 Compressor Switches Transducers and Sensors 2 11 a Compressor Discharge Pressure Transducer CDP 2 11 b Compressor Suction Pressure Transducer 2 11 Compressor Discharge Temperature Sensor CDT 2 11 Compressor Suction Temperature Sensor CST 2 12 FR 2 12 253 Lhe t died 2 12 2 3 9 Ambient Air Temperature Sensor 2 12 exce Eam i ERI c CC rm 2 12 BOTT CDS 2 12 24 COMPARTMENT SECTION 2 12 oct do 2 12 2 12 Expansion Value EVXV kg PR ered anes boa dees GOL RE 2 12 248 2 2 2 iota e xad ub ala Sea ela dO Gabi up dated 2 12 2 4 4 Compressor Suction Modulation Valve 2 12 245 Compartment 1 Evaporator Switches Transducers and Sensors 2 12 a Evaporator Outlet Pressure Trans
56. Low Speed 6 Cylinder 1 8 F 1 0 C 1 6 F 0 9 C Low Speed 4 Cylinder COOL 1 1 0 6 0 9 F 0 5 C Low Speed oy 0 4 F 0 2 C 2 Cylinder COOL 0 4 0 2 C 0 4 F 0 2 C 0 5 F 0 3 C Low Speed HEAT HTCON1 ere 3 2 F 1 8 C Pull Up HEAT HTCON1 amp HTCON2 RISING REFRIGERATED COMPARTMENT TEMPERATURE SWITCH POINT Switch Point Controlling Temperature Setpoint results are above setpoint results are below setpoint Switch points are the same for Perishable Range and Frozen Range except in Frozen Range heating is not allowed If the HIGH SPEED PULLDOWN Configuration is set to YES transition from pulldown is delayed from the indicated 3 2 F 1 8 C transition temperature until the temperature is 0 36 F 0 2 C above setpoint Figure 4 2 Continuous Operation Switch Points with Eco Mode set to NO 4 7 62 11524 FALLING REFRIGERATED COMPARTMENT TEMPERATURE SWITCH POINTS N Pulldown High Speed Transition to low speed at 6 Cylinder COOL Enter high speed at Start Start Stop Override Stop Override Functional Functional Parameter Parameter Value 2 Value 1 7 2 to 23 4 F 4 to 12 C 5 4 to 19 8 F 3 to 11 C Low Speed 6 Cylinder Enter cool at Start Stop COOL Override Functional Parameter Value 3 6 to 18 F 2 to 10 C 1 3 F 0 7 C 1 4 F 0 8 C 3 2 F 1 8 C 3 6
57. Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Model Number Verify that the model number on the nameplate matches the model num ber shown in the microprocessor Un it Data Enter the correct number in the data list Refer to Section 3 13 Check the fuel speed actuator Check FSA plunger Must move in and out freely Force high speed operation See Note 5 page 7 2 a Set Functional Parameter LOW SPEED START to zero and adjust setpoint at least 10 F 5 6 C above or below refrigerated compartment temperature then start the unit Set Functional Parameter back to original setting after complet ing repairs LED 27 must be ON Check operation of Speed Relay LED 27 must be ON Check voltage to FSA Must be 12 14 VDC Check resistance of FSA Refer to Section 2 13 for correct electrical values Check amp draw of FSA Use Component Test Mode to energize the Speed Relay circuit Section 5 2 2 Refer to Section 2 13 for correct electrical values View current draw in the Unit Data Refer to Section 3 13 f Inspect harness amp control box connector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors Check for proper voltage to the Engine Speed Control Unit ENSCU Pin 16
58. Refer to Section 8 6 2 Check Airflow Through Condenser Coil a Inspect condenser amp radiator Ninety percent or more of the coil surface must be undamaged No dead air spaces Condenser coil and radiator must be clean b Check airflow with unit running Even airflow through the entire coil No dead spots Check CSMV Check compressor suction modulation valve Refer to Section 8 8 5 Check System Pressures Install manifold gauge set and check and compare compressor discharge amp suction pressures with those shown on the microprocessor dis play Suction amp Discharge Pressures must have the same reading on gauges amp on microprocessor display NOTE Microprocessor suction CSP and evaporator EVOP pressure readings have a maximum value of 100 psig 7 5 bar The actual suction pressure must be lower than 100 psig in order to perform this test Perform Pretrip Check Clear Active Alarm list then run Pre trip amp check for any new alarms Any active alarms must be corrected and cleared before proceeding Check Compressor Reed Valves amp Gaskets Remove compressor heads amp in spect condition of all reeds amp gas kets Must be in good condition Install new parts and gas kets as required Check Expansion Valve EVXV Check operation of valve Refer to Section 8 8 6 Check System For Non Condensab les Check r
59. T NO v Unit may be running old software Upgrade software from http www transcentral carriercom Did you find and correct the condition T NO v Check functional parameter settings for air flow Does the setting show high NO Check setpoint System OK Is setpoint 10 4F Is setpoint 10 5F lower higher Is selected probe temperat NO ure greater than 3 6F from setpoint Is return air temperature equal to or colder than YES setpoint i Is speed relay LED27 NO illuminated on the YES micro Did you find and correct the condition Is there a voltage of 12V or higher at QC3 Check wiring for high resist y r ance or shorted con System OK NO nections Did you find and y correct the condition Is there 12V or higher at the ENSCU module pin 16 or FSA YES Check the ENSCU or FSA Did you find and correct the condition NO Review the test results with your supervisor If necessary go to the beginning of the tree and test again Figure 9 9 Micro Diagnostic Tree Cond 5 Unit Will Not Run In Low Speed 62 11524 9 18 CONNECTION OK Are the dates for the data on the download screen DataLink data recorder date amp time may be set wrong Set the corr
60. VAN aM WARNING 62 03957 00 amp 01 High Voltage 62 03958 00 Heat Warning UNIT MAY START AT ANY TIME SEPARATION OF GENERATOR IF THE ROTOR AND STATOR WILL RUN STOP CREATE A STRONG MAGNETIC SWITCH FIELD THAT CAN INTERFERE IS IN THE WITH CARDIAC IMPLANTS SUCH AS PACEMAKERS POSITION AND DEFIBRILLATORS 62 10358 00 REV A 62 02450 00 REV D NOTE The unit may be equipped with a KEEP CLEAR OF Diesel Off Standby switch DOES ROTATING BELTS or a START RUN OFF switch SROS The unit may start if the AND PULLEYS applicable switch is not in the OFF position 62 02144 03 REV D 1 7 62 11524 CAUTION THE ENGINE SPEED ON THIS UNIT MUST BE SET AT 1350 RPM ON LOW SPEED AND AT 1800 RPM ON HIGH SPEED INCORRECT SPEED SETTINGS MAY CAUSE THE GENERATOR TO RUN AT THE WRONG VOLTAGE J 62 11450 00 A WARNING CONTAINS AIR HEATER THAT COULD IGNITE FLUIDS NEVER USE STARTING AIDS INCLUDING ETHER FIRE AND SERIOUS INJURIES COULD RESULT 62 11302 REV C 2 CAUTIO RADIATOR COOLANT A INSTRUCTIONS _ TOP COOLANT INTO REMOVE RECOVERY BOTTLE ONLY FILLER CAP FILL EMPTY RADIATOR THROUGH SLOWLY FILLER NECK SLOWLY TO AVOID AIR 62 02142 REV B ENTRAPMENT REPLACE CAUTION COVERS AFTER SERVICING BATTERY TO INSURE PROTECTION OF BATTERY AND TERMINALS 62 02505 REV
61. lection is now in memory e Press the UP ARROW Key to continue to scroll through the Configuration list 5 2 2 Component Test Mode WARNING If the unit is Standby Operation and powered voltage will be applied to high voltage components i e the fan motor con tactor and those components will operate i e the fan blades will turn when those components are energized using Compon ent Test Mode 62 11524 Component Test Mode allows the technician to energize individual circuits for 5 minutes at a time The engine or compressor when in Standby Operation is not allowed to start when the microprocessor is in Component Test Mode To enter the Component Test Mode Enter the Technician Interface Component Test Mode as described in Section 5 2 b To read through the Component Test list press either the UP or DOWN ARROW keys The list is circular meaning that once the end is reached it is repeated from the beginning Refer to Table 5 1 for a list of component tests available Once the desired test is displayed the Mes sageCenter press the key to select that test For example if Buzzer is selected the buzzer will come on and BUZZER OFF IN 5 MINUTES will display in the MessageCenter The minutes will count down to 0 at which time the buzzer circuit will be de energized and the MessageCenter will display the last compo nent tested Should you need more than 5 minutes the timer
62. may be tested at the component plug The switch and interconnecting wiring may also be tested at the 1MP 2MP OC or EVC plug Remove plug and referring to the wiring schematic check for voltage from the micro processor through the switch to ground or from the voltage source through the switch to the microprocessor as applicable Some tests can only be conducted while the unit is operating The unit may be started au tomatically in either Engine Operation or Standby Operation For units equipped with a Main Power switch labeled ENGINE OFF STANDBY DOES place the DOES in the ENGINE or STANDBY position as desired For units equipped with a Main Power switch labeled START RUN OFF SROS place the switch labeled STANDBY ENGINE DES in the ENGINE or STANDBY position as desired and then place the SROS in the START RUN position ANS Alarm Cause Corrective Action 7 3 DRIVER OPERATOR ALARMS 1 LOW FUEL LEVEL WARNING Note This is an optional alarm which will not occur unless a fuel level sensor is present and configured ON e TRIGGER ON Fuel level is 15 or less for more than 30 seconds e UNIT CONTROL Engine Operation Alarm only Standby Operation this alarm will not activate in standby Operation e RESET CONDITION Auto reset when the fuel level is above 17 for more than 30 seconds or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until
63. when unit is operating Compressor gasket s defective 8 7 1 9 4 9 Abnormal Noise Loose mounting bolts Tighten Worn bearings 8 7 1 Compressor Worn or broken valves 8 7 1 Liquid slugging 9 4 11 9 4 12 Insufficient oil 8 7 5 Loose or striking shroud Check Condenser or evaporator fan Bearings defective 8 9 6 8 9 7 Bent shaft 8 9 6 8 9 7 Water pump belt Cracked or worn Replace 9 4 10 No Evaporator Air Flow Or Resiricted Air Flow Frost on coil 8 8 9 Evaporator coil blocked Dirty coil 88 1 Evaporator fan loose or defective 8 9 6 is usa evaporator Evaporator fan rotating backwards 8 9 6 Evaporator air flow blocked in refrigerated compartment Check 62 11524 9 6 Indication Trouble Possible Causes Action Refer ence Section 9 4 11 Evaporator Expansion Valve EVXV Malfunction not controlling correctly Compartment 1 only Low refrigerant charge 8 6 2 EVOT defective 8 9 10 EVOP defective 8 8 8 Coil not seated properly on valve heck EVXV inlet screen plugged Check and Re place Loose connector Check and Tighten 9 4 12 Evaporator Expansion Valve TXV Malfunction Low refrigerant charge 8 6 2 External equalizer line plugged Clean TXV not controlling correctly Ice formation at valve seat 8 6 4 Compartment 2 or 3 Wax or dirt plugging the valve or orifice 8 8 11 Broken capillary Loss of bulb charge 8 8 11 Superheat setting too high
64. 16 30 87 m Nyt xls 2 COMPARTMENT 477 777 Based 62 11451 6 56 P A B D E G H I J K L M N u P Q R U V X Y A Air Cleaner 2 9 8 11 Air Cleaner Service Indicator 2 9 8 11 Air System Engine 2 9 Alarms Driver Operator 7 3 Alarms Electrical 7 50 Alarms Maintenance 7 129 Alarms Microprocessor 7 133 Alarms Pretrip 7 90 Alarms Sensor 7 75 Alarms Shutdown 7 4 Alarms Start Up Engine 7 22 Alarms View Active 3 15 Alarms View Inactive 3 16 Alarms Warning Status 7 36 Battery 1 1 Battery Charger 2 9 8 39 9 3 Belt Water Pump 8 14 Blower Evaporator 8 37 Cargo Protect Mode 4 13 Charge Adding Complete 8 17 Charge Adjusting Level 8 16 Charge Checking 8 15 Charge Removing 8 15 Coil Condenser 2 12 8 27 Coil Evaporator 2 12 2 13 8 26 Component Test Mode 5 2 Compressor 2 9 Compressor Data 2 20 Compressor Cylinder Head 8 22 Compressor Oil Level 8 24 Compressor Oil Pump And Bearing Head 8 23 Compressor Removal and Replacement 8 21 INDEX Compressor Repair or Replacement Determination 8 20 Compressor Valve Plate 8 22 Configuration Mode 5 2 Configurations Microprocessor 5 12 Configurations Start Stop 4 4 Controls Engine 2 9 coolant capacity 2 19 Coolant Engine 1 1 Cooling System 8 13 Crankcase Breather 8 14 8 17 Current Draw Component 2 21 D Data Recorder 3 27 Data Component Resistance
65. 2 3 9 Ambient Air Temperature Sensor AAT The AAT provides microprocessor with condenser entering air temperature information to be displayed recorded in the DataLink data recorder and used to control the refrigeration system The sensor is located behind the front grill 2 3 10 Filter Drier The filter drier is a cylindrical shell containing a drying agent and filter screen It is installed in the liquid line and functions to keep the system clean and remove mois ture from the refrigerant 2 3 11 Receiver Liquid refrigerant from the condenser flows into the re ceiver The receiver serves as a liquid reservoir when there are surges due to load changes in the system as a storage space when pumping down the system and as a liquid seal against the entrance of refrigerant gas into the liquid line The receiver is provided with two bull s eye sight glasses for the observation of liquid level amp moisture content and a fusible plug 2 4 COMPARTMENT 1 EVAPORATOR SECTION The evaporator See Figure 2 4 fits into a rectangular opening in the upper portion of the front wall of compart ment 1 When installed the evaporator section is lo cated inside the compartment and the condensing sec tion is outside The evaporator assembly consists of an evaporator coil evaporator fan motor electronic expansion valve coil heaters heat exchanger defrost termination temperat ure sensor the supply and return air sensors and a high
66. 5 VDC for Display processor and LCD 11 5 Brown Display ground TP10 Pin 6 Orange TX the serial communications from the control to the display TP9 Pin 7 Blue RX the serial communications from the display to the control TP8 Pin 8 Yellow Display ground VOLTAGE TESTS Negative Test Lead Positive Test Lead Voltage Reading TP13 TP14 12 TP13 TP12 5 TP13 11 0 TP13 TP8 0 11 14 12 11 TP8 0 TP8 TP14 12 10 6 WIRING SCHEMATIC The wiring schematics are provided on the following pages 10 15 62 11524 10 11 le 13 14 15 16
67. 53 to 158 F 47 to 70 C UNIT CONTROL Engine and standby alarm only and superheat for EVXV will be calculated using SAT RESET CONDITION Auto Reset when Evap Temp Sensor is in range or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check Evap Temp Sensor 10 000 Ohms 77 F 25 C See Table 8 5 for resistance See Note 3 page complete table of temperatures and resistance 7 2 values Check Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins terminals 1MP No damage moisture or corrosion in connectors amp DP16 see wiring schematic Section 10 Power up the microprocessor see Voltage should be 2 5 VDC volts at harness plug be Note 2 page 7 2 Disconnect tween pins This verifies microprocessor output and sensor from harness Check for wiring connections to sensor 2 5 VDC at harness plug between pins 7 83 62 11524 Alarm Cause Corrective Action 133 CHECK REMOTE TEMP SENSOR
68. CARD LOCKED REMOVE CARD The lock switch on the PC Card is in the Locked position To use the PC Card move the switch to the Unlocked position CARD REMOVED DATA NOT COPIED The PC Card was removed before all data was copied onto the card CARD REMOVED REINSERT CARD The PC Card was removed from the card slot before the operation was completed Reinsert the PC Card into the card slot to perform the operation CFG LOAD TO CANCEL A Configuration Card has been inserted into the PC Card slot Press the key to load configurations into microprocessor CHARGE MODE HOLD TO EXIT Service Mode has the refrigeration system set so that it can be charged with refrigerant through the liquid line service valve Press the key to manually exit or wait until the charging is complete CHECK AT NEXT SERVICE INTERVAL The unit needs to be checked at next service interval There is currently an active non shutdown alarm in the alarm list CHECK DOOR Door switch indicates that a refrigerated compartment door is not closed CHECK FUEL LEVEL Requires Optional Sensor The level in the fuel tank is very close to empty CHK WIRES FROM MICRO TO KEYPAD There is a communication signal lost between the keypad display and control module Check and test the wiring to the keypad dis play COMPONENT TEST MODE Pressing the key while this message is being displayed will allow user ac
69. DataTrak is an optional feature The DataTrak option is installed by inserting a DataTrak PC Card into the PC Card slot of the microprocessor and following the on screen instructions on the keypad 62 11524 3 28 The DataTrak Option installation can be confirmed by scrolling through the Unit Data refer to Section 3 13 DataTrak will be listed under the Installed Options head ing if it is installed Once DataTrak is installed the Advance Micropro cessor must be properly configured for the provider that will be connecting to it This is done in the configuration list refer to section 5 2 1 The Satellite Com configura tion can be set for Qualcomm or Other If the provider is Qualcomm T2 Trailer Tracs 2 or any other provider then the Other setting is used If the pro vider is Qualcomm Trailer Tracs then the Qualcomm setting is used Carrier Transicold has worked with approved commu nication providers with recommended installation loca tions and wiring connections to Carrier units Instruc tions for installing this equipment is supplied by each individual provider and not by Carrier Transicold Com munications electrical harnesses and serial port split ters are available from Carrier Transicold Performance Parts Group PPG Communication Providers will connect into the wiring harness at the SATCOM port Testing the SATCOM port may be done using a serial port to PC cable 22 01690 00 and the ReeferManager p
70. Intake Air Heater Relay IAHR RELAY OFF IN X MINS Heater Contactor 1 1 HEATER CONT 1 OFF IN 5 MINS Heater Contactor 2 1HTCON2 HEATER CONT 2 OFF IN 5 MINS C2 Heater Contactor 1 2HTCON1 C2 HEATER CONT 1 OFF IN 5 MINS C2 HEATER CONT 2 OFF IN 5 MINS C2 Heater Contactor 2 2HTCON2 C3 Heater Contactor 1 1 C3 HEATER CONT 1 OFF IN 5 MINS Heater Contactor 2 2 C3 HEATER CONT 2 OFF IN 5 MINS Evaporator Motor Contactor 1EVCON EVAPORATOR CONT 1 OFF IN 5 MIN C2 Contactor 2EVCON EVAPORATOR CONT 2 OFF IN 5 MIN Contactor EVAPORATOR CONT 3 OFF IN 5 MIN Power Supply Contactor Relay PSCONR POWER SUPPLY CONT OFF IN X MIN Compressor Motor Contactor Relay CCONR COMPRESSOR CONT OFF IN X MINS Condenser Motor Contactor CDCON CONDENSER CONT OFF IN X MINS Generator Contactor Relay GENCONR GENERATOR CONT OFF IN 5 MINS C2 LSV C2 LSV OFF IN 5 MINS C3 LSV C3 LSV OFF IN 5 MINS Main Menu Press the key to go back to the the Configuration Mode or Service Mode selection menu Press the down or up arrow to continue scrolling the component test list 5 2 3 Service Mode CAUTION Service Mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating NOTE If the Main Power switch is toggled to the
71. May or may not be displayed depending on Parameter Configuration settings C2 RETURN AIR TEMP Compartment 2 Return air entering evaporator temperature RETURN AIR TEMP Compartment 3 Return air entering evaporator temperature SUPPLY AIR TEMP Compartment 1 Supply air leaving evaporator temperature C2 SUPPLY AIR TEMP Compartment 2 Supply air leaving evaporator temperature If installed DELTA T Supply air temperature minus return air temperature a negative value in dicates cooling and a positive value indicates heating AMBIENT AIR TEMP Ambient air entering condenser air temperature DEFROST TERM TEMP 1 Compartment 1 Defrost termination temperature C2 DEFROST TERM TEMP Compartment 2 Defrost termination temperature DEFROST TERM TEMP Compartment 3 Defrost termination temperature SUCTION LINE TEMP Suction line temperature at the compressor EVAP OUTLET TEMP Suction line temperature leaving the compartment 1 evaporator outlet COMP DISCHARGE TEMP Compressor discharge temperature BATTERY Battery voltage CURRENT DRAW DC Battery charging or discharging amps ENGINE RPM Engine speed UNIT AC CURRENT 1 High voltage current draw on circuit 1 UNIT AC CURRENT 2 High voltage current draw on circuit 2 SUCTION MOD VALVE open of CSMV FUEL LEVEL This is only displayed when the sensor is configured ON of fuel in tank E
72. NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 2 Light Bar Wiring a Inspect light bar amp connector No damage to light bar No damage moisture or corrosion in connector b Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damage moisture or corrosion in connectors wiring schematic Section 10 Check 2 Light Bar Check operation of 2 Light Bar Refer to Section 8 9 3 for information on testing the 2 Light Bar 7 57 62 11524 Alarm NO 85 CHECK UL1 CIRCUIT TRIGGER ON Front Unloader UL1 circuit is shorted The UL1 output from the microprocessor SMP12 is negative so the circuit will not be shorted to ground but is shorted either within UL1 itself or to a positive wire Alarm Cause Corrective Action UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset when the UL1 Coil current amp draw is normal or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above
73. Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Front Unloader 0111 Coil a Inspect Front Unloader UL1 coil amp connector No damage to coil No damage moisture or corrosion in connector b Check resistance of coil Refer to Section 2 13 for correct electrical values Cannot be opened infinite ohms shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check Front Unloader UL1 Current Draw Use Component Test Mode to test actual current draw of the circuit Refer to Section 5 2 2 Refer to Section 2 13 for correct electrical values View current draw in Data List Check Front Unloader UL1 Coil Wiring 62 11524 Inspect harness amp control box con nector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors Alarm NO Alarm Cause Corrective Action 86 CHECK UL2 CIRCUIT TRIGGER ON Rear Unloader UL2 circuit is shorted The UL2 output from the microprocessor SMP23 is negative so the circuit will not be shorted to ground but is shorted either within UL2 itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset when the UL2 Coil current
74. Remove coil and unbraze valve Clean all tube stubs so new valve fits on easily 3 Use a wet rag to keep the replacement valve cool and braze in place 4 Leak check and evacuate the low side Refer to Sec tions 8 6 3 and 8 6 4 8 8 7 High Pressure Switch a Replacing High Pressure Switch 1 Pump down the compressor Refer to section 8 6 2 2 Disconnect wiring from switch and remove switch 3 Install switch after verifying switch settings Refer to following step b 4 Leak check and evacuate the compressor Refer to Sections 8 6 3 and 8 6 4 b Checking High Pressure Switch WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 PSIG 160 bar Do not use oxygen in or near a refrigerant system explosion occur See Figure 8 30 Cylinder Valve and Gauge Pressure Regulator Nitrogen Cylinder Pressure Gauge 0 to 400 PSIG 0 to 27 2 bar Bleed Off Valve Switch oo Figure 8 30 Typical Setup for Testing High Pressure Switch 8 31 Remove switch as outlined in preceding section Connect ohmmeter or continuity light across switch terminals Ohmmeter will indicate resistance and continuity light will be illuminated if switch closed after relieving pressure Connect switch to a cylinder of dry nitrogen See Figure 8 30 Set nitrogen pressure regulator higher than open set ting for switch being tested For p
75. TEMP Displays maximum temperature setting for Range 2 Will only be dis played if Range Lock 2 is ON TEMPERATURE REMOTE Will only display when one or more of the optional sensors are con SENSOR 1 or 2 figured ON 2 Compartment units only Displays temperate reading of remote Temperature Sensor 1 or 2 DATALOGGER DataLink Displays the current Date and Time that the DataLink data recorder is data recorder using This may be different than local time depending on the Time Zone and Daylight Savings 3 19 62 11524 3 14 VIEW HOUR METERS HEAT COOL DEFROST ALARM START STOP CONTINUOUS 20 34F 1 SETPOINT BOX TEMPERATURE TOTAL ENGINE HOURS 0 HRS 1 Press the SELECT key until the MessageCenter dis plays PRESS Tl TO VIEW HOURMETERS 2 Press the green UP ARROW key The MessageCenter will display PRESS TL TO SCROLL THEN TO LOCK Continue to press the green UP ARROW key to move down the hour meter list or press the DOWN ARROW key to move up the list Displayed hour meters will depend on microprocessor configurations refer to Table 5 2 Typical displayed meters are TOTAL ENGINE HOURS STANDBY RUN HOURS and TOTAL SWITCH ON HOURS 4 Pressing the key will access all other meters and display OTHER METERS AND COUNTERS 5 The selected hour meter will remain in the MessageCenter for 10 seconds then the default message STATUS or other c
76. UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during Test 3 by holding Key for 6 seconds d Review active alarm list for Alarm If alarm is present follow steps 2 thru 5 If alarm is 187 not present follow steps 6 thru 9 Check 1HTCON1 a Inspect heater contactor coil and No damage to coil wire connections Wire connections to contactor coil are tight No damaged or corroded wires to contactor coil b Check contactor coil resistance Refer to Section 2 13 for correct electrical values Check 1HTCON1 Amp Draw Check 1HTCON1 amp draw Use Component Test Mode Section 5 2 2 to test Refer to Section 2 13 for correct electrical values View current draw in Data List Check 1HTCON1 Wiring Inspect harness amp control box con No physical damage to harn
77. USER SELECTED OVERRIDE OPERATION uae bad iar ete dos tex deos cog a nat ce 4 10 42721 PHONY CODING 52 eee Wax Sea Ries eee PPP 4 10 47 2 Supple 4 10 8723 Temperature Range 2 4 11 4 8 PREPROGRAMMED SOFTWARE OVERRIDES 4 13 45 1 argo Protec MOUB 4 13 4 8 2 Compressor Minimum Operating Time 4 13 453 ec eis tees RES 4 13 4ga Unibader Control bt eb Et jena beds E MER ERE d 4 14 ASS Dietrost Say Ovens E 4 15 MICROPROCESSOR INTERFACE 5 1 1 WNTEREADE METHODS 5 1 52 TECHNICIAN INTERFACE ane 5 1 1 UNIV AN EE 5 2 Component Test MOUE nie 5 2 523 5 3 C61 bis c e Ec TT 5 4 nd ILES 5 4 Handing PO Cas ADR et 5 4 5348 PO OCA dE A Eoo EE So OA Reda d ewes 5 5 543 5 6 gda DU PECAN p bed Sepa 5 6 5 15 Bownlosd PO DSi dori p Rat eoe c aec Erb e p do eni 5 6 SS REEFERMANAGER S REPORTS
78. When a PM hour meter is configured as a Mainten ance Days meter that meter will not count a specif ic instance such as hours of operation or number of cycles for a particular component The meter is connected to the real time clock and will activate the alarm after the entered number of days has elapsed OFF If both Range Locks are OFF the unit will operate normally If either Range 1 or Range 2 is not OFF the unit will operate as selected whenever the setpoint is within that range START STOP The unit will always operate in Start Stop whenever the setpoint is between the minimum amp maximum temperatures for that range see the following sub configurations CONTINUOUS The unit will always operate in Continuous Run whenever the setpoint is between the minimum amp maximum temperatures for that range see the following sub configurations Select the lowest temperature desired for this Range Select the highest temperature desired for this range 62 11524 Table 5 2 Microprocessor Configurations Continued selections 22 F TO 89 6 F Indicates to the microprocessor the desired minim MIN SETPOINT 30 C to 32 C um allowable set point Applies to Compartment 1 in 0 1 F or C in crements 22 F 89 6 F Indicates to the microprocessor the desired maxim MAX SETPOINT 30 to 32 C um allowable setpoint Applies to Compartment 1 in 0 1 F or C in crements C2 MINIMUM
79. and the unit continues to run due to another compartment not yet in range or another stop parameter has not been reached the off compartment will cycle back on when the temperature in that compartment moves above set point more than 3 6 F 2 0 C or below setpoint 5 5 F 3 0 C when the setpoint is in the perishable ange or 1 8 F 1 0 C when in the the f S S COMPARTMENT MODE ies ECONOMY When individual compartments reach setpoint and cycle off and the unit continues to run due to another compartment not yet in range or another stop parameter has not been reached the off compartment will cycle back on when the tem perature in that compartment moves above or be low setpoint by the Off Time Override Temperature Functional Parameter setting STAY ON CYCLE STAY ON The evaporator fan will operate F OFF CYCLE OFF The eva i porator fan will cycle off un FRESE NOLE FANS less the setpoint is between 14 to 41 F 10 to 5 C in which case they will remain on STAY ON CYCLE STAY ON The evaporator fan will operate FROZEN NUME MODE FANS CYCLE OFF The evaporator fan will not operate 5 21 62 11524 Table 5 2 Microprocessor Configurations Continued Selections Descipion OFF Frozen priority cooling is not active ON ON Frozen priority cooling is active FROZEN COMPARTMENT HIGH CAPACITY HIGH CAPACITY Frozen priority is active and PRIORITY compartments wi
80. b If no fault was found in previous tests Remove and replace contactor 7 112 Alarm Cause Corrective Action P185 C3 CHECK EVAP FAN MOTOR This device is checked twice Pretrip once in Test 2 and again in Test 8 TRIGGER ON TEST 2 Normal draw for the SEVCON contactor coil is 05 to 2 0 D C Amps 12 VDC The circuit tests outside this range TRIGGER ON TEST 8 Normal draw for the Compartment 3 Evap Fan motors is 0 1 to 2 0 A C Amps 460 VAC The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip mode is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during Test 3 by holding Key for 6 seconds d Review active alarm list for Alarm If alarm is present follow steps 2 thru 4 If alarm is 183 not present follow steps 5 thru 10 Check 3EVCON Inspect heater contactor
81. may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check PSCONR a Inspect standby contactor relay No damage to coil coil and terminals No damage or corrosion b Check contactor coil resistance Refer to Section 2 13 for correct electrical values Cannot be opened infinite ohms shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check PSCONR Current Draw Use Component Test Mode to test Refer to Section 2 13 for correct electrical values actual current draw of the circuit View current draw in Data List Refer to Section 5 2 2 Check PSCONR Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 62 11524 7 66 Alarm Cause Corrective Action 100 OVERLOAD GROUND FAULT TRIGGER ON Engine or Standby Operation is being called for and the overload ground fault module is reading more than 40 Amps on any A C current leg OR there is A C voltage leak
82. ply to any setpoint If TOGETHER is selected then the following Functional Parameter values will be available for use MINIMUM RUN TIME MINIMUM OFF TIME RESTART TEMPERATURE OVERRIDE TEMP MAXIMUM OFF TIME FROZEN SHUTDOWN OFFSET If SEPARATE is selected then the following Functional Parameter values will be available for use PERISHABLE MINIMUM RUN TIME PERISHABLE MINIMUM OFF TIME PERISHABLE RESTART TEMPERATURE PERISHABLE OVERRIDE TEMP PERISHABLE MAXIMUM OFF TIME FROZEN MINIMUM RUN TIME FROZEN MINIMUM OFF TIME FROZEN RESTART TEMPERATURE FROZEN OVERRIDE TEMP FROZEN MAXIMUM OFF TIME FROZEN SHUTDOWN OFFSET NOTE In the event that this Configuration was set to SEPARATE and the ten Functional Parameters for Perishable and Frozen have been set and then the Configuration is changed from SEPA RATE to TOGETHER The values from the Per ishable settings will be the ones that will be used 4 4 2 Stop Parameters Whenever the unit starts in Start Stop Operation it will remain in the Start Stop ON cycle until all five of the following criteria have been satisfied 1 It has run for the selected Minimum Run Time The MINIMUM RUN TIME is selected in the microprocessor Functional Parameters The purpose of this is to force the unit to run long enough to completely 62 11524 circulate the air inside the compartments and to ensure that the product temperature is at setpoint This value may be set from 4 to 60 minutes in 1 minu
83. rameters These conditions are called out in the various diagnostic charts to aid the technician in pinpointing the problem or in realizing that the unit is performing nor mally When using these trees it is important to verify the re ported symptom or problem and then correctly identify the appropriate tree for that particular condition Using the incorrect tree will lead to an incorrect diagnosis When using these diagnostic trees it is very important not to skip any steps Follow the flow of the trees in the order that they are laid out These trees are formatted into a logical diagnostic sequence Skipping around the trees will most likely lead to errors in diagnosis Throughout the trees the steps will point the technician to areas to look at or check for a problem Most of the steps will lead the technician to a circuit or other area of the unit to check test and possibly repair other than the microprocessor Some steps will point to a possible problem with the microprocessor Whenever reaching one of these steps it is a very good practice to install the new microprocessor then verify unit operation PRIOR TO writing hours Trailer ID Unit Serial Number etc into the new microprocessor Once the technician is sat isfied that a new microprocessor is required the hours trailer ID unit serial number customer configurations etc should be entered Should the problem remain even with the new microprocessor in place once
84. shutdown If setpoint is in the frozen range compartment 2 will run in reduced capacity cool RESET CONDITION Auto Reset when sensor is in range or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check Return Air Sensor resistance 10 000 Ohms 77 F 25 C See Note 3 page 7 2 Refer to Table 8 5 for complete resistance chart Check Sensor Wiring a Inspect harness amp control box con No physical damage to harness nector pins amp terminals 1MP amp damage moisture or corrosion in connectors 2EVC see wiring schematic Sec tion 10 Power up the microprocessor see Voltage should be 2 5 VDC volts at harness plug be Note 2 page 7 2 Disconnect tween pins This verifies microprocessor output and sensor from harness Check for wiring connections to the sensor 2 5 VDC at harness plug between pins Check remote sensor switch connector 62 11524 c Locate and inspect 10 position Connector must have cap on connector OC for
85. temperature switch Heating and defrost is accomplished by electric heaters mounted on the coil Automatic evaporator coil defrosting is initiated by either a differential air switch which senses the pressure drop across the coil or by the defrost timer in the micropro cessor 62 11524 2 4 1 Evaporator Coil The unit evaporator is a tube in fin type The operation of the compressor maintains a reduced pressure within the coil At this reduced pressure the liquid refrigerant evaporates at a temperature sufficiently low enough to absorb heat from the air The electric heaters HTR1 8 HTR2 are mounted on the inlet side of the coil 2 4 2 Electronic Expansion Valve EVXV The is an electronic device which controls the flow of liquid to the evaporator according to changes in superheat of the refrigerant leaving the evaporator The expansion valve maintains a relatively constant degree of superheat in the gas leaving the evaporator regard less of suction pressure The valve has a dual function automatic expansion control and prevention of liquid return to the compressor 2 4 3 Heat Exchanger The heat exchanger is the tube in tube type and is in stalled in the main suction line and liquid line The suc tion gas is used to cool the warm liquid refrigerant within the heat exchanger This results in greater system effi ciency 2 4 4 Compressor Suction Modulation Valve CSMV The CSMV opens and closes as required
86. to the light bar is shorted The light bar output from the microprocessor 3MP32 is negative so the circuit will not be shorted to ground but is shorted either within the light bar itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset when Auto light current amp draw is normal or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 2 Light Bar Wiring a Inspect light bar amp connector No damaged to light bar No damage moisture or corrosion in connector b Inspect harness amp control box physical damage to harness connector pins amp terminals See No damage moisture or corrosion in connectors wiring schematic Section 10 Check 2 Light Bar Check operation of 2 Light Bar Refer to Section 8 9 3 for information on testing the 2 Light Bar 91 CHECK 1HTCON1 RELAY COIL TRIGGER ON Heater Contactor 1 1HTCON1 circuit is shorted The contactor output from the microprocessor 4 13 is negative so the circuit will not be shorted to ground but is shorted either within the contactor coil itself or
87. unloaded and the CDT rises to 284 F 140 C UL1 will be de energized loaded and will remain de energized loaded until the CDT drops below 266 F 130 C for at least 2 minutes 12 Cargo Protect Mode Refer to Section 4 8 1 13 Start Stop Operation If the Off Cycle conditions have been met in Start Stop Mode Refer to Section 4 4 and the minimum run time has expired BUT a compartment temperature is not at setpoint both unloaders will be de energized loaded the compressor will operate on 6 cylinders until the unit cycles off 14 High Speed Pulldown When the Compartment 1 setpoint is in the perishable range and the unit is operating in Continuous Run and the High Speed Pulldown configuration is set for YES then the compressor will operate with both unloaders de energized 6 cylinder loaded operation until the re frigerated container temperature is 0 36 F 0 2 C above setpoint 4 8 5 Defrost Safety Override When any compartment is in defrost and the return air temperature rises to 95 F 35 C regardless of the temperature of the DTT the unit will go into low speed and all electric heaters in all compartments will be de energized The unit will remain in defrost with the heaters de energized until the return air temperature is less than 90 F 32 C In addition when Compartment 1 is in defrost and the supply air temperature rises above 135 F 45 C re gardless of the temperature of the DTT the
88. 1 Cover 2 Gasket Screen Figure 8 8 Electric Fuel Pump 8 9 8 5 5 Fuel Filter To replace filter a Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle b Place a shallow pan under filter item 7 Figure 8 5 and open the water separator 5 to drain contents c Remove water separator and O ring and then re move element d Install water separator on new element using new O ring e Fill new element with clean diesel fuel lubricate the seal and install Tighten firmly by hand f Start unit and check for leaks 8 5 6 Fuel Level Sensor FLS An optional fuel level sensor item1 Figure 8 9 supplies an input signal to the microprocessor as to the of fuel remaining in the fuel tank The microprocessor will activate the A1 LOW FUEL LEVEL WARNING alarm when the level reaches 15 and if configured to do so shuts the engine down when the level reaches 1096 The fuel tank level is be displayed in the Unit Data To Check The Fuel Level Sensor do the following a Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Verify that the fuse FLS is not open See Figure 8 9 Verify that the
89. 10 000 Hour Maintenance Perform complete annual Preventive Maintenance and the following Fuel System Clean and adjust injector nozzles Engine Service Guide e Oil Change Intervals Oil Type Oil Change ESI Filter Change Petroleum 3000 hours or 2 yrs Maximum oil drain interval is 2 years Mobile Delvac 1 4000 hours or 2 yr Maximum oil drain interval is 2 years Mobil Delvac1 is the only approved synthetic oil f Coolant Change Intervals Coolant Type Service Interval Standard 6000 hours or 2 yr Extended Life 12000 hours or 5 yr These maintenance schedules are based on the use of approved oils and regular Pretrip inspections of the unit Failure to follow the recommended maintenance schedule may affect the life and reliability of the refrigeration unit 8 3 62 11524 Table 8 2 Pre Trip Inspection Inspect battery cables for signs of wear abrasion or damage at every pre trip inspection 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 BEFORE STARTING ENGINE OK ADJUST Drain water from bottom of fuel tank Drain water from water separator on fuel filter if applicable Check radiator coolant level Check condenser amp radiator for cleanliness Check air cleaner and hoses Check engine oil level Check condition of water pump belt Check battery fluid level if a
90. 100 psig 7 5 bar The actual pressure must be lower than 100 psig in order to perform this test Check Rear Unloader UL2 Operation Unit must be running See Note 5 page 7 2 62 11524 Check operation of Rear Unloader UL2 See Section 8 7 6 Unloader must load and unload properly 7 122 Alarm Cause Corrective Action P199 C2 CHECK RETURN AIR SENSOR TRIGGER ON Compartment 2 Return Air Sensor is not within the range of 53 to 158 F 47 to 70 C e UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip mode is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Return Air Sensor a Inspect sensor amp connector No physical damage to harness No damage moisture or corrosion in connectors 10 000 Ohms 77 F 25 C b Check Return Air Sensor resistance Refer to Table 8 5 for complete resistance chart See Note 3 page 7 2 Check Return Air Sensor Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See
91. 13 28 2SAT A 31 21 EVOT 16 32 19 REMSN2 REMSN H 33 14 2RAT 2EVC J 33 23 1DTT 0 16 34 21 1SAT DP16 C 35 23 Unused terminals 1 2 4 24 25 27 62 11524 10 2 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED START RUN OFF Continued 2 MP Black Component Terminal OC C 2EVC F SP45 2CA D SP45 DAS CSMV D 3 5 5 6 8 19 20 32 EVXV B 16 11 12 22 23 35 EVXV E DP16 N 12 11 22 23 35 OC D 13 16 ENOPS 17 ENSCU 3 4 CSMV C 9 8 20 32 CSMV A 0 8 19 32 EVXV D DP16 M 1 2 11 12 23 65 EVXV A DP16 J 23 11 12 22 35 HC19 SP61 26 SP5 28 SP15 29 CSMV B 32 8 19 20 EVXV C DP16 L 35 11 12 22 23 Unused terminals 1 2 4 7 9 10 14 15 21 24 25 27 30 31 33 34 62 11524 10 8 Component Terminal SATCOM C GND 3 15 27 SLP C GND 5 13 17 29 2CA F 6 UL1 12 SLP E 13 5 17 29 SATCOM B RX 15 3 27 SLP A RX 17 5 13 29 2 18 LB H AMBER 19 32
92. 15 Figure 9 7 Micro Diagnostic Tree Cond 3 Main Power Switch Off Unit Fails To Stop 9 16 Figure 9 8 Micro Diagnostic Tree Cond 4 Unit Will Not Run In High Speed 9 17 Figure 9 9 Micro Diagnostic Tree Cond 5 Unit Will Not Run In Low Speed 9 18 Figure 9 10 Micro Diagnostic Tree Cond 6 DataLink Data Recorder Data Download Problems When Using ReeferManager and a Download Cable Data File Analysis Problems 9 19 Figure 9 11 Microprocessor Diagnostic Tree Cond 7 Card Problems 9 20 Figure 9 12 Micro Diagnostic Tree Cond 8 Programming Problems With PC 9 21 62 11524 xiv LIST OF TABLES TABLE NUMBER Page eT oor DELLI Mee Dc ahaa 2 2 Table 2 2 Additional Support Manuals aes 2 2 add wed aise aie Gee doe ease eed dC dO PE Gases 3 17 Tale gs Funcional PRSIBIBIBIS ccc teed Hebe AE Heke 3 22 Table 4 1 Intake Air Heat TIG ich ene Ra n EUR 4 2 Table 5 1 Component 5 3 Table 5 2 Microprocessor tokit D YE E NU E dria eA 5 12 Table 8 1 Maintenance Schedule
93. 16 1 3 19 2 7 44 6 4 92 5 26 14 1 4 20 7 8 46 6 6 96 2 24 12 1 5 223 9 48 6 9 99 9 23 10 17 23 9 10 50 7 2 103 7 22 8 18 256 13 55 8 0 115 4 21 6 1 88 27 3 16 60 8 7 126 1 20 4 2 0 291 18 65 9 5 137 4 19 2 2 1 30 9 21 70 103 149 4 18 0 2 3 32 8 24 75 11 2 162 1 17 2 2 4 34 8 27 80 12 1 175 5 16 4 25 36 8 29 85 13 1 189 6 14 6 2 7 38 9 32 90 14 1 204 5 13 8 28 41 1 35 95 15 2 220 2 12 10 3 0 43 3 38 100 16 3 236 8 11 12 3 1 45 6 41 105 17 5 254 2 10 14 3 3 48 0 43 110 18 8 272 4 9 16 3 5 50 4 46 115 20 1 291 6 8 18 3 7 52 9 49 120 21 5 311 8 7 20 3 8 55 5 52 125 23 0 332 9 6 22 4 0 58 1 54 130 24 5 355 0 4 24 421 60 9 57 135 26 378 1 3 26 4 4 63 7 60 140 27 7 402 3 2 28 4 6 66 5 63 145 29 5 427 6 1 30 4 8 69 5 66 150 31 3 454 0 8 46 SECTION 9 UNIT TROUBLESHOOTING PARAGRAPH NUMBER Page ENGINE 9 1 ST Engine Vel or Olan Ch bara De 9 1 9 1 2 Engine Stats Then SOPS T CHLERUE TERR SERE Rx doe es 9 2 913 Engine Wil Wot Shit OF T TC PER 9 2 gia Motor Cr 9 2 9 15 Malfunction In The Engine Starting Circuit 9 2 9 1 6 Miscellaneous Engine Troubleshooting 2 9 3 Dr ET ER CHARGER
94. 25 C AND the unit is running in defrost AND the en gine has been running less than 30 minutes since the Main Power switch was toggled from the OFF posi tion the unit will remain in low speed until the ambient temperature is above 77 F 25 C OR the engine has run for a minimum of 32 minutes since the switch was toggled When the engine is forced to low speed under these conditions the Message Center will display FORCED LOW ENGINE SPEED 2 RAT amp SAT Alarms When A122 CHECK RETURN AIR SENSOR and A123 CHECK SUPPLY AIR SENSOR alarms are activated microprocessor control may enter Cargo Protect Mode Refer to Section 4 8 1 3 High Speed To Low Speed Delay When the engine is operating in high speed and the microprocessor calls for low speed the engine will remain in high speed for 40 seconds OR until the actual AC current is less than the configured Diesel or Standby Maximum Generator Amps value less the Diesel or Standby Offset Maximum Amps value 4 Silent Mode When the Silent Mode Functional Parameter is set to ON the unit will operate in low speed only 5 Engine Coolant Warm Up The engine will run in low speed until the coolant is above 79 F 26 C 6 Defrost When the unit is in defrost the engine will operate in high speed when heaters are energized to supply power for the heaters the engine will operate in low speed when the heat ers are de energized 7 Door Remote Switc
95. 33 Thermostatic Expansion Valve Bulb and Thermocouple 8 34 Figure 8 34 Megohmmeter Connection to Ground Plate 8 35 Figure 8 35 High Voltage 22220252222 aae qos desk uo otis Sues 8 35 Figure 8 36 Light Bar E Er DRES MENA EEA 8 36 Figure 8 37 Overload Ground Fault Connections 8 36 Figure 8 38 Evaporator Blower Assembly 8 37 Figure 8 39 Condenser fame 8 38 Figure 8 40 Generator ASSEMBLY 2 2 2 lt 2 lt eke baw 8 42 Figure 8 41 Bolt Hole Pattern For Bell Housing and 8 42 Figure 9 1 ENSCU Diagnostic Tree 1 Long 1 Short LED Code 9 9 Figure 9 2 ENSCU Diagnostic Tree 2 Long 1 Short LED Code 9 10 Figure 9 3 ENSCU Diagnostic Tree 2 Long Short LED Code 9 11 Figure 9 4 ENSCU Diagnostic Tree 2 Long 7 Short LED Code 9 12 Figure 9 5 Micro Diagnostic Tree Cond 1 Main Power Switch On Unit Does Not Operate 9 14 Figure 9 6 Micro Diagnostic Tree Cond 2 Main Power Switch On Unit Operates But Not Properly 9
96. 450 22 2 72 113 040 62 2 144 23 050 193 3 380 740 16 7 2 799 180 23 3 74 107 600 63 3 146 22 160 198 9 390 670 156 4 750 470 24 4 76 102 460 644 148 21 310 204 4 400 600 144 6 705 060 25 6 78 97 600 656 150 20 500 210 0 410 540 13 3 8 662 690 267 80 92 990 683 155 18 980 215 6 420 490 12 2 10 623 150 27 8 82 88 630 71 1 160 16 940 221 1 430 450 111 12 586 230 280 84 84 510 73 9 165 15 450 226 7 440 410 10 0 14 551 740 30 0 86 80 600 76 7 170 14 070 232 2 450 370 8 9 16 519 500 31 1 88 76 890 79 4 175 12 870 237 8 460 340 7 8 18 189 690 322 90 73 380 82 2 180 11 750 243 3 470 310 6 7 20 461 170 333 92 70 040 850 185 10 750 248 9 480 280 5 6 22 434 790 344 94 66 880 87 8 190 9 870 2544 490 260 44 24 410 080 356 96 63 880 90 6 195 9 050 260 0 500 240 3 3 26 386 940 36 7 98 61 040 93 3 200 8 320 2 2 28 365 260 37 8 100 58 330 96 1 205 7 650 1 1 30 344930 389 102 55 770 989 210 7 050 8 45 62 11524 62 11524 Table 8 7 Temperature Pressure Chart Temperature Pressure Temperature Pressure F BAR PSIG F BAR PSIG 40 40 0 3 4 5 0 32 50 72 5 37 35 0 5 7 1 1 34 5 2 75 6 34 30 0 7 9 9 2 36 5 4 78 8 32 25 0 9 12 9 3 38 5 7 824 29 20 1 1 16 3 4 40 5 9 85 5 28 18 1 2 17 7 6 42 6 1 89 0 27
97. 6600MT SP50 SP64 2 5 6 1 4 X F16 SA i xs um m With Main Power Switch Labeled ENGINE OFF STANDBY i 0 5 6 CCONR COON SP57 2 COMPARTMENT T f 9 C 5115 gt Based 62 11580 6 56 D E F G H I J K L M N 0 Q R T X Y 10 11 12 13 14 15 16 P A B D E F G H I J K L N 0 Q R 1 CCON y X Y
98. 8 8 11 9 4 13 Compressor Suction Modulation Valve CSMV Malfunction Coil not seated properly Check Coil defective 8 8 5 Loose connector Check and CSMV not controlling correctly Tighten CST defective 8 9 10 CSP defective 8 8 8 CDT defective 8 9 10 CDP defective 8 8 8 9 7 62 11524 9 5 Speed Control System Diagnostics Table 9 1 ENSCU LED Fault Chart or open circuit Coil Resistance Spec 2 8 ohm 10 Fault LED flash code Diagnostic tree 1 Engine Over Speed more than 2 530 RPM One Long One Short Figure 9 1 2 No signal from ENSSN for 2 seconds after RPM Two Long One Short Figure 9 2 is greater than 1 000 RPM for 10 seconds OR for 5 seconds while engine cranking no voltage at ENSCU pin 18 3 Fuel speed actuator FSA wiring disconnected Two Long Three Short Figure 9 3 4 ENSCU supply voltage is greater than 26V Two Long Seven Short Figure 9 4 62 11524 9 8 START HERE Start unit Using strobe light 07 00177 01 or equivalent check engine NOTE Ensure the run relay is ener ses RPM equal to or over gized during test With ENSSN un plugged during testing unit will stall amp go through start sequence again Unit will not start This is normal Verify there is at least 11 VDC going into the ENSSN 12V terminal Check for high resist ance or an open in the Check high speed mechanical stop ENSSN grou
99. Any active alarms must be corrected and cleared be trip amp check for any new alarms fore proceeding Additional steps on the next page 7 55 62 11524 Steps Alarm Cause Corrective Action EVAP MOTOR OVERHEATED Continued 6 Check Evaporator Fan Motor Disconnect power plug at motor Test IP circuit for continuity using ohmmeter If open remove and replace motor If closed then an intermittent IP circuit is suspect Check phase to phase and phase to ground for short or open circuits Refer to Section 2 12 for correct electrical values If motor tests good check the DC IP circuit to microprocessor Check Motor Operation 62 11524 Turn the unit ON Check current on each phase must be less than shown on Section 2 12 Check voltage on each phase must be at within lim its shown in Section 2 12 um Alarm Cause Corrective Action 84 CHECK REMOTE ALARM LIGHT TRIGGER ON The fault output circuit amber check unit LED s to the light bar is shorted This output 3MP19 from the microprocessor is negative so the circuit will not be shorted to ground but is shorted either within the remote alarm light itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset when Alarm light current amp draw is normal or alarm may be manually reset via keypad or by turning the unit off then back on again
100. Based Requested Speed From The Microprocessor Check 12 VDC at pin 16 with unit running Must be 12 VDC when the microprocessor is calling for high speed Check engine RPM a Check actual engine RPM using hand held tachometer Check Speed Control System refer to Section 9 5 b Compare actual RPM with those shown on display Both readings within 50 RPM 62 11524 Additional steps on the next page 7 106 Steps Alarm Cause Corrective Action CHECK HIGH SPEED RPM Continued 6 Check engine air intake system a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check engine exhaust system Inspect the exhaust system Must be clear and unobstructed P176 C3 CHECK LSV VALVE TRIGGER ON In Test 2 Compartment Liquid Solenoid Valve 3LSV current is outside the range of 0 75A to 2 0A OR In Test 14 The suction pressure did not rise as expected when the 3LSV was energized opened e UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset when Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm
101. C power will be supplied to the fuel heater relay FHR Energizing FHR closes its normally open contacts to supply power through the fuel heater temperature switch FHTS to the heater Refer to Section 2 9 for FHTS settings 4 2 3 Transition To High Speed After a successful start the microprocessor may call for the engine to transition to high speed Three factors control this transition e First transition may be delayed if a time value is entered in either the START STOP HIGH SPEED DELAY or CONTINUOUS HIGH SPEED DELAY Configuration The delay may be set to OFF or from 0 to 255 minutes The factory default setting for Start Stop Operation is 10 minutes while the factory default setting for Continuous Operation is OFF If the entered value for the present mode of operation is OFF high speed operation is not allowed for two minutes following start e Second the engine cannot transition if the SILENT MODE functional parameter is set to YES The value may be set to YES or NO The factory default setting is NO Refer to Table 3 2 e Third transition will be based on the need for temper ature control Generally the engine will operate in high speed when a compartment is in Pulldown or Pull Up Mode full capacity required and in low speed when all three compartments are in most less than full capacity required operating states 4 3 TEMPERATURE CONTROL 4 3 1 Temperature Determination The microprocessor monitors the temper
102. CONTACTOR C 1MP7 11 3MP18 VCA LS al 70 9 2 1 E42 xw 1907 HEATER 2 5 cst IMPIS SPB FET 13 310 8 2ND COMPARTMENT ala g 1MP10 ET 13 3MP30 9 SP45 be 43 016 END COMPARTMENT HEATER CONTACTOR FE VMI 2 3 M2 E CD conii PEUT eMPS mer 2ND COMPAR ETUR nius Ed io PU SHTCON Sh CAMBER THEN THEATER E J12 R8 1 3RD ENT HEATEI 1 2 FET 16 wy Re 07 ee MESA FET 17 DEFROST LIGHT gis ai COMPAR PEA TERS FF TRL INTACT WK Pal SP4B pe 18 BUZZER aea e M Sel COMPARTMENT HEATER E AVC P8 FET 19 PSCON T 2 0 merous 2EVM3 016 77 IAHR Se COMPARTMENT HEATER E 1 3MP09 K HEATER sal e1 SPa AA IPC INTAKE AIR HEATER REL ET 21 1HTCON2 3MP08 SECON 5 Q eee ERNA COMPRESS rar quien 58242 EET UNLDADER CONTROL 2 sews EIPEVM INTERNAL PROTECTOR CUNDENSER FAN MOT FET 1MP22 23 UNLDADER 1 CONTROL 4 ape NTERNA PROTECTORS 2 COMPARTMENT MOTOR TOR 0216 0 atte ULI
103. Check mode of operation 62 11524 a Starting Unit with Remote Control Panel NOTES 1 The unit can be shutdown using either the remote panel or the unit switch panel mounted Main Power switch The remote panel cannot operate if the unit switch panel mounted Main Power switch is in the OFF position Also the Compartment Run Switch C2 and or C3 must be in the ON position in order for that compartment to operate 2 In order to prevent a constant drain on the battery the remote panel will de energize after two hours If the panel is equipped with a RESET button press the button to re energize the panel If the panel is not equipped with a RESET button the panel may be re energized by placing the unit switch panel mounted Main Power switch in the OFF position and then back in the desired position TEMPERATURE GAs COOL COMPARTMENT 1 9 1 Place unit switch panel TEMPERATURE mounted Main Power switch in the desired position 2 Press The SYSTEM ON OFF BB r Key The POWER Light will illu minate a Compartment Run HE gg Switch C2 and or C3 is in the ON un 6 position that compartment will also COMPARTMENT 99 SYSTEM Ld MAN DEFROST b Changing Setpoint With Remote Control Panel TEMPERATURE E FE HEAT 500 Press the UP or DOWN ARROW key for the desired compartment to in B crease or decrease
104. E 3E 1 niles ele Power supply contactor 1 PSCON Power supply contactor 2 PSCON 2 Generator contactor GENCON Compressor contactor CCON Compartment 1 evaporator heater contactor 2 1HTCON2 Compartment 1 evaporator motor contactor 1EVCON Condenser motor contactor CDCON Compartment 2 evaporator motor contactor 2EVCON Compartment 2 evaporator heater contactor 1 2HTCON1 Compartment 2 evaporator heater contactor 2 2 2 Compartment 1 evaporator heater contactor 1 1HTCON1 Figure 8 35 High Voltage Contactors 8 9 2 Phase Reversal Module PRM One principle of three phase motors is that the direction of rotation will be reversed if any two wires going to the motor are reversed When operating on the generator the wiring is not changed and therefore the PRM is not active However when operating on standby power the incoming power may be reversed The function of the phase reversal module is to monitor the incoming standby power and reverse the power to the motors if that incoming power will result in incorrect rotation When the unit is started in standby power is supplied to the PRM 12V terminal to activate the PRM Refer to wiring schema
105. FILE is being installed The microprocessor will continue and complete the loading in accordance with the instructions provided in Figure 5 3 62 11524 5 4 4 Option PC Card Option PC Cards allow installation of optional programming into the microprocessor Cards may be purchased with five or ten clicks Each click allows downloading to individual microprocessor To transfer data from the card to the microprocessor insert the card in accordance with the instructions provided in Figure 5 3 Press the key to load the option The MessageCenter will display INSTALLING OPTION PLEASE WAIT while the option is being installed The microprocessor will continue and complete the software loading in accordance with the instructions provided in Figure 5 3 In the INSTALLED REMOVE CARD message displayed at the end of the loading process the XX is the number of installs left on the card A click will not be removed from the card if it is inserted into a microprocessor that already has the option installed 5 4 5 Download PC Card Download PC cards allow coping of data from microprocessor DataLink data recorder to the card for use with the Reports feature of ReeferManager To copy data from the microprocessor to the card insert the card in accordance with the instructions provided Figure 5 3 When copying data to the card the MessageCenter will display COPING DATA PL
106. Fans should operate correctly Air should be directed operation in through the grill and into the engine compartment Check Water Pump Belt Check engine water pump belt No Glazing no cracking no slipping Check Engine Coolant Temperature Sensor a Inspect sensor amp connector pins amp No damage to sensor terminals No damage moisture or corrosion in connector b Check sensor resistance 10 000 Ohms 77 F 25 C Refer to Table 8 5 for See Note 3 page 7 2 complete table of temperatures and resistance val ues Additional steps on the next page 7 5 62 11524 Steps Alarm Cause Corrective Action HIGH COOLANT TEMPERATURE Continue d 7 Check Engine Coolant Temperature Sensor Wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage or corrosion in connectors b Check voltage at the sensor con nector with the microprocessor powered up Voltage reading should be 2 5 0 1 VDC This veri fies microprocessor output and wiring connections to sensor Check Engine Cooling System 62 11524 a Compare actual engine tempera ture to the microprocessor reading Temperature must be within 20 F 11 1 b Test operation of engine coolant thermostat Must operate correctly c Check water pump operation No seepage at wee
107. Follow maintenance interval recommendations in Section 8 2 224 STANDBY MAINTENANCE DUE e TRIGGER ON The Standby Hour Meter time has expired e UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad 1 Check Unit Maintenance Records Schedule unit into service facility for maintenance Must be done soon Perform Maintenance Perform appropriate engine amp unit maintenance Follow instructions on proper maintenance form Reset Standby Hour Meter a Check that the Standby Maintenance Hour Meter interval is set for your requirements Reset configured Interval if required b Reset Standby Maintenance Hour Meter for the next service interval 7 129 Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 62 11524 Alarm Cause Corrective Action 225 GENERAL MAINTENANCE DUE TRIGGER ON The General Maintenance Hour Meter time has expired e UNIT CONTROL Alarm Only Alarm Light will NOT be turned on e RESET CONDITION Alarm may be manually reset via keypad 1 Check Unit Maintenance Records Schedule unit into service facility for maintenance Perform Maintenance Perform appropriate engine amp unit maintenance Reset General Maintenance Hour Meter a Check that the General Reset configured Interval if required Maintenance Hour Meter interv
108. INSTALLED 21 6 to 0 12 to 0 C in 0 5 F or C in crements DEFAULT 5 4 3 C 21 6 to 0 12 to 0 C in 0 5 F or C in crements DEFAULT 1 8 1 C YES NO Value to be used to calculate the lowest allowable supply air temperature when in Continuous Opera tion in accordance with the formula Setpoint this value coldest allowable supply air temperature For example Fahrenheit if the setpoint is 35 F and the Configur ation value is set at 10 F the calculation is 35 7 10 25 F lowest allowed supply air temperature Celsius if the setpoint is 2 C and the Configuration value is set at 6 C the calculation is 2 6 4 C lowest allowed supply air temperature NOT INSTALLED A supply air sensor SAT2 is not installed in the remote evaporator INSTALLED A supply air sensor SAT2 is in stalled in the remote evaporator If this setting is chosen the following sub settings will also be avail able Value to be used to calculate the lowest allowable supply air temperature when in Start Stop Opera tion in accordance with the formula Setpoint this value coldest allowable supply air temperature For example Fahrenheit if the setpoint is 35 F and the Configur ation value is set at 10 F the calculation is 35 10 25 F lowest allowed supply air temperature Celsius if the setpoint is 2 C and the Configuration value is set at 6 C t
109. Inspect harness amp control box No physical damage to harness connector pins terminals 1MP No damage moisture or corrosion in connectors amp DP16 see wiring schematic Section 10 Power up the microprocessor see Voltage should be 2 5 VDC volts at harness plug be Note 2 page 7 2 Disconnect tween pins This verifies microprocessor output and sensor from harness Check for wiring connections to the sensor 2 5 VDC at harness plug between pins Check remote sensor switch connector c Locate and inspect 10 position Connector must have cap on connector OC for optional No corrosion or moisture inside connector sensors and switches If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 7 77 62 11524 Steps Alarm Cause Corrective Action 124 CHECK DEFROST TERM 1 SENSOR TRIGGER ON Defrost Termination Temperature Sensor 1DTT is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and standby If Alarm 122 is not active alarm and initiate defrost if 1 RAT is below 45 F 7 2 C If Alarm 122 is also active alarm and initiate defrost if 1SAT is below 45 F 7 2 C Under both of the above conditions defrost will end after 10 minutes If Alarms 122 and 123 are also both active alarm and d
110. J LP el ot AAT IMPL 3MP12 ULL p 42 T ilj ISAT 0 16 1 5 13 e 1MP23 SP12 2 28 7 EVAP 2 CONFIGURATION SANDBY DPI6 6 1 12 3MP20 LIGHT 086 gi Carat 0 16 1 2 lt SP12 3MP19 BHH BAR SP6 eo PSCONR GENCON PRM PSCON2 PSCON s 2EVC J 1MP33 3MP32 18 814 OPTION 58 3115 JN 51 ERAT 1 2 lt SP12 TH e350 t 11 110 012 11 12 Lez GENCONR 04 F4 Pie Apo FLSGA 6 s 14 1MP23 SP12 S 1 1 15 sarcom 595 9 AES wc contacts 2SAT C PRM PSCON2 STANDARD 3MP03 GND gt 5 DPTIDNS 25 IMP21 SP42 1MP26 52 NITE contacts EMSN H 1MP33 i RR MPQC4 SP3 11 12 SOE SP NUMERIC LOW CONNECTION ARE RERUN SENE RN 1MP14 lt SP1 gt 9 ENSCU13 SF abt VOET ZEHN CHNMEU HUN 2 CHASSIS GROUND 1MP3 spi ENOPS DPI6 F 2 0 C COMPONENT CONNECTION 15 DPI6 F 1 19 lt SP14 gt 5 6 E lt lt 17 ENSCU 16 PSCONR PSCONILK PSCON2ILK GENCON GENCONR 314 5113 59 21 22 SP64 F16 5A 2 30 87 gt 2 E ine e TA 8 T 8 i3 TAC 28 0 VECTOR 6600MT GPR TAH CCONR With Main Power Switch Labeled START RUN OFF
111. Main Power switch and speed relay The unit has an LED which may be used to diagnose failures within the electronic speed control system Refer to Section 9 5 for information on diagnosing failures ENSCU sends engine speed information to the microprocessor to be displayed in the Unit Data and recorded in the DataLink data recorder The ENSCU is mounted on the air cleaner bracket Figure 2 7 Engine Speed Control Unit 2 9 b Fuel Speed Actuator FSA The FSA combines the fuel shutoff solenoid and speed control solenoid into one component Fuel supply to the injectors and engine speed is controlled by varying rod position in accordance with the signal from the ENSCU The FSA is located on the front of the injection pump c Engine Speed Sensor ENSSN The ENSSN provides the ENSCU with information on the speed at which the engine is running The ENSSN is located in the gear case cover above the oil filter d Engine Oil Pressure Switch ENOPS The ENOPS is normally open and closes on pressure rise to signal to the microprocessor the engine has sufficient oil pressure for operation There is a 15 second delay after the engine starts to allow the oil pressure to build up before the microprocessor looks at the input from this switch The switch is located in the oil filter mounting assembly e Engine Coolant Temperature Sensor ENCT The ENCT provides the microprocessor with engine coolant temperature information
112. Micro is not the fault YES MPR Code 4 YES Replace micro and operate system in order to verify repair Did you find and correct the condition Y Micro is not the fault Remove new micro amp re install old micro i necessary go to the beginning of the tree and test again Review the test results with your supervisor If PC card slot may be defective Turn power off and verify status light is not blinking Check for bent pins in the card slot amp straighten as needed Did you find and correct the condition YES MPR Code 4 NO Y Are pins unable to be straightened or pins broken Figure 9 11 Microprocessor Diagnostic Tree Cond 7 PC Card Problems 62 11524 9 20 START HERE Are you trying to load an older Does the MessageCenter say version of software than the version OLD SOFTWARE CANNOT LOAD in the micro N O Insert the PC Card into the PC Card slot on YES the front of the micro Be certain that the instructions label on the download card is facing the Caution label on the micro Do not force the card into the slot Handle the Once a newer version is installed into the card from the edges Did you find and micro it is no longer possible to load previ correct the condition ous software Newer vers
113. Normal current draw for the 2HTCON 1 heaters is 1 0 to 7 0 A C Amps 460 VAC The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip mode is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during Test 3 by holding Key for 6 seconds d Review active alarm list for Alarm If alarm is present follow steps 2 thru 4 If alarm is 146 not present follow steps 5 thru 10 Check 2HTCON1 a Inspect heater contactor coil and No damage to coil wire connections No damage or corrosion b Check contactor coil resistance Refer to Section 2 13 for correct electrical values Check 2HTCON1 Amp Draw Check 2HTCON1 amp draw Use Component Test Mode Section 5 2 2 to test Refer to Section 2 13 for correct electrical values View current draw in Data List Check 2HTCON1 Wiring Inspect harness amp c
114. Off Time has expired In some ambient conditions there are times when the unit may remain in a Start Stop Off cycle for extended periods of time To ensure that the entire load stays within the normal restart temperature range the MAXIMUM OFF TIME Functional Parameter may be used to force the unit to restart in low speed with the evaporator fans operating to ensure there are no hot spots and the temperature sensor is accurately reflecting the temperature of the product The parameter value may be set to OFF or from 10 to 225 minutes in 1 minute intervals If the MAXIMUM OFF TIME is OFF there is no maximum off time for Start Stop and the unit will remain off The factory default setting is OFF 4 The Minimum Off Time has expired The MINIMUM OFF TIME Functional Parameter setting allows the unit to remain off for extended periods of time maximizing fuel power economy The unit may not be restarted until the MINIMUM OFF TIME has expired and the temperature in one compartment is greater than the PERISHABLE RESTART value selected in the Functional Parameters away from setpoint In the Frozen Range restart is allowed when the temperature in one of the compartments is greater than the FROZEN RESTART value above setpoint The MINUMUM OFF TIME parameter value may be set from 10 to 90 minutes in 1 minute intervals The factory default setting is 20 minutes The RESTART TEMPERATURE value may be set from 0 5 to 18 F 2 to 10 C in 0 5 F o
115. PSCON three readings must be 460V 1096 L1 L2 L2 L3 L1 L3 b Check for voltage at PSCON All three readings must be 460V 1096 L1 L2 L2 L3 L1 L3 Check Connections Check for bad connections in the Connections and wire crimps must be tight control box Check Phase Reversal Module PRM a Check for voltage at 5MP04 Must be 12 VDC b Check Phase Reversal Module for See Section 8 9 2 Replace PRM if defective correct operation 7 51 62 11524 Alarm NO Corrective Action Alarm Cause 75 COMP MOTOR OVERLOAD TRIGGER ON Compressor Motor Internal Protector IPC circuit is open e UNIT CONTROL Engine Operation engine and unit shutdown and alarm Standby Operation refrigeration system shutdown and alarm with PSCON still energized e RESET CONDITION Auto Reset when motor overload input is within limits or change to engine Operation or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check For Alarm13 A13 or 113 High Pressure Alarm 13 will always cause this alarm to activate even when there are no p
116. RESET VALUE SHORE cessor when the next service interval alarm will be activated If the value entered is 0 the alarm fea ture is turned off OFF When the switch on maintenance hour meter is re 50 TO 30 000 set the value selected here will be added to the to iQ the present meter reading to indicate to the micro SWITCH ON RESET VALUE d hour in processor when the next service interval alarm will be activated If the value entered is 0 the alarm feature is turned off PM 1 5 Preventative Maintenance OFF OFF This selection will turn this meter OFF will Hour meters ENGINE not display PROTECT ENGINE HOURS this meter will count the engine HOURS hours until the next reset interval SWITCH ON SWITCH ON HOURS this meter will count the PROTECT switch on hours until the next reset interval HOURS STANDBY HOURS this meter will count the STANDBY HOURS standby hours until the next reset interval START CYCLES START CYCLES this meter will count how many HIGH SPEED times the engine has started until the next reset HOURS interval COMPRESSOR HIGH SPEED HOURS this meter will count the RUN HOURS number of hours the engine operated in high speed MAINTENANCE until the next reset interval COMPRESSOR RUN HOURS this meter will DAYS count the number of hours the compressor has op erated until the next reset interval MAINTENANCE DAYS this meter will count the number of days until the next reset interva
117. SETPOINT 22 F TO 89 6 F Indicates to the microprocessor the desired minim OR 30 C to 32 C um allowable set point in 0 1 F or C in C3 MINIMUM SETPOINT crements C2 MAXIMUM SETPOINT 22 F 89 6 F Indicates to the microprocessor the desired maxim OR 30 C to 32 C um allowable setpoint in 0 1 F or C in C3 MAXIMUM SETPOINT crements ALARM amp ALARM amp SHUTDOWN If standby power is lost SHUTDOWN unit is to shutdown SWITCH TO EN SWITCH TO ENGINE If standby power is lost GINE engine will be started TOGETHER TOGETHER When the Minimum Run Time Mini SEPARATE mum Off Time Restart Temperature Maximum Off Time and Override Temperatures are set in the Functional Parameter List the same values will be used for both Frozen and Perishable setpoints SEPARATE When the Minimum Run Time Mini mum Off Time Maximum Off Time and Override Temperatures are set in the Functional Parameter List different values may be entered for Perishable and Frozen setpoints REMOTE TEMP SENSOR 1 or 2 OFF ON A remote sensor has been added to the unit 2 Compartment units only and connected into the wire harness OFF There is no Remote Sensor 2 in this unit NO A C POWER S S PARAMETERS 62 11524 5 18 Table 5 2 Microprocessor Configurations Continued selections Deschpion SWITCH FOR TWO COMPARTMENT UNITS SWITCH FOR TWO COMPARTMEN
118. SP4 22 50078 03 SP52 SP5 SP61 2MP26 Unused terminals 5 6 10 12 amp 13 Component Terminal 2HTCON1 A2 2HT CON2 A2 B 2EVC C 2HTCON2 14 2EVC D 2EVCON A2 SP45 4 2 1 1 6 2 2 1 2 1 Unused terminals A H 10 5 62 11524 10 1 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED ENGINE OFF STANDBY Continued 2C10 3CA 22 01997 20 22 50078 03 Component Terminal Component Terminal 7 2 1 2HTCON 1 T1 1 1 1 1 2 1 C 2HTCON1 T3 1 2 2 2 D 3EVC C 2HTCON2 T1 SHTCONGSTO 3EVCON A2 SP46 2HTCON2 T3 LAE D 2bEVCON T1 nused terminals 2bEVCON T2 PE Plate Unused terminals 11 12 3EVC 22 04191 10 AI 3C10 22 01997 20 Component Terminal a 3HTCON1 T1 1 1 2 Terminal 3HTCON1 T3 3MPOS SLSV A 3HTCON2 T1 SP5 Compartment 3 Remote Evap B 3HTCON2 T2 Power 3HTCON2 T3 3EVHTS 3CA D 3EVCON TI 2 Compartment 3 Remote Ground GROUND GND 2 3EVCON T3 3EVM1 2 3 4 IP SP46 PE Plate OCF Compartment 3 Door Switch Unused termina
119. SP5 EN RE EMT x EM ERE MI IRA DPIE H 1 lt 12 gt 3MP23 5 024 pre SRD COMPARTMENT LTOUID VALVE DPI6 G op 2 C4 C9 MICRUPRUCESSUR SDLENDID VALVE 2RA 2EVC J MS SP12 3MP19 E SEVM4 PANEL CONNECTOR VCH P33 3MP32 mu Ge SP12 OPTION E4 PWR BVERL DAD GRDUND F JUMPER i ME E i EVAP 2 CONFIGURATION No PRM MERI POWER ND FAULT MODULE Cesar 1MP23 SP125 3MP15 B 15 PSCUN POWER REVERSAL MODULE 3MP3 5 9 10 STANDBY 02 514 PSCUNe CONTACTOR 25 1 21 GND gt SP5 A A PSCONR EVAP 3 CONFIGURATI 014 015 PSCDNI POWER SDURCI spe ENDPS EVOT OPISE SP42 8 Api 6 X s ies 20 5 8 5115 GENCON PRM ION PSCONR Paves SOURCE CONTACTOR M OR p us DPI6 F ie 55 CR SP57 2 SP6 0 11 11 A m INIIS1 PSCON2 PSCON 24 RR RE MITE RELAY 2e 47 RR 1 26 4 17 12 5 a2 ESR RUN CONTROL RELAY ND 73 he FHR SSR Fe 0A SP3 dod 013 RETURN AIR TEMPERAT pon 307 41 9 ENSC 43 ele 5 87 S 013 PRM SUPPLY AIR TEMPERA ec 1 ENS 1 IN S2 PSCON2 is SERIAL CB COMMUNICATIONS CD SP64 87 CU 16 11 5 SS SERIALACUNMONIGA TEINS PORT INNECTOR 16
120. STARTER CIRCUIT TRIGGER ON Engine speed fails to reach 50 RPM during 2 start attempts UNIT CONTROL Standby Operation this Engine Operation engine and unit shutdown and alarm alarm will not activate in standby Operation RESET CONDITION Change unit to standby Operation or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check That Engine Has Actually Sta rted Check that engine starts runs for a few seconds then shuts off If NO continue with Step 2 below If YES check wiring to RPM sensor for a broken wire Check Starter Relay Circuit a Check operation of starter solenoid relay Energize Circuit See Note 2 page 7 2 Relay contacts closed when SSR85 is grounded b Check relay socket and terminals No signs of discoloration from overheating No corrosion c Check voltage to starter solenoid relay Negative lead on 85 Positive lead on 86 12 VDC Negative lead on Gnd Positive lead on 87 amp 30 12 VDC d Inspect wiring to starter solenoid and starter motor See wiring schematic Section 10 No physical damage to wiring or battery cable end No damage or
121. Service Mode is not required for this procedure Verify that the suspected leak area high or low side has sufficient pressure minimum 20 psig 1 4 bar to detect the leak The larger the leak the less pressure is required The smaller the leak the greater the pres sure required The recommended procedure for finding leaks from a system is with an electronic leak detector Checking joints with soapsuds is satisfactory only for locating large leaks or pinpointing small leaks once a general area has been located Some leaks may be repaired by simply tightening a connection Others may require removal of the charge refer to Section 8 6 2 5 Check for proper unit operation by running Pretrip Refer to Section 3 4 b Leak Checking a System Without Charge The refrigeration system must be leak checked once it is closed and all repairs complete 1 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Connect refrigerant system equipment if not already connected Refer to Figure 8 18 CAUTION Only a refrigerant cylinder containing R404A should be connected to this refriger ation unit in order to pressurize the system However dry nitrogen may be used to in crease pressure Any other gas or vapor will contaminate the system and require add
122. Starter Solenoid connector 9 5 62 11524 9 2 Indication Trouble Possible Causes Action Refer ence Section 9 1 6 Miscellaneous Engine Troubleshooting Loss of power Air cleaner or hose restricted 8 5 9 Air in fuel system 8 5 2 Air vent restricted in fuel tank cap Clean Restricted fuel lines Engine Manual Defective fuel injection pump Engine Manuall Defective injector s or incorrect type Engine Manual Incorrect fuel injection pump timing Engine Manuall Incorrect valve timing Engine Manual Poor compression Engine Manual Vibration Engine shockmounts defective Replace Poor compression Engine Manual Overheating Air cleaner or hose restricted 8 5 9 Exhaust pipe restriction Remove Restriction in water jacket Engine Manual Restriction in radiator 8 5 12 Coolant level too low 8 5 12 Loose water pump Engine Manual Defective thermostat Engine Manual Defective water pump belt Engine Manual Excessive crankcase pressure Plugged crankcase breather 8 5 14 9 2 BATTERY CHARGER Indication Trouble Possible Causes Action Refer ence Section F7 or F8 or F29 if applicable fuse blows Short in 12 volt wiring causing overload of charger 8 9 8 Internal short 8 9 8 Charging rate does not taper back after charging for a few min u
123. Type of Manual 62 11369 Parts Look Up System PLUS disc 62 11503 Operator s Manual 62 11525 Easy To Run 62 11524 2 2 Condenser amp Radiator 5 Ambient Air Temperature Sensor 6 ATT behind grille 7 Model Serial Number Nameplate 8 Compressor Suction Temperature Sensor CST 9 10 Power Supply Receptacle PSR Under Unit Compressor Sight Glass Compressor C Front Unloader Valve UL1 Compressor Suction Modulation Valve CSMV Condenser Fans and Motors CDM1 amp CDM2 Figure 2 1 Front View Refrigeration System Components 2 3 62 11524 12 Note Junction box may be located on front or rear of compressor 1 Defrost Air Switch DAS 8 Compressor Discharge Pressure 2 Receiver amp Sight Glasses Transducer CDP 3 Filter Drier 9 High Pressure Switch HP1 4 Liquid Line Service Valve 10 Compressor Suction Pressure 5 Compressor Suction Service Valve Transducer CSP 6 Compressor Discharge Service Valve 11 Rear Unloader Solenoid Valve 012 7 Compressor Discharge Temperature 12 Compressor Junction Box IPC location Sensor CDT Figure 2 2 Road Side Rear Compressor View Refrigeration System Components 62 11524 2 4 Exhaust Location Coolant Bottle Location Air Cleaner amp Air Cleaner Service Indicator Behind bracket Engine Speed Control Unit ENSCU Engine Coolant Temperature Sensor ENCT Intake Air Heater
124. UL2 23 SATCOM A TX 27 3 15 SLP B TX 29 5 13 17 2CA G 30 LB B GREEN 32 19 2CA E 34 Unused terminals 1 2 4 7 8 9 10 11 14 16 20 21 22 24 25 26 28 31 33 35 10 2 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED START RUN OFF Continued Component Terminal CCONR 1 SP60 CDCON A2 1EVCON A2 SP55 CCONR 2 CDCON A1 GENCONR 2 CT2 OGF SP54 CT2 3 amp 4 BLACK CT3 OGF SP53 1 1 1HTCON2 A1 1EVCON A1 FHR 2 Unused terminals 11 12 Component Terminal MPQCC9 SP52 1 SP56 2RS B PSCONR 2 BUZZER GPR 85 SSR 85 Unused terminals 3 5 11 12 Component Connector Terminal DISP 1 BLK A 1 DISP 2
125. UNLOADER SERVICE 8 20 8 7 1 or Replacement seca m doe Ea CER Up RA ep ES CER pi Ead Rep urs 8 20 8 7 2 Removal and Replacement of Compressor 8 21 8 7 3 Cylinder Head and Valve Plate Service 8 22 974 Oil Pump And Bearing Head reas neds ied wae 8 23 55 DCompressar DII Level 2 FEDORA 8 24 a Checking Compressor Oil Level 8 24 b Adding Oil With Compressor In System 8 24 Removing Ol From The Compressol 8 25 omo WE grill Ea E E O E EE A 8 25 a Unioader Checkout procedure 8 25 b Unloader Coll Heplacsemert iis sen ERR ERE 8 25 c Replacing Unloader Valve Internal 8 26 d Unloader Valve Replacement E Sr EG E Geen ea Rd a 8 26 88 REFRIGERANT SYSTEM COMPONENT SERVICE 8 26 Evaporator Cole 8 26 Comers COl 8 27 4 SIGNING 8 27 i Condenser Coll FebISCemaellt 22222222042 cage pis aside 8 27 5g
126. YES When the 11 LOW ENGINE OIL 5 SURE alarm has been activated three times in the last two hours of engine operation the A21 ENGINE OIL PRESS SHUTDOWN TECHNICIAN RESET REQUIRED alarm will be activated NO A21 will not be activated YES When the A12 HIGH COOLANT TEM PERATURE alarm has been activated three times in the last two hours of engine operation the A21 HIGH ENGINE TEMP SHUTDOWN TECHNICIAN RESET REQUIRED alarm will be activated NO A21 will not be activated NO DEVICE NO DEVICE There is no fuel level sensor SWITCH installed in the fuel tank INSTALLED SWITCH INSTALLED A low fuel level switch is 0 5 VDC installed in the fuel tank D 0 5 VDC An older style low fuel level sensor 0 25 4 79 VOG 5 bolt mounting flange with a 0 to 5 VDC signal range is installed in the fuel tank FUEL SENSOR 0 25 4 75 VDC A low fuel level sensor with a 0 25 4 75 VDC signal range is installed in the fuel tank Sensor with 1 2 MPT mounting or newer ultrasonic sensor If a low fuel level sensor 0 to 100 sensor is in stalled the low fuel level warning Alarm 1 will come on when the level reaches 15 or less and the unit will shutdown Alarm 19 when the level reaches 10 62 11524 5 14 Table 5 2 Microprocessor Configurations Continued selections OFF OFF No fuel sensor is installed in the tank 30 Gallons 30 to 120 GALLON Size fo fuel tank
127. a Door Latch Maintenance Proper maintenance is important for smooth operation of the latch assemblies and the latch pins that are moun ted on the unit s frame See Figure 8 1 In order to keep the movable parts clean and lubricated CTD re commends the use of a de greasing cleaner and LPS 2 lubricant This lubricant should be available at any local automobile and truck parts suppliers b Cable Replacement 1 Remove circular clip that secures the cable to the paddle assembly See Figure 8 3 62 11524 8 6 2 Slide cable from paddle and rotate other end out of latch assembly NOTE The side door lower cable is inserted through the upper cable eyelet The lower cable is to be removed to gain access to the upper cable 3 Reverse above steps to install new cable Paddle Assembly Typical Front amp Side Doors Circular Clips Typical Front amp Side Doors Lower Cable Upper Connection Side Doors Only Upper Cable Side Doors Only Figure 8 3 Door Latch Cable Removal 8 4 4 Display amp Keypad Assembly a Disassembly 1 Place the Main Power switch in the OFF position Dis connect the negative battery cable Disconnect the high voltage source and lockout tagout the recept acle Attach a grounded wrist strap Carrier Transicold part number 07 00304 00 and ground it to a good unit frame ground Disconnect wiring between the keypad amp display as sembly and harness Loosen and remove t
128. a Self Test refer to Section 3 3 and then start the unit automatically Ensure the 2nd Compartment Run C2 and or the 3rd Compartment Run C3 switch is in the ON pos ition if operation is desired 62 11524 3 2 STARTING STANDBY OPERATION WARNING Be aware of HIGH VOLTAGE supplied at the power plug or from the generator When performing ser vice or maintenance procedures ensure any two way communication is disabled in accordance with the manufacturer s instructions ensure the Main Power switch is in the OFF position and whenever practical disconnect the high voltage source lockout tagout the receptacle and disconnect the neg ative battery connection NEVER dis assemble the generator HIGH MAGNETIC FIELD INSIDE This field can interfere with cardiac implants such as pacemakers and defibrillators WARNING Ensure the power plug is clean and dry before connecting to any electrical outlet receptacle WARNING Do not connect power plug to any electrical outlet without checking that it meets the 460 3 60 and 30 Amp electrical requirements of the unit Starting units with a Main Power switch labeled ENGINE OFF STANDBY 1 Ensure the switch labeled ENGINE OFF 2 Ensure the external power circuit breaker is off STANDBY is in the OFF position connect standby cable to unit and then turn the ex ternal power circuit breaker on COOL DEFROST
129. a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink Alarm Cause Corrective Action 123 CHECK SUPPLY AIR SENSOR TRIGGER ON Supply Air Temperature Sensor 1SAT is not within the range of 53 to 158 F 47 to 470 C UNIT CONTROL Engine and standby If Alarm 122 is not active and functional parameter Temperature Control is set for Supply Air and the setpoint for Compartment 1 is in the perishable range alarm only and switch to return air control If Alarm 122 is active set unit control as described in Alarm 122 RESET CONDITION Auto Reset when Supply Air Sensor is in range or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connectors No damage to sensor No damage moisture or corrosion in connectors b Check sensor resistance See 10 000 Ohms 9 77 F 25 See Table 8 5 for Note 3 page 7 2 complete table of temperatures and resistance values Check Sensor Wiring a
130. a temper ature rise to de energize the electric heaters if the tem perature in a compartment reaches the cut out point It is located on the end tube sheet of an evaporator coil b Defrost Termination Temperature Sensor 2DTT or 3DTT The DTT is located on the end tube sheet of an evapora tor coil It provides the microprocessor with evaporator temperature information to be displayed recorded in the DataLink data recorder and used to determine ter mination of defrost c Return Air Temperature Sensor 2RAT or 3RAT The RATs are temperature control probes which provide the microprocessor with information on the temperature of the air entering the evaporator The reading is dis played recorded in the DataLink data recorder and used to control the refrigeration system It is located on on the return air grille d Supply Air Temperature Sensor 2SAT The 2SAT is an optional temperature control probe which provides the microprocessor with information on the temperature of the air leaving the evaporator The reading is displayed recorded in the DataLink data re corder and used to control the refrigeration system It is located in a supply air outlet opening 2 6 SYSTEM OPERATING CONTROLS AND COMPONENTS Temperature control is provided by the Carrier Transicold Advance microprocessor the microprocessor is set at the desired temperature the unit will operate automatically to maintain the desired temperature within ve
131. activated Condition Three If a shutdown alarm occurs and the RAT is further away from setpoint than the limit set in the Out Of Range Alarm Functional Parameter 4 5 or 7 F 2 3 or 4 C the configured action Alarm only after 30 minutes or Alarm and Shutdown after 45 minutes will be activated regardless if the refrigerated compartment temperature has been in range not UNIT CONTROL Engine and standby Operation If the microprocessor is not configured for shutdown alarm only If the microprocessor is configured for shutdown the unit will shutdown and alarm RESET CONDITION Condition 1 Auto Reset If the unit is running in Pulldown Mode and the SAT is greater than 1 F 0 56 C below the RAT or if the unit is running in Pull Up Mode and the SAT is greater than the RAT Condition 2 amp 3 Auto Reset when the temperature is within 2 7 F 1 5 C for perishable setpoints or 2 7 F 1 5 for frozen setpoint For either Condition alarm may be manually reset via Keypad OR by turning the unit off then back on again NOTE The 30 or 45 minute timer is reset and starts again whenever unit cycles off and restarts in Start Stop eThe unit goes into and comes out of Defrost NOTE This alarm does not go into the Inactive alarm List when it becomes inactive or is cleared NOTE This alarm will not be activated in Sleep Mode NOTE For Condition Two the temperature criteria for this alarm is rese
132. active the evaporator fans will start 10 seconds after the Compartment 1 fan If all three compartments are active Compartment 2 will start ten seconds after Compartment 1 and Compartment 3 five seconds after Compartment 2 4 3 2 Perishable And Frozen Setpoint Ranges There are two ranges defined for setpoint a Perishable Range 129 b Frozen Range 129 4 3 3 Pull Down Pull Up When in Pulldown the refrigeration system will operate with the compressor loaded six cylinders the EVXV and or TXV controlling superheat to allow maximum flow and in Engine Operation in high speed setpoints above 10 4 F setpoints of or below 10 4 F When in Pull Up and Engine Operation the engine will operate in high speed If operating Compartment 1 only both banks of heaters are operated If operating Compartment 1 and additional compartment s only one bank of heaters will operate in Compartment 1 Pulldown Pull Up will be entered following a Start Up e following a setpoint change e following an operational change Start Stop Opera tion vs Continuous Operation or Engine Operation vs Standby Operation e following a defrost termination e when in a Start Stop ON Cycle and all other Stop Parameters have been met except the compartment temperature Stop Parameter Pulldown Pull Up will end when one of the following occurs e when in Engine Operation and the microprocessor is calling for low speed d
133. alarm 56 Must be corrected and cleared to continue Perform Pretrip Check Clear Active Alarm list then run Pretrip amp check for any new alarms Any active alarms must be corrected and cleared betore proceeding Check For Low Delta T Read Delta T from Unit Data 7 47 In Cool the Delta T must be greater than cooling more than 1 F 0 56 In Heat the Delta T must be greater than 0 1SAT must be higher than 1RAT 62 11524 Alarm Cause Corrective Action 63 BOX TEMP OUT OF RANGE Compartment 3 TRIGGER ON Condition One If the unit is running in Pulldown Mode and the SAT is not greater than 1 F 0 56 C below the RAT or if the unit is running in Pull Up Mode and the SAT is not above the RAT the configured action Alarm only after 30 minutes or Alarm and Shutdown after 45 minutes will be activated NOTE If the Out Of Range Alarm Functional Parameter is set to OFF the following conditions will not trigger an alarm or shutdown Condition Two If the refrigerated compartment temperature has been within 2 7 F 1 5 for perishable setpoints or 2 7 F 1 5 C for frozen of setpoint at least once since the unit was started and is now further away from setpoint than the limit set in the Out Of Range Alarm Functional Parameter 4 5 or 7 F 2 3 or 4 C the configured action Alarm only after 30 minutes or Alarm and Shutdown after 45 minutes will be
134. all re pairs are made the original microprocessor is to be rein stalled into the unit to avoid unnecessary costs to the customer or having the Warranty Request rejected if there is no problem found with the returned micropro cessor All steps leading to replacement of the microprocessor have a number associated with them When filling out the MPR tag that will be attached to the returned part write the step number on the upper half of the tag in the Failure Description Field Include the same information in the Failure Description Field when entering the war ranty claim information on line This will show which diagnostic tree was used and the path that was followed to determine the micro was at fault Refer to the following table to identify the correct tree to use Table 9 2 Microprocessor Diagnostics Condition Description Diagnostic tree 1 Main Power switch On Unit Does Not Operate Figure 9 5 2 Main Power switch On Unit Operates But Not Properly Figure 9 6 3 Main Power switch Off Unit Fails To Stop Figure 9 7 4 Unit Will Not Run In High Speed Figure 9 8 5 Unit Will Not Run In Low Speed Figure 9 9 6 DataLink Data Recorder Data Download Problems When Using Figure 9 10 ReeferManager and a Download Cable Data File Analysis Prob lems Using Reports 7 PC Card Problems Figure 9 11 8 Programming Problems With PC Cards Figure 9 12 9 13 62 11524 START HERE Disconnect two
135. amp draw is normal or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Rear Unloader UL2 Coil a Inspect Rear Unloader UL2 coil amp connector No damage to coil No damage moisture or corrosion in connector b Check resistance of coil Refer to Section 2 13 for correct electrical values Cannot be opened infinite ohms shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 Use ammeter Check Rear Unloader UL2 Current Draw Use Component Test Mode to test actual current draw of the circuit Refer to Section 5 2 2 Refer to Section 2 13 for correct electrical values View current draw in Data List Check Rear Unloader UL2 Coil Wiring Inspect harness amp control box con nector pins amp terminals See wiring schematic Section 10 7 59 No physical damage to harness No damage moisture or corrosion in connectors 62 11524 ae Alarm Cause Corrective Action 89 CHECK REMOTE AUTO LIGHT Light Bar TRIGGER ON The normal operation output circuit green Status OK
136. amp fre quency at Low Speed 345 vac 45 hz 3 phase Resistance 0 73 to 0 778 ohms phase to ground 1 476 to 1 556 phase to phase Output 20 7 0 84 p f 1800 rpm Input 360 460 VAC Single Phase Output amps 20A Maximum Output voltage 14 8 VDC 77 F 25 C Input 360 460 VAC Three Phase eae Output amps 40A Maximum Output voltage 14 8 VDC 77 F 25 C Trips On High Current 40 Amps OG Module Trips on Ground Fault 150 Battery Voltage 2 volt nominal 90 amp hour capacity old cranking amps 425 DIN 500 IEC 725 BCI Standby Power Voltage 460 3 60 with a 30A Circuit Breaker required Requirements Current Full Load Draw 25A Locked Rotor Draw 99A Standby Extension Cord engin 50 minimum length 78 M ximum length 2 13 COMPONENT RESISTANCE amp CURRENT DRAW DATA Component Ohms Amps Remote Liquid Line Solenoid Valve 10 9 Ohms 1 1 Amps Unloader Solenoid Valve 9 6 0 8 Ohms 1 0 2 0 Amps 12VDC Relay GPR SSR FHR 72 Ohms 10 0 14 0 18 Amps 12VDC Relay PSCONR GENCONR CCONR RCR 80 Ohms 15 0 12 0 17 Amps 12VDC Relay HTCON1 HTCON2 CDCON 1EVCON 2 2HTCON1 2 2 48 Ohms 10 0 25 Amps 10 12VDC Relay PSCON1 PSCON2 GENCON CCON 15 5 Ohms 10 0 77 Amps 10 Fuel Speed Actuator FSA 2 8 Ohms 10 68 F 20 C 4 Amps Max In
137. and Current Draw 2 21 Data Compressor 2 20 Data Electrical 2 20 Data Engine 2 19 Data Refrigeration System 2 20 DataTrak 3 28 Decals Safety 1 6 Defrost 4 3 Defrost Initiation And Start 4 9 Defrost Manual 3 13 Defrost Modes 4 9 Defrost Termination 4 9 Display 8 6 Door Latch 8 6 E Electrical Data 2 20 Engine 2 9 9 1 Engine Data 2 19 Engine Speed Control Unit 2 9 Evacuation Complete System 8 19 Evacuation Compressor 8 20 Evacuation Low Side 8 20 1 62 11524 INDEX Continued F Fan Condenser 8 38 Filter Drier 2 12 Filter Drier Checking 8 28 Filter Drier Replacement 8 28 Filter Engine Oil 8 10 Filter Fuel 8 9 Frozen Range 4 3 Fuel Speed Actuator 2 9 Fuel Heater 2 9 8 10 Fuel Pump Electric 8 9 Fuel Pump Mechanical 8 8 Functional Parameters Microprocessor 3 22 Fusible Plug 8 28 G Generator 2 9 8 39 9 4 Grille Insert 8 5 H Heat Exchanger 2 12 Heaters Evaporator 8 37 Hour Meters View 3 20 Indicator Lights 2 16 Intake Air Heater 4 2 8 12 K Keypad 2 17 8 6 L Language Selection 3 25 Languages 2 13 Leak Checking Charged System 8 17 Leak Checking Compressor 8 18 62 11524 Leak Checking System Without Charge 8 17 Leak Checking With Low Side Pumped Down 8 18 Light Bar 2 18 8 36 lockout tagout 1 1 Main Display 2 16 Megohmmeter Test Procedure 8 34 MessageCenter 2 16 2 17 Message
138. and remove coil WARNING Do not unscrew enclosing tube nut all the way before breaking seal Entrapped pres sure could result in injury Loosen the enclosing tube nut see Figure 8 24 us ing installation removal tool supplied with repair kit Ensure tube is loose and seal is broken then remove tool enclosing tube nut enclosing tube plunger with plunger spring and o ring Check plunger for restriction due to a corroded or worn parts 0 foreign material lodged in valve bent or dented enclosing tube Install new parts Do not over tighten enclosing tube assembly Torque to a 100 inch pounds 11 3 Nm Remove tool and install coil refer to preceding step b Leak check and evacuate the compressor Refer to Sections 8 6 3 and 8 6 4 Check operation refer to preceding step a Unloader Valve Replacement Pump down the compressor Refer to Section 8 6 2 Disconnect and remove coil WARNING Do not unscrew unloader valve body mounting bolts all the way before breaking seal Entrapped pressure could result in injury Loosen the valve body mounting bolts Tap the valve body to break the seal and then remove bolts and gasket Remove small screen from inside the compressor head and ensure it is not obstructed Clean or replace as required Place new gasket onto replacement unloader valve body with flat side toward the head and using un 62 11524 8 26 loader ring pliers Ca
139. and test for acidity If acid is present a system cleanup may be ne cessary Remove all external compressor components such as the unloader coils discharge strainer switches transducers temperature sensors amp fittings Note Location of items 5 amp 6 may be reversed C yeas Om Mt Torque 33 to 37 ft Ibs BACK VIEW 44 to 50 Nm Compressor Discharge Pressure Transducer High Pressure Switch Unloader Coil Compressor Discharge Temperature Sensor Junction Box Serial Model Plate Discharge Service Valve Flange Cylinder Head Torque 60 to 70 ft Ibs 81 to 95 Nm FRONT VIEW 9 Valve Plate 10 Suction Pressure Transducer Location 11 Oil Level Sight Glass 12 Oil Drain Location 13 Oil Pan 14 Motor End Cover 15 Suction Service Valve Flange 16 Oil Fill Port Figure 8 19 Compressor model 06D 8 21 62 11524 WARNING Do not unscrew replacement compressor lifting eyelet blankoff plate mounting capscrews all the way before breaking seal Entrapped pressure could result in injury i Loosen the suction and discharge lifting eyelet blankoff plate mounting bolts Tap the center of the blankoff plates to break the seal and then remove bolts plates and gaskets If required add oil to the replacement compressor Add only 7 0 pints 3 3 liters of oil when first adding oil to the compressor This procedure is designed to compensate for excess o
140. at which speed changes unloading changes heater operation and change to Null Mode occur while operating in Continuous Operation 62 11524 The switch points will differ depending on the setting of the microprocessor ECO MODE Functional Parameter This value may be set to YES or NO The factory default setting is NO With ECO MODE set to NO the microprocessor will control temperature closer to setpoint yielding maximum product protection With ECO MODE set to YES the microprocessor uses the Start Stop Override Functional Parameter setting even though the unit is in Continuous Operation and will control temperature within a wider band yielding improved fuel economy When neither heating or cooling is required in a compartment the compartment will enter Null Mode In Null Mode the electronic expansion valve EEXV for Compartment 1 is closed to 096 OR liquid line solenoid valve LSV for Compartment 2 amp 3 is de energized while the evaporator fan s continue to run When Null Mode is required in all compartments and the System is operating in e Engine Operation the compressor will shutdown while the engine condenser fan and evaporator fans will continue to operate e Standby Operation the compressor will shutdown while the evaporator fans will continue to operate FALLING REFRIGERATED COMPARTMENT TEMPERATURE SWITCH POINT Pulldown High Speed 6 Cylinder COOL 3 6 F 2 0 C 3 2 F 1 8
141. be corrected and cleared be fore proceeding Check Compressor a Perform Pump Down Test Refer to Section 8 7 1 Must hold a vacuum and not equalize in a short peri od of time b Cover condenser and build up discharge pressure Must be able to pump up to 400 psig 27 2 bar c Disassemble and inspect compressor valve plates reeds pistons etc 7 21 Must be intact clean and in good working order 62 11524 Alarm Cause Corrective Action 7 5 START UP ENGINE ALARMS 30 FAILED TO RUN MINIMUM TIME TRIGGER ON The unit has shutdown an alarm 3 times without having run for at least 15 minutes between each shutdown not including Door shutdowns e UNIT CONTROL Engine Operation engine and unit shutdown and alarm Standby Operation refrigeration system shutdown and alarm with PSCON still energized RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back again If the Unit Operation configuration is set to Rail Mode this alarm will reset after 4 hours NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Alarms Check for shutdown alarms Alarm conditions must be corrected and the alarm s cleared
142. be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check Engine Exhaust System 62 11524 Inspect the exhaust system Must be clear and unobstructed Alarm NO Alarm Cause Corrective Action 39 CHECK ENGINE RPM TRIGGER ON In Engine Operation and Alarm 130 is not active and engine speed is less than 1250 rpm for 2 seconds or greater than 2100 rpm for 5 minutes or engine speed drops to less than 1200 rpm for 3 seconds after the engine speed has been greater than 1250 rpm UNIT CONTROL shutdown and alarm Engine Operation alarm only or if configured for shutdown engine and unit Standby Operation this alarm will not activate in standby Operation RESET CONDITION Auto Reset if engine rpm is greater than 1150 and less than 2000 for 5 minutes or after 15 minutes if the engine has been shutdown or change unit to standby Operation or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Model Number Verify that the model number on the nameplate matches the model number shown in the microprocessor
143. before the reading enters a vacuum If the suction pressure does not change this is an in dication the valve is stuck and the piston and drive motor assembly is to be replaced 8 29 d Replacing the Drive and Motor Assembly 1 Pump down the low side Refer to section 8 6 2 2 Remove valve piston and motor assembly and re place with a new assembly and gasket The power head should be set to 100 open when received from the warehouse This is to ensure the Teflon valve seal is not damaged when it is installed Ensure the valve is fully open by using the stepper motor tester to manually open the valve to 100 before it is installed Torque nut to 47 4 Nm 35 ft lb Leak check evacuate the low side Refer to Sections 8 6 3 and 8 6 4 e Emergency Repair Procedures In the event that the SMV system has a failure and replacement components are not readily available in an emergency A LIMP HOME procedure can be done as follows 3 Install a manifold gauge set Pump down the low side Refer to section 8 6 2 Remove SMV power head by loosening the 2 1 8 inch diameter nut see Figure 8 26 and sliding the power head out Remove the piston by loosening the Allen screw and removing the piston and screw Install the power head assembly without piston torque to 47 to 54 Nm 35 to 40 ft lb Leak check and evacuate the low side Refer to Sec tions 8 6 3 amp 8 6 4 Start the unit Adjust the
144. between 0 5 VDC be tween FLSC and ground wire from unit with sensor disconnected um Alarm Cause Corrective Action 20 MAXIMUM COMPRESSOR ALARMS e TRIGGER ON This option must be installed and alarm must be enabled by configuring the Compressor Alarm Shutdown to YES Alarms 13 17 18 27 or 28 individually occur 3 times within the last 2 hours UNIT CONTROL Engine Operation engine and unit shutdown and alarm Standby Operation refrigeration system shutdown and alarm with PSCON still energized RESET CONDITION Reset from inactive alarm list only Can not be reset by turning switch OFF and then ON again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Alarm Caused This Alarm To Be Active a Check active alarm list for One or more of these alarms will be present Alarm 5 13 17 18 27 28 or 29 b Follow the steps for the alarm s All alarms condition must be fixed found above and correct the alarm condition Reset Alarm Reset all alarms from the inactive All alarms must be cleared to start unit alarm list 21 TECHNICIAN RESET REQUIRED e TRIGGER ON The High Engine Temp Shutdown Configuration and or Engine Oil Pressure Shu
145. cleared there will be no noticeable change the units operation The Inactive Alarm list is cleared in the same way When the inactive alarm list is cleared both the inactive and active lists are cleared Clearing the inactive alarm list removes the alarm from the microprocessor Many electrical circuits may be tested by powering the microprocessor without starting the unit Two methods are available to do this METHOD ONE Place the microprocessor in PC Mode Refer to Section 5 3 METHOD TWO Set the NO A C POWER Configuration to ALARM amp SHUTDOWN and ensure the unit is disconnected from standby power Start the unit in standby For units equipped with a Main Power switch switch labeled ENGINE OFF STANDBY DOES place the DOES in the STANDBY position For units equipped with a Main Power switch labeled START RUN OFF SROS place 62 11524 7 2 Note 3 Note 4 Note 5 the switch labeled STANDBY ENGINE DES in the STANDBY position and then place the SROS in the START RUN position Sensors may be tested at the component plug The sensor and interconnecting wiring may also be tested at the 1MP plug Remove plug and using an ohmmeter measure resistance Be careful not to damage the connector pins Refer to Section 8 9 10 for chart of resistances for different sensors The switches Remote 1 amp 2 Door High Pressure Engine Oil Pressure Defrost Air and Evaporator High Temperature 1 2 or 3
146. coil and No damage to coil wire connections No damage moisture or corrosion in connections b Check contactor coil resistance Refer to Section 2 13 for correct electrical values Check 3EVCON Amp Draw Check 3EVCON amp draw Use Component Test Mode refer to Section 5 2 to test Refer to Section 2 13 for amp values View current draw in Data List Check 3EVCON Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Additional steps on the next page 7 113 62 11524 Steps Alarm Cause Corrective Action C3 CHECK EVAP FAN MOTOR Continued 5 Check Amp Draw of Compartment 3 evaporator fan motor circuit Use a clamp on ammeter to check the current draw of all 3 legs Must be within range shown in Section 2 12 for all three legs Check Compartment 3 evaporator fan motors a With the unit off visually check fan motors and blower wheels No visual physical damage No blockage due to debris Blower wheels spin freely Remove and replace if required b With the unit off check resistance of the evaporator fan motor windings No open windings phase to phase No continuity from any high voltage lead to ground Check Compartment 3 evaporator fan motor connections Inspect high voltage fan motor con necti
147. condition of product If product is warm and moist frequent defrost cycles can be expected Check Switch Wiring a Inspect switch amp connector pins amp terminals No physical damage to switch No damage or corrosion in connector b Check switch circuit See wiring schematic Section 10 Check wiring from switch to microprocessor terminal 2MP6 is not shorted to a power source providing false signal Check Defrost Air Switch Defrost Circuit and Tubing 62 11524 a Perform testing and reset switch if required Refer to Section 8 8 9 page 8 31 ALARM CAUSE CORRECTIVE ACTION 57 CHECK REMOTE SWITCH 1 1 TRIGGER ON Remote Switch 1 is set to activate an alarm if the switch is activated opened closed depending on switch type for more than five seconds UNIT CONTROL May be configured as alarm only alarm and force low engine speed or alarm and shutdown Compartment 1 RESET CONDITION Alarm Only Auto Reset after the switch has de activated for more than five seconds Shutdown Auto Reset after three minutes minimum off time for door open condition and the switch has de activated for more than five seconds NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occu
148. connections No damage moisture or corrosion in connectors Check coil resistance See Section 8 8 6 Check EVXV operation See Section 8 8 6 Check basic refrigeration system Pressures normal Compressor operation normal Check the EVXV electrical Check for good continuity in all circuits from micro to system EVXV Inspect component and wire No physical damage to harness connections No damage moisture or corrosion in connectors Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damage moisture or corrosion in connectors wiring schematic Section 10 62 11524 7 108 Alarm Cause Corrective Action P178 CHECK UL1 TRIGGER ON The pressure differential between suction and discharge pressures did not change as expected when the Front Unloader UL1 was de energized loaded discharge pressure should rise and suction pressure should drop or when it was energized unloaded discharge pressure should drop and suction pressure should rise UNIT CONTROL Engine and Standby Operation Pretrip will fail in teat 13 and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset viakey pad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the a
149. control probe which pro vides the microprocessor with information on the tem perature of the air entering the evaporator section The reading is displayed recorded in the DataLink data re corder and used to control the refrigeration system It is located on on a bracket behind the center of the return air grille f Supply Air Temperature Sensor 1SAT The 1SAT is a temperature control probe which provides the microprocessor with information on the temperature of the air leaving the evaporator section The reading is displayed recorded in the DataLink data recorder and used to control the refrigeration system It is located in the roadside of the supply air outlet housing 2 5 REMOTE EVAPORATOR S The remote evaporator s See Figure 2 5 are moun ted to the ceiling of compartment 2 and or Compartment 3 The evaporator assembly consists of one or more evaporator coils evaporator fan motors liquid line solenoid valves thermal expansion valves coil heaters defrost termination temperature sensors high tempera ture switches 12 V drain line heaters and a return air sensor Compartment 1 is also be fitted with a supply air temperature sensor For Compartment 2 the supply air temperature sensor is an option Heating and defrost is accomplished by electric heaters mounted on the coil Automatic evaporator coil defrosting may be initiated manually or by the microprocessor To place the unit in the operation the micropro
150. corrosion in connectors schematic Section 10 7 61 62 11524 Alarm NO Alarm Cause Corrective Action 93 CHECK START UP BUZZER TRIGGER ON The Buzzer circuit is shorted The Buzzer output from the microprocessor 5 8 is negative so the circuit will not be shorted to ground but is shorted either within the Buzzer itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset when Buzzer amp draw is normal or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Buzzer a Inspect Buzzer amp wire connections No damage to buzzer No damage or corrosion b Check resistance of buzzer Refer to Section 2 13 for correct electrical values Cannot be opened infinite ohms shorted Zero Ohms or shorted to ground Check Buzzer Wiring Inspect harness amp control box con nector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors Check Buzzer Current Draw Use Component Test Mode
151. de energized and the gas bypass port is closed Solenoid Valve Valve Stem Gas Bypass Port Spring Guide Spring Piston Bypass Valve Bleed Orifice 9 Strainer 10 Suction Manifold 11 Cylinder Discharge Valve 12 Valve Plate 13 Cylinder Suction Valve 14 Discharge Check Valve Assembly 15 Discharge Manifold Figure 2 9 Compressor Cylinder Head Loaded c Loaded Operation With the solenoid valve 1 Figure 2 9 de energized the solenoid valve stem will close the gas bypass port 3 Pressure from the discharge manifold item 15 through the strainer 9 and bleed orifice 8 will build behind the piston 6 This increased pressure will overcome the bypass valve spring 5 tension and force the piston 6 forward clos ing the gas bypass from the discharge manifold to the suction manifold 10 Cylinder discharge pressure will force the discharge check valve assembly 14 open Refrigerant gas will then flow into the compressor discharge manifold The loaded cylinder bank will continue to operate fully loaded until the solenoid valve is energized and the gas bypass port is opened 2 3 7 Compressor Switches Transducers and Sensors a Compressor Discharge Pressure Transducer CDP The CDP provides a signal to the microprocessor equivalent to pressure leaving the compressor The reading is displayed recorded in the DataLink data recorder and used to control the refrigeration system It is
152. displays in the MessageCenter when the key is pressed and the unit is in Continuous Operation Refer to Table 5 2 for more information on Configurations 62 11524 If the unit fails to start after three start attempts the 1 FAILED TO START AUTO alarm will be activated While running if the unit shuts down an internal counter keeps track of the shutdowns Should the unit shutdown three consecutive times without running a minimum of 15 minutes between shutdowns the A30 FAILED TO RUN MINIMUM TIME alarm will be activated The shut down counter is cleared when the unit has run for 15 mi nutes 3 8 SLEEP MODE COOL DEFROST SETPOINT START STOP CONTINUOUS BOX TEMPERATURE SLEEP MODE SETTINGS EJ TO ENTER SLEEP MODE MANUAL DEFROST ALARM SELECT CONTINUOU Press the SELECT key until the MessageCenter displays PRESS Tl TO VIEW SETTINGS Press the UP ARROW key until the Functional Parameter SLEEP MODE SETTINGS is displayed Press the key The MessageCenter will then display TO SCROLL THEN TO SAVE Press either the UP or DOWN ARROW key until SLEEP MODE YES is displayed The MessageCenter will flash indicating that this change has not been entered into memory Press the key to save the setting ti memory the MessageCenter will stop flashing the unit is now in sleep mode Additional Functional Parameter sub menu
153. equal reading across all phases 62 11524 b Generator Removal 1 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle 5 Unbolt snubber Unplug the ENSCU 2 Remove the nuts 2 from the exhaust connection 6 Remove the locking plates from the rear engine mounting bolts and then remove the engine frame bolts Leave front bolt on pump side loose 7 Place the engine support tool P N 86 04751 00 8 Unbolt battery cable clamps 3 Disconnect ground wire 4 Cut the generator cables Leave the same length as new generator wires 9 Remove fuel filter assembly Unclamp hoses 62 11524 8 40 NOTE Do not remove and use the shim from a replace ment generator the replacement generator shim must remain in place until the generator is installed 10 Use tool Carrier Transicold part number 07 60083 00 to lock the engine flywheel 15 Remove 3 of the 6 flywheel bolts on the generator 16 Insert 3 guiding rods P N SKM 5671 17 Place the mica shim P N 54 00630 25 between the rotor and the stator prior to loosening any other bolts 18 Remove the last 3 flywheel bolts 11 Pull the harness on the top of generator out of the way 12 Swing out the engine 13 Remove the fan cover 4 bolts 14 Remove the fan blade center screw Usin
154. fan for any foreign material or damage or anything that will prevent the blade and motor from turning freely Blower wheel must be in good condition No sticks or other material obstructing its movement No ice build up preventing blade rotation Check For 12 VDC At 4MP3 If 12VDC Alarm should have cleared itself b If no power OVDC Continue with step 2 below Check IPC Circuit a Use Component Test Mode to ener gize Evaporator Motor Contactor circuit Refer to Section 5 2 2 FET 20 will be on Unplug the connector to the evapo rator fan motor and check voltage IP EVM white wire 12 VDC between pin 4 in the engine harness connector and Ground Check 9 There should be 12 VDC MPQC9 to Ground Test continuity through IPC Should be 0 Ohms If the evaporator fan motor is extremely warm allow it to cool off then recheck IPC continuity Test IP circuit from evaporator fan motor junction box to microproces sor 12 VDC at 4MP3 Check Evaporator Fan Motor Conta ctor a Inspect the wire connections to the contactor See wiring schem atic Section 10 No signs of overheating of the contactor Wiring is routed correctly to the contactor b Check tightness of the contactor wire connections Tighten with screwdriver and check for discoloration of wires Perform Pretrip Clear Active Alarm list then run Pre
155. fault LED b OGF Checkout Procedure 1 Check the FAULT LED on the module If the LED is illuminated the module has activated and 12 VDC power supply is correct Perform a megohm test refer to Section 8 9 1 to determine if a fault to ground exists This test will also help determine if an excessive current condition exists due to leakage to ground Repair wiring or components as required problem with the module is suspected check for 12VDC power to the module at the 12V terminal and ground at the OV terminal Correct wiring as re quired Reset module by placing the Main Power switch in the OFF position and then back in the de sired position Check for 12 VDC at the S terminal If LED is off and the module normally closed connec tion is open replace module module is OK check for 12 VDC at SP61 and wir ing through to microprocessor terminals 2MP26 4MP7 amp 5MP7 as required problem with the current sensors is suspected check sensor output Current sensor inputs to the module are rated at 16 7mV per Amp For every Amp that is read at the wires coming from the GENCON T1 T2 and terminals with an amp meter there should be a corresponding voltage reading on the blue brown amp orange wires to the black wire For ex ample 20Amps 0 33VAC S 12V OV 10 00451 00 iy LRANSICOLD GROUND FAULT BLUE BROWN TO CURRENT ORANGE S Figure 8 37 Overload Ground Fault Conn
156. flat side toward valve plate ensur ing that the gasket and cylinder head are properly positioned on the valve plate Torque the capscrews in a diagonal pattern 42 to 55 ft lbs 57 to 74 Nm o Leak check and evacuate the compressor Refer to Section 8 6 3 and Section 8 6 4 8 7 4 Oil Pump And Bearing Head a Pumpdown the compressor Refer to Section 8 6 2 b Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle c Loosen the eight capscrews tap the pump to relieve any remaining pressure and then remove the oil pump bearing head assembly gasket and thrust washer See Figure 8 22 Oil Pump amp Bearing Head Thrust Washer Oil Pickup Tube Oil Inlet Port PONS Figure 8 22 Oil Pump and Bearing Head Assem bly 62 11524 d If it is determined that the oil pump is not operating properly the entire oil pump and bearing head as sembly must be replaced Replacement parts for the pump are not available except for the cover plate O ring However in the event the pump requires inspec tion or cleaning refer to Figure 8 23 for disassembly and reassembly Clean all parts coat all moving parts with compressor oil before proceeding with reas sembly 1 Capscrews 7 O Ring 2 Cover 8 Oil Pump amp Bearing 3 Eccentric Ring 9 DowelPin 4 Rotor 10 Re
157. for capacity control of the refrigeration system cooling cycle It is located in the suction line at the exit of the evaporator assembly 2 4 5 Compartment 1 Evaporator Switches Trans ducers and Sensors a Evaporator Outlet Pressure Transducer EVOP The EVOP provides the microprocessor with evaporator outlet pressure information to be displayed recorded in the DataLink data recorder and used to control the refrigeration system It is located in the suction line near the electronic expansion valve b Evaporator High Temperature Switch 1EVHTS 1EVHTS is a safety switch which opens on a temperat ure rise to de energize the electric heaters if the tem perature in compartment 1 reaches the cut out point It is located on the roadside tube sheet of the evaporator coil c Evaporator Outlet Temperature Sensor EVOT The EVOT provides the microprocessor with evaporator outlet temperature information to be displayed recorded in the DataLink data recorder and used to control the refrigeration system It is located on the suction line near the electronic expansion valve d Defrost Termination Temperature Sensor 1DTT The 1DTT is located on the curbside tube sheet of the evaporator coil It provides the microprocessor with evaporator temperature information to be displayed re corded in the DataLink data recorder and used to de termine termination of defrost e Return Air Temperature Sensor 1RAT The 1RAT is a temperature
158. hour meter menu NO This hour meter will not be displayed during the startup messaging sequence It will be dis played with the other meters and counters YES This hour meter will be displayed during the startup messaging sequence and will be in hour meter menu NO This hour meter will not be displayed during the startup messaging sequence It will be dis played with the other meters and counters YES This hour meter will be displayed during the startup messaging sequence and will be in hour meter menu NO This hour meter will not be displayed during the startup messaging sequence It will be dis played with the other meters and counters DISPLAY TOTAL ENGINE HR DISPLAY STANDBY RUN HR DISPLAY TOTAL SWITCH ON HR 5 15 62 11524 Table 5 2 Microprocessor Configurations Continued selections Description OFF When the engine maintenance hour meter is reset DIESEL RESET VALUE 50 TO 30 000 the value selected here will be added to the to the re in 5 in present meter reading to indicate to the micropro Refer to Table 8 1 for oil filter ene cessor when the next service interval alarm will be change intervals activated If the value entered is 0 the alarm fea ture is turned off OFF When the standby maintenance hour meter is reset 50 TO 30 000 the value selected here will be added to the to the in 5 in present meter reading to indicate to the micropro STANDBY
159. ing procedure should be done to determine if the prob lem is with the microprocessor display or interconnect ing wiring NOTE For diagnoses of problems with the micropro cessor DataLink data recorder downloading file analysis using Reports or use of PC cards refer to Section 9 6 CAUTION Most electronic components are suscepti ble to damage caused by electrical static discharge ESD In certain cases the hu man body can have enough static electric ity to cause resultant damage to the compo nents by touch This is especially true of the integrated circuits found in the Advance mi croprocessor a Attach a grounded wrist strap CTD P N 07 00304 00 and ground it to a good unit frame ground With the microprocessor powered up check the Mi croprocessor Status LED See Figure 2 10 is blinking at a 1 second pulse and without removing the spade connectors check voltage between micro processor terminal QC1 and QC2 Minimum voltage to microprocessor is 11 VDC If voltage is not correct repair wiring to microprocessor Unplug the 6MP connector from the microprocessor With the negative meter lead on QC2 without remov ing the spade connector test voltage at the micro processor 6 1 terminal see Figure 5 5 nominal 12 VDC is not present the microprocessor has failed and must be replaced Figure 5 5 Connector 6MP Connections 62 11524 e With the negative meter
160. instru ment as follows 1 Ohmmeter or Continuity Device 2 Adjustment Screw 0 050 socket head size 3 Low Side Connection 4 Pressure Line or Aspirator Bulb Carrier Transicold part number 07 00177 01 5 Magnehelic Gauge Carrier Transicold part number 07 00177 00 6 High Side Connection Figure 8 31 Defrost Air Switch Test Setup e Ensure magnehelic gauge is in proper calibration NOTE The magnehelic gauge may be used in any position but must be re zeroed if position of gauge is changed from vertical to horizontal or vice versa USE ONLY IN POSITION FOR WHICH IT IS ZEROED f With air switch in vertical position connect high pres sure side of magnehelic gauge a tee and and aspir ator to high side connection of air switch Tee is to be placed approximately half way between gauge and air switch or an improper reading may result See Figure 8 31 g Attach an ohmmeter to the air switch electrical con tacts to check switch action 62 11524 NOTE Use a hand aspirator Carrier Transicold part number 07 00177 01 since blowing into tube by mouth may cause an incorrect reading h With the gauge reading at zero apply air pressure very slowly to the air switch An ohmmeter will indi cate continuity when switch actuates The switch contacts should close and the ohmmeter needle move rapidly to 0 Any hesitation in the ohmmeter in dicates a possible problem with the switch and it should be replaced
161. is completed because of its inherent inaccuracy 3 Standard service hoses not recommended for evacuation purposes Evacuation hoses are recommended for this procedure Evacuation of the Complete System Evacuate only after pressure leak check Refer to Section 8 6 3 If possible keep the temperature of the major com ponents condenser evaporator compressor receiv er and remote evaporator above 60 F 15 6 C to speed evaporation of moisture If the temperature is lower than 60 F 15 6 C ice might form before moisture removal is complete Heat lamps heat guns or alternate sources of heat may be used to raise sys tem temperature The recommended method to evacuate the system is to connect three evacuation hoses with vacuum pump and vacuum indicator see Figure 8 18 Ensure that the microprocessor MessageCenter dis plays RECOVER LEAK CHK EVAC during the evacuation and dehydration procedures Refer to Section 5 2 3 If the microprocessor switches to charge mode during the process switch it back to the RECOVER LEAK CHK EVAC MODE Backseat turn counter clockwise the liquid line ser vice valve suction service and discharge service valves With the unit service valves closed back seated and the vacuum pump and vacuum indicator valves open start the pump and draw a deep vacuum Shut off the pump and check to see if the vacuum holds This operation is to test th
162. is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Alarm List Check for Alarm 41 When alarms 41 and 130 occur at the same time generally the engine has run out or is running out of fuel This causes the engine to surge Check fuel in tank and add fuel as necessary Check fuel lines between the fuel tank and the fuel pump inlet to endure air is not being drawn in Check Engine Speed Sensor ENSSN Inspect circuit ENSCU No damage to sensor or wiring terminal to microprocessor No damage moisture or corrosion in connector connection 2MP18 amp connector b Compare actual engine speed with Must be 20 RPM that shown on the display using Must be a steady reading hand held tachometer c Check for 12 VDC between Must be 12 VDC ENSSN 12V terminal amp ENSSN ground d Check for 12 VDC at ENSSU Must be 12 VDC terminal 25 to ground Check Circuits With Test Sensor Substitute known good sensor and Must be within 20 RPM of reading on tachometer check Unit Data reading Refer to Section 3 13 62 11524 7 82 m Steps Alarm Cause Corrective Action 131 CHECK EVAP TEMP SENSOR TRIGGER ON Evaporator Outlet Temperature Sensor EVOT is not within the range of
163. lead on QC2 without remov ing the spade connector test voltage at the micro processor 6MP4 terminal see Figure 5 5 If nominal 5 VDC is not present the microprocessor has failed and must be replaced f Plug the 6MP connector back into the micropro cessor g Disassemble display to gain access to the display test points Refer to Section 8 4 4 for display disas sembly Figure 5 6 Display Test Points h With the negative meter lead on TP 12 test voltage at TP14 see Figure 5 6 If nominal 12 VDC is not present check wiring from microprocessor to display With the negative meter lead on TP13 test voltage at TP12 see Figure 5 6 If nominal 5 VDC is not present check wiring from microprocessor to display connections are good replace the display board 5 7 MICROPROCESSOR REPLACEMENT amp SET UP CAUTION Under no circumstances should techni cian electrically probe the microprocessor at any point other than the connector termi nals where the harness attaches Micropro cessor components operate at different voltage levels and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could perma nently damage the microprocessor Some microprocessor inputs operate at voltage levels other than the conventional 12 VDC These inputs in clude but are not limited to the pressure transducers and temperature sensors Under no circumstances should 12 V
164. located on the compressor center head b Compressor Suction Pressure Transducer CSP The CSP provides a signal to the microprocessor equivalent to pressure entering the compressor cylinders The reading is displayed recorded in the DataLink data recorder and used to control the refrigeration system It is located on the front of the compressor oo Discharge Temperature Sensor The CDT provides a signal to the microprocessor equivalent to the temperature of the gas leaving the compressor The reading is displayed recorded in the DataLink data recorder and used to control the refrigeration system It is located on the compressor center head 62 11524 d Compressor Suction Temperature Sensor CST The CST provides a signal to the microprocessor equivalent to to the temperature of the gas entering the compressor suction service valve It is located on the line entering the valve e High Pressure Switch HP1 HP1 is normally closed and opens on pressure rise to signal to the microprocessor to shutdown the engine or shutdown the system if operating on standby power It is located on the compressor center head 2 3 8 Condenser Coil The condenser coil is a microchannel type and acts as a heat exchanger in which the compressed refrigerant gas is lowered in temperature and condensed into a li quid Air movement over the condenser is provided by two electric motor driven fans mounted in the condens ing section
165. location See Figure 8 41 0 5 in 12 7mm 8 O CLOCK 5 O CLOCK One in eight o clock location One in eleven o clock location Figure 8 41 Bolt Hole Pattern For Bell Housing NOTE and Crankshaft The remaining four stator mounting bolts will be 2 Remove the flywheel and inspect it for any debris or installed and will all be torqued after the fan damage cover is installed 3 2 9 Figure 8 40 3 40 OMO the Bell 13 Torque the rotor bolts to 90 110 foot pounds 122 to 9 9 ping 149 Nm using an alternating sequence NOTE NOTE Install the spacer so the irregularly shaped Mark each rotor screw after it is torqued to piece covers the starter opening ensure that all the screws are torqued 62 11524 8 42 14 Remove the mica shim that is between the stator and the rotor 15 Install the fan onto the rotor NOTE The fan must be installed with blades away from the engine 16 Torque the fan screw to 10 12 foot pounds 14 to 16 Nm 17 Feed all the wires through the inside of the fan cover side opening Ensure there are no loops or wires lay ing on the stator end 18 Install the fan cover Item 3 onto the generator sta tor and install the remaining mounting screws and washers NOTE Make sure the insulation on lead wires is not damaged during assembling of the fan cover Each mounting screw must be assembled with two washers 8 43 19 Torque the stator mounting screws to 33 37 foot pounds 44 8Nm
166. locked out The unit must be brought to a Carrier Transicold Dealer for service TEST 1 to 15 XX COMPLETE Pretrip is currently running this test and is XX complete TIME SELECTION NOT CHANGED A time change was started but not entered saved in Configuration List TRIP START ENTERED The Trip Start marker has been placed in the DataLink data record er UNIT BATTERY TOO LOW The unit battery has dropped below 7 volts for more than 10 sec onds UNIT SHUTDOWN DOOR OPEN The unit has shutdown because the refrigerated compartment door is open 6 5 62 11524 MessageCenter MESSAGES Continued Message Description UNIT SHUTDOWN SEE ALARM LIST An active shutdown alarm has shut the unit down UNIT SHUTDOWN 1 2 The unit has shutdown because switch is open be connected to a door or a remote control switch UNKNOWN CARD REMOVE CARD A defective or different type of PC Card has been inserted into the PC Card slot The microprocessor can not recognize any data on the card The card may be safely removed from the micropro cessor WARNING DIESEL RESTART ON When electric power is not available while the unit is operating in Standby Operation the unit will switch to Engine Operation WARNING NO TEMP CONTROL The temperature sensor s have failed in one or more compart ments and the compartment has entered Cargo Protect Mode Re fer t
167. motor contactor 2EVCON circuit is shorted The contactor output from the microprocessor is negative so the circuit will not be shorted to ground but is shorted either within the contactor coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 2EVCON a Inspect compartment 2 evaporator fan contactor coil and terminals No damage to coil No damage or corrosion b Check coil resistance Cannot be opened infinite ohms Shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check 2EVCON Current Draw Use Component Test Mode to test actual current draw of the circuit Refer to Section 5 2 2 Refer to Section 2 13 for correct electrical values View current draw in Data List Check 2EVCON Wiring Inspect harness amp control box con nector pins amp terminals See wiring schematic Section 10 7 73 No physical damage to harness No dam
168. nearest Carrier Transicold dealer for replacement 62 11524 1 3 SAFETY DECALS WARNING UNIT OR CHAS IS ATTACHED TR RAIL CAR MET THIS UNIT HAS A EGATIVE GROUND SYSTEM NOT REVERSE POLARITY ERSED POLARITY WILL CAUSE IMMEDIATE FAILURE OF ELECTRICAL SYSTEM 62 02133 01 RE WARNING THE RECEIVER KING VALVE THIS VALVE MUST LIQUID LINE SERVICE VALVE AND DISCHARGE SERVICE NE is D es VALVES MUST BE OPENED BEFORE STARTING ENGINE 62 03853 00 REV NOTE This tag is attached to the liquid line ser vice valve and discharge service valve at assembly 62 11524 WARNING CONTAINS HOT SURFACES THAT WILL IGNITE COMBUSTIBLES AND FLAMMABLE MATERIALS SUCH AS BIRD NESTS LEAVES TREE LIMBS OR MAINTENANCE MATERIALS SUCH AS SHOP RAGS DO NOT OPERATE WITHOUT INSPECTION FIRES AND SERIOUS INJURIES MAY RESULT SAFETY INSTRUCTIONS INSPECT UNIT DAILY PRIOR TO OPERATION REMOVE ANY COMBUSTIBLE FOREIGN MATERIAL ENSURE FACTORY INSTALLED ENCLOSURES AND PROTECTIVE EQUIPMENT ARE IN PLACE AND IN WORKING CONDITION 62 11282 00 REV amp 62 11283 00 REV
169. next page 7 119 62 11524 Steps Alarm Cause Corrective Action CHECK EVAPORATOR FAN MOTOR Continued 5 Check Amp Draw of 1EVCON Evap Fan Motor Circuit a With the unit running in either HEAT or COOL use a clamp on ammeter to check the current draw of all 3 legs Must be within range shown in Section 2 12 for all three legs b Check fuses for evaporator fan mo tor F26 F27 and F28 must not be blown c Check voltage at 1EVCON con tacts Must be within range shown in Section 2 12 for L1 L2 L1 L3 and L2 L3 Must be within range shown in Section 2 12 for T1 T2 T1 T3 and T2 T3 Check Compartment 1 Evaporator Fan Motor a With the unit off visually check fan motor and blower wheel No visual physical damage No blockage to blower wheels Blower wheels spin freely Remove and replace if required b With the unit off check the resist ance of the evaporator fan motor windings See Section 2 12 for correct resistance Resistance Ohms must be in range No continuity from any high voltage lead to ground Check Compartment 1 Evaporator Fan Motor Connections Inspect high voltage fan motor con nections at evaporator No corrosion water damage or burning discolor ation Remove repair or replace if required Verify Accuracy of AC Current Sensor 62 11524 Put microprocessor in PC Mode Re fer to Section 5 3 page 5
170. of devices to the micro the sensor input circuits Reset Microprocessor a Place the Main Power switch in the Microprocessor powers up OK OFF position for 30 seconds then back to the desired position b Alarm 249 remains active Download if possible and replace microprocessor Refer to Section 5 7 62 11524 7 140 SECTION 8 SERVICE PARAGRAPH NUMBER Page SECTION LAYOUT qu EROR eee p o EDS UR es 8 1 B2 SCHEDULED MAINTENANGE 5 8 1 PRE TRIP INSPECTION Rd aue Ep EE CREEK CBAR ER 8 1 8 4 EXTERNAL SURFACE SERVICE ii43 opbpet d 8 5 Grle E Rau 8 5 SAS ROMEA 8 6 8 4 3 Door Latch Maintenance And Replacement 8 6 844 Display amp Keypad Assembly eee n e 8 6 85 ENGINE AND ENGINE RELATED SYSTEMS SERVICE 8 7 Ol Fuer SYS chews 8 7 2 5 2 jug Ehe Fuel SY STS eem ee adage eth dp bag Step rie reb eine es 8 8 5 5 2 Mechanical Fuel Pump roh UR bre mb einen eon 8 8 2 54 Fuel Pump ss iue creber 8 9 Av 8 9 95 6 Fuel Level Sensor FLS
171. on engine speed control unit ENSCU 22 Must be 12 VDC Check for proper voltage to the Engine Speed Control Unit ENSCU Pin 16 Based On Requested Speed From The Microprocessor Check voltage at pin 16 with unit run ning Must be 0 VDC Check engine RPM a Check actual engine RPM using hand held tachometer Check Speed Control System refer to Section 9 5 b Compare actual RPM with those shown on display Both readings within 50 RPM Check engine intake air system a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check engine exhaust system Inspect the exhaust system 7 105 Must be clear and unobstructed 62 11524 Alarm Cause Corrective Action P175 CHECK HIGH SPEED RPM TRIGGER ON With Speed Relay energized voltage at the Engine Speed Control Unit for high speed operation engine RPM is NOT between 1700 and 1900 e UNIT CONTROL Engine Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED Standby Operation This test is not made e RESET CONDITION Auto Reset if Pretrip is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2
172. plug Heater resistance per Section 2 12 Remove and replace heaters if required a Inspect plugs plug seal and con nectors No corrosion water damage or burning discoloration Remove and replace if required Verify Accuracy of AC Current Sensor 62 11524 Put microprocessor in PC Mode Re fer to section 5 3 page 5 4 Must have 0 AC1 Amps and 0 AC2 Amps in Unit Data 7 116 Alarm Cause Corrective Action P188 CHECK HEATER 2 CIRCUIT This device is checked twice Pretrip once in Test 2 and again in Test 8 TRIGGER ON TEST 2 unit not running Normal draw for the 1HTCON2 contactor coil is 0 05 to 2 0 Amps 12 VDC The circuit tests outside this range TRIGGER ON TEST 8 unit running Normal draw for the 2 heaters is 1 0 to 3 5 Amps 460 VAC The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of
173. position the unit started and then the valve will be opened while the microprocessor monitors suction pressure If there is a problem with the valve stepper motor or microprocessor wiring to the valve the test will fail a Diagnostics Microprocessor or Wiring 1 Locate the wires on the engine harness side of the SMV connector labeled CSMVA CSMVB CSMVC and CSMVD These will correlate to the connector pins labeled A B C and D Refer to Table 8 3 Table 8 3 CSMV Connections Connector Pin Wire Color Winding Pole A BLACK 1A B WHITE 1B C RED 2B D GREEN 2A 2 Power the microprocessor by toggling the Main Power switch out of the OFF position DO NOT AL LOW THE UNIT TO START When the Message Center displays SMV CLOSING measure the AC voltage between pins A amp B and then between C amp D A voltage 10 to 16 VDC should be read by the digi tal voltmeter for each pair of wires If the reading is present on the wire pairs there is a good signal com ing from the microprocessor the reading is not present on one or more of the wire pairs check the wiring between the micropro cessor and the SMV connector or check the micro processor for proper model number Configuration Change 09 11 b Diagnostics Stepper Motor The valve stepper motor may be tested using a stepper motor drive tester or ohmmeter 1 test with a stepper motor drive tester Carrier Transicold part numb
174. problem Check engine coolant temperature Is coolant temperature 122 F 50 or below 1 NO Is unit in defrost YES gt _ s the the 95 F or higher OR the SAT 115 F or higher YES 1 pv YES Y n Check door switch Does the unit havea Ec 15 the switch configured Is the door __ wiring for an open door remote switch for low speed open Did you find and cor NO NO rect the condition Y Are alarms A122 amp A123 both present Is setpoint 10 F or lower the com OR alarms A137 amp A138 both present partment with the active alarms NO NO Y Has the unit been running less that the selected YES Continuous Operation High Speed Delay minutes Is the unit in Continuous operation Is the unit in Start Stop operation Has the unit been running less than the selected Start Stop Operation High Speed Delay minutes YES Has the unit restarted from an Off Cycle due to any YES override other than compartment temperature m NO Y Is the setpoint NO 10 5 F or higher YES gt TU dfe ju Is selected probe temp S reum Ar t
175. remote sensors or switches in the unit the con nector may be removed and each individual wire sep arated from the others terminated and insulated with heat shrink 62 11524 Alarm Cause Corrective Action 62 C2 TEMP OUT OF RANGE Compartment 2 TRIGGER ON Condition One If the unit is running in Pulldown Mode and the SAT is not greater than 1 F 0 56 C below the RAT or if the unit is running in Pull Up Mode and the SAT is not above the RAT the configured action Alarm only after 30 minutes or Alarm and Shutdown after 45 minutes will be activated NOTE If the Out Of Range Alarm Functional Parameter is set to OFF the following conditions will not trigger an alarm or shutdown Condition Two If the refrigerated compartment temperature has been within 2 7 F 1 5 for perishable setpoints or 2 7 F 1 5 C for frozen of setpoint at least once since the unit was started and is now further away from setpoint than the limit set in the Out Of Range Alarm Functional Parameter 4 5 or 7 F 2 3 or 4 C the configured action Alarm only after 30 minutes or Alarm and Shutdown after 45 minutes will be activated Condition Three If a shutdown alarm occurs and the RAT is further away from setpoint than the limit set in the Out Of Range Alarm Functional Parameter 4 5 or 7 F 2 3 or 4 C the configured action Alarm only after 30 minutes or Alarm and Shutdown after 45 minutes wil
176. s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during Test 3 by holding Key for 6 seconds d Review active alarm list for Alarm If alarm is present follow steps 2 8 3 If alarm is not 176 present follow step 4 Test 2 alarm Check Compartment 3 LSV Coil a Inspect coil and connector No damage to coil No damage moisture or corrosion in connector Use component test mode to check circuit b Check resistance of coil Refer to Section 2 13 for correct electrical values Test 2 alarm Check Compartment 3 LSV Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Test 14 alarm Check Compartment 3 LSV Valve Check operation of Compartment 3 Refer to section 8 8 10 vs valve for proper opening and Compartment 3 LSV must open and close correctly closing 7 107 62 11524 Alarm Cause Corrective Action P177 CHECK EVAP SUPERHEAT e TRIGGER ON With the unit running in Test 12 after the microprocessor closes the EVXV to 0 evaporator pressure fails to drop by 20 psig 1 36
177. selections for wake up time and run pretrip at wake will now be available and may be saved to memory following the key stroke sequence in the preceding step Refer to the following paragraphs for information on these settings TO EXIT SLEEP MODE Place the Main Power switch in the OFF position then back to the desired position Sleep Mode is generally used in cold ambients when the unit will be off for an extended period of time with no product inside the refrigerated compartments Many times units are difficult to start due to a discharged bat tery thickened engine oil etc after time in cold ambient There is NO TEMPERATURE CONTROL in Sleep Mode and it should never be used if a compartment con tains perishable or frozen products In Sleep Mode and Engine Operation the unit will Wake Up periodically and start the engine to keep the battery charged and the engine warm In Sleep and Standby Mode if the unit is connected to standby power the battery charger is energized and will keep the battery charged The engine will not run with the switch in the STANDBY position ADDITIONAL SUB MENUS 1 WAKE UP TIME a When WAKE UP TIME is set to NO the unit will remain in Sleep Mode until it is taken out manually refer to TO EXIT SLEEP MODE instruction above b When WAKE UP TIME is set to YES the SET WAKEUP TIME menu will become available 62 11524 Pressing the key will allow the user to select the d
178. setpoint H COMPARTMENT 2 TEMPERATURE TEMPERATURE 6 g8 COMPARTMENT 3 Mi re TRANSICOLD 8 SYSTEM m DEFROST vector 62 11524 3 30 c Lock Unlock the Remote Control Panel LOCKING THE PANEL Press and hold the Carrier Logo for TEMPERATURE approximately one second and then 808 release BB The lock indicator light will illuminate COMPARTMENT 1 9 TEMPERATURE UNLOCKING THE PANEL Press the Carrier Logo for 10 seconds H H The lock indicator light will de energize L COMPARTMENT 2 CARRIER LOGO TEMPERATURE BB L COMPARTMENT 3 POWER TRANSICOLD SYSTEM CMAN LOCK INDICATOR LIGHT d Pre setting Setpoint With Remote Control Panel The control panel allows the user to pre set 5 different temperatures NOTE Once preset setpoints have been chosen only those 5 designated setpoints can be used 1 Place the unit switch panel mounted Main Power switch in the desired position and the Compartment Run Switches in the ON position TEMPERATURE CONPARTMENT i 3 Press UP ARROW for the de sired compartment for 10 sec TEPERT onds P1 will be displayed 4 Set lowest setpoint required COMPARTMENT 2 5 Press Carrier logo and P2 will ERE be displayed Set next highest B temperature required BB 88 M 6 Follow same procedure for the COMPARTMENT 9 9 next three temperatures 7 Repeat steps 3 through 6 to MAN DEFROST
179. should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 2HTCON2 a Inspect heater contactor coil and terminals No damage to coil No damage or corrosion b Check contactor coil resistance Cannot be opened infinite ohms Shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check 2HTCON 2 Current Draw Use Component Test Mode Refer to Section 5 2 2 to test actual current draw of the circuit Refer to Section 2 13 for correct electrical values View current draw in Data List Check 2 2 Wiring 62 11524 Inspect harness amp control box con nector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors Alarm Cause Corrective Action 105 CHECK 3HTCON1 RELAY COIL Remote heater contactor 1 1 circuit is shorted The contactor output from the microprocessor is negative so the circuit will not be shorted to ground but is shorted either within the contactor coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning
180. side of the refrigeration system the filter drier EVXV evaporator coil evaporator outlet pressure transducer CSMV heat exchanger suction line remote evaporators TXV s liquid line solenoids etc may be serviced or replaced without having to completely remove the refrigerant charge from the system by pumping down the low side and temporarily storing the refrigerant in the condenser and receiver 1 Install a manifold gauge set to allow reading of suction and discharge pressure See Figure 8 18 2 Start the unit Frontseat the liquid line service valve w 4 Shut down the unit when the suction pressure drops to 2 psig 0 2 bar There should be very little refriger ant remaining in the low side of the system at this point Monitor the gauges The suction pressure should not rise rapidly If the suction pressure continues to rise the liquid line service valve may not be closed properly In this case the low side cannot be pumped down and the entire refrigerant charge must be removed from the system Refer to pre ceding step c Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Frontseat close by turning clockwise the discharge service valve and the refrigerant will be trapped be 62 11524 8 16 tween the compressor discharge service valve an
181. slot and all data from the DataLink data recorder is being copied onto the PC Card DO NOT REMOVE THE CARD WHILE THIS MESSAGE IS BEING DISPLAYED DATA RECORDER FAILURE The microprocessor has stopped recording Unit Data DEFROST CYCLE STARTED The unit has gone into defrost DOOR OPEN A refrigerated compartment door is open 62 11524 6 2 MessageCenter MESSAGES Continued Message Description DOOR OPEN LOW SPEED A refrigerated compartment door is open forcing the unit to run in low speed ENTERING SERVICE MODE The initial message for Service Mode ERROR ENG HRS gt SWITCH ON HRS ERROR HI SP HRS gt TOTAL ENG HRS ERROR SBY HRS gt SWITCH ON SBY HRS When setting up a replacement microprocessor incorrect hours have been entered EVAC CHARGE MODE The unit is in Service Mode and the refrigeration system is ready to be evacuated then charged with refrigerant Refer to Section 5 2 3 EXITING PRETRIP MODE Pretrip has been aborted either by user or by a pretrip alarm EXITING SERVICE MODE Service Mode has been turned off and unit is returning to normal operation FORCED LOW ENGINE SPEED Due to current ambient conditions and power requirements the engine is being set to operate in Low Speed See Section 4 8 3 step 1 for more information FUNCTION NOT CHANGED The key was not pressed in the allotted amount of time to sel
182. tagout the receptacle and disconnect the neg ative battery connection NEVER dis assemble the generator HIGH MAGNETIC FIELD INSIDE This field can interfere with cardiac implants such as pacemakers and defibrillators WARNING Under no circumstances should ether or other starting aids be used to start engine MODE LIGHTS MAIN DISPLAY e me STAR con 20 34 1 BOX TEMPERATURE SWITCH BOARD a ALTERNATE CONFIGURATION 99 3 Oo o s 1G S 7 ENGINE START RUN STANDBY Main Power Switches MessageCenter KEYPAD DOOR UNITS WITH A MAIN POWER SWITCH UNITS WITH A MAIN POWER SWITCH LABELED ENGINE OFF STANDBY Place the Main Power switch in the ENGINE posi tion The microprocessor will perform a Self Test refer to Section 3 3 and then start the unit automatically Ensure the 2nd Compartment Run C2 and or the 3rd Compartment Run C3 switch is in the ON po sition if operation is desired LABELED START RUN OFF Place the SWITCH LABELED standby engine in the ENGINE position Then place the Main Power switch in the START RUN position The microprocessor will perform
183. terminals 1MP amp see wiring schematic Sec tion 10 No physical damage to harness No damage moisture or corrosion in connectors Power up the microprocessor see Note 2 page 7 2 Disconnect sensor from harness Check for 2 5 VDC at harness plug between pins Voltage should be 2 5 VDC volts at harness plug be tween pins This verifies microprocessor output and wiring connections to the sensor Check remote sensor switch conne ctor c Locate and inspect 10 position connector OC for optional sensors and switches Connector must have cap on No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated 7 8 with heat shrink 7 62 11524 Alarm Cause Corrective Action 139 C2 CHECK DEFROST SENSOR TRIGGER ON Defrost Termination Temperature Sensor for Compartment 2 2DTT is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and Standby Operation If Alarm 137 is not active alarm and initiate defrost if 2RAT is below 45 F 7 2 C and defrost will end after 10 minutes OR If Alarm 137 is active and 2SAT is installed and Alarm 136 is not active alarm and and initiate defrost if 2SAT is below 45 F 7 2 C and defrost will end after 10 minutes If Alarm 1
184. the key for 5 seconds PRETRIP STOPPED BY USER will display in the MessageCenter Once Pretrip is started If the unit is running the micro processor will shut the unit down NOTE Before completing Pretrip the microprocessor looks at the status of alarms and if certain alarms are active for example Low Fuel Warn ing Check Engine Oil Level Check Coolant Level Check Coolant Temperature Pretrip will display FAILED indicating that the unit is not ready to be sent out for a load but that the alarm list should be checked and all present alarm si tuations corrected TIP It is always a good idea to clear all alarms from both Alarm Lists before starting Pretrip The technician will then know that any alarms pres ent following Pretrip occurred during Pretrip and are not old alarms that had not been cleared NOTE The operator MUST be present and validate Test 1 by watching the microprocessor display The microprocessor will illuminate all the Mode Lights and all segments of the Main Display Following Test 1 the operator MUST verify that during the first 5 seconds of Test 2 the buzzer is energized 62 11524 3 6 Test 1 Display Test The microprocessor activates the display and both lights on the Light Bar This test will last 5 seconds All segments of the display all LEDs on the microproces sor both lights of the Light Bar will be on during this test This portion of the Pretrip requires that th
185. the microprocessor See Voltage should be 2 5 VDC volts at harness plug be Note 2 page 7 2 Disconnect tween pins This verifies microprocessor output and sensor from harness Check for wiring connections to the sensor 2 5 VDC at harness plug between pins Check remote sensor switch connector Locate and inspect 10 position Connector must have cap on connector OC for optional No corrosion or moisture inside connector sensors and switches If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 7 75 62 11524 Alarm Cause Corrective Action 122 CHECK RETURN AIR SENSOR TRIGGER ON Return Air Temperature Sensor 1RAT is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and Standby Operation If Alarm 123 Check Supply Air Sensor is not active alarm only and switch to supply air control If Alarm 123 is also active Cargo Protect Mode refer to section 4 8 1 and the functional parameter Temperature Control is set for Return Air and the setpoint is in the perishable range alarm and shutdown If Alarm 123 is also active Cargo Protect Mode refer to section 4 8 1 and setpoint is frozen alarm and unit will operate in reduced capacity COOL mode Refer to Section 4 8 1 RESET CONDITION Auto Reset when Re
186. the unit in Standby Operation Wait for the MessageCenter to display UNIT SHUTDOWN SEE ALARM LIST Perform the following test on the wiring coming from the microprocessor Place the positive voltmeter lead on pin E the negative voltmeter lead on pin and observe the meter for several seconds The voltage reading will be very low then rise to battery voltage approxim ately 12 3VDC with a good battery for a few seconds then drop back to a lower reading 4 Repeat for pins B C and D 5 If there is no voltage reading or if the voltage never rises to battery voltage level there is a problem in the wiring or the microprocessor Test all wiring from the EVXV connector to the microprocessor and verify 62 11524 PIN C YELLOW PIN D BLACK PIN E GRAY Figure 8 29 Electronic Expansion Valve 1 To test the valve internal mechanism install a mani fold gauge set on the suction service valve and a stepper motor drive tester Refer to Section 8 8 6b 2 Start the unit set the step rate to 200 steps per second refer to Section 8 8 6 step b and close the valve while watching the suction pressure Within one minute the suction pressure should begin to fall 8 30 3 If the suction pressure does not change this is an in dication the valve is stuck and the piston and drive motor assembly is to be replaced d Replacing Expansion Valve amp Screen 1 Pump down the low side Refer to section 8 6 2 2
187. the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 3HTCON1 a Inspect heater contactor coil and terminals No damage to coil No damage or corrosion b Check contactor coil resistance Cannot be opened infinite ohms Shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check 3HTCON 1 Current Draw Use Component Test Mode Refer to Section 5 2 2 to test actual current draw of the circuit Refer to Section 2 13 for correct electrical values View current draw in Data List Check 3HTCON1 Wiring Inspect harness amp control box con nector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors 106 CHECK 2 RELAY COIL TRIGGER ON Remote heater contactor 2 3HTCON2 circuit is shorted The contactor output from the microprocessor 8MP07 is negative so the circuit will not be shorted to ground but is shorted either within the contactor coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only
188. to 50 1 Nm NOTE Mark each stator screw after it is torqued to ensure that all the screws are torqued 20 Assemble the strain grommet Item 12 21 Reconnect wires 22 Reassemble engine into unit 8 9 10 Sensor Checkout An accurate ohmmeter must be used to check resistance values shown in Table 8 5 or Table 8 6 Due to variations and inaccuracies in ohmmeters thermometers or other test equipment a reading within 2 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 the tables Two preferred methods of determining the actual test temperature at the sensor is an ice bath at 32 F 0 C or a calibrated temperature tester 62 11524 Table 8 5 Sensor Resistance Sensors AAT 1RAT 1SAT ENCT EVOT CST DTT REMSN 1 8 2 2DTT 2RAT 2SAT F Ohms F Ohms F Ohms F Ohms 40 40 336 500 18 7 8 49 060 76 24 4 10 250 134 56 7 2 809 38 38 9 312 600 20 6 7 46 230 78 25 6 9 760 136 57 8 2 697 36 37 8 290 600 22 5 6 43 580 80 26 7 9 299 138 58 9 2 590 34 36 7 270 300 24 4 4 41 100 82 27 8 8 862 140 60 0 2 488 32 35 6 251 500 26 3 3 38 780 84 28 9 8 449 142 61 1 2 390 30 34 4 234 200 28 2 2 36 600 86 30 0 8 057 144 62 2 2 297 28 33 3 218 200 30 1 1 3
189. to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 1HTCON1 a Inspect heater contactor relay coil No damage to coil and connector No damage moisture or corrosion in connector b Check contactor coil resistance Refer to Section 2 13 for correct electrical values Cannot be opened infinite ohms shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check 1 Current Draw Use Component Test Mode to test Refer to Section 2 13 for correct electrical values actual current draw of the circuit View current draw in Data List Refer to Section 5 2 2 Check 1HTCON1 Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 62 11524 7 60 um Alarm Cause Corrective Action 92 CHECK 1HTCON2 RELAY COIL TRIGGER ON Heater contac
190. to be displayed recorded in the DataLink data recorder and used to control the refrigeration system The sensor is located on the starter side of the engine near the 4 Injector 2 3 4 Generator GEN The generator is directly bolted to the engine and sup plies nominal 460V 3 60Hz power when the engine is in high speed and nominal 300 30 45 2 power in low speed 2 3 5 Compressor The compressor assembly includes the refrigerant com pressor suction and discharge service valves high pressure switch compressor discharge temperature sensor and the suction and discharge pressure trans ducers The compressor draws refrigerant gas from the evaporator and delivers it to the condenser at an in creased temperature and pressure The pressure is such that refrigerant heat can be absorbed by the sur rounding air at ambient temperatures 2 3 6 Unloaders The compressor is equipped with unloaders as standard equipment Unloaders are used as a compressor pacity control to unload the cylinder banks during peri ods of reduced cooling loads This provides closer tem perature control and reduces the power required to operate the compressor thus reducing fuel consump tion a Major Working Parts Solenoid and valve system Spring loaded piston type bypass valve Spring loaded discharge check valve located on the valve plate 62 11524 Solenoid Valve Valve Stem Gas Bypass Port Spring Guide Spring Piston Bypa
191. to harness No damage moisture or corrosion in connectors b Check Return Air Sensor resistance 10 000 Ohms 9 77 F 25 C See Note 3 page 7 2 Refer to Table 8 5 for complete resistance chart Check Compartment 3 Defrost Sensor Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Check Remote Sensor Connector Locate and inspect remote sensor Cap is in place connector No physical damage No moisture or corrosion 62 11524 7 128 Steps Alarm Cause Corrective Action 7 10 MAINTENANCE ALARMS 223 ENGINE MAINTENANCE DUE e TRIGGER ON The Engine Maintenance Hour Meter time has expired e UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad 1 Check Unit Maintenance Records Schedule unit into service facility for maintenance Must be done soon Perform Maintenance Perform appropriate engine amp unit maintenance Follow instructions on proper maintenance form Reset Engine Maintenance Hour Meter a Check that the Engine Maintenance Hour Meter interval is set for your requirements Reset configured Interval if required b Reset Engine Maintenance Hour Meter for the next service interval Hour Meter reset is a Functional Parameter
192. to test actual current draw of the circuit Refer to Section 5 2 2 Refer to Section 2 13 for correct electrical values View current draw in Data List 94 CHECK COMP CONTACTOR 1 TRIGGER ON Compressor motor contactor relay CCONR circuit is shorted The relay output from the microprocessor 4MP5 is negative so the circuit will not be shorted to ground but is shorted either within the relay coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check CCONR a Inspect compressor contactor relay coil and terminals No damage to coil No damage or corrosion b Check contactor coil resistance Refer to Section 2 13 for correct electrical values Cannot be opened infinite ohms shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check CCONR Wiring Inspect harness amp control box con nector pins amp terminals See wiring schematic Section 10 No
193. transcentral carriercom component Old component is 2 problem Did the software load not the fault correctly Fuel speed actuator is System OK re install remote communication dis connected earlier po YES Remove connectors from unit one at a time to determine if any other devices are providing power feedback causing the micro to remain powered Did you find and correct the condition Review the results of above tests with your supervisor If necessary go to the beginning of the tree amp test again Go To Condition 8 Programming Problems with PC Cards if using a PC Card to upgrade software Did the software load correctly Figure 9 7 Micro Diagnostic Tree Cond 3 Main Power Switch Off Unit Fails To Stop 62 11524 9 16 START HERE Check the fuel speed ac Unit may be running old soft ware Upgrade tuator and plunger for correct operation NO gt software from http www transcentral carrier Did you find and correct the condition YES System OK com Did you find and correct the condition v Check system suction pressure at compressor Is suction pressure 2 psig or lower T NO Y Does the message center show YES Check speed overrides Section 4 8 3 FORCED LOW ENGINE SPEED Did you find and correct the
194. unit will go into low speed and all electric heaters in all compart ments will be de energized The unit will remain in defrost with the heaters de energized until the Com partment 1 supply air temperature is less than 108 F 42 C 62 11524 SECTION 5 MICROPROCESSOR INTERFACE PARAGRAPH NUMBER Page INTERFACE METHODS S der d d log dei o ie 5 1 Se TECHNICIAN INTERFACE And CREER ARE Er REO Ed 5 1 Se MOS 25d pac RE ER Robe o ER oppido s 5 2 5 92 2 aue Siete Sta ene ce p 5 2 DaS 5 3 5 4 VPLOABES aids bas died pde alee said aes Gabe 5 4 SAT Faning FECAS tmm 5 4 54 9 OCA Ie idest 5 5 53 Onin PU CA 5 6 Sas CUORE Cal ridin adobe qe eU ania dor 5 6 SAS Download POLUM 5 6 55 BEErERMANAGER amp REPORTS 5 6 o e 5 6 56 MICROPROCESSOR DISPLAY DIAGNOSTICS 5 8 57 MICROPROCESSOR REPLACEMENT amp SETUP 5 8 57 1 Pre Replacement SIBDS 5 9 57 2 Microprocessor Replacement 5 9 5 7 2 Mior propessor Gel
195. unless individually locked out by Reefer Manager YES NO YES When the A39 CHECK ENGINE RPM alarm is active the alarm light will illuminate and the engine will shutdown SHUTDOWN NO When the 9 CHECK ENGINE RPM alarm is activated the alarm light will illuminate and the engine will continue to run 62 11524 5 12 Table 5 2 Microprocessor Configurations Continued Configuration Selections LOW PRESSURE SHUTDOWN SHUTDOWN DELAY HIGH SUCT PRESS SHUTDOWN CHECK REFRIG SYS SUCTION PRESSURE COMPRESSOR ALARM SHUTDOWN This Configuration is an option it will not display if the option is not in stalled CURRENT FOR S S SHUTOFF VOLTAGE FOR S S RESTART ENG TEMP FOR S S RESTART 0 255 seconds in 1 second incre ments 255 SECS 30 PSIG 2 0 BAR 0 50 psig 0 to 3 4 bar in 1 psig 0 1 bar increments 7 0A TO 10A in 0 5A incre ments 12 2V 12 0 TO 12 8V 10 F 12 2 C 10 F to 32 F 12 2 C to 0 C Description YES When the 18 LOW REFRIGERANT PRESSURE alarm is active the alarm light will illu minate and the unit will shutdown When the 18 LOW REFRIGERANT PRESSURE alarm is activated alarm light will illu minate and the unit will continue to run If the Low Pressure Shutdown Configuration is set to YES shutdown is to be delayed for this amount of time after the Low Pressure Shutdown signal is rec
196. value the remote sub configuration will also be avail panel SYSTEM ON OFF key will be enabled The able switch panel mounted Main Power switch must be toggled out of the OFF position and the remote panel SYSTEM ON OFF key must be pressed for the compartment to operate ALARM ONLY ALARM ONLY When Door Switch indicates that COMPARTMENT the door is open warning alarm will be displayed SHUTDOWN in the MessageCenter COMPARTMENT SHUTDOWN When Door DGOR cup es Switch indicates that the door is open a warning alarm will be displayed in the MessageCenter and DATA RECORDER the compartment will shutdown ONLY REMS1 Remote Switch 1 NOT INSTALLED Switch not installed There is no remote switch or OR DOOR OPEN panel SWITCH OPEN DOOR OPEN SWITCH OPEN The remote switch REMS2 Remote Switch 2 DOOR OPEN will be used as a door switch The switch contacts NOTE SWITCH CLOSED will be OPEN whenever the door is OPEN REMS1 controls Compartment 1 SWITCH ON DOOR OPEN SWITCH CLOSED The remote while REMS2 controls Compartment ONTACTS OPEN SWitch will be used as a door switch The switch 2 If the configuration is set for a contacts will be CLOSED whenever the door is switch not for a panel the following SWITCH ON OPEN eee eee SWITCH ON CONTACTS OPEN The remote switch will be used as a remote control switch The REMOTE PANEL switch contacts will be OPEN whenever the switch C1 or C2 is
197. voltage at GENCON T1 T2 T1 T3 2 3 Must be nominal 460 VAC b Check voltage at CCON with compressor operating T1 T2 T1 T3 T2 T3 Must be nominal 460 VAC Verify AC Current Sensor Accuracy Power the microprocessor Refer to Note 2 page 7 2 Unit AC Current 1 and 2 reading in Data List must be 0 0 1 0 amp Perform Pretrip Check Clear Active Alarm list then run Pre trip amp check for any new alarms Any active alarms must be corrected and cleared before proceeding Check High Voltage Components A mp Draw 62 11524 a Check condenser fan amp draw at CDCON on all 3 legs b Check evaporator fan motor amp draw at 1EVCON 2EVCON amp 3EVCON if applicable on all legs The unit must be running for these tests to be per Check compressor amp draw at CCON on all 3 legs formed Refer to Section 2 12 for correct electrical values Check evaporator heater amp draw at 1HTCON1 1HTCON2 2HTCON1 2HTCON2 3HTCON1 AND 3HTCON2 if applicable on all 3 legs 7 8 aum Alarm Cause Corrective Action 15 BATTERY VOLTAGE TOO HIGH e TRIGGER ON Voltage at the microprocessor is greater than 17 VDC e UNIT CONTROL Engine Operation engine and unit shutdown and alarm Standby Operation refrigeration system shutdown and alarm with PSCON still energized RESET CONDITION Auto Reset after 15 minutes when the voltage at the microprocessor is bet
198. when valid Functional Parameters are entered or alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Functional Parameters Check Functional Parameters All must be set for selectable values Check Software Version Check microprocessor Software version Upgrade to the latest version of software Newer versions may contain functional parameters that were not present in older versions of microprocessor software Refer to Section 5 4 2 Reset Microprocessor 62 11524 a Place the Main Power switch in the OFF position for 30 seconds then back to the desired position Microprocessor powers up OK b Check for valid Functional Parame ters in Functional Parameters List Valid number is set for all parameters Alarm is cleared c Valid Functional Parameter s can not be entered and alarm remains active Download and replace microprocessor Refer to Section 5 7 7 134 Alarm Cause Corrective Action 238 CONFIGURATIONS 1 ERROR TRIGGER ON There is an error in the Configuration settings that are stored in the microprocessor memory UNIT CONTROL Incorrect Con
199. wiring No damage moisture or corrosion in connectors schematic Section 10 7 123 62 11524 Alarm Cause Corrective Action P206 CHECK CONDENSER FAN CIRCUIT TRIGGER ON Normal draw for the CDCON contactor coil is 0 05 to 2 0 Amps 12 VDC cir cuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check CDCON a Inspect CDCON contactor coil and No damage to coil wire connections No damage moisture or corrosion in connections b Check contactor coil resistance Refer to Section 2 13 Check CDCON Amp Draw Check CDCON contactor coil amp Use Component Test Mode Section 5 2 2 to test draw Refer to Section 2 13 for amp values View current draw in Data List Check CDCON Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 P2
200. 0 3 Ds GENERATOR CONTACTOR pc2 8 2 4 2 19 4 1 5 60 27 814 GENCDNR GENERATOR RELAY hL 17 aes o v IPC 2HTCON2 GENERATOR 0 DELHI spss ACH C7 HIGH DISCHARGE PRESSURE SWITCH SP4 Y 2010 4 1 CONTACTOR TU Sese XV Driek ie CDCUN 4CDMis 5 CDM2 J205 INTCONe 1 HEATER CONTACTOR lt A E HEATER 1 TENE 6 0 E DPIG N 2MP12 MP TB 5 62 EVAP 2 5 20075 72 029 1 NS HTR2 HEATER 2 TEVCON EVM HEATER 10 97 2ND COMPARTMENT HEATER CONTACTOR 4 15 SAn4 2010 6 13 L3 2HTCON2 2ND COMPARTMENT HEATER CONTACTOR 2 13 D D 1MP30 SP7 FET LEGEND 5 59 2MP03 C C 1 5 AMPIA 1HTCDNe IP CW VIEW FROM INLET eHTRL 2ND COMPARTMENT HEATER 1 2ND COMPARTMENT 5 6 7 1 16 1 CDCON ALA c eges A HCIB 2EVCON K16 TAH INTAKE AIR HEATER 2 re ala IMP30 GSPD FET 2 4MP13 1HTCON1 2010 7 J7 D16 INTAKE AIR HEATER RELAY UC 1 29 FET 3 mE AN c 5 2 IPC INTERNAL PROTECTOR COMPRESSOR 5 16 gt ON 4MP4 SP5 2010 10 e 2010 8 72 2 e K9 IPCDML2 INTERNAL PROTECTORS CONDENSER FAN MOTORS a FETS ART 2HTCDNe 4 2
201. 00 psig 7 5 bar The actual pres sure must be lower than 100 psig in order to per form this test Reset Microprocessor a Place the Main Power switch in the OFF position for 30 seconds then back to the desired position Microprocessor powers up OK Wait 2 3 minutes then check to see if A 243 becomes active again Suction and Evaporator pressure values are reading OK when compared to test gauges Alarm is cleared Disconnect positive battery cable from the battery wait 30 seconds then reconnect and place the Main Power switch the desired position Microprocessor powers up OK Wait 2 3 minutes then check to see if A 243 becomes active again Suction and Evaporator pressure values are reading OK when compared to test gauges Alarm is cleared Valid readings are not appearing for either or both the Suction and Evaporator Pressures in the Unit Data 7 137 Download and replace microprocessor Refer to Section 5 7 62 11524 Alarm Cause Corrective Action 245 CANNOT SAVE SETTING TRIGGER ON There is an error in sending and saving new settings in the Microprocessor memory UNIT CONTROL Alarm only RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset con
202. 07 CHECK COMPRESSOR CONTACT CIRC TRIGGER ON Normal draw for the CCONR and CCON relay coils is 0 0 to 1 0 Amps 12 VDC The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset viakey pad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check CCONR Inspect CCONR CCON No damage to coil contactor coils and wire No damage moisture or corrosion in connections connections b Check contactor coil resistance Refer to Section 2 13 Check CCONR Amp Draw a Check CCONR and CCON contac Use Component Test Mode Section 5 2 2 to test tor coil amp draw Refer to Section 2 13 for correct electrical values View current draw in Data List FET 2 On b Listen for CCON to pull in If CCON contactor pulls in CCONR and CCON are OK If CCON contactor does not pull in check for 12 VDC at CCON coil 12 VDC indicates defective CCON coil No voltage check CCONR Check CCONR Wiring Inspect harness amp control box con No physical damage to harness nector p
203. 1 134 CHECK REMOTE TEMP SENSOR 2 Note Remote sensors are available on 2 Compartment units only TRIGGER ON Remote Temperature Sensor REMSN1 REMSN2 is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and Standby Operation Alarm only RESET CONDITION Auto Reset when Remote Temperature Sensor is in range or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary IF A SENSOR IS INSTALLED Check Sensor a Inspect sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check Remote Temp Sensor 10 000 Ohms 77 F 25 See Table 8 5 for resistance See Note 3 page complete table of temperatures and resistance 7 2 values Check Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals 1 No damage moisture or corrosion in connectors amp REM see wiring schematic Section 10 Power up the microprocessor see Voltage should be 2 5 VDC volts at harness plug be Note 2 page 7 2 Disconnect tween pins This verifies microprocessor output and sensor fr
204. 1045 c dida acie dos d EXER E Er obi Qd eos icc Aa e 10 7 10 8 CONTROL BOX INTERIOR SPLICE POINTS FOR UNITS WITH A MAIN POWER SWITCH LABELED ENGINEJOPF STABDBY oi iia ed ada edd 10 13 10 4 CONTROL BOX INTERIOR SPLICE POINTS FOR UNITS WITH A MAIN POWER SWITCH LABELER STABTIBUN DPE ois i440 aco XAR dd d cd ORCI dE 10 14 10 8 DISPLAY TEST POINTS 10 15 10 6 WIRING SCHEMATIC Re eR EREA C b Rer TEND 10 15 62 11524 xii LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 1 1 Eackont anon uua ados dA E OE deles Sach Ado ACER oos doa EA Gb hea gaa aca MO 1 1 Figure 2 1 Front View Refrigeration System Components 2 3 Figure 2 2 Road Side Rear Compressor View Refrigeration System Components 2 4 Figure 2 2 Front View Engine Components i34 433 rA dave 2 5 Figure 2 4 Evaporator Section Grille Removed 2 22 2 2 6 Figure 2 5 Remote Evaporator Cover Removed 2 7 Figure 2 5 Caniml BOX 2 8 Figure 2 7 Engine Speed Control Api Re pe Sede ERR dan pde 2 9 Figure 2 8 Compressor Cylinder Head Unloaded 2 10 Figure 2 9 Compressor Cylinde
205. 16 L 35 11 12 22 23 Unused terminals 1 7 9 10 14 15 21 24 25 27 28 30 31 33 34 62 11524 Unused terminals 1 2 4 10 11 14 16 20 21 22 24 25 26 28 31 35 10 1 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED ENGINE OFF STANDBY Continued Component Terminal 1 SP60 CDCON A2 Component Terminal SP52 1 SP56 PRM OUT 2RS B PSCONR 2 BUZZER IAHR 85 SSR 85 Unused terminals 3 5 11 12 1EVCON A2 SP55 CCONR 2 CDCON A1 GENCONR 2 CT BROWN OGF BROWN SP54 CT BLACK CT BLUE OGF BLUE SP53 1 1 2 1 1EVCON A1 FHR 2 Unused terminals 11 12 Component Connector Terminal DISP 1 BLK A 1 DISP 2 WHT DISP 3 RED DISP 4 GRN DISP 5 BRN DISP 7 BLU DIS
206. 177 to 182 F 81 to 83 C Fully open at 203 F 95 C Fuel System Fuel Winter Diesel No 1 Summer Diesel No 2 Maximum 5 Bio Diesel is also allowed Fuel Heater Temperature Switch Close on a temperature fall 45 F 7 2 C Open on a temperature rise 75 F 24 C Firing Order 1 3 4 2 Intake Air Heater Amperage 42 amps at 12 VDC Lubrication System Oil Pressure 40 to 62 psig 2 8 To 4 2 Bar Engine in high speed Oil Pressure Switch ENOPS Closes on pressure rise at 18 psig 1 22 Bar Opens on pressure fall at 12 psig 0 82 Bar Oil Capacity with Filter 15 quarts 14 2 liters Lube Oil Viscosity API CG or better OR Mobil Delvac 1 Outdoor Temperature Grade SAE Below 32 F 0 C 10W 30 or Mobil Delvac 1 5W 40 Above 32 0 C 10W 30 or Mobil Delvac 1 5W 40 or 15W 40 Oil Change Intervals Refer to Section 8 2 for information on service intervals 62 11524 2 10 COMPRESSOR DATA Compressor Model 06D Number of Cylinders 6 Type Semi hermetic Reciprocating 325 16 1478 kg 7 6 pints 3 6 liters Mobil Arctic EAL 68 Weight Oil Charge Approved 2 11 REFRIGERATION SYSTEM DATA Defrost Air Switch DAS Defrost Timer micro controlled Initiates Defrost 1 40 07 inch 85 1 8 mm WG 1 5h 3h 6h or 12 hours Opens on temperature rise at 130 5 F 559 2 8 C Closes on
207. 3 SP55 EVHTS B 5MP 2 PRM 12V DOES 6 10 13 F 16A 2CA A F 17A 3 compartment only 62 11524 10 4 CONTROL BOX INTERIOR SPLICE POINTS FOR UNITS WITH A MAIN POWER SWITCH LABELED START RUN OFF Splice Point No Component Splice Point No Component F5 A HC 16 GPR 30 F6 A SSR 30 F9 A HC 15 MPQC 2 PRM OV CCON A2 GENCONR 3 LOW VOLT GND BUZZER 5 1 OGF 12V F9 B CCONR 3 PSCONR 3 SSR 86 HC 18 MPQC 9 EVM 4 EVHTS A SP52 8 SP59 DES A 4 1 CCONR 1 HC 11 RCR 5 SP62 CT BLUE 4MP 10 HC 19 OGF S 1 PSCONR 1 OGF BLUE CT BROWN 4 8 SP52 SP59 CDM2 4 OGF BROWN 4 4 SP55 EVHTS B 1 2 1HTCON2 A2 F 16A 2CA A SP63 62 11524 5MP 2 PRM 12V DES B 10 14 10 5 DISPLAY TEST POINTS NOTE Refer to Section 5 6 for microprocessor and display diagnostic procedures Test Point Pin Color Description TP14 Pin 1 Black 12 VDC for Display backlighting and indicator TP13 Pin 2 White Ground for backlighting and indicator LEDs TP13 Pin 3 Red Ground for backlighting and indicator LEDs TP12 Pin 4 Green
208. 3 26 1 Multiple Langages ERROR 2 13 262 Sid 2 13 SH FOSIUIDS 2 14 2 6 4 Component Description And Location 2 14 2 GL NN PIT 2 14 b Main Display MessageCenter Indicator Lights 2 16 0 2 17 2 17 27 ELECTRONIC MODULES 2 18 271 Overload Ground Fault Module OG 2 18 eJ Friese Reversal Module PRM 22254535 OU Rd mierda sheeted 2 18 Co OPONT qois dado GE PN eae 2 18 26 0 Stee ae gees 2 18 Bos HEMOR ONIES uae Crude cnc ina aes ce deo dl dune 2 18 28 3 Remote Temperature 2 19 28 42 Remote Control Panel 2 19 CIAR IT p nr 2 19 210 COMPRESSOR DATA T dS 2 20 211 REFRIGERATION SYSTEM DATA d ble DESERT Rara x EE Eg 2 20 212 odio oss Sear ia Marne 2 20 2 13 COMPONENT RESISTANCE amp CURRENT DRAW DATA 2 21 214 DEVICES Fa RP ESSE
209. 34 238 CONFIGURATIONS 1 ERROR herman ees 7 135 242 Dis PRESS CALIBRATE ERROR Enki 7 136 243 SUCTIONEVAP CALIBRATE ERROR i5 actae act doce ac 7 137 245 CANNOT SAVE SETTING ERE ra 7 138 EEPROM WRITE FAILURE i 7 138 248 CONFIGURATION HP2 ERROR Kol Or CR ce oe 7 139 249 MICROPROCESSOR ERROR 7 140 62 11524 viii TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page cg eame 8 1 84d SECTION PAYOUT iua ie Fe Eat oe DERE ER UE Ad id at qr dete ee ap dudo 8 1 52 SOHBEDUEED MAINTENANGE sccicccteccteies REA RUE Ea len dor Roe d 8 1 BE IPN 8 1 B4 EXTERNAL SURFACE SERVICE 8 5 Gale inset ex hs 8 5 Surround REMOVAL hs reo Sr EUR ER E 8 6 8 4 3 Door Latch Maintenance And Replacement 8 6 A Door latch Maintenance Phen ee meen eee 8 6 Cable ete eines 8 6 8 4 4 Display amp Keypad Assembly 8 6 CA ep T ETE 8 6 D bass mb
210. 37 is active and there is no 2SAT OR if both Alarm 137 and 136 are active alarm and defrost is not allowed for compartment 2 RESET CONDITION Auto Reset when sensor is in range or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check sensor resistance Note 3 page 7 2 see 10 000 Ohms 77 F 25 C Refer to Table 8 5 for complete resistance chart Check Sensor Wiring a Inspect harness amp control box con nector pins amp terminals 1MP amp 2EVC see wiring schematic Sec tion 10 No physical damage to harness No damage moisture or corrosion in connectors Power up the microprocessor see Note 2 page 7 2 Disconnect sensor from harness Check for 2 5 VDC at harness plug between pins Voltage should be 2 5 VDC volts at harness plug be tween pins This verifies microprocessor output and wiring connections to the sensor Check remote sensor switch connector 62 11524 c Locate and inspect 10 position connector OC for o
211. 4 Must have 0 AC1 Amps and 0 AC2 Amps in Unit Data 7 120 Alarm Cause Corrective Action P190 CHECK CONDENSER FAN MOTOR TRIGGER ON Normal draw for the condenser fan motors is 0 8 to 3 5 Amps 460 VAC The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Amp Draw of Condenser Fan Motor Circuit a With the unit running use a clamp on ammeter to check the current draw at CDCON on all 3 legs Must be within range shown in Section 2 12 for all three legs If higher than normal draw is read the wiring for the motors must be separated and each motor tested in dividually b Check fuses for condenser fan mo tors F26 F27 and F28 must not be blown c Check voltage at CDCON contacts Must be within range shown in Section 2 12 for L1 L2 L1 L3 and L2 L3 Must be within range shown in Section 2 12 for T1 T2 T1 T3 and T2 T3 Check Condenser Fan Motors a Check
212. 4 1 It has run for the selected Minimum Time 4 4 2 The engine coolant temperature has warmed eee eek see oen 4 4 4 The battery is fully charged Voltage rx EROR RE ERE 4 4 4 The battery is fully charged Amperage ER 4 4 5 The compartment temperature requirement is satisfied 4 5 DE P 4 5 1 Engine coolant temperature drops below selected microprocessor Configuration value 4 5 2 Battery voltage falls below selected microprocessor Configuration value 4 5 3 The Maximum Off Time has expired 4 5 4 The Minimum Off Time has expired m ERR 4 5 5 Compartment temperature has exceeded the Override Functional Parameter value 4 5 iii 62 11524 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page CONTINUOUS OPERATIIN cce 4 6 4 6 452 COMMONS OPAO 4 6 AS DEFROST 4 9 45 1 Befrost Initiation And Stat adn 4 9 Denost based oi coil condilion uus ase cane SOG Lae AG BARRENS se 4 9 Doros poced oN UMO 4 9 4 9 a Nola DETSSL NIGUE aside Sede Sieh dele hh Sed te eid nigh Elia 4 9 B Natural Defrost i Ge Oh Heng 4 9 4 9 a7
213. 4 560 88 31 1 7 686 146 63 3 2 208 26 32 2 203 400 32 0 32 650 90 32 2 7 334 148 64 4 2 124 24 31 1 189 700 34 1 1 30 850 92 33 3 7 000 150 65 6 2 042 22 30 177 000 36 2 2 29 170 94 34 4 6 684 155 68 3 1 855 20 28 9 165 200 38 3 3 27 590 96 35 6 6 384 160 71 1 1 687 18 27 8 154 300 40 4 4 26 100 98 36 7 6 099 165 73 9 1 537 16 26 7 144 200 42 5 5 24 700 100 37 8 5 828 170 76 7 1 402 14 25 6 134 800 44 6 6 23 390 102 38 9 5 571 175 79 4 1 281 12 24 4 126 100 46 7 7 22 160 104 40 0 5 327 180 82 2 1 171 10 23 3 118 100 48 8 9 20 990 106 41 1 5 095 185 85 0 1 072 8 22 2 110 500 50 10 19 900 108 42 2 4 874 190 87 8 983 6 21 1 103 600 52 11 1 18 870 110 43 3 4 665 195 90 6 902 4 20 97 070 54 12 2 17 900 112 44 4 4 465 200 93 3 829 2 18 9 91 030 56 13 3 16 980 114 45 5 4 275 205 96 1 762 0 17 8 85 400 58 14 4 16 120 116 46 7 4 095 210 98 9 702 2 16 7 80 160 60 15 5 15 310 118 47 8 3 923 215 101 7 647 4 15 6 75 270 62 16 6 14 540 120 48 9 3 759 220 104 4 598 6 14 4 70 720 64 17 7 13 820 122 50 0 3 603 225 107 2 553 8 13 3 66 460 66 18 9 13 130 124 51 1 3 454 230 110 0 511 10 12 2 62 500 68 20 0 12 490 126 52 2 3 313 235 112 8 473 12 11 1 58 790 70 21 1 11 880 128 53 3 3 177 240 115 6 438 14 10 0 55 330 72 22 2 11 310 130 54 4 3 049 245 118 3 406 16 8 9 52 090 74 23 3 10 760 132 55 6 2 926 250 121 1 378
214. 6 Water Pump VS BOIE dose ere d sod eate 8 14 Figure 8 17 Engine Crankesse Brealhe RE 8 14 Figure 8 18 Refrigerant System Service Equipment 8 15 Figure 8 19 Compressor model 8 21 Figure 8 20 Cylinder Head amp Valve Plate 2 DER 8 22 Figure 8 21 Checking Suction VAVE Y EX eMe 8 23 Figure 8 22 Oil Pump and Bearing Head Assembly 8 23 eM EUER 8 24 Mq eT 8 25 Figure 8 25 Condenser Radiator Assembly 8 27 Figure 8 26 Suction modulation valve CSMV 8 28 gis 8 29 Figure 8 28 Electronic expansion valve 2 2222 xps dock die d 8 30 Figure 8 29 Electronic Expansion Value case 8 30 Figure 8 30 Typical Setup for Testing High Pressure 8 31 Figure 8 31 Detrost Air Switch Test Setup eR RI tens 8 32 Figure 8 32 egre line Solenoid VANE su uibs eas tie ue cisco a trate Ai a 8 33 Figure 8
215. 62 11524 1 4 CAUTION Running the engine for an extended period of time with the manual plunger up can cause a priming pump failure CAUTION Torque fuel level sensor mounting screws to 15 to 18 inch pounds DO NOT over tight en as little as 20 inch pounds will damage gt o gt o o CAUTION When changing oil filters the new filters should be primed partially filled with clean oil if possible If the filters are not primed the engine may operate for a period with no oil supplied to the bearings CAUTION NEVER POUR COLD WATER INTO A HOT ENGINE however hot water can always be added to a cold engine CAUTION Only refrigerant cylinder that has previ ously been used with R404A should be con nected to this refrigeration unit CAUTION Only a refrigerant cylinder containing R404A should be connected to this refriger ation unit in order to pressurize the system However dry nitrogen may be used to in crease pressure Any other gas or vapor will contaminate the system and require addi tional removal and evacuation CAUTION Do not vapor charge R404A Only charging through the liquid line service valve is acceptable CAUTION Ensure that thrust washer does fall off dowel pins while installing oil pump CAUTION overcharge of will reduce system ca pacity and possibly cause internal com pressor damage C
216. 7 TIP CHK WIRES FROM MICRO TO KEYPAD in dicates there is a wiring problem between the microprocessor and the display module 3 15 62 11524 3 12 VIEW INACTIVE ALARMS COOL DEFROST 20 SETPOINT ALARM 34 BOX TEMPERATURE START STOP CONTINUOUS 1 NO INACTIVE ALARMS Press and hold both the ALARM LIST key and the UP ARROW key for six seconds If there are no inactive alarms the display will read NO INACTIVE ALARMS for five seconds 2 If there are inactive alarms the display will be T in front of the alarm number and message 3 Press the ALARM LIST or UP or DOWN key to scroll through the list of alarms 4 When you reach the end of the alarm list LIST END TO CLEAR ALARMS is displayed for 5 seconds 5 To clear the active and inactive alarm list press the key while LIST END TO CLEAR ALARMS is being displayed ALL ALARMS CLEAR is displayed The microprocessor can hold up to 16 alarms in the combined Active and Inactive Alarm lists The lists can be read via the MessageCenter or using the Reefer Manager PC Program There are two sections in the Alarm list an Active Alarm Section and Inactive Alarm Section Alarms in these sections are in the order in which the alarms activate and inactivate respectively On startup all alarms are marked as inactive in the en tire list If an inactive alarm becomes active the alarm is moved from the
217. 9 cycles on defrost DTT malfunction 8 9 10 Hot Load Allow time to pull down Defective or insufficient refrigerated compartment insula Correct tion or air leak 9 5 62 11524 INDICATION TROUBLE Possible Causes Action Refer ence Section 9 4 8 Abnormal Pressure Condenser coil dirty 8 8 2 Condenser fans rotating backwards Check Wiring High discharge pressure Condenser fan inoperative Check Refrigerant overcharge or noncondensibles 8 6 2 Discharge service valve partially closed Open Compressor valves s worn or broken 8 7 1 Low discharge pressure Low refrigerant charge 8 6 2 Suction modulation valve malfunction 8 8 5 Filter drier partially plugged 8 8 3 Low refrigerant charge 8 6 2 Expansion valve malfunction 9 4 11 9 4 12 Liquid line solenoid valve malfunction 8 8 10 Low suction pressure No evaporator air flow or restricted air flow 9 4 10 Excessive frost on evaporator coil 9 4 7 Evaporator fan rotating backwards heck Wiring Suction modulation valve malfunction 8 8 5 Liquid or suction line service valve partially closed Open Compressor valves s worn or broken 8 7 1 High suction pressure Compressor gasket s defective 8 7 1 Heater contactor stuck closed Check Suction and discharge Compressor valves defective 8 7 1 pressures tend to equalize
218. AS BEEN REACHED will display the MessageCenter when either of these conditions is reached Setpoint may be changed any time the Main Power Switch is not in the OFF position or when the unit is in PC Mode EXCEPT when 62 11524 e Viewing the Alarm List Data List or Functional Para meters OR When the unit is in OR e When the unit is in Sleep Mode Pressing the key will cause the new displayed setpoint value to become active and SETPOINT CHANGED will be displayed If the new value is not entered after 5 seconds of no keypad activity the entire display and Light Bar will flash and the buzzer will be energized for 15 seconds with SETPOINT NOT CHANGED dis played and then revert back to the last entered setpoint All other keys are active at this time and if pressed while the display is flashing will stop the flashing and perform the requested function TIP The setpoint may be changed quickly by press ing and holding the UP ARROW or DOWN AR ROW key The longer the key is held the faster the setting will change 3 6 START STOP OPERATION START STOP LIGHT COOL DEFROST ALARM 20 34F SETPOINT BOX TEMPERATURE START STOP MODE SELECTED START STOP CONTINUOUS 1 START STOP CONTINUOUS Press the START STOP CONTINUOUS key until the START STOP Light on the microprocessor illuminates 2 Verify that START STOP MODE SELECTED
219. ATA THEN TO LOCK Continue to press the green UP ARROW key to move down the Data List or press the DOWN ARROW key to move up the Data List Refer to Table 3 1 3 The selected Data Item will remain in the MessageCenter for ten seconds then the de fault message STATUS or other customer specified message will display 4 To lock an item in the MessageCenter for continuous viewing press the key The Data item will flash continuously to indicate it is locked 5 Pressing the UP or DOWN ARROW key will unlock that item and move to the next data item Pressing the key will unlock the item and after ten seconds the de fault message will be displayed Table 3 1 Unit Data Displays information or setting entered in the microprocessor Configurations May or may not be displayed depending on Parameter Configuration settings Data readings are presented starting with SUCTION PRESSURE and progress ing down the list using the green UP ARROW key DATA DEFINITION SUCTION PRESSURE Compressor suction pressure DISCHARGE PRESSURE Compressor discharge pressure EVAPORATOR PRESSURE Leaving evaporator pressure ENGINE COOLANT TEMP Engine coolant temperature RETURN AIR TEMP Compartment 1 Return air entering evaporator temperature 3 17 62 11524 Table 3 1 Unit Data Continued Displays information or setting entered in the microprocessor Configurations
220. AUTION Use only Carrier Transicold approved Poly ol Ester Oil POE Buy quantities of one gal lon or less When using this hygroscopic oil immediately reseal Do not leave con tainer of oil open or contamination will oc cur CAUTION Extreme care must be taken to ensure the hose is immersed in the oil at all times Otherwise air and moisture will be drawn into the compressor CAUTION Ensure all parts are assembled into the solenoid valve enclosing tube in proper se quence to avoid premature coil burnout Do not over tighten or damage the enclosing tube assembly CAUTION Before connecting megohmmeter place the Main Power switch in the OFF position Disconnect the high voltage source lock out tagout the receptacle and disconnect the negative battery connection Isolate the microprocessor by disconnecting all con nectors and wires going to it Observe Na tional Electric Manufacturer s Association NEMA rules and test equipment manufac turers instructions CAUTION A mica shim Carrier Transicold num ber 54 00630 25 must be installed before removal of the generator The generator is to be removed as one piece with the shim in place DO NOT attempt to remove the rotor from the stator CAUTION Under no circumstances should anyone at tempt to repair the keypad display or in ternal control module components Should a problem develop with these components contact your
221. CONDENSER MOTOR OVERHEATED Continued 6 Check Condenser Fan Motors Disconnect power plug at motor Test IP circuit for continuity using ohmmeter If open remove and replace motor If closed then an intermittent IP circuit is suspect Check phase to phase and phase to ground for short or open circuits Refer to Section 2 12 for correct electrical values If motor tests good check the DC IP circuit to microprocessor Check Motor Operation Turn the unit ON Check current on each phase must be less than shown on Section 2 12 Check voltage on each phase must be within voltage limits shown in Section 2 12 62 11524 7 54 Alarm NO Alarm Cause Corrective Action 77 MOTOR OVERHEATED TRIGGER ON The evaporator fan motor Internal Protector is open UNIT CONTROL Engine and Standby Operation Shutdown and alarm RESET CONDITION Auto Reset after a 15 minute off time when motor overload input is within limits or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Evaporator Fan Blades for Free Operation Visually inspect evaporator
222. D There is no serial connection Is the micro status light blinking 1 second on amp 1 Verify the integrity of the download cable and connections Did you find and correct the condition Use the tech interface con nector to verify that down load port wiring is correct and doesn t have an open high resistance or a short Refer to Section 5 2 Did you find and correct the condition Verify the correct com port is selected in the PC software See Help gt Contents gt PC Setup for additional information Did you find and correct the condition Verify com port availability infrared devices turned off PDA applica tions turned off computer has 9 pin serial port or use a recommended USB to serial port adapter Did you find and correct the condition Use PC Download Card to download data Figure 9 10 Micro Diagnostic Tree Cond 6 DataLink Data Recorder Data Download Problems When Using ReeferManager and a Download Cable Data File Analysis Problems Using Reports 9 19 62 11524 START HERE Make sure the Main Power switch is ON or the microprocessor is in PC Mode Refer to Section 5 3 Using either or computer with a download cable hooked into the serial port download plug load current version of the software into micro Insert PC card into the PC card slot on the micro What does the MessageCenter display say about the PC C
223. DC be applied at these connection points CAUTION Most electronic components are suscepti ble to damage caused by electrical static discharge ESD In certain cases the hu man body can have enough static electric ity to cause resultant damage to the compo nents by touch This is especially true of the integrated circuits found in the Advance mi croprocessor Grounded wrist cuffs are available from Carrier P N 07 00304 00 These should be worn whenever han dling a microprocessor Although there is less danger of electrical static dis charge ESD damage in the outdoor environment or in repair shop where the processor is likely to be han dled proper board handling techniques should always be used Advance Microprocessors should always be handled by the plastic cover and not the exposed printed circuit board This not only precludes the possibility of ESD damage but also lowers the possibility of physical damage to the electronic components When field diagnosis of Carrier Transicold refrigeration unit determines that an Advance Microprocessor is not performing properly and must be replaced the replacement microprocessor must be setup for this unit and customer by entering the required Configurations Functional Parameters and DataLink data recorder settings If the replacement microprocessor is not loaded with the most recent software it should be updated If software is loaded it should be verified that i
224. Download microprocessor and DataLink data record er data via serial port communications directly to the computer Display edit and send unit and remote evaporator model numbers unit serial number and trailer ID to the microprocessor Display edit and send Functional Parameters and Configuration settings to the microprocessor and DataLink data recorder or to a PC Card Write hour meter values to replacement micropro cessors during the first 25 hours Initiate Pretrip and Defrost operations Support Download Configuration and Program PC Card operations Provide a security log on system controlled by a Sys tem Administrator b Reports The Reports Program enables the user to do the following Read DCX download files from the Advance micro processor Create various customized reports that include set point sensors and events Create various customized graphical reports Print numerical graphical and event reports View and print refrigeration system historical settings and changes Filter download data by date range and desired sensors and events Search for a sensor or event of interest Synchronize multiple graphical and numerical win dows to better understand historical operation PC Setup enables the user to select how to display various parameters for use in the graph and text win dow Easily adjust x and y axis and color scheme to accom modate various data Export data to a spreadsheet friend
225. Ds that are illuminated when a circuit is energized Automatic Engine Starting Functional Parameter locks Alarms are stored in microprocessor memory for fu ture reference 2 6 4 Component Description And Location The hardware associated with the Advance microprocessor includes the control module display keypad and switch board The hardware is housed for driver access in the control box on the lower roadside corner of the unit CAUTION Under no circumstances should anyone tempt to repair the keypad display or in ternal control module components Should a problem develop with these components contact your nearest Carrier Transicold dealer for replacement a Control Module The control module Figure 2 10 consists of the microprocessor with status LEDs 3 fuses F1 F2 amp F3 a DC current sensor CT1 2 relays RR amp SR 2 status LED s LED30 8 LED31 6 input output connectors QC 6 digital input output connectors 62 11524 MP a programming card slot with status LED s and twenty three FET indicating LEDs The microprocessor is totally self contained and does not contain serviceable components Microprocessor activity can be determined by observing the LED s and FET s see Figure 2 10 and Table 5 1 If the microprocessor is calling for a circuit to be energized the indicator is illuminated The PC card slot allows programming of the microprocessor using Carr
226. EASE WAIT When the copy is complete the MessageCenter will display COPY COMPLETE REMOVE CARD X The X is the number or empty spaces remaining on the card NOTE Only a copy of the data will be written to the card The actual data will remain inside the DataLink data recorder For complete instructions on working with the data using the Reports program refer to manual 62 10889 5 5 REEFERMANAGER amp REPORTS 5 5 1 The ReeferManager amp Reports program allows the user to access and download data using a computer when the unit is not running and without starting the eight hour DataLink data recorder timer Using the computer will provide additional programming and configuring capabilities that will not be available through the keypad The DataLink data recorder may also be configured and downloaded using the ReeferManager program Introduction For complete instructions on using ReeferManager amp Reports refer to manual 62 10889 NOTE For diagnoses of problems with the micropro cessor DataLink data recorder downloading file analysis using Reports or use of PC cards refer to Section 9 6 a ReeferManager ReeferManager enables the user to do the following Monitor in real time via the download port an RS 232 connection the current status of the micro processor inputs outputs refrigeration electrical engine and temperature sensors and alarms Record sensor data to a file for diagnostic purposes
227. EMATIC rx di r do CAE er CE AOI SE E e CAO I o oe d 10 15 62 11524 1MP NATURAL SECTION 10 WIRING 10 1 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED ENGINE OFF STANDBY Component Terminal REM1 REM E 2 compartment only 3 14 3DTT REMSN2 REMSN H 2 compartment only CDP 3 EVOP 3 DP16 S ENCT 2DTT 2 CDT 55 1RAT DP16 H REM1 REM F SP1 2 compartment only REM2 REM G SP1 2 compartment only 1 NATURAL Continued Component Terminal 1 5 16 15 29 30 1 5 16 CDP 1 EVOP 1 DP16 P ENCT SP2 CST SP14 EVOT DP16 F SP14 CDT 1DTT 2DTT 2SAT 2SAT B SP42 3DTT 1 SP42 AAT 1SAT DP16 D SP12 1RAT DP16 G SP12 2RAT 2EVC H SP12 3EVC H SP12 FLS C CSP 3 CSP 2 SP7 CDP 2 SP7 EVOP 2 SP7 DP16 R 2SAT A SAT A EVOT DP16 E 2RAT 2EVC J 1DTT DP16 A 1SAT DP16 C Unused terminals 1 2 13 24 25 27 28 62 11524 10 1 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SW
228. ER ID available by scrolling through the available list characters long Numbers Letters and a space are This Configuration will display when a replacement microprocessor is installed It allows entry of the hours from the existing microprocessor SET NEW HOURS into replacement microprocessor This Configuration will only display until one of the hour meters reaches 25 hours Changes to these values may be made for up to 60 minutes SHORT Indicates to the microprocessor which engine is in LONG the system INTAKE HEATER ONG Glow Plug equipped and longer glow times are used TV engines GLOW TIME SHORT Glow Plug equipped and shorter glow times are used DI engines INTAKE HEATER Intake Heater equipped Tier 4 engines NOTE Refer to Table 4 1 for glow times YES YES When the refrigerated compartment temper ature has been out of range for 45 minutes the alarm light will come on and the unit will shutdown NO When the refrigerated compartment tempera ture has been out of range for 30 minutes the alarm light will come on and the unit will continue to OUT OF RANGE SHUTDOWN F r Refer to Alarm A53 BOX TEMPERATURE OUT OF RANGE A63 C2 BOX TEMPERATURE OUT OF RANGE or A63 BOX TEMPERAT URE OUT OF RANGE Section 7 for more inform ation YES NO YES Functional Parameters cannot be changed using the keypad PARAMETERS LOCKOUT NO Functional Parameters can be changed using the keypad
229. F 2 0 C Pull Up HEAT HTCON1 amp HTCON2 RISING REFRIGERATED COMPARTMENT TEMPERATURE SWITCH POINTS Switch Point Controlling Temperature Setpoint results are above setpoint results are below setpoint Switch points are the same for Perishable Range and Frozen Range except in Frozen Range heating is not allowed Figure 4 3 Continuous Operation Switch Points with Eco Mode set to YES 62 11524 4 8 4 6 DEFROST Defrost is an independent cycle overriding cooling and heating functions in order to de ice the evaporators When the unit is in defrost the DEFROST LED will be on the MessageCenter will display DEFROST CYCLE STARTED for 5 seconds The center of the Main Display will show dF When defrost is initiated the microprocessor will attempt to initiate defrost in all compartments However defrost will not be allowed in any compartment where the DDT is above 40 0 F 4 4 C and defrost may be staged based on the number of enabled compartments and the remote evaporator models installed 4 6 1 Defrost Initiation And Start Defrost can be initiated by pressing the MANUAL DEFROST key or automatically by the microprocessor Microprocessor initiation is based on coil condition or expiration of the defrost timer a Defrost based on coil condition Defrost based on coil condition will be initiated when e blockage is sufficient to cause an air pressure differ ential across the coil great enough to clos
230. FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during Test 3 by holding Key for 6 seconds d Review active alarm list for Alarm If alarm is present follow steps 2thru 4 If alarm is not 189 present follow Steps 5 thru 8 Check 1EVCON a Inspect Evaporator Fan Motor damage to tactor coil and wire connections No damage moisture or corrosion in connections b Check contactor coil resistance Refer to Section 2 13 Check 1EVCON Amp Draw Check 1EVCON amp draw Use Component Test Mode Section 5 2 2 to test Refer to Section 2 13 for correct electrical values View current draw in Data List Check 1EVCON Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Additional steps on the
231. FET 22 2 CONTROL J14 SATCOM SATELLITE COMMUNICATIONS CONNECTOR 23 UNLDADER 1 CONTROL YE SP5 ENSCU24 J6 SLP SERIAL COMMUNICATIONS PORT 3MP12 L3 SM STARTER MOTOR 1MP22 ane 2 HIS SR SPEED RELAY OP16 C 1 5 lt L16 SS STARTER SOLENDID 1SA IMPRA tSpi PUES L3 SSC STARTER SOLENOID CONTACTOR 3MP19 8 7 2 CONFIGURATION 28 015 SSR STARTER SOLENOID RELAY RA DP16 H 1MP12 aii EE J13 UNLDADERL2 DPi6 G 1 2 SP18 3MP3e 8 8 F9 10A E 1MB33 PSCONR GENCON PRM PSCON2 PSCON 2RA NE peepee 3MP27 DO 28 5258 3115 51 EU a 15 FLS 345 2 11 0012 GENCONR REMS Cense REW G 1 14 SPD 3MP3 GND gt 5 5 6 AFLs 4 sP6 es 25 4 16 SP57 SPLICE POINT 2SA HR eser 2SAT B 1 21 5 42 POCS Pues 26 4 STANDARD options CONTACTS Biss EVOT zu 1MP32 RR 0 4 ps 593 CONNECTION 71 EE UN pe 1MP19 SP14 E ane 3 SP NUMERIC LOW VOLT PIN CONNECTION TE A 2MP17 SR FP SP6 SP ALPHA HIGH VOLT CQ COMPONENT CONNECTION 72 CHASSIS GROUND 550 SSR 47 ENSCU 16 14 PSCONR PSCON PSCON2 GENCON GEN srs 20 FHR 30 87 HCB 59 SP6 p NEONA De 3g TARR HCI6 R bse 21 22 21 M 22 xw TEN nea M INTERLOCK INTERLOCK VECTOR
232. FF If Door Switch Unit Shutdown is selected temperature 120 to 20 F 49 to OFF the unit will shutdown at any ambient tem 29 C perature Value when ambient temperature is below the entered value shutdown will be allowed When ambient temperature is above the entered value the unit will not shutdown e e RUN LOW SPEED BELOW OFF If Door Switch Low Engine Speed is selected temperature 120 to 20 F 49 to OFF the unit will transition to low speed at any 29 C ambient temperature Value when ambient temperature is below the entered value the engine will be forced to low speed will be allowed When ambient temperature is above the entered value the engine will not be forced to low speed 5 19 62 11524 Table 5 2 Microprocessor Configurations Continued Configuration Selections DOOR SWITCH FOR THREE COMPARTMENT UNITS ONLY SWITCH NOT SWITCH NOT INSTALLED There is no door INSTALLED switch DOOR OPEN DOOR OPEN SWITCH OPEN A Door Switch has DOOR SWITCH SWITCH OPEN been installed The switch contacts will be OPEN NOTE DOOR OPEN whenever the door is OPEN On a three compartment unit the SWITCH CLOSED DOOR OPEN SWITCH CLOSED A Door Switch door switch controls Compartment REMOTE PANEL has been installed The switch contacts will be 3 If the configuration is set for a C3 CLOSED whenever the door is OPEN switch not for a panel the following REMOTE PANEL If set to this
233. FROST CYCLE STARTED for 5 seconds or flash CANNOT START DEFROST CYCLE for five seconds When defrost mode cannot be manually initiated CAN TIP NOT START DEFROST CYCLE is displayed in the The Manual Defrost Key can be used at any time to start a Defrost Cycle as long as the pre e DTT 2DTT and or 3DTT are above 40 F 4 C De ceding conditions are met In Defrost Mode all frost may be entered any time one of the DTT s is be refrigerated compartments will enter defrost at low 40 F 4 C OR the same time e The engine has not run 15 seconds after starting OR e The unit is in PC Mode OR NOTE The unit is in Pretrip OR Refer to Section 4 6 for more detailed informa e There is an active shutdown Alarm tion on DEFROST 3 13 62 11524 3 10 TRIP START HEAT COOL DEFROST ALARM START STOP CONTINUOUS 20 34F 1 SETPOINT BOX TEMPERATURE TRIP START ENTERED MANUAL ALARM gn aron SELECT m EU 1 To mark the start of a trip in the DataLink data recorder press the SELECT key until the MessageCenter displays PRESS TO MARK TRIP START 2 Press the key 3 If trip start is acknowledged by the DataLink data recorder TRIP START ENTERED will be displayed for five seconds and then the display will revert back to the normal display Otherwise CANNOT EN TER TRIP START will flash and then the display will revert back to the normal display
234. GGER ON The Maintenance Hour Meter 4 time has expired e UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad 1 Check Unit Maintenance Records Schedule unit into service facility for maintenance Perform Maintenance Perform appropriate engine amp unit maintenance Reset Maintenance Hour Meter 4 a Check that Maintenance Hour Meter 4 interval is set for your requirements b Reset Maintenance Hour Meter 4 for the next service interval Must be done soon Follow instructions on proper maintenance form Reset configured Interval if required Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 230 SERVICE SOON PM 5 DUE TRIGGER ON The Maintenance Hour Meter 5 time has expired e UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad 1 Check Unit Maintenance Records Schedule unit into service facility for maintenance Must be done soon Perform Maintenance Perform appropriate engine amp unit maintenance Follow instructions on proper maintenance form Reset Maintenance Hour Meter 5 62 11524 a Check that Maintenance Hour Meter 5 interval is set for your requirements Reset configured Interval if required b Reset Maintenance Hour Me
235. HCB L16 55 STARTER MOTOR AY F16 5A A ZAT Pans FH S3 B L3 SSC STARTER SOLE F17 5 FHTS gt SP6 psc 2815 SSR STARTER SOLENOID A PSCON J13 ULLe SISTER SOLENOID CUM TMCITUR 14 zi FANS PSCON2 EY B 13 7114 AF 2EVC D SPE 2 E22 GENCONR STANDARD OPTION 8 CONTACTS D 3EVC D A s rM SPE INTERLOCK PLUG CONNECTION FONS reco G F SP6 8 PIN CONNECTION 7 GROUND PE SP NUMERIC L I ps CHASSIS H OW VOLT J uni CCON INENT CONNECTION IGH VOLT L VT M 35 5 57 x MPARTMENT on 62 1158 0 ART8 S8 RF y Y A B D G H I J K L M N P Q R T U V X Y N CCON
236. HECK COOLANT TEMPERATURE TRIGGER ON Coolant temperature is below 32 F 0 C after the engine has been running for 5 minutes UNIT CONTROL Engine Operation alarm only Standby Operation this alarm will not activate in standby Operation RESET CONDITION Auto reset when coolant temperature is higher than 36 F 2 2 C or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Coolant Temperature Check temperature of coolant or Must be above 32 F 0 C upper radiator hose Check Engine Coolant Sensor a Check resistance of engine Refer to Section 8 9 10 coolant sensor See 7 2 md b Check harness and control box No physical damage to harness connector pins and terminals See No damage moisture or corrosion in connectors wiring schematic Section 10 c Check voltage harness Must be 2 5 0 5 VDC This verifies microprocessor connection to ENCT output and wiring to sensor 7 27 62 11524 Alarm NO Alarm Cause Corrective Action 37 CHECK LOW SPEED RPM TRIGGER ON The microprocessor is set for low engine speed operation and engine speed is les
237. He 5333 SC REB SU eM sole rq dais ne 8 28 a 8 28 b Replace Filer Diet Ene ee 8 28 8 8 4 Replacing Receiver Sight Glass Or Fusible Plug 8 28 8 8 5 Compressor Suction Modulation Valve 8 28 886 Expansi n Valve Rebel Ren Rd 8 29 Bor JH Pies 8 31 808 Possum codes xa duod te pied Qa wd dob e doa iue pat dupla 8 31 Bo ee Epod dob Sab EA eco da doe d appo eae 8 31 8 8 10 Liquid Line Solenoid Valve 2LSVISLSV Ron 8 32 a HO ORE EROR DOR d E DR GO dr DECRE 8 32 p a SUE 8 33 5 5 11 Thema Expansion VANG a ied 1405 d d ed Vos Robe a 8 33 89 ELECTRICAL SYSTEM COMPONENT SERVICE n 8 34 8 9 1 Megohmmeter Test Procedure meh mb eer dep ges erem d 8 34 8 9 2 Phase Reversal Module PRM tti bade eee CORE 8 35 62 11524 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page Bs EIGN Bae cuoi eed s Qd doe XA ed cs oa ORA 8 36 894 Overload Ground Fault OGF
238. Heater 1 Number of heaters Three elements 1 assembly Resistance 196 ohms 10 ohms per phase Current Low Speed 2 6 amps nominal Current High Speed 3 4 amps nominal Compartment 1 Heater 2 Number of heaters Four elements 1 assembly Heaters Resistance 196 ohms 10 ohms per phase Current Low Speed 2 6 amps nominal Current High Speed 3 4 amps nominal Remote Evaporator Heaters Resistance 100 ohms minimum per phase 50 ohms minimum per heater Current High Speed MHD1100 MHS1100 3 5 amps MHD2200 MHS2200 5 1 amps 62 11524 2 12 ELECTRICAL DATA Continued Compartment 1 Evaporator Fan Motor Full Load Amps FLA 1 9 amps 460 vac 60 hz Horsepower 1 35 hp 1007 watts 60hz Speed 3500 rpm 60 hz Voltage and Frequency 310 to 660 VAC 45 to 65 Hz Bearing Lubrication Factory lubricated additional grease not required Rotation Clockwise when viewed from shaft end Fan Motor Each Resistance 34 2 to 41 8 ohms Full Load Amps FLA 0 45 amps Horsepower 0 25 hp 180 watts 400VAC Remote Evaporator Speed 2700 rpm 60 hz Approx Bearing Lubrication Factory lubricated additional grease not required Rotation Clockwise looking into grille Generator Nominal voltage amp fre quency at High Speed 460 vac 60 hz 3 phase Nominal voltage
239. IT DURING COOLING eee 2 25 2 16 REFRIGERANT CIRCUIT HEATING AND DEFROSTING 2 25 62 11524 SECTION 2 UNIT DESCRIPTION 21 INTRODUCTION WARNING Advance microprocessor equipped units may start automatically at any time the Main Power switch is not in the OFF position Also the unit may be fitted with two way communication equipment that will allow starting of the unit from a remote location even though the switch is in the OFF posi tion WARNING aware of HIGH VOLTAGE supplied at the power plug or from the generator When performing service or maintenance proced ures ensure any two way communication is disabled in accordance with the manufac turer s instructions ensure the Main Power switch is in the OFF position and whenever practical disconnect the high voltage source lockout tagout the receptacle and disconnect the negative battery connec tion NEVER dis assemble the generator HIGH MAGNETIC FIELD INSIDE This field can interfere with cardiac implants such as pacemakers and defibrillators This manual contains operating data electrical data and service instructions for the Vector 6600MT refrigeration system The system consists of a host unit see Figure 2 1 and one or two remote evaporators see Figure 2 5 mounted in additional refrigerated com partments Refer to Table 2 1 for model information Additional support manuals are listed
240. ITCH LABELED ENGINE OFF STANDBY Continued 2 MP Black Component Terminal Component Terminal 3RS B HC9 SATCOM C GND 15 27 REMOTE SWITCH OC C SLP C GND 13 17 29 SP46 3 compartment only 2HTCON2 A1 2CA F SP45 2 1 DAS 1 CSMV D 2 3 4 5 6 8 19 20 32 3LSV 3EVC A EVXV B DP16 K 11 12 22 23 35 UL1 3 5 6 7 8 9 1 2 EVXV E DP16 N 12 11 22 23 35 SLP E 13 5 17 29 SATCOM B RX 15 3 27 REMOTE SWITCH OC D 13 SLP A RX 17 5 13 29 DOOR SWITCH DS B 2 compartment only 16 2LSV 2EVC A 18 LB H AMBER 19 32 DOOR SWITCH OC E 3 compartment only 16 UL2 SATCOM A TX ENOPS 17 SLP B TX ENSCU 3 2EVCON A1 2CA G CSMV C 9 8 20 32 LB B GREEN CSMV A 0 8 19 32 1 1 EVXV D DP16 M 1 2 11 12 23 85 2HTCON1 A1 2CA E EVXV A DP16 J 23 11 12 22 35 HC19 SP61 26 SP15 29 CSMV B 32 8 19 20 EVXV C DP
241. Inactive Alarm list to the Active Alarm list As additional alarms occur they will be placed first in the Active Alarm list Each alarm can only be present in ei ther the Active or Inactive Alarm List at any given time As conditions change alarms may be moved from the Active Alarm list to the Inactive alarm list and back Alarms are also recorded in the DataLink data recorder They are recorded at the time they occur become ac tive and the time they become inactive 62 11524 For a complete list of Alarms and troubleshooting infor mation Refer to Section 7 TIP When alarms are cleared from the Inactive Alarm List both active and inactive alarm lists are cleared If there is a safety shutdown UNIT SHUTDOWN SEE ALARM LIST will be displayed Pressing the Alarm List key will bring any Active Alarms into the Mes sageCenter Refer to Section 7 for a complete list of Alarms and their descriptions NOTE The Inactive Alarm List is also called the Techni cian s List Only qualified refrigeration techni cians should access the inactive list It is not in tended for the use of drivers or operators 3 13 UNIT DATA HEAT COOL DEFROST ALARM START STOP CONTINUOUS 20 34 1 SETPOINT BOX TEMPERATURE PRESS TO VIEW DATA 1 Press the SELECT key until the MessageCenter displays PRESS TL TO VIEW DATA 2 Press the green UP ARROW key The MessageCenter will display PRESS TL TO VIEW D
242. JE 2 12 2 B16 F7 FUSE 26 COMPARTMENTS 15 A 2MP03 DD MP 4 6 H 3HTR1 5 Ble F19 FUSE lt ECET DRAIN HIS S DELAY 5 6 7 5 5 5 1MP30 SP7 ds Sirene Ko uA 2HTCON2 ENTERA Ee FUSE L ANS ISAMP Y gt 5 IMPS gt FET LEGEND 40515 1EVCUN T p 95162 2010 4 3HTCON2 525 FHR FUEL HEATER 12 TIME DELAY MP16 5 FHTS EATER RE oc 2 FE Ant EVAP 2 1 114 FL FUEL HEAT LAY TE EE uer DM MEM IP sP59 270 12 Hi 19 A re LEVEL n 9 CCON 2 FSA PUMP IONAL 4 A2 2C10 TZ E 14 515 FUEL TONAL avi 2 OMM CW VIEW FROM INLET s TH HC3 9 4 27 GENERATOR CONTACTER n z I 4 4 A 2 3 TA EVAP 3 514 R 06 E tie 510 H G DP16 P ET 7 6 EATER 2 GEN ENERATOR ale 1 17 FT 8 AUTO RESTART LIGHT 2 2HTCON2 2 o 2EVCON c HPL PENERATOR CUNIAGTUR REERT NSOUIS 2 FE A SP5 2210 10 1 2C10 7 3 CW VIEW FROM 1HTCONL HIGH DISCHARGE g 2 18 Bye 3MP34 BHTCOND r1 EVCON INLET amp 3905 1 HEATERI PRESSURE SWIT 2 FET 10 2CA E 2010 8 1 NS MIRI E 1 HEATER CONTACTOR 5 FE 1HTCDNI Bit O 9 1 20 8 2EVHTS T2 77 H 1
243. L EQUALIZER COMPARTMENT 2 EVAPORATOR2 MICROPROCESSOR HEAT EXCHANGER RECEIVER FUSIBLE PLUG FILTER DISCHARGE SERVICE LIQUID LINE SERVICE VALVE SUCTION SERVICE SUBCOOLER VALVE COMPRESSOR am DISCHARGE LINE LIQUID LINE SUCTION LINE CONDENSER Figure 2 15 Refrigerant Circuit 62 11524 2 24 SECTION 3 OPERATION PARAGRAPH NUMBER Page 41 STARTING ENGINE OPERATION TEE E Rad 3 1 32 STARTING STANDBY OPERATION 3 2 ma 3 4 44 3 5 en OAHANGING SETPOINT PRATER YER RM reins 3 8 nant cisci e dnd ached nnd awesome 3 9 CONTINUOUS OPERATION xe 3 10 SLEEP MADE caini EO 243 Gia eae 3 11 4g MANUAL DEFROST 3 13 2 10 TRIP START OO tute 3 14 OM MER S ALARN n D TE 3 15 112 VIEW INACTIVE ALARMS dax aped e RUE E 3 16 ests oko Ta Ld tie VE doe b Ed e o WR oe dO 3 17 VEW FOUR ME TERG iode cdd s Seale abe daba eia 3 20 FUNCTIONAL
244. NTACTOR ees mm m 3 CN GND 2 14 CONDENSER MOTOR 1 Hid EVM DM2 CONDENSER MOTOR 2 48025 1 1 3 d 5 CHNPARTHEH HEATER EVAP 2 REMOTE SWITCH 1 2 ISS 16 L 13 08 CSMV COMPRESSOR SUCT S TON MODULATION VALVE RCR 0 5 9 11 26 CDCIIN D10 CSP COMPRESSOR SUCTION PRESSURE TRANSDUCER SP57 1 SP16 1MP15 4h fan spy i gt EST COMPRESSOR SUCTION TEMPERATURE SENSOR He TD F9 4 CH HT DC CURRENT SENSOR DOES m SPT Je CT2 3 4 CURRENT SENSOR RCR 1 4 10 a De DAS DEFROST AIR SWITCH n e 4 7 565 4MP9 SP57 SPW DOOR SWITCH le 2 A 2 6 13 1 3 a DEFROST TEMPERATURE SENSOR EVAPS 1 2 o EK Ira D4 DOES DIESEL OFF ENGINE STAN 4 1 B A D11 ENCT ENGINE COOLANT TEMPERATURE n 3 reas WHT B15 ENDPS ENGINE DIL PRESSURE SWITCH SP56 STBY 6 5 2 6MP2 2 E C B 11A 03 ENSCU ENGINE SPEED CONTROL UNIT SMP4 MPQC9 RED 477 d 99 4 1 EVAPORATOR FAN CONTACTOR spse med D Su GND 1 LOWER COIL WU 9 Jiao 2EVCON 2 EVAPORATOR FAN CONTACTOR e sPse sisi 4 HEATER T3 EVM EVAPORATOR FAN MOTOR m BRN E IHTCON2 010 13 eEVMi 4 2ND COMPARTMENT EVAPORATOR FAN MOTORS 5 5 TIMED 2 2 BLU lt gt DRIP DRAIN T py
245. NTAGHER 9 29 ACRX gt 1HTCUN 010 13 EVA TUR CONT RMS 1 Duo d PEVMI 4 EN FAN ACTOR SP6 neton 2 52 z evans COEBAC EVAPORATOR ERN MH Lil VAPOR ORS ACM 4 2MP3 SMP8 HTR1 TA TIME 2EVHTS HIGH TEMPERA ATOR FAN MOTO 2 D 12 3EV 2 EVAP HI TURE SWITCH RS m pep UO 2 26 ESA UPPER COIL lt a F13 F14 F15 010 HIGH TEMPERATURE SWITCH XV Ae apt 13 4 7 199 LY 5 5 HEATER 3 iig 154 E EVAPIRATIR N 0 2 8 2 2 16 SMP7 8S1 T M mS FH FUEL NEATE TEMPERATURE SENSOR EATER VE D 2 20 ee G4 FUE SMP9 27 71 COMPARTMENT 2 MS FUEL HEATER RELAY Tn MS 2 2 SMP10 85 86 FUSE Sen Seen Tcov FUSE RUN RELAY TS AMP 219 DP16 1 2 2 T1 COMPARTI Le FUSE 0 mores late EVXV B en emp3s 4 1 2 2 c 3 Dis 57 8 89 FUSE SMICRD POWER 15 0916 8 2MP11 4 5 5 60 ai 4 R7 mE KUSE S CONTACTER ER S AME DBEAN Mia 4 3 E DP16 N 4MP2 eU Rei IPC 210 3 amp 24 che HEATERS 12 TIME DELAY 2 13 E
246. NTROL and alarm Alarm only or if configured for shutdown engine and unit shutdown RESET CONDITION Auto reset when fuel level is above 12 for more than 1 minute or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check For Low Fuel Level Warning Alarm Check for alarm 1 Must be cleared Check For Low Fuel Level Check fuel level in tank Add fuel as needed to the fuel tank Check Low Fuel Level Sensor terminals a Inspect sensor amp connector pins amp No damage to sensor No damage moisture or corrosion in connector b Check Low Fuel Level Sensor Refer to Section 8 9 10 for sensor check out proced ure Check Low Fuel Level Sensor Wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors b Check voltage at the Low Fuel Level Sensor connector with the microprocessor powered up 62 11524 Voltage reading should be 12 13 VDC between ter minals FLSA and FLSB Voltage reading should be
247. Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during Test 3 by holding Key for 6 seconds d Review active alarm list for Alarm If alarm is present follow steps 2 amp 3 If alarm is not 168 present follow step 4 Test 2 alarm Check Compartment 2 LSV Coil a Inspect coil and connector No damage to coil No damage moisture or corrosion in connector Use component test mode to check circuit b Check resistance of coil Refer to Section 2 13 for correct electrical values Test 2 alarm Check Compartment 2 LSV Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Test 14 alarm Check Compartment 2 LSV Valve Check operation of Compartment 2 Refer to section 8 8 10 mad valve for proper opening and Compartment 2 LSV must open and close correctly closing 62 11524 7 104 Alarm Cause Corrective Action P174 CHECK LOW SPEED RPM TRIGGER ON in Test 5 With Speed Relay turned off engine speed is NOT between 1250 and 1450 rpm TRIGGER ON in Test 7 15 seconds aft
248. OFF position the microprocessor will exit service Mode To enter Service Mode a Enter the Technician Interface Service Mode as scribed in Section 5 2 e b ENTERING SERVICE MODE will display in the MessageCenter When entering Service Mode the microprocessor opens the CSMV and EXV to 100 open and energizes the remote liquid line solenoid valves 2LSV amp 3 LSV c Once the valves are open RECOVER LEAK CHK MODE is displayed in the MessageCenter 5 3 d Refrigerant recovery leak checking or evacuation may be performed on the unit at this time Refer to Service Procedures in Section 8 The unit should remain in the RECOVER LEAK CHK EVAC MODE as these service procedures are per formed If the unit shifts to Charge Mode and CHARGE MODE HOLD TO EXIT is displayed in the MessageCenter DO NOT perform refrigerant re covery leak checking or evacuation Exit Service Mode and then re enter making sure that RE COVER LEAK CHK EVAC MODE is displayed in the MessageCenter before continuing any of these service procedures The microprocessor will monitor the pressure trans ducer readings during evacuation Once all pressure transducers CDP CSP and EVOP have dropped below 20 in hg 0 68 Bar and then 2 of the 3 pres sure transducers rise above 5 PSIG 0 34 Bar the microprocessor will close CSMV and EXV to 0 open and de energize the remote liqu
249. OU 20 34 F SETPOINT BOX TEMPERATUR HEHERI E 1 B Indicator lights Keypad Door Main Display MessageCenter Keypad Up and Down Arrow Keys Enter Key Manual Defrost Key Alarm List Key Start Stop Continuous Key Select Key Switch Board 0 090 2oON ENGINE ENGINE 1 START RUN E Os MAIN POWER SWITCHES MAIN POWER SWITCHES Diesel Off Engine Standby Switch DOES Note switch is labeled ENGINE OFF STANDBY START RUN OFF Switch SROS Diesel Electric Switch DES Note switch is labeled STANDBY ENGINE 2nd Compartment Run Switch Note switch is labeled C2 3rd Compartment Run Switch Note switch is labeled C3 13 14 15 16 17 Figure 2 11 Display And Keypad Assembly b Main Display MessageCenter amp Indicator Lights see figure Figure 2 11 Indicator Lights The display has six LEDs across the top to indicate operational status These indicators are Heat Indicator Amber Illuminated when the unit is in Heat Mode Cool Indicator Green Illuminated when the unit is Cool Mode Defrost Indicator Amber Illuminated when the unit is in Defrost Mode Alarm Indicator Red Off or Flashes at a rate of 0 5 s
250. Operating Time Each time the compressor is started it must operate for a minimum of 3 minutes before it can be de energized If during the 3 minutes a compartment is operating in the frozen range refer to Section 4 3 2 that compartment will operate in cooling If the only operating compartment is operating in the perishable range that compartment will continue to cool with the heaters energized as required to maintain setpoint 4 8 3 Engine Speed Overrides This section lists the different factors that determine engine speed high or low in addition to the speed controls used in temperature control Speed Control Overrides in priority order are 1 The microprocessor will force the unit to run in low speed when Forced Low Speed When the ambient temperature is less than 0 F 17 7 C AND the unit is running in low speed heat with the AC current less than 8 Amps for 10 minutes the unit will remain in low speed until the ambient tem perature is above 0 F 17 7 C OR the AC current is more than 8 amps for 10 minutes When the ambient temperature is less than 0 F 17 7 C AND the unit is running in either cool null or defrost AND AC current is less than 12 Amps for10 seconds the engine will be forced to low speed The unit will remain in low speed until the ambient temper ature is above 0 F 17 7 C OR the AC current is more than 10 Amps for 10 minutes When the ambient temperature is less than 77 F
251. Otherwise air and moisture will be drawn into the compressor In an emergency where an oil pump is not available oil may be drawn into the compressor through the suction service valve 1 2 With both manifold gauge set valves frontseated leave the suction connection connected to the com pressor suction service valve port and connect the common connection to a vacuum pump Remove the discharge hose from the manifold gauge set connect the end with the Schrader depressor to the compressor oil fill port Item 12 Figure 8 19 and immerse the other end in a container of refrigeration Pump down the compressor Refer to Section 8 6 2 oil Start the vacuum pump throttle the manifold gauge set suction valve and pull a vacuum on the compressor while watching the the oil level in the glass Fill to 1 4 glass Shut down pump and remove oil fill line from the oil fill port Break any remaining vacuum raise to 0 psig bar with refrigerant remaining in the system crack open the suction service valve or from a fresh cylinder of refrigerant Evacuate the compressor crankcase to 500 microns Remove service equipment backseat suction and discharge service valves and recheck oil level Removing Oil From The Compressor Check compressor oil level refer to preceding step a If the oil level is above the middle of the sight glass item 11 Figure 8 19 oil must be removed from the compressor Pump down the compr
252. P 6 ORN DISP 8 YEL Unused terminals None 10 3 62 11524 10 1 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED ENGINE OFF STANDBY Continued Terminal 1DTT 1DTT 1SAT 1SAT EVOT EVOT 1RAT 1RAT EVXV A EVXV B EVXV C EVXV D EVXV E EVOP 1 EVOP 2 EVOP 3 Unused terminals None Component Terminal 2MP 18 FSA 1 ESSN S SP3 HC 2 STARTER MOTOR SP6 GND SP5 ENSSN 3 FSA 2 Unused Terminals 1 2 4 5 6 8 9 11 12 14 15 17 20 21 22 23 Qo JU ZzzETr ACIQOTImUoOQOU 62 11524 10 4 10 1 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED ENGINE OFF STANDBY Continued 2EVC HC Plu Control parce 22 04191 10 170 O 1e Component Terminal 3MP18 2LSV A SP5 Compartment 2 Remote B Evap Power EVHTS 2CA B 2CA C 2CH Compartment 2 Remote Evap OGF OV 1MP15 Ground GROUND GND 2 MPQC 3 ENSCU 16 2 1 2 3 4 IP SP45 Component MPQC4 SP3 1MP23 SP12 2RAT RCR 2 OC B 1MP33 2RAT SSR 87 SS 1MP8 2DTT 3RS B 2MP2 IMP21 SP42 2DTT SP60 CCON IPC REMS2 SP 6 IAHR 87 IAH Unused terminals None SP57 GND 1 FHR 5 FHTS 2CA RCR 3 DOES 3
253. PARAMETERS oh rer bentes 3 21 wae LANGUAGE SELECTION 14 54i 3 25 ddr STOPPING UNIT Up dra a RUE des 3 26 218 Datalink DATA RECORDER Sarees 3 27 3 18 1 Microprocessor to EE p p ele deme eS e tulo pd seh come een 3 27 2182 Daa SCORE Hber OS BREVES FEET COS CD P HE Od nd 3 27 2 18 24 Data DOMAIN 3 27 3 18 4 Datalink Data Recorder PowereUp tiritiri Rak ha de ees 3 27 OPTIONS ay Leo Sede SERE SR SHE d pp Se 3 28 NOB DISSE rA baba io died S 3 28 2 19 2 Remote Control Panel 3 29 62 11524 SECTION 3 OPERATION 3 1 STARTING ENGINE OPERATION WARNING Advance microprocessor equipped units may start automatically at time the Main Power switch is not in the OFF position Also the unit may be fitted with two way communication equipment that will allow starting of the unit from a remote location even though the switch is in the OFF position WARNING aware of HIGH VOLTAGE supplied at the power plug or from the generator When performing ser vice or maintenance procedures ensure any two way communication is disabled in accordance with the manufacturer s instructions ensure the Main Power switch is in the OFF position and whenever practical disconnect the high voltage source lockout
254. POWER SOURCE CONTACTOR RELAY nc 1 1MP17 FET 8 HT CON 2EVHTS PSR STANDBY POWER PLUG ee et 3MP34 2CA E 2EVC C o RETURN AIR TEMPERATURE 2MP31 FET 9 215 2 2 D7 REMS1 REMOTE SWITCH 1 l niu ENSCU3 2MP18 FET 10 3MP18 2EVC lt lt D8 REMS2 REMOTE SWITCH 2 clo 2MP07 FET 11 2EVCON SP45 2 3 4 013 REMSN 1 REMOTE TEMPERATURE 1 Fle ENCT 1MP07 FET 12 3MP30 IAT IAD 015 REMSN 2 REMOTE TEMPERATURE 2 CETIS 1MP18 lt SP2 FET 13 abis nee S Sper Yat S IT 1MPID 2 5 D13 1SAT SUPPLY AIR TEMPERATURE CST FAULT LIGHT SATCUM SATELLITE COMMUNICATIONS CONNECTOR cle 548 1 19 14 gt FET 15 T 2 26 SLP SERIAL COMMUNICATIONS PORT I 1MP09 FET 16 DEFROST LIGHT S Hs SPEED RELAY 1 L n DPA oA EE 4 5 e D4 SROS START RUN OFF SWITCH 11 DIT 1 BUZZER L16 SS STARTER SOLENOID TEE 2 SP42 Er 19 L3 SSC STARTER SOLENOID CONTACTOR 12 Py typ tt VCK 1 08 ANN Jg SSR STARTER SOLENDID RELAY E es EL imper sp4 E 20 1 ECON ne 2EVM4 J13 ULi 8 UNLDADERI 2 bdg REMSNI MB cpi FET 28 UNLOADER 2 CONTROL pl larg 23 UNLOADER 1 CONTROL SP5 gt ENSCU24
255. PRESSOR SUCTION TEMPERATIURE SENSOR B BTY guts 1 E AA e H H EVM CT2 3 4 CURRENT SENSOR D6 DAS DEFROST AIR SWITCH 3 804 gt 5 DES DIESEL ELECTRIC SWITCH SP43 Tes 1556 fa 112 DIT DEFROST TEMPERATURE SENSOR SM c i OM CDCUN Die DEFROST TEMPERATURE SENSOR COMPARTMENT 2 RCR 5 16 5 ENCT ENGINE COOLANT TEMPERATURE i F1 NE SPEED CONTROL UNIT Ru SRUS SPS I 7 54 MPQC1 ESSN ENGINE SPEED SENSOR 5 SAD 4 9 SP57 SP6 sp 1EVCON 1 EVAPORATOR 4 513 9 0 PWR MPQC2 e ACIS F10 EVM EVAPORATOR FAN MOTOR N 6MP1 BLK A 1 B 4 2ND COMPARTMENT EVAPORATOR MOTORS 2ND COMPARTMENT EVAPORATOR CONTACTOR 5 04 WHT gt 1EVHTS 1 EVAP HIGH TEMPERATURE SWITCH ees E T EVAPERATOR PRESSURE SENSOR 2MP02 MPQC9 6 3 4 4 EM EVAPORATOR OUTLET TEMPERATURE SENSOR SP52 SP52 6MP4 GRN yD 4 ud HEATER reg FUSE PDVER 5 5 1 BRN 1HTCON2 F1O F11 F 12 F2 FUSE SPEED RELAY 10 AMP T SMP2 di PET 5 DRIP DRAIN F3 FUSE RUN RELAY 75 FUSE 80 AMP e 56 6 6 gt 6 5 HEATER F6 FUSE MICRO POWER 15 DES ORG F7 8 FUSE BATTERY CHARGER 3 AMP TIME DELAY 5 6MP7 7 F9 FUSE 10 AMP ale 6
256. PT a Verify that correct wires are con nected to each transducer Plugs to transducers are the same The correct wire plug must be connected to the proper transducer b Verify that correct transducer is be ing used in each position Mechanical connections to transducers are the same The Discharge Transducer should have a RED mark ing dot on it The Suction Transducer should have a BLUE mark ing dot on it Check Compressor Operation Check compressor operation Refer to Section 8 7 1 If compressor does not pass all tests repair or re place compressor Check Suction Modulating Valve 62 11524 a Visually inspect CSMV No damage to valve b Inspect CSMV coil and wire con nections Refer to Section 8 8 5 No damage to coil mE No damage moisture or corrosion in connector c Check CSMV operation Refer to Section 8 8 5 Must perform correctly d Check wires from CSMV to micro processor No visual damage to wires Continuity test verifies that each wire is good 7 110 Alarm Cause Corrective Action P184 C2 CHECK EVAP FAN MOTOR This device is checked twice Pretrip once in Test 2 and again in Test 8 TRIGGER ON TEST 2 Normal draw for the 2EVCON contactor coil is 05 to 2 0 D C Amps 12 VDC The circuit tests outside this range TRIGGER ON TEST 8 Normal draw for the Compartment 2 Evap Fan motors is 0 1 to 2 0 A C Amps 460 VAC The cir
257. Power F9 4 Fuse F26 26 Microprocessor Power Fuse F6 5 Fuse F12 27 Power Source Contactor PSCON 6 Fuse F11 28 Power Source Contactor PSCON2 7 Fuse F10 29 Generator Contactor GENCON 8 Fuse F8 30 Overload Ground Fault Module OGF 9 Fuse F7 31 Compressor Contactor CCON 10 Fuse F29 32 Heat Contactor 1HTCON2 11 AC Current Sensor CT2 3 4 33 Evaporator Motor Contactor 1EVCON 12 Phase Reversal Module PRM 34 Condenser Motor Contactor CDCON 13 Fuel Heater Relay FHR 35 Evaporator Motor Contactor 2EVCON 14 Run Control Relay RCR Used with 36 Heat Contactor 2HTCON1 Remote Control Panel Only 37 Heat Contactor 2HTCON2 15 Power Source Contactor Relay PSCONR 38 Heat Contactor 1HTCON1 16 Generator Contactor Relay GENCONR 39 Fuse F15 17 Compressor Contactor Relay CCONR 40 Fuse F14 18 Main Fuse F5 41 Evaporator Motor Contactor 19 Intake Air Heater Relay IAHR 42 Heat Contactor 3HTCON1 20 Starter Solenoid Relay SSR 43 Contactor 2 21 Buzzer 22 Fuse F19 Figure 2 6 Control Box 62 11524 2 8 2 3 CONDENSING SECTION The condensing section see Figure 2 1 amp Figure 2 2 consists of engine generator drive package compressor condenser fans condenser coil radiator refrigerant controls defrost air switch piping wiring and associated components The engine generator drive package see Figure 2 3 includes t
258. Pretrip to check unit operation 8 5 ENGINE AND ENGINE RELATED SYSTEMS SERVICE Procedures for servicing the engine fuel system engine cooling system and air cleaner are provided in the following sub paragraphs 8 5 1 Fuel System The fuel system see Figure 8 5 consists of the fuel tank mechanical lift pump fuel filter fuel injection pump the injectors and interconnecting tubing The fuel system may also be equipped with an optional electric pump and or optional electric fuel heater Two fuel system configurations have been used The first has the leak off line at the inlet side of the filter with an outlet line check valve and the second has the leak off line at the outlet side of the filter without an outlet line check valve 62 11524 N y p Item 8 Leak off line connected at the fuel inlet side Item 8 Leak off line connected at the fuel outlet side 1 Fuel Tank 8 Filter Leak Off Line 2 Supply Line 9 Check Valve 3 Electric Pump 10 Injection Pump 4 Mechanical Pump 11 Injector Nozzles 5 Water Separator 12 Bleed Screw 6 Heater 13 Return Line 7 Filter 14 Level Sensor CHECK VALVE USED WHEN LEAK OFF LINE IS INSTALLED AT THE INLET CON NECTION ONLY Figure 8 5 Fuel System Diagram 8 5 2 Priming The Fuel System The mechanical fuel lift pump See Figure 8 6 is mounted on the en
259. Procedure 98 50553 00 Inert Gas Brazing 8 1 SECTION LAYOUT Service procedures are presented herein under the following major sections Scheduled Maintenance Section 8 2 Pretrip Inspection Section 8 3 External Surface Service grille surround doors and display amp keypad assembly Section 8 4 beginning on page 8 5 Engine And Engine Related Systems Service Sec tion 8 5 beginning on page 8 7 e Refrigerant System Service Section 8 6 beginning on page 8 14 Compressor and Unloader Service Section 8 7 be ginning on page 8 20 Refrigerant System Component Service Section 8 8 beginning on page 8 26 Electrical System Component Service Section 8 9 beginning on page 8 34 Refer to the Table Of Contents to locate specific topics 8 2 SCHEDULED MAINTENANCE For the most reliable operation and for maximum life your unit requires regular maintenance This includes oil and filter changes fuel and air filter replacement coolant replacement pretrip inspections Maintenance is to be performed in accordance with the procedures provided in Table 8 1 8 3 PRE TRIP INSPECTION Pre trip inspection should be performed before every trip at regular maintenance intervals Pre trip procedures are provided in Table 8 2 62 11524 Table 8 1 Maintenance Schedule System Operation je a Pre Trip Inspections 1 Pre Trip Inspection before st
260. R 2 CIRCUIT This device is checked twice Pretrip once in Test 2 and again in Test 8 TRIGGER ON TEST 2 Normal draw for the 2HTCON2 contactor coil is 05 to 5 0 D C Amps 12 VDC The circuit tests outside this range TRIGGER ON TEST 8 Normal draw for the 2 2 heaters is 1 0 to 7 0 A C Amps 460 VAC The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip mode is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during Test 3 by holding Key for 6 seconds d Review active alarm list for Alarm If alarm is present follow steps 2 thru 4 If alarm is 146 not present follow steps 5 thru 10 Check 2HTCON2 Inspect heater contactor coil and No damage to coil wire connections No damage or corrosion b Check contactor coil resistance Cannot be opened infinite ohms Shorted Zero Ohms or shorted t
261. Remote Heater SHTCON1 Remote Heater 2 Evaporator Motor Contactor 1EVCON Evaporator Motor Contactor 2EVCON Evaporator Motor Contactor Liquid Line Solenoid 2LSV Liquid Line Solenoid 3LSV Each component will be individually checked for proper current draw An alarm will be activated for any compo nent not drawing amperage in the expected range Contactor for Compartment Contactor for Compartment Contactor for Compartment Contactor for Compartment PRETRIP Continued Test 3 Refrigeration System Equalization Check With the engine and the unit off the CSMV will open to 50 and the EVXV will open to 100 so that the pres sure in the refrigeration system can equalize Test 4 Temperature Sensor Check Check the condition of all of the system temperature sensors Test 4 will last approximately 5 seconds If a problem is detected with any of the sensors the corresponding alarm will be activated NOTE Tests 5 6 an 7 are only performed when unit is in Engine Operation When in Standby Opera tion pretrip will skip to Test 8 Test 5 Engine Low Speed The engine starts up in low speed with condenser fans on The microprocessor verifies that engine speed is in low speed range If the engine is not operating within the low speed range the P174 CHECK LOW SPEED RPM alarm will be activated Test 6 Engine High Speed The engine switches to high speed and energi
262. SSAGES Continued Message Description REMOVE CARD BATTERY TOO LOW If a PC card is inserted when battery is below 7 0 volts this mes sage will be displayed until card is removed REMOTE SWITCH 1 2 OPEN Remote switch is open May be connected to a refrigerated compartment door or a remote control switch REMOTE SWITCH 1 2 OPEN LOW SPEED Shows that the remote switch is open and that the unit is running in low speed Switch may be connected to a refrigerated compart ment door or a remote control switch REMOVE JUMPER The Configuration Technician Test Mode has been entered Re move the jumper wire before continuing SAME SW TO LOAD T TO CANCEL A Program PC Card has been inserted into the PC Card slot and the program on the PC Card is the same as the program currently in the microprocessor Press the key to reload the same program or press the UP ARROW key to cancel and remove card SERVICE MODE Selection in Configuration and Technician Test Modes which is used when servicing the refrigeration system Refer to Section 5 2 3 SETPOINT CHANGED The new setpoint has been entered saved into microprocessor memory the new setpoint will be used SETPOINT NOT CHANGED The new setpoint has NOT been entered NOT saved into micro processor memory the old setpoint will be used SETTING SMV XXX The Main Power switch has been toggled out of the OFF position and the CSM
263. T is not within the range of 40 to 392 F 40 to 200 C UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again Check Sensor refer to procedure for alarm 125 P161 CHECK SUCTION TEMP SENSOR CST TRIGGER ON Suction Temp Sensor CST is not within the range of 53 to 158 F 47 to 70 C e UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset when suction temperature sensor is in range or alarm may be manually reset via keypad or by turning the unit off then back on again Check Sensor refer to procedure for alarm 127 7 99 62 11524 Alarm Cause Corrective Action P163 C3 CHECK HEATER 1 CIRCUIT This device is checked twice Pretrip once in Test 2 and again in Test 8 TRIGGER ON TEST 2 Normal current draw for the 3HTCON1 contactor coil is 05 to 2 0 D C Amps 12 VDC The circuit tests outside this range TRIGGER ON TEST 8 Normal current draw for the 3HTCON 1 heaters is 1 0 to 7 0 A C Amps 460 VAC The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip mode is started again or alarm ma
264. T UNITS ONLY I POOR SWITCH FOR TWO COMPARTMENT UNITS ON rariora NOT SWITCH NOT INSTALLED There is no door INSTALLED switch DOOR OPEN DOOR OPEN SWITCH OPEN A Door Switch has DOOR SWITCH SWITCH OPEN been installed The switch contacts will be OPEN DOOR OPEN whenever the door is OPEN SWITCH CLOSED OPEN SWITCH CLOSED A Door Switch has been installed The switch contacts will be CLOSED whenever the door is OPEN ALARM ONLY ALARM ONLY When Door Switch indicates that UNIT SHUTDOWN the door is open a warning alarm will be displayed LOW ENGINE SPEED in the MessageCenter UNIT SHUTDOWN When Door Switch indicates that the door is open a warning alarm will be dis DATA RECORDER Played in the MessageCenter and the unit will shut ONLY down If this setting is chosen the following unit shutdown below setting will also be available LOW ENGINE SPEED When Door Switch indi cates that the door is open the engine will be forced to low speed If this setting is chosen the e DOOR SWITCH following run low speed below setting will also be available NOTE The DataLink data recorder will record every time the door is opened or closed when using any of the preceding alarm shutdown speed change settings DATA RECORDER ONLY The DataLink data re corder will record every time the door is opened or closed There will be no alarms or messages dis played in the MessageCenter ee UNIT SHUTDOWN BELOW O
265. T1 terminal of power supply contactor 1 PSCON See Figure 8 35 Set the megohmmeter reading to 1000V Turn on the meter and record reading It should be greater than 200 MQ If the reading is less than 200 MQ run the unit for 15 minutes to dry out the windings and test again If the reading does not improve to above 200 MQ after run ning 15 minutes check for a short to ground by NOTE It is not necessary to remove the trough covers unless it is determined that a problem exists within the trough Isolate and test harness with in the trough by disconnecting the connector at in the remote evaporator Visually inspecting the tested component for any poor connections or chafed wires Isolating the component and wire harness Retesting the harness and component i e the motor windings with the megohmmeter to determine where the short to ground is located Continue testing each of the red wires on PSCON T2 and T3 terminals Each should measure greater than 200 If not follow the procedure outlined in Step f above To complete the test all high voltage contactor con nections must be tested on their T1 T2 and T3 ter minals See Figure 8 35 The fuses and the Overload Ground Fault Module OGF do not need to be tested Following the completion of all testing reconnect the generator ground wire at the unit ground plate 8 35 2 ich dm
266. TIC FIELD INSIDE This field can interfere with cardiac implants such as pacemakers and defibrillators WARNING Under circumstances should ether or any other starting aids be used to start engine 62 11524 1 2 WARNING Ensure the power plug is clean and dry be fore connecting to any electrical outlet re 5 9 WARNING Do not connect power plug to any electrical outlet without checking that it meets the 460 3 60 and 30 electrical requirements of the unit WARNING Always place the Main Power switch in the OFF position and turn off the high voltage power supply before disconnecting the high voltage power plug from the unit WARNING If the unit is Standby Operation and powered voltage will be applied to high voltage components i e the fan motor con tactor and those components will operate i e the fan blades will turn when those components are energized using Compon ent Test Mode WARNING Do not toggle the Power switch out of the OFF position when in PC Mode or the unit will start WARNING Do not remove the cap from a hot radiator or bottle if the cap must be removed do so very slowly in order to release the pressure o o lt WARNING Caution and good electrical practices must be used when working around and with high voltage circuits WARNING Disconnect batteries before doing any el
267. TROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again Check Sensor refer to procedure for alarm 123 P155 CHECK COOLANT TEMP SENSOR TRIGGER ON Engine Coolant Temperature Sensor ENCT is not within the range of 58 to 266 F 50 to 130 UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again Check Sensor refer to procedure for alarm 129 P156 CHECK BATTERY VOLTS TRIGGER ON Battery voltage is less than 11 VDC or greater than 17 VDC UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Refer to procedure for alarm 15 for high voltage condition or pr
268. TROL BOX SIDE Figure 8 36 Light Bar Connections 8 9 3 Light Bar The light bar may be tested using a 12 VDC source To test the light bar a Connect the ground from the power source to B on the light bar side of the connector b The green LEDs will illuminate when the 12 VDC side of the power source is connected to pin G c With the connection as in the preceding steps on and on pin the amber LEDs will illuminate when the ground from the power source is also connected to pin G 8 9 4 Overload Ground Fault OGF a Operation The OGF is designed to detect current overload and fault to ground in the AC voltage circuits The function of the OGF is to shut down the power supply generator or 62 11524 8 36 standby when current is over 40 amp for 2 seconds or leakage to ground is more than 150mA Power from SP52 energizes the OGF at terminal 12 V The module is grounded by the microprocessor at the OV terminal through microprocessor terminal 1MP15 This power also flows through the OGF normally closed contacts and the S terminal to the GENCONR relay PSCONR relay and microprocessor terminal 2MP26 If an overload or excessive leakage to ground condition exists the OGF contacts open to de energize the relays and stop the flow of power to microprocessor terminal 2MP26 Loss of power at 2MP26 activates the A100 OVERLOAD GROUND FAULT alarm and illuminates the OGF mounted
269. This compact panel can be mounted to suit the individual operator s preferences for example flush mounted inside the trailer near the rear door Refer to Section 3 19 2 for more information on the remote control panel 2 8 4 Remote Control Panel The unit may be fitted with and the remote switch door switch configurations set for an optional remote control 2 9 ENGINE DATA Engine Model NOTE The remote switch door switch configurations may be set for use as individual switches or for use with a remote panel not both V2203L DI E3B CTD 5 26 00128 15 Displacement 135 in 2 2 liters No Cylinders 4 Rated Power 32 hp 24 KW 1800 rpm NOTE Refer to Table 2 1 for engine speed settings Weight 440 Ibs 199 6 kg Coolant Capacity 2 U S gallons 7 6 liters 50 50 mix ethylene glycol antifreeze with inhibitors never to exceed 60 40 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 60 6 con centration of anti freeze Use a low silicate anti freeze meeting GM specifi cations GM 6038M for standard life coolant or use Texaco Havoline ex tended life coolant or any other extended life coolant which is Dexcool ap proved and has 5 150 5 years 150 000 miles on the label Thermostat Starts to open
270. To See If DS1 Has Activated Inspect device used to activate DS1 For example Compartment door must be closed and switch must be de activated Check DOOR SWITCH Configuration Verify that Configuration is set for the type of switch being used i e when Switch is activated switch contacts are closed etc Configuration must agree with switch type Refer to DOOR SWITCH Configuration Table 5 2 Check Wiring a Visually inspect wiring to DS1 Wiring must be connected b Visually inspect condition of switch Must not be damaged wet corroded etc c Check circuit See wiring schemat ic Section 10 With the switch contacts closed check for 12 VDC through the wiring and switch to the correct micropro cessor terminal refer to applicable wiring schematic Section 10 Temporary Solution Tip In the event of a defective switch that can not be repaired or replaced and the switch is forcing the unit into a Shutdown this alarm may be tem porarily overridden by setting the correct Functional Parameter In the Functional Parameter list set OVERRIDE REMS1 SHUTDOWN to YES IF A SWITCH IS NOT INSTALLED Locate and inspect 10 position con nector for optional sensors and switches REMSN see wiring sche matic Section 10 7 45 Connector must have cap on No corrosion or moisture inside connector If there is a problem with the connector and there are no
271. To place the microprocessor in the Technicians Interface Mode a Place the Main Power switch in the OFF position b Locate the serial download port item 14 Figure 2 3 remove the protective plug to gain access to the wire terminals c Plug in a Configuration Jumper or install an insulated jumper see Figure 5 1 NOTE For units equipped with a switch labeled ENGINE OFF STANDBY DOES The DOES may be placed in either the ENGINE or STANDBY position to enter the technician in terface mode If actual operation of the high voltage components i e the evaporator fan motor is desired the power plug is to be con nected and then the DOES is to be placed in the STANDBY position when entering the techni cian interface mode For units equipped with a switch labeled START RUN OFF SROS The switch labeled STANDBY ENGINE DES may be placed in either the ENGINE or STANDBY position to enter the technician inter face mode If actual operation of the high voltage components i e the evaporator fan motor is desired the power plug is to be con nected the DES is to be placed in the STANDBY position and then the SROS is to be placed in the START RUN position when enter ing the technician interface mode Place the Main Power switch in the desired position The alarm LED will come on the setpoint will display but the refrigerated compartment temperature will not and REMOVE JUMPER will display for 10 seconds Remove th
272. Trailer Refrigeration a gt OPERATION amp SERVICE MANUAL for VECTOR 6600MT Multi Temp Trailer Refrigeration Units With Advance Microprocessor 62 11524 Rev A Change 09 11 TRANSICOLD OPERATION amp SERVICE MANUAL for VECTOR 6600MT Multi Temp Trailer Refrigeration Units With Advance Microprocessor TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY PRECAUTIONS 1 1 Td SAPEIY PRECAUTIONS up S anes 1 1 12 SPECIFIC WARNING AND CAUTION STATEMENTS 1 2 USS 1 6 UNIT DESCRIPTION oru RARE ERA TEE 2 1 21 INTRODUCTION 322355913 stni kE ES desee due d aae d epp ted 2 1 22 GENERAL DESCRIPTION 2 1 23 CONDENSING SECTION p ERES 2 9 mE ERE 2 9 CER MEZ gel o Em NC rece 2 9 2233 IS Ier CEU 2 9 Engine Speed Control Unit gno ek x kee qae ness 2 9 Actuation PSA Lass ea DERE EUER ORAE HEC Rae UE RC DR A 2 9 c Engine Speed Sensor ENSON iu sec sek a cem duo RUE V RR RUE 2 9 d Engine Oll Pressure Switch ENOPS eb icem cene as 2 9 e Engine Coolant Temperature Sensor ENCT 2 9 2 9 235 DONDSSBOl dpa ap ide ad occi op d ot dup 2 9 beads
273. Trip Start places the present time and date as a stamp in the DataLink data recorder memory to allow easy review of the data from the last trip and to allow downloading data from a specific trip A trip begins at a Trip Start and ends at the next Trip Start 62 11524 3 14 3 11 VIEW ACTIVE ALARMS ALARM LIGHT HEAT COOL DEFROST ALARM START STOP CONTINUOUS 20 4 1 SETPOINT BOX TEMPERATURE NO ACTIVE ALARMS Press the ALARM LIST key If there are no active alarms NO ACTIVE ALARMS will display for 5 seconds If there are active alarms the alarm number will be displayed with the letter A in front and the alarm message following The last alarm that occurred will be the first alarm displayed and so on Press the ALARM LIST UP ARROW key to scroll through the list of alarms 4 When you reach the end of the alarm list LIST END TO CLEAR ALARMS is displayed for five seconds 5 To clear the alarm list press the key while LIST END TO CLEAR ALARMS is being displayed ACTIVE ALARMS LIST CLEAR is displayed This will move all Alarms to the Inactive Alarm list Alarms are stored in the Alarm List in the micropro TIP cessor Stored alarms may be viewed in the Message Another way to clear active alarms is to turn the Center microprocessor OFF and then back on using For a complete list of alarms their meanings and trou the Main Power switch bleshooting refer to Section
274. Unit Data Enter the correct number in Configurations Refer to Section 5 2 1 Check For Flash Code On Engine Speed Control Unit ENSCU Check for flash codes on the ENSCU Refer to ENSCU LED Fault Chart Section 9 5 must be no LED alarm codes occurring to continue Check Fuel Speed Actuator Check plunger on fuel speed actuator Must move in and out freely Spring tension must hold rod firmly extended and in place Check Fuel System a Check for Alarm 1 Fill tank as needed b Check fuel flow Unrestricted fuel flow through system Fuel not gelled c Check fuel system prime No air in fuel system Check Engine Air Intake System a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Force Low Speed Operation a Using Functional Parameters set the High Speed Delay for at least 10 minutes so the unit starts in low speed Unit will run in low speed RPM must be within range shown above for each specific model Refer to ENSCU LED Fault Chart Section 9 5 must be no LED alarm codes occurring to confinue b Check operation of Speed Relay LED LED 27 must be OFF when the microprocessor is calling for Low Speed Additional steps on the next page 7 31 62 11524 Steps Alarm Cause Corrective Action CHECK ENGINE RPM Con
275. V is opening SLEEP MODE OFF ON TO WAKE The unit is cycled off in Sleep Mode Place the Main Power switch in the OFF position then back to the desired position to wake the microprocessor up SLEEP WARNING DOOR OPEN The unit is configured for Rail Mode and the unit is in Sleep Mode and a refrigerated compartment door is open The unit will start as needed for Sleep Mode SLEEP WARNING NO TEMP CONTROL The unit is running in Sleep Mode to charge the battery and in Engine Operation warm the engine coolant It is not running to provide temperature control SLEEP WARNING REMS1 2 OPEN The unit is configured for Rail Mode and the unit is in Sleep Mode and a remote switch is open The switch may be connected to a refrigerated compartment door or to a remote control switch The unit will start as needed for Sleep Mode SMV CLOSING WAIT XXX SECONDS Power Up and the CSMV is closing XX indicates the number of seconds remaining until valve is fully closed START STOP LOCKED The setpoint has been locked into Start Stop Operation Continu ous Run can not be selected START STOP MODE SELECTED Start Stop Operation has been selected STATUS OK COMPARTMENT X The compartment X 1 OR 2 is operating correctly TECHNICIAN RESET REQUIRED A21 AL11 Low Engine Oil Pressure or AL12 High Coolant Temperat ure has been activated three times in the last two hours and the unit has been
276. VAC Check Compartment 2 Evaporator Motors Disconnect power plug at motor Test IP circuit for continuity using ohmmeter If open remove and replace motor If closed then an intermittent IP circuit is suspect Check phase to phase and phase to ground for short or open circuits If motor tests good check the DC IP circuit to microprocessor Perform Pretrip Check Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding 62 11524 7 68 Alarm Cause Corrective Action 102 EVAP MOTOR OVERHEATED One or more of the 3EVM1 2 3 4 Internal Motor Protectors IP is open UNIT CONTROL Engine and Standby Operation Compartment 3 shutdown only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Compartment 3 Evaporator Motor Contactor a Inspect the three contacts behind the top cover If the contactor buttons are blue due to chattering caused by a defective IP replace the contactor b Check tightness of the contactor wire connections
277. WARNING Always place the Power switch in the OFF position and turn off the high voltage power supply before disconnecting the high voltage power plug from the unit 60 O G O O O HEAT COOL DEFROST ALARM START STOP TINUOU unit off SETPOINT BOX TEMPERATURE To stop the unit place the 2nd Compartment Run switch C2 and or 3rd Compartment Run switch C3 in the OFF position as required and then place the Main Power switch in the OFF position The diesel engine or compressor will stop and the micro NOTE processor will display MICRO WILL STOP IN The microprocessor will close the Electronic SECONDS At the end of the countdown time the Mi Expansion Valve EVXV and the CSMV to 0 croprocessor Main Display MessageCenter and all in open before turning off dicator LEDs will then turn off NOTE Due to internal processing within the micropro cessor turning the Main Power switch off then back on will result in a 4 to 50 second delay be tween the display going off and coming back on again 62 11524 3 26 3 18 DataLink DATA RECORDER T
278. WHT DISP 3 RED DISP 4 GRN DISP 7 BLU DISP 5 BRN DISP 6 ORN DISP 8 YEL Unused terminals None 10 9 62 11524 10 2 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED START RUN OFF Continued Component Terminal 1DTT B 1DTT A 1SAT A 1SAT B EVOT A EVOT B 1RAT A 1RAT B EVXV A EVXV B EVXV C EVXV D EVXV E EVOP A EVOP B EVOP C Unused terminals None Component Terminal 2MP 18 FSA 1 ESSN S SP3 HC 2 STARTER MOTOR SP6 GND SP5 ENSSN 12V FSA 2 Unused Terminals 1 2 4 5 6 8 9 11 12 14 15 17 20 21 22 23 Qo JU ZzzETr ACIQOTImUoOQOU 62 11524 10 10 10 2 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED START RUN OFF Continued 2EVC HC Plug 22 04191 10 Control Box Side 1 10 0 170 O 1e Component Terminal 3MP18 SP5 2CA B 2CA C Component GND 2 OGF OV HC 1 SP45 MPQC 3 OC G MPQC 1 SP12 MPQC4 1MP33 RCR 2 1MP8 SSR 87 5 42 SP60 C6 D F5 B Unused terminals None GPR 87 2CA S 5197 22 50078 03 RCR 3 SP52 SP61 Unused terminals 5 6 9 10 amp 13 zirXcirag
279. XPANSION VALVE open of EVXV START MODE AUTO if the engine will start automatically MANUAL if the engine must be started manually INSTALLED OPTIONS This is only displayed when one or more options is configured ON Lists installed options Press to access the list SOFTWARE REVISION Revision of the software that is operating the microprocessor DISPLAY SOFTWARE REV Revision of the software that is operating the display CONTROL SERIAL Serial Number of the microprocessor TRAILER ID ID as configured by the user UNIT SERIAL Unit serial number UNIT MODEL Unit model number C2 EVAPORATOR Model number of the evaporator unit installed in Compartment 2 EVAPORATOR Model number of the evaporator unit installed in Compartment 3 HOURS TO ENGINE This is only displayed when the meter is configured ON Number of en MAINTENANCE gine hours until the next programmed engine maintenance HOURS TO S B MOTOR This is only displayed when the meter is configured ON MAINTENANCE Number of hours until the next programmed electric standby motor main tenance 62 11524 3 18 Table 3 1 Unit Data Continued Displays information or setting entered in the microprocessor Configurations May or may not be displayed depending on Parameter Configuration settings HOURS TO UNIT This is only displayed when the meter is configured ON Number of MAINTENANCE switch on hours until the next programmed general uni
280. Y AIR SENSOR 7 77 124 CHECK DEFROST TERM 1 SENSOR iiitr is iri iri 7 78 125 CHECK COMP DISCHARGE SENSOR 7 79 126 CHECK FUEL SENSOR CIRCUIT 7 79 127 CHECK SUCTION TEMP SENSOR 7 80 128 LOWUNBALANCED NC AMPS REA 7 80 129 CHECK ENG COOLANT SENSOR D IE EES e es 7 81 130 CHECK ENGINE RPM SENSOR iira 7 82 141 CHECK EVAP TEMP SENSOR rd od aol pool Ge qure Pod be dup aoo 7 83 123 CHECK REMOTE TEMP SENSOR AOI dnbio 7 84 194 CHECK REMOTE TEMP SENSOR Z EC c PORE 7 84 198 CHECK SUPPLY AIR SENSOR 7 85 jay OS CHECK RETURN AIR SENSOR Od LU t pde DERE Up 7 86 188 CS CHECK RETURN AIR SENSOR 7 87 139 C2G HECK DEFROST SENSOR ek rre OR CIE 7 88 HU Gos CHECK DEFROST SENSOR EC OH ER REI ERR CO e 7 89 TOFREITRIPF BLA LAT 7 90 PIAI PHEIBIF SIOPPED BY UGER bes MUR RUNE bade ook 7 90 P144 CHECK ULI CIRCUIT ER 7 90 CRECK SPEED SOL GIRGUIT
281. YEL H A aus 05 FUSE HEATERS QUICK BLOW 4 15 FUSE REMOTE COMPARTMENTS 12 ce 5 5 5 C lt GNDSLP TH F13 F14 F15 C16 F16 FUSE 2CPT REMOTE DRAIN HTR 6 DAS 17 1H 2 15 14 F13 2 12 Pe F26 27 28 FUSE FANS 1 TIME DELAY 3Mp29 TRI 114 FLS FUEL LEVEL SENSOR OPTIONAL SP3 SPIS UPPER Cilk 43 1 L3 B B 115 FUEL PUMP OPTIONAL T 2MP29 FSA FUEL SPEED ACTUATOR HEATER 214 515 GENERATOR CONTACTOR 5 08 SP52 57 814 vi 15 GENCUNR GENERATUR CUNTACTUR RELAY t 2 3 Ren 2MP26 GEN GENERATOR Ji C COMPARTMENT 2 SETCONI 16 78 GPR GLOW PLUG RELAY 7 at YT FSR C7 HIGH DISCHARGE PRESSURE SWITCH 2 16 Ss 39 04 1 CONTACTOR IMP30 SPK7 gt zT 4906 1HTCON2 1 HEATER CONTACTOR o o zeve c 2MP13 IMP28 5 9 Org zm NS HTRI HEATER 1 t Su REMS2 z J1 empen 1MP13 5MPA10 5 E 2 2HTRI 210 1 72 BHTCONI BND ELMPARTMENT HEATER 1 CONTACTOR SMPALL 4 2 0 COMPARTMENT HEATER 2 CONTACTOR 2ND COMPARTMENT HEATER 1 L 2MP32 N8 2ND COMPARTMENT HEATER 2 2 19 4 1 SP DE TON 60 EONA K16 IAH INTAKE AIR HEATER 2MP23 AMPS T gt 8m IPC INTERNAL PROTECTOR COMPRESSOR To RS KTK
282. a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check For Low Fuel Level Check fuel level in the fuel tank Add fuel as needed to the fuel tank Check Fuel Level Sensor Refer to procedure for Alarm 126 7 3 62 11524 Alarm Cause Corrective Action 7 4 SHUTDOWN ALARMS 11 LOW ENGINE OIL PRESSURE TRIGGER ON Engine oil pressure is below 12 psig 0 82 bar for longer than 5 seconds while the engine is running UNIT CONTROL Engine Operation Shutdown and alarm Standby Operation Will not activate in standby RESET CONDITION Auto Reset or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the active alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active active alarm occurs Continue with the steps below as necessary 1 Check Engine Oil Level Check engine oil dipstick Add engine oil as needed Check Engine Oil Pressure Switch Wiring a Inspect switch amp connector pins amp terminals No physical damage to switch No damage or corrosion in connector b Check switch circuit
283. above the suction pressure when in alarm only for either trigger or auto reset after Minimum Off Time Functional Parameter setting when shutdown is configured or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Verify Compressor Is Running Check compressor amp draw on all three legs Readings must be in the range as shown in Section 2 12 Check System Pressures Install manifold gauge set and check and compare compressor discharge amp suction pressures with those shown on the microprocessor dis play Suction pressure must be above 3 psig 0 2 bar Discharge pressure must be more than 5 psig 0 3 bar higher than the suction pressure Suction amp Discharge Pressures must have the same reading on gauges amp on microprocessor display NOTE Microprocessor suction CSP and evap orator EVOP pressure readings have a maxi mum value of 100 psig 7 5 bar The actual suc tion pressure must be lower than 100 psig in or der to perform this test Perform Pretrip Check Clear Active Alarm list then run Pre trip amp check for any new alarms Any active alarms must
284. age moisture or corrosion in connectors 62 11524 Nm Alarm Cause Corrective Action 111 CHECK SEVCON RELAY COIL TRIGGER ON Evaporator fan motor contactor circuit is shorted The contactor output from the microprocessor 3 08 is negative so the circuit will not be shorted to ground but is shorted either within the contactor coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 3EVCON a Inspect compartment 3 evaporator No damage to coil fan contactor coil and terminals No damage or corrosion b Check coil resistance Cannot be opened infinite ohms Shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check 3EVCON Current Draw Use Component Test Mode to test Refer to Section 2 13 for correct electrical values actual current draw of the circuit View current draw in Data List Refer to Section 5 2 2 Check SEVCON Wiring Inspect harness amp control bo
285. ageCenter will be displayed in Portuguese NOTE 1 This parameter can be quickly accessed by pressing and holding the Select Key for 6 seconds NOTE 2 If the padlock is visible when accessing language from the Functional Parameter List the language cannot be changed However when accessing the language by pressing and holding the Select Key for 6 seconds the language can be changed even if the padlock is displayed 3 24 3 16 LANGUAGE SELECTION HEAT COOL DEFROST ALARM START STOP CONTINUOUS 20 34 1 SETPOINT BOX TEMPERATURE ESPANOL ay MANUAL ALARM LIST ELECT Y DEFROST CONTINUOU vi 1 Press hold the SELECT key for 6 seconds until Mes sageCenter displays the current language ENGLISH ESPANOL FRAN AIS or PORTUGUES 2 Press the UP or DOWN ARROW key until the MessageCenter indicates the de sired language Press the key The new language will now be active If the key is not pressed within 10 seconds the MessageCenter will change to FUNCTION NOT CHANGED This will flash for 5 seconds then return to the current language If no further keys are pressed the default display will return in another 10 seconds TIP If the language is set to one that the user does not understand press and hold the SELECT key for 6 seconds to bring up the Language Parameter so that it can be changed 3 25 62 11524 3 17 STOPPING UNIT
286. al is set for your requirements b Reset General Maintenance Hour Meter for the next service interval Must be done soon Follow instructions on proper maintenance form Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 226 SERVICE SOON PM 1 DUE TRIGGER ON The Maintenance Hour Meter 1 time has expired e UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad 1 Check Unit Maintenance Records Schedule unit into service facility for maintenance Must be done soon Perform Maintenance Perform appropriate engine amp unit maintenance Follow instructions on proper maintenance form Reset Maintenance Hour Meter 1 62 11524 a Check that Maintenance Hour Meter 1 interval is set for your requirements Reset configured Interval if required b Reset Maintenance Hour Meter 1 for the next service interval Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 7 130 Alarm Cause Corrective Action 227 SERVICE SOON PM 2 DUE TRIGGER ON The Maintenance Hour Meter 2 time has expired e UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad 1 Check Unit Maintenance Records Sched
287. all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during Test 3 by holding Key for 6 seconds d Review active alarm list for Alarm If alarm is present follow steps 2 thru 4 If alarm is 188 not present follow steps 5 thru 10 Check 1HTCON2 Inspect heater contactor coil and No damage to wire connections No damage moisture or corrosion in connections b Check contactor coil resistance Refer to Section 2 13 Check 1HTCON2 Amp Draw Check 2 amp draw Use Component Test Mode Section 5 2 2 to test Refer to Section 2 13 for correct electrical values View current draw in Data List Check 1HTCON2 Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Check Evaporator High Temperature Switch EVHTS Inspect for open EVHTS per wiring If open replace switch as required schematic Section 10 Additional steps on the next page 7 117 62 11524 Steps Alarm Cause Corrective Action CHECK HEATER 2 CIRCUIT Continued 6 Check Amp Draw of 1HTCON2 Heater Circuit a With the unit running and calling for pull up in Compartment 1 use a clamp on ammeter to check the cur rent draw of all 3 legs Must be within range shown in Section 2 12 for all th
288. amp test again Replace ENSSN Did you find and correct the condition Remove new ENSSN and re install old ENSSN back into unit ENSSN is not the fault Review results of above tests with your supervisor If necessary go to the beginning of the tree amp test again Figure 9 2 ENSCU Diagnostic Tree 2 Long 1 Short LED Code 62 11524 9 10 START HERE Does the engine starter engage amp turn the engine over Go to Advance Micro diagnostic tree Figure 9 6 YES Verify the proper voltage going into FSA terminal 1 12 VDC when Check for high resistance or an open on the FSA ground circuit terminal 2 Did you find and correct the condition Using jumper wire are the proper voltages present NO 4 YES Main Power switch is at ENSCU terminal 7 first turned on for the pull in voltage 1 VDC for hold in voltage amp 0 8 VDC YES during starter engagement YES Do you have the correct NO voltage m o YES EN Replace ENSCU Did you find and correct the condition Check for open or high resistance on circuit between FSA and ENSCU With the FSA disconnected check the resistance of the FSA coil Spec is Did you find and correct 2 8 ohms 10 the condition Is ohm reading within spec NO YES Remove the FSA from the NO
289. and flywheel Locate them and turn the engine to line up the guide rods in the crankshaft with the off set holes in the generator rotor NOTE The generator rotor does not turn in the stator 9 Slide the generator rotor over the guide rods and 1 Bolt Stator 7 Bolt Rotor mate the stator with the spacer installed in step 3 2 Washer Stator 8 Stator Ensure the dowel pins in the bell housing are fully en 3 Fan Cover 9 Spacer gaged in the stator 4 Fan Mount Bolt 10 Rotor NOTE 5 Fan Mount Washer 11 Generator Leads The generator should slide freely on the guide 6 Fan 12 Grommet rods if the holes in the generator rotor are Figure 8 40 Generator Assembly matched correctly with the crank shaft holes therwise it will bi the stat ill not 1 Verify the existence and condition of the two original M bine Ep ene mate properly with the spacer dowel pins in the bell housing See Figure 8 41 CTD P N 34 06210 00 not included in the kit The 10 Using new screws DO NOT reuse old screws in pins are to be installed with the chamfer facing out stall three screws and three washers to the rotor and tighten NOTE The screws will be torqued later 11 Remove the guide rods and assemble and tighten the remaining three rotor screws and washers NOTE The screws will be torqued later 12 Install and tighten three stator screws and two wash ers with each screw in the following locations One in five o clock
290. anking Check voltage output at alternator Is voltage 26 VDC or higher Remove new ENSCU and re install old ENSCU back into unit ENSCU is not the fault Review results of above tests with your supervisor If necessary go to the Starting at terminal 13 at the ENSCU check circuit for induced voltage creating the 26 VDC signal Did you find and correct the condition YES E Replace alternator Did you find and correct the condition NO Remove new alternator and re install old alternator back into unit alternator is not beginning of the fault Review the tree amp test again results of above tests with your supervisor If necessary go to the beginning of the tree amp test again Review results of above tests with your super visor If necessary go to the beginning of the tree amp test again Figure 9 4 ENSCU Diagnostic Tree 2 Long 7 Short LED Code 62 11524 9 12 9 6 Microprocessor Diagnostics The purpose of the following procedure is to provide a logical and straightforward guide to be used when dia gnosing operational or other problems occurring with the microprocessor Often users and technicians have mistakenly worked to correct a problem that has ended up being normal operation The microprocessor has several different conditions contributing to operating pa
291. ar TEMPERATURE SWITCH p HIGH TEMPERATURE SW d 6 ORG 6 110 EVAPORATOR OUTLET PRESSURE TE RANSDUG ER 6MP7 7 C15 EVAPORATOR OUTLET TEMPERATURE SENSOR ale pe pud YEL H 1HTCDNI 79 EVXV ELECTRONIC EXPANSION VALVE 8 A TM G4 F1 FUSE PDWER 7 5 AMP ORS 3MP5 11 ED H15 F2 FUSE SPEED RELAY 10 AMP DAS 3MP17 3 F13 F14 F15 HD FUSE RUN RELAY 75 AMP 5 2CP FUSE MAIN 80 AMP i SP15 ere HTRL iB 205524 D4 F6 FUSE MICRO POWER 15 2 29 3MP13 UPPER COIL T 3 E paste BATTERI CHARGER 5 AMP TIME DELAY CONTACTORS 10 AMP OPTION SMPB 05 F10 11 12 FUSE HEATERS 12 AMP TIME DELAY By e R7 F13 14 15 FUSE REMOTE COMPARTMENT 12 AMP TIME DELAY DS A DSB 16 2MP26 9 16 F16 FUSE 2 REMOTE DRAIN HTR 5 AMP DS GENCONR SP61 B16 F19 9 7 2 FUSE FUEL HEATER 20 F26 27 28 FUSE FANS TIME DELAY OC H 0 2 2 1 PSCONR K16 FH FUEL HEATER SP6 CPT1 REMS1 0 5 7 2010 1 4 4 5 15 FHR FUEL HEATER RELAY 2EVC M 2EVC G 0C D 2MP13 SMP9 TAH 2 1 016 FHTS FUEL HEATER THERMOSTATIC SWITCH CPT2 REMS2 4 lt 8 86 SE X33 c 3 4 Lig FLS FUEL LEVEL SENSOR lt DPTIONAL EVAP 2 FUEL PUMP OPTIONAL D 2MP8 5 HEATER FSA FUEL SOLENOID ACTUATOR OMP32 MP11 261
292. ard UNKNOWN CARD CARD LOCKED REMOVE CARD CARD FULL REMOVE CARD MessageCenter has addition PC Card error messages Doesn t acknowledge that a PC Card has been inserted PC Card may be defective Try a different card Did you find and correct condition NO Y If you have tried 2 or more PC cards on one particular micro take those same suspect PC cards and try them on another micro If the cards function properly on the second micro it proves the first micro is not reading the PC cards properly Is the micro at fault The card Write Protect switch is ON Unlock PC Card by sliding Write Protect switch to the OFF position amp re insert the card Operate the System in order to verify the repair Download card has no more empty memory space Use ReeferManager to extract downloaded data amp then erase card Operate the System in order to verify the repair Refer to Section 6 1 for a list of MessageCenter error messages Find your specific error mes sage and follow the di rections in the descrip tion column Repair as needed Operate the System in order to verify the repair PC Card is not seated properly Remove card from slot wait 10 seconds amp re insert card Did you find and correct the condition
293. arries an explanation is given with the appropriate consequences DANGER warns against an immediate hazard which WILL result in severe personal injury or death WARNING warns against hazards or unsafe condi tions which COULD result in severe personal injury or death CAUTION warns against potential hazard or unsafe practice which could result in minor personal injury or product or property damage The following statements are specifically applicable to this refrigeration unit and appear elsewhere in this manual These recommended precautions must be un derstood and applied during operation and maintenance of the equipment covered herein WARNING Advance microprocessor equipped units may start automatically at any time the Main Power switch is not in the OFF position Also the unit may be fitted with two way communication equipment that will allow starting of the unit from a remote location even though the switch is in the OFF posi tion WARNING aware of HIGH VOLTAGE supplied at the power plug or from the generator When performing service or maintenance proced ures ensure any two way communication is disabled in accordance with the manufac turer s instructions ensure the Main Power switch is in the OFF position and whenever practical disconnect the high voltage source lockout tagout the receptacle and disconnect the negative battery connec tion NEVER dis assemble the generator HIGH MAGNE
294. arting 8 3 2 Pre Trip Inspection after starting 8 3 3 Run Microprocessor Pretrip Before loading 3 4 4 Check Engine Hours 14 b Every Service Interval or Yearly Engine 1 Check engine oil and filter change interval refer to Section e Section e of this table 2 Check low oil pressure switch Check 3 Clean crankcase breather 8 5 14 4 Check engine speeds Table 2 1 5 Check water pump belt Check Fuel System 1 Clean mechanical and electric if equipped fuel pump screens 8 5 3 amp 8 5 4 2 Change fuel filter 8 5 5 3 Check fuel heater if equipped 8 5 7 Cooling 1 Check coolant change interval refer to Section f of this table 8 5 12 System If replacement is not required check antifreeze concentration using a refractometer Carrier Transicold part number 07 00435 00 8 5 12 2 Clean condenser amp radiator surfaces Check 3 Check water pump Check 4 Check water temperature sensor Exhaust 1 Check mounting hardware Check System 2 Check muffler and exhaust pipes Check Air Intake 1 Change air cleaner filter element 8 5 9 System 2 Check and reset air filter indicator if equipped Check Starting 1 Clean battery connections and cable ends Check Replace Circuit 2 Check battery hold down clamps Check Replace 3 Check battery condition Check 4 Check starter operation Check Charging 1 Check battery charger output voltage 2 12 Circuit 2 Check battery charger amperage 2 12 A C 1 Check voltage output 12 Generator 2 Check amperage output 2 12 Unit 1 Che
295. ata recorder date and time were not set earlier they can be set from this screen by clicking on Tools Set Date and Time 5 7 7 Microprocessor Final Checkout a Start the unit and allow it to run for a few minutes b While the unit is running scroll through the Data List of the microprocessor Verify that all the data is now accurately displayed Initiate a Pretrip test Allow the unit to complete the Pretrip and check for any alarms Make any neces sary repairs before returning the unit into service 62 11524 Table 5 2 Microprocessor Configurations NOTE Configurations are presented at the beginning of the list and progressing using the green UP arrow key AE Seecions Unit Family types Indicates to the microprocessor the model number and then a list of of the unit There are several model numbers UNIT MODEL NUMBER configurable model provided in the list Scroll to the Vector Family numbers entries and select the model number printed on the Model Serial Number nameplate 5200 The evaporator model installed in Compartment 2 is 2200 entered C2 EVAPORATOR MHD1100 MHS1100 The evaporator model installed in Compartment 3 is 1100 entered C3 EVAPORATOR MHD2200 MHS2200 The unit S N may be entered This may be up to 10 UNIT SERIAL NUMBER characters long Numbers Letters and a space are available by scrolling through the available list The ID may be entered This may be up to 10 TRAIL
296. ate and time the unit is to automatically wake up The wake up time must be at least 1 hour and no more than 8 days from the time the clock is set The following information can be entered Month 1 to 12 Day 1 to 31 Year 1998 to 2037 Hour 0 to 23 Minute 0 to 59 NOTE The clock is a 24 hour clock Hours 1 thru 12 are AM and hours 13 thru 24 are PM 2 RUN PRETRIP TEST AT WAKE a When PRETRIP TEST AT is set to NO the unit will wake up at the designated time and con trol to setpoint b When PRETRIP TEST AT is set to YES the unit will wake up at the designated time automat ically run Pretrip and then control to setpoint PRE TRIP PASS FAIL will remain in the MessageCenter until it is manually cleared If Sleep Mode is selected with the switch the ENGINE position when the unit is not running during a Start Stop Off Cycle any remaining Minimum Off Time will be ig nored and the engine will start It will run for 4 minutes minimum until the engine coolant temperature is above 50 C 122 F and the battery is fully charged O K displays in the Data List voltage line and charging amps are less than the configured setting While the unit is running in Sleep Mode SLEEP WARNING NO TEMP CONTROL will flash in the MessageCenter and the main display setpoint and compartment temperat ures will be off 62 11524 If the unit is already running when Sleep Mode is se lec
297. ates defective GENCON coil No voltage check GENCONR Check GENCONR Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 7 125 62 11524 Alarm Cause Corrective Action P209 CHECK STANDBY CONT CIRCUIT TRIGGER ON Normal amps for the PSCONR relay coil and PSCON or PSCON2 contactor coils 0 0 to 1 0 Amps 12 VDC The circuit s test outside this range During this test either PSCON or PSCONe will be tested depending on the phase reversal module UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary NOTE IF PRETRIP IS DONE IN STANDBY MODE THIS PRETRIP ALARM WILL GENERATE MANY OTHER PRETRIP ALARMS THEREFORE IT SHOULD BE ADDRESSED FIRST 1 Check PSCONR Inspect PSCONR PSCON and PSCON2 contactor coils and wire connections No damage to coils No damage moisture
298. ation Skip to Step 11 any leaks are found they must be repaired before proceeding 10 Repeat steps 4 thru 9 as necessary 11 Evacuate the system after all leaks are repaired Refer to Section 8 6 4 Leak Checking With Low Side Pumped Down The low side of the system must be leak checked once it is closed and all repairs complete 1 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle CAUTION Only a refrigerant cylinder containing R404A should be connected to this refriger ation unit in order to pressurize the system However dry nitrogen may be used to in crease pressure Any other gas or vapor will contaminate the system and require addi tional removal and evacuation 2 Connect refrigerant system equipment if not already connected Refer to Figure 8 18 62 11524 CAUTION Do not vapor charge R404A Only charging through the liquid line service valve is acceptable 3 Ensure that the microprocessor MessageCenter dis plays RECOVER LEAK CHK EVAC during the pressurizing and leak checking procedures Re fer to Section 5 2 3 If the microprocessor switches to charge mode during the process switch it back to the RECOVER LEAK CHK EVAC MODE 4 Pressurize the low side of the system to 5 to 10 psig
299. ator compressor receiv er and remote evaporator above 60 F 15 6 C to speed evaporation of moisture If the temperature is lower than 60 F 15 6 C ice might form before moisture removal is complete Heat lamps heat guns or alternate sources of heat may be used to raise sys tem temperature The recommended method to evacuate the system is to connect three evacuation hoses with vacuum pump and vacuum indicator see Figure 8 18 Ensure that the microprocessor MessageCenter dis plays RECOVER LEAK CHK EVAC MODE during the evacuation and dehydration procedures Refer to Section 5 2 3 If the microprocessor switches to charge mode during the process switch it back to the RECOVER LEAK CHK EVAC MODE Leave the liquid line service valve and the discharge service valve frontseated and then midseat the suc tion service valve Start the vacuum pump Evacuate unit until the elec tronic vacuum gauge indicates 2000 microns Close the vacuum pump valve and shut off the pump Wait a few minutes to be sure the vacuum holds Break the vacuum with dry nitrogen through the liquid line service valve Raise system pressure to approxi mately 2 psig 0 1 bar Ensure that the micropro cessor does not switch to the Charge Mode If this oc curs switch it back to the RECOVER LEAK CHK EVAC MODE Refer to Section 5 2 3 Purge nitrogen from the low side of the system at the suction service valve Open the vacuum pump valve a
300. ature readings from the supply if applicable and return temperature sensors to determine the mode of operation required to maintain compartment temperature in accordance with the setpoints The sensor used for temperature control is dependent on the selection made in the TEMP CONTROL functional parameter selection is RETURN AIR the return air sensor RAT will be used for any setpoint e the selection is SUPPLY AIR the microprocessor will switch to the supply air sensor SAT when operating with a perishable setpoint refer to Section 4 3 2 for more information on frozen and perishable setpoints and the return air sensor will continue to be used for frozen setpoints The modes of operation include Pulldown Pull Up Cooling Heating and Null NOTES 1 The compressor is always started with both unloaders energized unloaded After 10 seconds of operation for UL1 or 1 minute of operation for UL2 they are allowed to transition to the unloader state required for the present mode of operation The condenser fan will operate any time the engine or compressor is operating If suction pressure is below 100 psig 6 8 bar the evaporator fan in compartment 1 will start 10 seconds after compressor start If suction pressure is above 100 psig 6 8 bar the fan start will be delayed until suction pressure is below 100 psig 6 8 bar or until 20 seconds has elapsed If only one remote compartment is
301. ay communication equipment that will allow starting of the unit from a remote location even though the switch is in the OFF posi tion WARNING aware of HIGH VOLTAGE supplied at the power plug or from the generator When performing service or maintenance proced ures ensure any two way communication is disabled in accordance with the manufac turer s instructions ensure the Main Power switch is in the OFF position and whenever practical disconnect the high voltage source lockout tagout the receptacle and disconnect the negative battery connec tion NEVER dis assemble the generator HIGH MAGNETIC FIELD INSIDE This field can interfere with cardiac implants such as pacemakers and defibrillators 7 INTRODUCTION This section provides guidance for troubleshooting alarms The alarm light will be illuminated when there is one or more alarm s stored in the microprocessor Instructions for reviewing the alarm lists are provided in sections 3 11 amp 3 12 When an alarm occurs look through both Active and Inactive alarm lists in the microprocessor and make note of all alarms Each alarm begins with an A active or inactive followed by an alarm number and description Alarms are listed in this guide by alarm number in ascending order Before beginning to actually troubleshoot an alarm visually inspect the unit in particular the area of the unit that is causing a problem In many cases the cause of the problem wi
302. bar or fails to go below 0 psig bar OR the EVXV appears not to be opening to the full capacity position UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Refrigerant Level Check refrigerant charge Refer to Section 8 6 2 Check System Pressures Install manifold gauge set and check Suction and Evaporator Outlet pressures must be and compare compressor dis above 3 psig 0 2 bar charge amp suction pressures with those shown on the microprocessor Suction Evaporator Outlet amp Discharge Pressures display must have the same reading on gauges amp on microprocessor display NOTE Microprocessor Suction CSP and Evaporator EVOP pressure readings have a maximum value of 100 psig 7 5 bar The actual pressure must be lower than 100 psig in order to perform this test Check EVXV a Visually inspect EVXV for Check to see if coil is seated on valve properly damage Inspect EVXV coil and wire No physical damage to harness
303. be cleaned on a regular schedule such as unit pre trip or when the oil and fuel filters are changed Refer to Section 8 2 Nut Banjo Fitting Figure 8 7 Mechanical Fuel Pump 1 Screen 3 Copper Rings To check or replace Screen a Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Turn nut counter clockwise to loosen and remove it Item 2 Figure 8 7 Remove banjo fitting Item 4 and let it hang loose Discard copper rings Item 3 and replace with new ones Turn screen 1 counter clockwise and remove Check and clean e To install reverse above steps f Start unit and check for leaks 8 5 4 Electric Fuel Pump Screen To check or replace Screen a Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Remove 3 screws from cover See Figure 8 8 Remove cover gasket and screen WARNING Use the required protective eye wear and clothing when working with solvents Wash screen in cleaning solvent and blow out with air pressure Clean cover To Install reverse above steps f Start unit and check for leaks
304. between ENSCU13 and ENSCU19 and between ENSCU24 and ENSCU19 with Run Relay energized d Inspect Fuel Solenoid Actuator FSA amp connector pins amp terminals No damage to FSA No damage moisture or corrosion in connector e Inspect harness amp control box connector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors f Check Splice Pack 6 SP6 See wiring schematic Section 10 No corrosion or oxidation 12 VDC reading to battery cable Check Fuel System a Check fuel system prime No air in fuel system b Check fuel flow Unrestricted fuel flow through system Additional steps on the next page 7 23 62 11524 Alarm Cause Corrective Action FAILED TO START AUTO MODE Continued 6 Check Engine Air intake Heater System This step only applies when the engine coolant temperature is less than 77 F 25 C a Check voltage to heater Must be 11 VDC or higher b Check operation of intake air heater relay CAUTION DO NOT leave the circuit energized for the full 5 minutes if full amperage is shown as the intake air heater element life will be greatly shortened Using Component Test Mode refer to Section 5 2 2 energize the intake air heater relay LED 30 must be illuminated Amperage must be correct refer to Section 2 9 for correct electrical va
305. both Alarm Lists before starting Pretrip The technician will then know that any alarms pres ent following Pretrip occurred during Pretrip and are not old alarms that had not been cleared During the Pretrip test the MessageCenter displays the current test number and description and the of the test that has been completed When Pretrip is complete the MessageCenter will display one of three different messages e PRETRIP PASS OR e PRETRIP FAIL IN TEST X OR e PRETRIP FAILED amp COMPLETE Alarm light will be on Press the ALARM LIST key to review the alarms triggered by the Pretrip tests TIP The Pretrip test PASS of FAIL results mes sage will stay displayed until any key is pressed or until the Main Power switch is placed in the OFF position Once Pretrip is started the control panel keys are dis abled until Pretrip is completed 62 11524 PRETRIP Continued TIP If CAN NOT START PRETRIP is displayed the MessageCenter check to see if the unit is in PC Mode Refer to Section 5 3 or Defrost mode or check the alarm list Section 3 11 for active shutdown alarms NOTE Pretrip will run until completed unless an alarm occurs that causes Pretrip to be aborted Only alarms that will result in other erroneous alarms or will affect future Pretrip tests will abort Pre trip TIP Pretrip may be stopped by the user by either turning the unit off then back on again or by pressing and holding
306. c model Refer to Speed Control System Diagnotics Section 9 5 Clear all fault codes before continuing b Check operation of Speed Relay LED LED 27 must be OFF c Check voltage at engine speed control unit ENSCU 16 Must be 0 VDC Check Engine RPM a Check actual engine RPM using hand held tachometer Refer to Table 2 1 b Compare actual RPM with those shown on display Both readings within 50 RPM Check Engine Air Intake System a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check Engine Fuel System a Check fuel tank level Must have enough fuel to run engine b Check fuel lines Connections are tight and not leaking No kinks or sharp bends in the lines c Check fuel screen Fuel screen is located in the inlet fitting to the lift pump Screen must be clean d Check fuel filters Fuel filters must be clean and allow full flow of fuel through them Check Engine Exhaust System 62 11524 Inspect the exhaust system Must be clear and unobstructed Alarm NO Alarm Cause Corrective Action 38 CHECK HIGH SPEED RPM TRIGGER ON The microprocessor is set for high engine speed operation and engine speed is less than 1650 rpm or greater than 1950 rpm for more than 60 seconds 120 seconds when the m
307. cause severe burns Do not remove the cap from a hot radiator or bottle If the cap must be removed cover it with a rag and remove very slowly in order to release the pressure without spray Refrigerants The refrigerant contained in the refrigeration system of this unit can cause frostbite severe burns or blindness when in direct contact with the skin or eyes For this reason and because of legislation regarding the handling of refrigerants we recommend that you contact your nearest Carrier Transicold authorized repair facility whenever service of the refrigerant system is required Battery This unit is equipped with a lead acid type battery The battery normally vents small amounts of flammable hydrogen gas Do not smoke when checking the battery A battery explosion can cause serious physical harm and or blindness Standby Power Be aware of HIGH VOLTAGE supplied at the power plug Even with the unit off power is present from the plug to the inside of the control box Whenever practical disconnect the high voltage source when performing service or maintenance procedures and lockout tagout the receptacle in accordance with your companies procedures The recommended lockout device Carrier part number 07 60129 00 is shown in Figure 1 1 Figure 1 1 Lockout Tagout 62 11524 1 2 SPECIFIC WARNING AND CAUTION STATEMENTS To help identify the label hazards on the unit and explain the level of awareness each one c
308. ccurs Continue with the steps below as necessary 1 Check For Engine Running Verify that engine is still running Engine should not be running Check For Bad Engine RPM Sensor Alarm Check for Alarm 130 Alarm conditions must be corrected and the alarm cleared to continue Check Engine Oil Pressure Switch a Inspect switch amp connector pins amp terminals No physical damage to switch No damage or corrosion in connector b Check engine oil switch operation Contacts close on a pressure rise at 15 psig 1 02 bar Contacts open on a pressure fall at 12 psig 0 82 bar Check Engine Oil Switch Harness a Inspect harness amp control box connector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors b Check for shorted circuit in harness and continuity through the harness Energize circuit See Note 2 page 7 2 Battery voltage reading 12 13 VDC between wires in plug Check Fuel Speed Actuator FSA amp Circuit a Check Run Relay LED LED 28 must be OFF b Check voltage at harness to ENSCU 0 VDC between ENSCU13 and ENSCU19 and between ENSCU24 and ENSCU19 c Check FSA plunger 7 25 Must be free to move to the stop position extended out of the solenoid 62 11524 Alarm NO Alarm Cause Corrective Action 35 CHECK
309. cess to Component Test Mode CONFIG ERROR REMOVE CARD There was an error configuring the microprocessor with the Config uration PC Card Remove the PC Card from the slot CONFIGS COMPLETE TO EXIT The user has reached the end of the Configurations List Pressing the UP or DOWN ARROW key will start list over Press the key to exit Configuration List CONFIGURATION MODE Press the key to enter Configuration Mode CONFIGURATION NOT CHANGED New configuration selection was not entered saved within the 5 second time limit CONTINUOUS LOCKED The current setpoint is within a range that has been locked into the Continuous Run Mode Start Stop can not be selected CONTINUOUS RUN MODE SELECTED The unit operating mode has been changed from Start Stop to Continuous Run COPY COMPLETE REMOVE CARD XX A DownLoad PC Card has been inserted into the PC Card slot and all data from the DataLink data recorder has been copied onto the PC Card You may safely remove PC Card from the slot XX number of empty download slots remaining on the card COPY ERROR REMOVE CARD XX A DownLoad PC Card has been inserted into the PC Card slot and an error occurred while the data was being copied onto the PC Card You may safely remove the PC Card from the slot XX indicates the number of empty download slots remaining on the card COPYING DATA PLEASE WAIT A DownLoad PC Card has been inserted into the PC Card
310. cessor energizes opens the liquid line solenoid valve 2LSV 3LSV Refrigerant flows from the main liquid line through the LSV to the thermal expansion valve TXV The TXV controls the flow of liquid to the coil s according to changes in superheat of the refrigerant leaving the evaporator 2 5 1 Evaporator Coil s The evaporator is a tube in fin type The operation of the compressor maintains a reduced pressure within the coil At this reduced pressure the liquid refrigerant evaporates at a temperature sufficiently low enough to absorb heat from the air The electric heaters 2HTR1 2HTR2 SHTR1 8 2 are mounted on the inlet side of the coil s 2 5 2 Liquid Line Solenoid Valve 2LSV or 3LSV The LSV is energized opened by the microprocessor to allow flow of liquid refrigerant into the coil s when cooling is required 2 5 3 Thermal Expansion Valve TXV The TXV is a mechanical device which controls the flow of liquid to the coil s according to changes in superheat of the refrigerant leaving the evaporator The expansion valve maintains a relatively constant degree of super heat in the gas leaving the evaporator regardless of suction pressure The valve has a dual function auto matic expansion control and prevention of liquid return to the compressor 2 5 4 Remote Evaporator Switches Transducers and Sensors a Evaporator High Temperature Switch 2EVHTS or 3EVHTS An EVHTS is a safety switch which opens on
311. cessor will begin to monitor return air temperature in the perishable compartment s after 5 minutes of priority cooling operation If the temperature within that compartment rises to setpoint the Perishable Priority Temperature Setting Priority Cooling will be suspended 4 7 2 Supply Air Limit Control Supply Air Limit Control is available for Compartment 1 when the setpoint is at or between 32 to 65 F 0 to 18 4 C Compartment 1 is operating in cool and no other compartment is operating in cool Supply Air Limit Control is available for Compartment 2 when an optional supply air sensor is installed the sensor is configured ON the setpoint in Compartment 2 is at or between 32 to 65 F 0 to 18 4C Compartment 2 is operating in cool and no other compartment is operating in the Cool Mode Supply Air Limit Control is not available for Compartment 3 Supply Air Limit is NOT a positive temperature control drift above and below the Supply Air Limit will be seen as the system balances out Control of the actual supply air temperature will be accomplished by varying the position of the CSMV for Compartment 1 or cycling of the liquid line solenoid valve for Compartment 2 Supply Air Limit Configuration values can be set independently for Compartment 1 and Compartment 2 as well as allowing for a different limit for Start Stop than used in Continuous Run Supply Air Limit Control is set using the Perishable Sensitive Product F
312. ch two seconds during the cranking period The engine is considered to be running and the start sequence will be stopped when engine speed is greater than 1000 rpm During the second and third attempts the microprocessor will monitor additional inputs When engine speed reading is less that 1000 rpm ambient temperature is above 32 F 0 C and the ENOPS is closed the A130 CHECK ENGINE RPM SENSOR alarm will be activated and the engine will be considered running When engine speed reading is less that 1000 rpm ambient temperature is below 32 F 0 C the ENOPS is closed and DC current is more than 2 amps the A130 CHECK ENGINE RPM alarm will be activated and the engine will be considered running Once the engine is considered running the microprocessor will keep the intake air heater energized for an additional O to 180 seconds of Post Heat depending on engine coolant temperature refer to Table 4 1 During the start sequence the microprocessor monitors engine speed while cranking If engine speed drops below 50 rpm for three seconds the starter solenoid contactor will be de energized and the A35 CHECK STARTER CIRCUIT alarm will be activated If the unit fails to start after three start attempts the A31 FAILED TO START AUTO alarm will be activated 62 11524 If the unit is equipped with a fuel heater the microprocessor will monitor ambient temperature If ambient is below 77 F 25
313. charge pressures rise rapidly the liquid line service valve requires replace ment before the compressor can be further tested Backseat the liquid line service valve and restart the unit Slowly frontseat the suction service valve Shut down the unit when the suction pressure drops to 2 psig 0 2 bar Monitor the gauges If the suction and discharge pressures do not equalize rapidly the compressor is not at fault d Check condition of and repair cylinder heads and valve plates Refer to Section 8 7 3 8 7 2 Removal and Replacement of Compressor a Pumpdown the compressor Refer to Section 8 6 2 b Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle WARNING Do not unscrew service valve mounting capscrews all the way before breaking seal Entrapped pressure could result in injury Loosen the suction and discharge service valve mounting bolts Tap the valve bodies to break the seal and then remove bolts Locate the compressor junction box item 5 Figure 8 19 Note location if the power wires on the terminal plate then remove wiring and compressor junction box Disconnect all low voltage connectors Remove compressor mounting bolts Remove compressor Refer to Section 2 10 for weight of compressor Draw a small sample of compressor oil
314. charger If charging current is between 3 and 20 Amps for 20 amp single phase chargers or 3 and 40 amps for 40 amp three phase chargers the battery charger is functioning correctly If charging Amps 0 check the AC input voltage to the charger The AC input voltage range should be between 350 and 600 VAC If there is AC voltage ensure the unit will not start automatically by disabling any two way communica tion and placing the Main Power switch in the OFF po sition Disconnect the high voltage source and lock out tagout the receptacle Check battery charger fuses and inspect fuse holder wire connections Inspect plugs pins and wires at charger connections If input voltage wiring connections and the fuses good replace the battery charger 8 9 9 Generator GEN a Preventive Maintenance and Operating Precau tions WARNING aware of HIGH VOLTAGE supplied at the power plug or from the generator When performing service or maintenance proced ures ensure any two way communication is disabled in accordance with the manufac turer s instructions ensure the Main Power switch is in the OFF position and whenever practical disconnect the high voltage source and disconnect the negative battery connection NEVER dis assemble the generator HIGH MAGNETIC FIELD INSIDE This field can interfere with cardiac im plants such as pacemakers and defibrillat ors 8 39 WARNING Do not di
315. cing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle b From inside of trailer remove back panel and grille see Figure 8 38 c Disconnect the motor electrical connector Access panel grille Nozzle Supply Air Sensor Blower Assembly Motor Stator Mounting Brackets Support Bracket Figure 8 38 Evaporator Blower Assembly 62 11524 5 Remove the supply air sensor and then remove the nozzle Loosen the four bolts on the underside of the support bracket that fasten the two mounting brackets Slide the blower assembly off the support bracket and out of the unit To remove the fan loosen the nut holding the blade to the motor shaft using impact gun TO remove motor remove four bolts that hold motor to the stator Complete the assembly in reverse order of removal Coat motor shaft with never seize before assembly Torque Fan Nut 37 to 43 ft lbs 50 to 58 Nm Motor Mounting 5 5 to 7 5 65 7 5 to 10 Nm Bolts Mounting Bracket 510 7 ft lbs 6 8 to 9 5 Nm Bolts 8 9 7 Condenser Fan Assemblies a Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle b Disconnect the motor electrical connec
316. ck ars 1 2 Figure 8 10 Engine Oil Level Engine Block Oil Pan Oil Filter Engine Oil Connection Oil Pressure Switch Ore Figure 8 11 Engine Oil Flow Diagram b To Change Engine Oil 1 Warm up the engine and then stop it by placing the Main Power switch in the OFF position Ensure the unit will not start automatically by disabling any two way communication Disconnect the high voltage source and lockout tagout the receptacle If available install oil drain tool CTD P N 68 15763 00 See Figure 8 12 The Oil Drain Tool not only directs the oil over the door latch pin bracket and bottom panel on units so equipped but also holds a typical drain bucket in place while the oil is draining from the engine Remove drain plug drain engine oil Replace plug and refill engine with oil Continue with step c and change oil filter Figure 8 12 Oil Drain Tool c To Change Engine Oil Filter 1 If not continuing from preceding step b warm up the engine and then stop it by placing the Main Power switch in the OFF position Ensure the unit will not start automatically by disabling any two way commu nication Disconnect the high voltage source and lockout tagout the receptacle Remove oil filter Ensure filter mounting is clean CAUTION When changing oil filters the new filters should be primed partially filled with clean oil if possible If the filters are not primed the engine may opera
317. ck For Low Fuel Level Check fuel level in tank Add fuel as needed Check Sensor Fuse amp Wiring Perform sensor check procedure NOTE If new sensor is not available the sensor may refer to Section 8 5 6 be configured OFF temporarily Refer to Section 5 2 1 Configurations 7 79 62 11524 Steps Alarm Cause Corrective Action 127 CHECK SUCTION TEMP SENSOR TRIGGER ON Compressor Suction Temperature Sensor CST is not within the range of 53 to 158 F 47 to 70 UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check sensor resistance See 10 000 Ohms 77 F 25 See Table 8 5 for Note 3 page 7 2 complete table of temperatures and resistance values Check Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins terminals 1MP gt damage moisture or corrosion in connectors see wiri
318. ck unit and remote evaporator mounting bolts Check amp Remote 2 Check engine and compressor mounting bolts Check Evaporators 3 Check door latches amp hinges 8 4 3 4 Check unit and remote evaporator switches and Check electrical connections 5 Check all electrical ground connections Check 6 Check control box condition Check 62 11524 8 2 Table 8 1 Maintenance Schedule Continued Reference tem ration 3 Syste Operatio Section b Every Service Interval or Yearly Continued Refrigeration 1 Check air switch and calibrate 8 8 9 System 2 Check amp clean Compartment 1 Compartment 2 and 8 8 1 Compartment 3 evaporator coils and all defrost drain hoses 3 Install manifold gauge set and check refrigerant pressure Check 4 Check Compartment 1 Compartment 2 and 3 9 Compartment 3 manual defrost operation 5 Perform Microprocessor Pretrip 3 4 Electrical 1 Check all ground connections for corrosion amp tightness Check System 2 Check Stand by plug for signs of wear or damage Check 3 Check condenser fan amperage 2 12 4 Check Compartment 1 Compartment 2 2 12 and Compartment 2 evaporator fan amperages 5 Check compressor amperage 2 12 6 Check Compartment 1 Compartment 2 and 12 Compartment 3 heater amperages 7 Perform insulation resistance verification for high voltage wiring refer to Section 8 9 1 c Every Second Service Interval or 2 years O1 Cooling Drain and flush cooling system System d Every
319. cked by reading the Battery Voltage in the Data List If OK appears after the voltage reading bat tery voltage is sufficient to allow the unit to cycle off If only one compartment is operating and it is not in Pulldown or Pull Up that compartment will remain in operation with the compressor and heaters off If in Engine Operation the engine and the evaporator fan s will continue to operate If in Standby Operation and the compressor has cycled off a PSCON relay will energize to supply power to the battery charger until battery voltage is 13 4 volts or 20 minutes has elapsed The compartment will remain in this condition until this stop parameter has been met OR cooling heating is required in any compartment and the Minimum Off Time Functional Parameter has been met 4 The battery is fully charged Amperage The microprocessor will calculate the average current draw over a 20 second period Once this average drops below the selected value shutdown will be allowed The CURRENT FOR START STOP SHUTOFF is selected in the microprocessor Configurations The value may be set from 1 to 10 amps in 0 5 amp intervals The factory default setting is 7 amps If only one compartment in operating and it is not in Pulldown or Pull Up that compartment will remain in operation with the compressor and heaters off If in Engine Operation the engine and the evaporator fan s will continue to operate The compartment will remain in this condi
320. condenser fan motors No visual physical damage No blockage due to debris Remove and replace if required b With the unit off visually check fan motors and fan blades No visual physical damage No blockage to fan blades Fan blades spin freely Remove and replace if required c With the unit off check the resist ance of the condenser fan motor windings See Section 2 12 for correct resistance Resistance Ohms must be in range No continuity from any high voltage lead to ground Check Condenser Fan Motor Connections Inspect high voltage connections at the condenser fan motors No corrosion water damage or burning discolor ation Remove repair or replace if required Verify Accuracy of AC Current Sensor Put microprocessor in PC Mode Re fer to Section 5 3 page 5 4 7 121 Must have 0 AC1 Amps and 0 AC2 Amps in Unit Data 62 11524 Alarm Cause Corrective Action P191 CHECK UL2 TRIGGER ON The pressure differential between suction and discharge pressures did not change as expected when the Rear Unloader UL2 was de energized loaded discharge pressure should rise and suction pressure should drop or when it was energized unloaded discharge pressure should drop and suction pressure should rise UNIT CONTROL Engine and Standby Operation Pretrip will fail in test 13and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip
321. corrosion in connections e Check voltage to starter solenoid Must be above 11 5 VDC f Check voltage to starter motor Must be above 10 VDC while cranking Check Fuel Speed Actuator FSA amp circuit a Check Run Relay LED LED 28 must be ON b Check for 12 VDC on the Run Relay circuit Must be 0 VDC Check SPK20 for voltage Must be 12 VDC d Check ENSCU terminals 13 amp 15 for voltage Must be 12 VDC e Check FSA plunger Must be free to move Check Starter a Inspect starter and wiring See wiring schematic Section 10 No damage or corrosion Wiring and battery cable must be clean and tight b Check resistance of starter motor Refer to Section 2 13 for correct electrical values c Check amperage draw of starter Refer to Section 2 13 for correct electrical values Check Battery Voltage a Inspect battery cable ends and posts Must be clean and tight No corrosion b Test voltage at battery with unit off Must be above 11 VDC c Test specific gravity of battery Must be 1 225 or higher d Perform load test on battery Follow battery manufacturer s procedure and guidelines Check For Correct Engine Oil 62 11524 Check for correct oil viscosity weight for conditions Refer to Section 2 9 Must be correct for ambient conditions um Alarm Cause Corrective Action 36 C
322. croprocessor a Place the Main Power switch in the Microprocessor powers up OK OFF position for 30 seconds then back to the desired position b Alarm 246 remains active Download and replace microprocessor Download and replace microprocessor Refer to Section 5 7 62 11524 7 138 Alarm Cause Corrective Action 248 CONFIGURATION MODE HP2 ERROR TRIGGER ON EEPROM configuration is out of range e UNIT CONTROL Shutdown and alarm e RESET CONDITION Auto Reset only when valid info is available for the microprocessor are entered Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check microprocessor a Check setpoint setting Must be between 22 and 89 6 F 30 and 32 C b Enter new setpoint Must be between 22 and 89 6 F 30 and 32 C c Check Functional Parameters All settings must be valid Check Software Revision Check microprocessor software Upgrade to the latest revision of software The latest revision revision may contain configurations that were not present in older revisions b Check Functional Parameters All settings must be valid Send desired settings to microprocessor using the latest version of ReeferManager or a PC Card Do NOT
323. ct the data from the PC card and place it on the computer hard disk 3 18 4 DataLink Data Recorder Power Up The DataLink data recorder records data the entire time the Main Power switch is not in the OFF position A Con figuration exists which allows the user to select either an additional 8 hours of sensor data be recorded after the Switch is placed in the OFF position or to stop recording at the same time the switch is placed in the OFF posi tion The factory setting is to stop recording at the same time the switch is placed in the OFF position Refer to Section 5 2 1 62 11524 3 19 OPTIONS 3 19 1 DataTrak DataTrak allows remote communication with the Ad vance microprocessor cellular satellite etc One way Communication providers can request data from the Advance microprocessor and transmit it via their equipment to another location This is typically done via the Internet to any destination in the world WARNING Advance microprocessor equipped units may start automatically at any time the Main Power switch is not in the OFF position Also the unit may be fitted with two way communication equipment that will allow starting of the unit from a remote location even though the switch is in the OFF posi tion Two Way Communication providers can also send com mands via their equipment to the Advance micropro cessor to start or stop the unit change settings and the way the microprocessor is operating the unit
324. cuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip mode is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during Test 3 by holding Key for 6 seconds d Review active alarm list for Alarm If alarm is present follow steps 2 thru 4 If alarm is 184 not present follow steps 5 thru 10 Check 2EVCON Inspect heater contactor coil and No damage to coil wire connections No damage moisture or corrosion in connections b Check contactor coil resistance Refer to Section 2 13 for correct electrical values Check 2EVCON Amp Draw Check 2EVCON amp draw Use Component Test Mode refer to Section 5 2 to test Refer to Section 2 13 for amp values View current draw in Data List Check 2EVCON Wiring Inspect harness amp control box con No physical damage to harness nector
325. d If the NO POWER SWITCH TO DIESEL Functional parameter is set to Yes and the NO A C POWER Configuration is set to Switch To Diesel the unit will remain off for 5 minutes then start the engine The unit will remain in Engine Operation until the minimum run time has expired regardless if the unit is set for Start Stop or Continuous and until standby power has been restored continually for 5 minutes e RESET CONDITION Auto Reset when AC power is restored or the alarm may be manually reset via keypad or by turning the unit off then back on If the unit is running in Engine Backup when the A C power has been restored for 5 continuous minutes and the above conditions have been met the engine will stop and the unit will restart in Standby Operation NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Circuit Breaker On The Main External Power Supply a Check circuit breaker 30A supply circuit breaker Must be on b Check the voltage in the plug 460V 3 60Hz Check Power Cord a Inspect connections in the socket Connections must be tight and the plug b Inspect the cable Cable must not be frayed cut or damaged Check For Power In The Control Box a Check for voltage at
326. d but is shorted either within the valve coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check LSV2 a Inspect coil and connector No damage to coil No damage moisture or corrosion in connector b Check coil resistance Cannot be opened infinite ohms Shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check LSV2 Current Draw Use Component Test Mode Refer to Refer to Section 2 13 for correct electrical values Section 5 2 2 to test actual current View current draw in Data List draw of the circuit Check LSV2 Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 108 CHECK 3LSV CIRCUIT TRIGGER ON Compartment Liquid Solenoid Valve 3LSV circuit is shorted The 3LSV output from the microprocessor 3 09 is
327. d the liquid line service valve Before opening up any part of the low side of the sys tem a slight positive pressure should be indicated on the pressure gauge If the pressure is below 0 psig bar slowly open the liquid line service valve slightly and then frontseat the valve again Repeat as neces sary in order to raise the pressure above 0 Connect a refrigerant recovery device and a clean re frigerant recovery cylinder to the suction and dis charge service valves and remove any remaining re frigerant from the low side DO NOT bring the low side pressure below 0 psig bar 10 After making necessary repairs leak check and evacuate the low side of the refrigeration system Refer to Sections 8 6 3 and 8 6 4 e Pumping Down The Compressor The compressor or any of the components attached to it unloaders high pressure switch discharge and suction pressure transducers discharge temperature sensor compressor heads and oil etc may be serviced or replaced by pumping the compressor down and isolating the compressor from the rest of the system 1 Install a manifold gauge set to allow reading of suction and discharge pressure See Figure 8 18 If the compressor is operational start the unit and slowly frontseat the suction service valve Shut down the unit when the suction pressure drops to 2 psig 0 2 bar Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Pow
328. d Maximum Temperature of 42 F 5 6 C Range 2 has been set for a Minimum Temperature of 22 F 30 C and a Maximum Temperature of 89 6 F 32 C The unit will switch to Continuous when the temperature is between 32 and 42 F 0 and 5 6 C because when the ranges overlap each other the Range 1 settings will take priority 4 8 PREPROGRAMMED SOFTWARE OVERRIDES 4 8 1 Cargo Protect Mode The microprocessor will activate Cargo Protect Mode when both the A122 CHECK RETURN AIR SENSOR and A123 CHECK SUPPLY AIR SENSOR alarms for Compartment 1 or the A137 CHECK RETRUN AIR SENSOR alarm for Compartment 2 or the A138 CHECK RETURN AIR SENSOR alarm for Compartment 3 are activated If the setpoint in the compartment for which the alarm s have activated is in the perishable range refer to Section 4 3 2 the EXV or LSV for that com partment will shutdown If the setpoint in the compartment for which the alarm s have activated is in the Frozen Range and the unit is in Engine Operation the compressor will operate fully loaded and the engine will go to low speed If the setpoint in the compartment for which the alarm s have activated is in the Frozen Range and the unit is in Standby Operation the compressor will operate unloaded The MessageCenter will display WARNING NO TEMPERATURE CONTROL when displaying information for the compartment s operating in Cargo Protect Mode 4 8 2 Compressor Minimum
329. d attached to allow access to the mounting clips Refer to Section 8 4 2 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle b Remove the 3 grille insert mounting bolts on each side of the grille insert See Figure 8 1 c Remove the 2 grille insert mounting bolts on top of the grille insert d The grille is fitted with locating tabs along the bottom To remove swing insert down and lift out of locating slots e Reverse above steps to install grille insert 8 5 GRILLE INSERT GRILLE INSERT MOUNTING BOLTS SURROUND LUBRICATE LATCHES AND PINS Figure 8 1 Grille Insert Removal And Door Latch Maintenance 62 11524 8 4 2 Surround Removal NOTE It is not necessary to remove the grille before removing the surround a Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle b Open both side and front doors c Remove the bolts that secure the surround to the unit see Figure 8 2 d Reverse above steps to install surround MOUNTING BOLTS REMOVE DECAL PLATE TO ACCESS UNIT MOUNTING STUD Figure 8 2 Surround Removal 8 4 3 Door Latch Maintenance And Replacement
330. d suction line Leak check and evacuate the low side Refer to Sec tions 8 6 3 and 8 6 4 Install bulb and power head in sulation Check and adjust superheat in accordance with the preceding step a 8 9 ELECTRICAL SYSTEM COMPONENT SERVICE Procedures for servicing or maintaining the high voltage electrical system components are provided in the following sub paragraphs 8 9 1 Megohmmeter Test Procedure This instruction will aid in the check of the electrical wiring insulation integrity and field electrical connections A megohmmeter test instrument commonly known as a Megger can be purchased locally at most electrical supply centers This test requires a meter that can be set to 1000V CAUTION Before connecting megohmmeter place the Main Power switch in the OFF position Disconnect the high voltage source lock out tagout the receptacle and disconnect the negative battery connection Isolate the microprocessor by disconnecting all con nectors and wires going to it Observe Na tional Electric Manufacturer s Association NEMA rules and test equipment manufac turers instructions a Disconnect the generator ground wire GEN GRD green wire marked with red tape from the unit ground plate PE plate inside the control box See Figure 8 34 b Connect a megohmmeter lead to the ground plate Figure 8 34 Megohmmeter Connection to Ground Plate Connect the remaining lead to the red wire at the
331. d the en gine will start In standby operation the buzzer will sound then the fans and compressor will start 3 4 PRETRIP 1 Place the switch labeled ENGINE OFF STANDBY in the desired po sition OR place the switch labeled START RUN OFF in the START RUN position HEAT COOL DEFROST 20 SETPOINT TEST 1 3 Press the key to start Pretrip KEYPAD MANUAL ALARM LISTI DEFROST LA 2 Press the SELECT key until the MessageCenter displays PRESS THE KEY TO START PRETRIP ALARM START STOP CONTINUOUS 34 1 BOX TEMPERATURE XX COMPLETE START STOP SELECT CONTINUOU 4 Verify that during TEST 1 the complete display is turned on and that all lights on the Light Bar come on Verify during Test 2 that the that the buzzer comes on for the first five seconds 5 The remainder of Pretrip will take 7 to 15 minutes and will run itself automatically Pretrip is a set of tests run by the microprocessor to check unit operation It is recommended that a Pretrip be run prior to loading It will indicate a failure when one is detected TIP A Pretrip can be started at any box temperat ure If Pretrip is started while the unit is in a Start Stop off cycle the unit will start during the course of the test If the unit is running when Pretrip is started it will shutdown for the first three tests TIP It is always a good idea to clear all alarms from
332. dby RESET CONDITION Auto Reset after 15 minutes if the engine coolant temp falls below 212 F 100 C or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Coolant Level Check coolant level in overflow Level must be in the normal range bottle WARNING Do not remove the cap from a hot radiator or bottle if the cap must be removed do so very slowly in order to release the pressure without spray b Inspect connecting tube between Connections must be airtight No leakage or holes in overflow bottle and radiator tube Check For Bad Eng Coolant Sensor Alarm Check for Alarm 129 Alarm conditions must be corrected and the alarm cleared to continue Check Freeze Point Of Coolant Use Coolant Tester to check Must be between 40 to 60 Ethylene Glycol to concentration of anti freeze water mixture mixture Check Airflow Through Radiator amp Condenser Coil a Inspect condenser amp radiator Ninety percent or more of the coil surface must be undamaged No dead air spaces Condenser Ra diator coil must be clean b Check condenser fan rotation
333. dition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Microprocessor Software Revision Check microprocessor software revi Will be a 6 digit number upgrade if required Refer to sion Section 5 4 2 Reset Microprocessor a Place the Main Power switch in the OFF position for 30 seconds then back to the desired position b Check Active Alarm List Alarm is cleared microprocessor is OK c Alarm 245 remains active Unit will operate but changes to the settings will not be retained in the microprocessor memory Download and replace microprocessor Refer to Section 5 7 246 EEPROM WRITE FAILURE TRIGGER ON here is an error in the ability to write information to be stored in the memory e UNIT CONTROL Alarm only e RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Microprocessor a Check setpoint setting Must be between 22 and 89 6 F 30 and 32 b Enter new setpoint Must be between 22 and 89 6 F 30 and 32 C Reset Mi
334. ducer 2 12 b Evaporator High Temperature Switch 1 2 12 Evaporator Outlet Temperature Sensor EVOT 2 12 Defrost Termination Temperature Sensor 1DTT 2 12 Return Air Temperature Sensor 1RAT 2 12 f Supply Air Temperature Sensor 1SAT 2 13 i 62 11524 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 25 REMOTE EVAPORATOR 2 13 21 2 13 252 Liquid Line Solenoid Valve 2LSV or 3ESV 2 13 25 0 Thermal Expansion valve IAW a Lua a dab Ra 2 13 2 5 4 Remote Evaporator Switches Transducers and Sensors 2 13 a Evaporator High Temperature Switch 2 5 2 13 b Defrost Termination Temperature Sensor 2DTT or 2 13 Return Air Temperature Sensor 2RAT 2 13 Supply Air Temperature Sensor 25 2 13 26 SYSTEM OPERATING CONTROLS AND COMPONENTS 2 1
335. dure b Condenser Coil Replacement Note If the condenser coil Item 3 Figure 8 25 re quires replacement the entire condenser radi ator assembly 1 must be removed from the unit and disassembled reassembled on the bench 8 27 Ambient Air Temperature Sensor ATT Condenser Radiator Assembly Mounting Bolts Radiator Frame Mounting Bolts Radiator Mounting Brackets 10 Condenser Coil Mounting Brackets Figure 8 25 Condenser Radiator Assembly 1 Remove the refrigerant charge Refer to Section 8 6 2 Drain coolant completely by removing radiator cap and then the lower radiator hose Remove the surround with the grille attached Refer to Section 8 4 2 4 Remove hoses from radiator 5 Unsolder refrigerant lines from condenser coil 6 Disconnect the hail and bug screen sufficient to reach the ambient sensor 6 and wiring Remove sensor and wiring from radiator frame 5 Remove the eight bolts 7 securing the condenser radiator assembly to the unit Remove the condenser radiator assembly from the unit Remove the eight bolts 8 securing the radiator frame to the condenser frame 2 and set radiator frame aside 62 11524 10 Separate the radiator 4 from the condenser radiat or assembly by removing the top and bottom radiator mounting brackets 9 Set radiator aside 11 Remove condenser coil by removing th
336. e The additional choice allows the unit to be set so that the configured action will always take place OR the configured action will only take place when the ambi ent temperature is below a certain temperature For example if the shutdown low speed temperature choice is set to 77 F 25 C the unit will only shut down go to low speed if the ambient temperature is below 77 F 25 C Additionally a Functional Parameter override set ting will be available for each switch configured to shut the unit down The Functional Parameter may be set to YES or If the Parameter is set to NO the configured action will not be overridden If the Parameter is set to YES the alarm will be activated but the unit will not shutdown 2 8 3 Remote Temperature Sensors Two compartment units are provisioned to connect one or two remote temperature sensors directly to the microprocessor The microprocessor may be configured to display the sensor reading in the Unit Data and to record the sensor reading in the DataLink data recorder A user specified name may be configured for each sensor This name will be displayed rather than the default Remote Sensor 1 or Remote Sensor 2 name in the unit data list panel The panel displays refrigerated compartment setpoints compartment temperatures and operating modes heat cool or defrost The setpoint may be set and the unit may be started and stopped using the remote panel
337. e MAL12345678 Press the UP ARROW key again and the ID field will appear Press the key then the UP ARROW key You will see a blinking cursor in the field Using the Up or DOWN ARROW key scroll through the Num ber Letter list until the first letter number of the ID appears Press the key to enter that number let ter and advance the cursor to the next place Repeat this process until the entire ID number is entered If the cursor is still blinking in a blank space after you are finished slowly wait 2 3 seconds between presses press the key to leave blanks in the re maining spaces When you reach the end the mes sage Tl TO SCROLL THEN SELECT will display Now press the DOWN ARROW key until SET TIME appears Press the key then the UP ARROW key to enter that menu CAUTION Ensure that the clock you are using is ac curate Also some customers are located in different time zones from the repair loca tion If you know the owners desired loca tion time enter that time If you don t enter the current time at your location When MONTH appears press the key then the UP ARROW key The MessageCenter will begin to flash indicating that it is ready to accept changes Use the UP or DOWN ARROW key to scroll through the number list until the correct number of the current month appears Press the key to enter that number for the month 62 11524 h Press the UP ARROW key to go t
338. e liquid line service valve connection Place the cylinder on a weight scale so the refrigerant going into the cyl inder can be monitored 4 Start the unit and run in high speed cool Cover the condenser to raise the discharge pressure to as high 62 11524 as 375 psig 25 5 bar Do not let the discharge pres sure exceed 400 psig 27 2 bar Open the refrigerant cylinder valve and allow the refrigerant to flow into the cylinder The amount of refrigerant going into the cylinder can be monitored by watching the weight of the cylinder Shut down the unit when the suction pressure drops to 2 psig 0 2 bar There should be very little refriger ant remaining in the system at this point 6 Place the unit in Service Mode Refer to Section 5 2 3 Ensure that the microprocessor Mes sageCenter displays RECOVER LEAK CHK EVAC MODE during the refrigerant removal procedures If the microprocessor switches to charge mode during the process switch it back to the RECOVER LEAK CHK EVAC MODE Connect a refrigerant recovery device and a clean re frigerant recovery cylinder or continue to use the same cylinder used in step 3 as shown in Figure 8 18 and remove any remaining refrigerant from the system Refer to instructions provided by the manufacturer of the refrigerant recovery unit After making necessary repairs leak check evacu ate and recharge the system d Pumping Down The Low Side Components on the low
339. e Configuration Jumper or insu lated jumper at this time The MessageCenter will then display T TO SCROLL THEN TO SELECT for 10 seconds Press the UP ARROW Key to scroll through the Menu beginning at the top Press the DOWN ARROW Key to scroll through the Menu beginning at the bottom 62 11524 f Select the Mode you wish to access Configuration Mode Component Test Mode eService Mode and press the key Information on these test modes is provided in the following sub paragraphs 5 2 4 Configuration Mode a Enter the Technician Interface Configuration Mode as described in Section 5 2 b To read through the Configuration list press either the UP or DOWN ARROW keys The list is circular meaning that once the end is reached it is repeated from the beginning Refer to Table 5 2 for information on the settings and resultant microprocessor actions c To change one of the Configurations bring the de sired Configuration into the MessageCenter and press the The MessageCenter will then dis play TO SCROLL THEN TO SAVE for 10 seconds Then the selected Configuration will flash displaying the current selection Press the UP or DOWN ARROW Key to scroll through the list of avail able selections for this Configuration d Once the desired selection is displaying in the Messa geCenter press the Key to save the selection The MessageCenter will stop flashing The new se
340. e Light Bar is an external indicator light which can be seen in the driver s rear view mirror from the cab of the tractor The green LED indicates STATUS The amber LED indicates CHECK UNIT The amber light is illuminated when the microprocessor illuminates the fault light Alarms can be read on the microprocessor display 62 11524 Figure 2 14 Light Bar 2 8 2 Remote Switch es The unit is provisioned to connect remote switches DS or REMS directly to the microprocessor These switches include REMS1 Shut down alarms for Compartment 1 REMS2 Shut down alarms for Compartment 2 DS Provides Door alarms and For 2 compartment units shut the unit down For 3 Compartment units shuts down Compartment 3 only Two types of switches may be used 1 A switch with contacts that are open when the switch is activated 2 A switch with contacts that are closed when the Switch is activated Four Configurations are available for each switch 1 Activate an alarm only while the switch is activated 2 Activate an alarm and shut the unit down while the Switch is activated The unit will remain shut down for a minimum of 3 minutes under this setting 3 Activate the alarm and bring the engine into low speed while the switch is activated 4 Record the switch activation in the DataLink data recorder f configured to shut the unit down or bring the engine to low speed an additional choice will be availabl
341. e condenser coil mounting brackets 10 12 Reassemble condenser radiator assembly in re verse order using new coil CAUTION Do not bend copper tubing denser coil when installing the new con denser Bend the unit tubing if tubes do not align correctly Note Before applying heat to the new condenser ap ply a wet rag to the entire copper to aluminum transition area to avoid melting the protective heat shrink or damaging the joint 13 Reassemble condenser radiator assembly into unit 14 Leak check evacuate and charge the system Re fer to Sections 8 6 3 8 6 4 amp 8 6 2 15 Refill engine coolant Refer to Section 8 5 12 8 8 3 Filter Drier a Check Filter Drier The unit must be running in cool for this test 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 replaced b Replace Filter Drier 1 Pump down the low side refer to Section 8 6 2 2 Remove bracket loosen the inlet connection to re lieve any remaining pressure then remove drier 3 Procure new O rings Lubricate the O rings back side of sleeves and coupling nuts Using a backup wrench at each connection torque 30 to 38 ft lbs 41 to 51 Nm 4 Leak check and evacuate the low side of the system Refer to Sections 8 6 3 amp 8 6 4 8 8 4 Replacing Receiver Sig
342. e connector sensors and switches If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink Alarm Cause Corrective Action 125 CHECK COMP DISCHARGE SENSOR TRIGGER ON Compressor Discharge Temperature Sensor CDT is not within the range of 40 to 392 F 40 to 200 C UNIT CONTROL Engine and Standby Operation Alarm Only RESET CONDITION Auto Reset when Compressor Discharge Sensor is in range or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check sensor resistance See 100 000 Ohms 77 F 25 C See Table 8 6 for Note 3 page 7 2 complete resistance chart Check Compressor Discharge Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins terminals 1MP damage moisture or corrosion in connectors see wiring schematic Section 10 Power up
343. e evacuation setup for leaks Re pair if necessary Midseat the refrigerant system service valves En sure that the MessageCenter displays RECOVER LEAK CHK EVAC MODE Start the vacuum pump Evacuate unit until the vac uum indicator indicates 2000 microns Close the va cuum pump valve and shut off the pump Wait a few minutes to ensure the vacuum holds Break the vacuum with dry nitrogen through the dis charge service valve Raise system pressure to approximately 2 psig 0 1 bar Ensure that the micro processor does not switch to the charge mode If this 62 11524 occurs switch it back to the RECOVER LEAK CHK Refer to Section 5 2 3 10 Purge nitrogen from system at the suction service valve 11 Open the vacuum pump valve and start the pump Evacuate unit to 500 microns Close the vacuum pump valve and shut off the pump Wait a few minutes to be sure the vacuum holds below 2000 microns 12 If vacuum holds below 2000 microns continue to step 14 If vacuum rises above 2000 microns contin ue to step 13 13 Repeat steps 8 through 11 until the vacuum stays below 2000 microns 14 Once the system holds a good vacuum it is ready to be charged with refrigerant Refer to Section 8 6 2 b Evacuation of the Low Side 1 Evacuate only after a low side pressure leak check Refer to Section 8 6 3 If possible keep the temperature of the major com ponents condenser evapor
344. e for several days data contained on the card may be damaged PC cards should never be Dropped Bent Twisted Squeezed Submersed in any liquid Exposed to electrostatic discharge Exposed to intense ultraviolet light Exposed to nearby magnetic or electromagnetic fields Low X Ray exposure i e that experienced while passing through a security screen should not harm the card data High X Ray exposure i e that experienced in a medical or dental environment may damage the card data PC cards should not be exposed to magnets such as a pocket screwdriver with a magnetic end PC cards should be kept in a hard plastic jewel case when not in use Replacement cases P N 58 50109 00 are available from Carrier Transicold s Performance Parts Group Power the microprocessor by toggling the Main Power switch out of the OFF position or enter PC Mode refer to section 5 3 Insert the card into the PC card slot on the front the micro processor Be certain that the instruction label is facing the Caution label Do not force card into slot Hold the card at the end opposite the plug end DO NOT squeeze the card in the middle while inserting FAULT LED The MessageCenter will display messages while the required action is performed the green PC CARD STATUS LED will flash Do not remove the card until prompted to do so When the required action is completed the PC Card Status LED will be on solid The message c
345. e has been greater than 98 psig 6 7 bar for more than 10 minutes e UNIT CONTROL Engine Operation alarm only or if configured for shutdown engine and unit shutdown and alarm Standby Operation alarm only or if configured for shutdown refrigeration system shutdown and alarm with PSCON still energized e RESET CONDITION Auto reset when suction pressure is less than 75 psig 5 1 bar for 5 minutes and configured for Alarm Only or Auto Reset after 15 minutes if configured as a Shutdown Alarm or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check System Pressures Install manifold gauge set and check and compare compressor discharge amp suction pressures with those shown on the microprocessor dis play Suction pressure must be above 3 psig 0 2 bar Suction amp Discharge Pressures must have the same reading on gauges amp on microprocessor display NOTE Microprocessor suction CSP and evap orator EVOP pressure readings have a maxi mum value of 100 psig 7 5 bar The actual suc tion pressure must be lower than 100 psig in or der to perform this test Check For Refri
346. e microprocessor Suction amp Discharge Pressures must have the same reading on gauges amp on microprocessor display Pressures must be in the normal range for ambient amp refrigerated compartment temperature conditions If discharge pressure is in normal range proceed to step 4 NOTE Microprocessor suction CSP and evaporator EVOP pressure readings have a maximum value of 100 psig 7 5 bar The actual suction pressure must be lower than 100 psig in order to perform this test Check Airflow Through Condenser Coil a Inspect condenser amp radiator Ninety percent or more of the coil surface must be undamaged Condenser coil and radiator must be clean b Check airflow with unit running Even airflow through the entire coil No dead spots c Check condenser fans Both fans should operate correctly Check rotation air should be pulled in through the grill and discharge into the engine compartment Check For Refrigerant Overcharge Check refrigerant charge Refer to Section 8 6 2 Check HP1 Switch Inspect switch amp connector pins amp terminals No physical damage to switch No damage moisture or corrosion in connector Check HP1 Switch Harness a Inspect harness amp control box connector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors b Check
347. e operator de termines PASS or FAIL A defective display is indicated any LCD LED segments are not visible or any LEDs or lights do not illuminate Anything that fails during this test should be repaired at the conclusion of the Pretrip cycle Pretrip will continue regardless of the outcome of this test A faulty display or light bar will not affect the op eration of the unit but will affect what is displayed during unit operation Test 2 Sound and 12VDC Electrical Component Amperage Check At the beginning of this test the microprocessor activ ates the buzzer for 5 seconds the operator is to determ ine if the sound test is PASS or FAIL If the sound test fails it should be repaired at the conclusion of the Pretrip cycle Pretrip will continue regardless of the outcome of the sound test A faulty buzzer will not affect the opera tion of the unit but will lead to operation without proper audible warning on start up Test 2 will continue with a check of the amperage cur rent draw of the following components Battery DC Current All Components Turned Off Front Unloader Solenoid UL1 Rear Unloader Solenoid UL2 Intake Air Heater IAH Engine Speed Control Unit ENSCU Condenser Motor Contactor CDCON Compressor Motor Contactor CCON Generator Contactor GENCON Standby Contactor PSCON Heater Contactor 1HTCON1 Heater Contactor 1HTCON2 Remote Heater 2HTCON 1 Remote Heater 2HTCON 2
348. e required for this unit refer to the model serial number nameplate or Table 2 1 and procure a refrigerant cylinder with sufficient weight of refrigerant Place cylinder on scale and connect charging line from cylinder to liquid line service valve 3 Note weight of cylinder and refrigerant 4 Open liquid valve on cylinder Midseat liquid line ser vice valve and allow the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added NOTE It is possible that all liquid may not be pulled into the receiver as outlined in step 4 In this case add the additional refrigerant in accordance with the charge adjustment procedures refer to preceding step f When scale indicates that the correct charge has been added close liquid line valve on cylinder and backseat the liquid line service valve Remove charg ing hose 8 6 3 Leak Checking The condition that the system may be in when leak checking is required include when the system is charged when the system is without charge when the low side has been pumped down and when only the compressor is to be leak checked Procedures for each condition are provided in the following subsections a Leak Checking a Charged System 1 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle NOTE
349. e the con tacts of the defrost air switch DAS OR when the compartment RAT DTT temperature is greater than 36 F 20 C in Compartment 1 or 18 F 10 C in the remote compartments for 15 continuous minutes This method of defrost initiation will only be used for 3 consecutive defrosts After three consec utive defrost initiations by this method the counter will be reset to allow this defrost initiation again only after a defrost cycle is initiated by another method timer air switch or manual TIP Ice is not the only thing that will cause the air dif ferential to increase across the evaporator coil Shrink wrap paper plastic bags and other such items when caught in the return air stream and pulled up against the evaporator coil or the return air grille can also cause the DAS contacts to close b Defrost based on time Time interval between defrosts is selected in the microprocessor Functional Parameters The parameter value may be set to 1 5 3 6 or 12 hours The factory default setting is 6 hours NOTE 1 The defrost timer will not count when the unit is in defrost the unit is in a Start Stop off cycle or all DTT s are greater than 40 0 F 4 4 C There is a single defrost timer When the timer expires initiation of defrost in the compartments may be staged depending on the number of compartments enabled and the models of remote evaporators installed 4 6 2 Defrost Modes There are two defrost mode
350. ears in the MessageCenter there is a communication error between the keypad and the microprocessor With no communication there will not be an associated alarm Should this occur check the wire connections behind the keypad assembly at the keypad itself remove the rear cover to check and at connector 6MP on the microprocessor Check for microprocessor status led blinking at 1 second rate 1 second ON 1 second OFF When working on the refrigeration system an accurately calibrated manifold gauge set should always be installed It is not necessary to connect an additional high pressure gauge at the liquid line service valve The compressor suction pressure compressor discharge pressure and evaporator outlet pressure can be read in the unit data list In high or low ambients it may be necessary to cool or warm the refrigerated compartment temperature before performing specific tests providing that the compartment is not loaded with perishable product 62 11524 7 2 NOTES Note 1 Note 2 The active alarm list may be cleared by scrolling to the end of the list LIST END TO CLEAR ALARMS will appear in the MessageCenter Pressing will inactivate the alarms That is the alarm is cleared from the active alarm list and moved to the inactive alarm list for later review if the condition that caused the alarm has been corrected When Shutdown Alarms are cleared the unit will attempt to restart When non Shutdown Alarms are
351. eat in the required range 12 Once the valve s are adjusted read compressor suction temperature and pressure from the micro processor Convert the suction pressure using the P T chart Subtract the converted suction temperat ure from the actual suction pressure to obtain the suction superheat The suction superheat should be between 70 to 90 F 38 to 50 C 62 11524 8 34 13 For final verification allow Compartment 2 temperat ure to pull down to 20 30 C Repeat the above procedure Evaporator superheat should be 10 to 12 F 5 5 to 6 6 C while the suction superheat should be between 35 to 40 F 19 to 22 C 14 11 superheat cannot be brought within the required ranges the valve s must be replaced Replacing Expansion Valve Pump down the low side of the system refer to Sec tion 8 6 2 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Note location of bulb on the suction line and then re move the valve bulb and the insulation from the ex pansion valve power head Heat inlet outlet and equalizer connections to valve body and remove valve Clean all tube stubs so new valve fits on easily Install new valve Clean the suction line where the bulb will make con tact Install bulb and firmly tighten the straps around the bulb an
352. ec trical welding on unit or chassis to which unit is attached trailer container rail car metal building etc WARNING Use the required protective eye wear and clothing when working with solvents WARNING Beware of moving poly V belt and belt driv en components WARNING When working with belts beware of pinch points WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 psig 159 9 bar Do not use oxygen in or near a refrigerant system occur See igure 8 30 WARNING Do not unscrew replacement compressor lifting eyelet blankoff plate mounting capscrews all the way before breaking seal Entrapped pressure could result in injury WARNING Do not unscrew cylinder head mounting capscrews all the way before breaking seal Entrapped pressure could result in injury WARNING Do not unscrew enclosing tube nut all the way before breaking seal Entrapped pres sure could result in injury WARNING Do not unscrew unloader valve body mounting bolts all the way before breaking seal Entrapped pressure could result in injury 1 3 WARNING Do not direct water or steam into the gener ator openings Do not allow any soap and water solutions to enter the generator WARNING Generators of this type should not be flashed Operation with external voltage source or momentar
353. econds Start Stop Indicator Green Illuminated when Start Stop Operation has been selected Continuous Indicator Green Illuminated when Continuous Operation has been selected 62 11524 NOTE When the unit is in Null mode fan only the mode indicators cool heat and defrost are all off NOTE There is an opening between the Alarm and Start Stop LEDs that is not used at this time Main Display The microprocessor will display the refrigerated compartment setpoint to the left compartment temperature in the center and the compartment number to the right The display will alternate every 5 or 10 seconds providing the information for compartment 1 and then the information for compartment 2 and then the information for compartment 3 Temperatures will be displayed as signed or whole numbers The compartment temperature will be followed by a letter indicating the information is in degrees Fahrenheit F or degrees Centigrade C Message Center Messages generated by the microprocessor are displayed in the MessageCenter As the main display scrolls every 5 to 10 seconds from one active compartment to another the applicable message for that particular compartment will also be displayed Details of the messages are described in Section 6 1 MessageCenter c Switch Board 3rd Compartment Run Switch 3RS This switch is placed in the ON position to signal the microprocessor that the compartment 3 evapora
354. ect the new Functional Parameter setting The new setting was not stored and the old setting will be used HOUR METERS NOT CHANGED Indicates that no changes have been made to the hour meters in either the configuration or functional parameter lists INACTIVE ALARMS IN MEMORY There are inactive alarms in the microprocessor alarm list which have not yet been cleared INSTALLED REMOVE CARD XX An Option PC Card has been inserted into the PC Card slot and the option has been installed in the microprocessor The PC Card may safely be removed from the slot XX indicates the number of option installations remaining on card INSTALLING OPTION PLEASE WAIT An Option PC Card has been inserted into the PC Card slot and the option is being installed in the microprocessor DO NOT RE MOVE THE CARD WHILE THIS MESSAGE IS BEING DIS PLAYED INSTALL STOPPED REINSERT CARD An Option PC Card has been inserted into the PC Card slot and the install process has been stopped by the PC Card not being fully inserted in the slot or by being removed Remove and reinsert PC Card to continue KEYPAD LOCKED BATTERY TOO LOW Once the battery voltage goes below 7 0 Volts for 10 seconds all of the keys on the keypad will be locked LIST END TO CLEAR ALARMS The end of the Alarm list has been reached Pressing the key will clear the Alarm list LOADING INFO A Configuration PC Card has been inserted into the PC Card
355. ect date amp time Did you find and correct the condiditon Did you have a communication failure during a download When viewing down loaded data does all the data appear on Jan 01 1970 or Jan 01 1998 When viewing the download in Reports a specific sensor or event does not show up in the data file The Reports data filter settings may be set incorrectly or specific sensors and events may not be recorded DataLink data recorder is not configured properly Use the Reports Data Filter pull down menu to set sensors amp events to be viewed OR use ReeferManager to correctly set up recording parameters Operate the system in order to verify the repair DataLink data recorder date amp time have never been set Set date amp time Operate the system in order to verify the repair START HERE What does the ReeferManager program display on the bottom of the screen of your PC Go to Condition 1 Unit does not operate Intermittent communication problem Ensure AC cord is properly connected or PC batter is fully charged Did you find and correct the condition Verify PC power saving features are OFF screen saver monitor time out hard disc time out auto power down sleep mode Did you find and correct the condition Verify the integrity of the download cable and connections Did you find and correct the c ondition Use PC Download Card to download data NOT CONNECTE
356. ections 8 9 5 Evaporator Heaters NOTE A good preliminary test of the heaters is to runa Pretrip and check for heater alarms a Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle b Remove the lower back panel or coil cover as applic able c To determine which heater assembly needs to be re placed disconnect the suspect heater assembly and check pin to pin resistance For heater resistance refer to Section 2 12 d Remove the Compartment 1 heater mounting brack ets or note location of and remove remote unit heater mounting clips e Remove and replace faulty heater If removing a drain pan heater carefully remove heater from the clips on the drain pan f When reinstalling Compartment 1 brackets torque to 6 to 7 ft Ibs 8 1 to 9 5 Nm Rods should move freely from side to side when installed g Route and secure electrical cables For Compart ment 1 route along the lower side of the heat ex changer at the 5 o clock position on the side closest to the evaporator coil Ensure that all wires are clear of heaters 8 9 6 Compartment 1 Evaporator Blower amp Motor NOTE The blower motor bearings are factory sealed and do not require additional grease a Ensure the unit will not start automatically by dis abling any two way communication and pla
357. efrigeration system for non condensable gas es No non condensable gas es may be present Refer to Section 8 6 2 62 11524 IR Alarm Cause Corrective Action 18 LOW REFRIGERANT PRESSURE TRIGGER ON The compressor is operating with the suction pressure less than 10 in Hg 0 3 BAR with both the Front UL1 and the Rear UL2 unloaders energized and the time that is selected for the LP Shutdown Delay Configuration has expired since UL1 was energized Note The MessageCenter does not display in Hg This alarm triggers on when the display shows less than 4 7 psig UNIT CONTROL Engine Operation alarm only or if configured for shutdown engine and unit shutdown and alarm Standby Operation alarm only or if configured for shutdown refrigeration system shutdown and alarm with PSCON still energized RESET CONDITION If alarm only auto reset when either UL1 or UL2 is de energized If unit and system shutdown and alarm auto reset after 15 minutes Alarm may be manually reset via keypad or by turning the unit OFF then ON again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Refrigerant Charge Check for undercharged system Refer to Section 8 6 2
358. efrost will not be allowed in Compartment 1 RESET CONDITION Auto Reset when 1DTT is in range or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connectors No damage to sensor No damage moisture or corrosion in connectors b Check sensor resistance See 10 000 Ohms 77 F 25 See Table 8 5 for Note 3 page 7 2 complete table of temperatures and resistance val ues Check Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals 1MP No damage moisture or corrosion in connectors amp DP16 see wiring schematic Section 10 Power up the microprocessor see Voltage should be 2 5 VDC volts at harness plug Note 2 page 7 2 Disconnect between pins This verifies microprocessor output sensor from harness Check for wiring connections to the sensor 2 5 VDC at harness plug between pins Check remote sensor switch connector 62 11524 Locate and inspect 10 position Connector must have cap on connector OC for optional No corrosion or moisture insid
359. eived USE FACTORY DEFAULT SETTING ONLY DO NOT OPERATE UNIT WITH DIFFERENT SETTING YES When the A27 HIGH SUCTION PRES SURE alarm is activated the alarm light will illumin ate and the unit will shutdown NO When the 27 HIGH SUCTION PRESURE alarm is activated the alarm light will illuminate and the unit will continue to run YES When the A28 CHECK REFRIG SYS alarm is activated the alarm light will illumin ate and the unit will shutdown When the A28 CHECK REFRIG SYSTEM alarm is activated the alarm light will illuminate and the unit will continue to run Pressure to maintain if discharge pressure trans ducer is opened or shorted If the Compressor Alarm Shutdown option has been installed refer to Unit Data this setting will be available YES The unit will shutdown and not restart when alarm 13 17 18 27 28 or 56 occur 3 times within 2 hours of continuous engine operation NO Normal shutdown rules for above alarms In Start Stop Operation the charging current must drop below this value before the unit is allowed to shutdown The engine will restart from a Start Stop Off cycle or a Sleep Mode Off cycle when the battery drops to this value A lower selection may result in a longer off cycle based on battery voltage and possibly overall shorter battery life A higher selection may result in a shorter off cycle based on battery voltage and possibly overall l
360. em is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Unit Operation Did engine shutdown Yes Check No Check F2 Check Fuses a Locate blown fuse s Will have open circuit b Verify fuse size Refer to Section 2 14 for correct electrical values Must be correct rating for circuit See wiring schematic Section 10 c Inspect fuse amp fuse holder Terminals tight No signs of overheating melting or discoloration Check Circuit a Check amperage draw on Speed Refer to Section 2 14 for correct electrical values Relay circuit b Check amperage draw on Run Refer to Section 2 14 for correct electrical values Relay circuit 62 11524 7 50 um Alarm Cause Corrective Action 73 NO POWER CHECK POWER CORD TRIGGER ON The unit is set to operate in standby AND no AC power e UNIT CONTROL Engine Operation this alarm will not activate in Engine Operation Standby Operation If the NO POWER SWITCH TO DIESEL Functional Parameter is set to No or the NO POWER SWITCH TO DIESEL Functional Parameter is set to Yes and the NO A C POWER Configuration is set for Alarm and shutdown the refrigeration system will shutdown because of the loss of power with the alarm on and PSCON still energize
361. emove the PC Mode con nector The microprocessor will return to normal op eration when the Main Power switch is toggled out of the OFF position 62 11524 5 4 PC CARDS PC Cards that are available include Program Cards Configuration Cards Option Cards and Download Cards General instructions for using the cards is provided in Figure 5 3 Specific information on use is provided the following sub paragraphs NOTE For diagnoses of problems with the micropro cessor DataLink data recorder downloading file analysis using Reports or use of PC cards refer to Section 9 6 5 4 1 Handling PC Cards While these cards are not constructed for a rugged en vironment they are not intended to be stored in a techni cian s toolbox back pocket or on the dashboard of a vehicle The label on each card clearly states that the card is to be handled with care not to be bent dropped or ex posed to impact Heat moisture and direct sunlight should be avoided PC cards are designed to be used in a wide temperature range of 40 to 185 F 40 to 85 When a PC card is connected to an Advance microprocessor or com puter at temperatures outside this range data transmis sion between the card and the other device may not be performed correctly Retention of programmed data for extended periods of time requires a temperature range of 4 to 149 F 20 to 65 C When PC cards are exposed to temperatures outside of this rang
362. emp equa 1o NO within 3 6 F of setpoint or colder than setpoint Is speed relay LED27 Nae illuminated on micro Check the F2 circuit t for excess amp draw The micro is calling for low speed operation If you believe this is not YES YES or short to ground Did you find and correct lt 2 ae 2 correct review your testing with Is the F2 fuse blown the condition your supervisor before changing NO microprocessor NO Is there voltage at QC3 M YES NO ystem Replace relay Did you gt A Check for proper operation of No find and correct the condition J YES the speed relay Is the relay operating properly NO Review the test results Y with your supervisor If Check for proper operation necessary go to the Micro is calling for high YES of the Engine Speed Con beginning of the tree speed Is there 12V at FSA trol Unit or FSA and and ENSCU pin 16 pue Check wiring and connections from QC3 to ENSCU or FSA Repair or replace ENSCU or Did you find and correct the condition actuator as needed Figure 9 8 Micro Diagnostic Tree Cond 4 Unit Will Not Run In High Speed 9 17 62 11524 START HERE Is the unit operating in defrost
363. ent Sensor Check microprocessor current value Power up microprocessor in PC Mode Refer to Sec tion 5 3 Must be 2 0 to 1 5A with no load Check Wire Direction Through Current Sensor Visually inspect wire at current sensor Must go through current sensor in the direction of the arrow on the sensor away from the 5 80A fuse Check Battery Charger Wiring a Check output amp ground wire unit OFF Negative lead on Ground terminal Positive lead on Output terminal same as battery voltage b Check battery charger input Check for AC voltage between SPZ SPX amp for 40 amp 3 phase chargers SPX Check fuses F7 F8 and for 40 amp 3 phase chargers F29 c Inspect harness amp control box connector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors d Check output and ground wire voltages unit running When the unit is started battery voltage at the bat tery will begin near 12 0 VDC and slowly rise toward 13 5 VDC as the battery charges NOTE Do not test for voltage at the output connec tor of the battery charger without the connector being connected to the battery Without the battery con nected any reading will be very inaccurate Refer to Section 8 9 8 for more information on checking bat tery charger Check For Add on Equipment Draw ing Too Much Current Check am
364. enter will display a re move card message The PC card may then be removed When the card is removed the MessageCenter will return to the default message If any other messages display refer to Section 6 1 Message Center for an explanation of the error message If there is an error the PC CARD FAULT LED will be on until the card is re moved CROPROCESSOR STATUS LED PC CARD STATUS LED Figure 5 3 PC Card Interaction 5 4 2 Program PC Card A program card is used to load software into the microprocessor The card may contain any software version however only one version may be loaded to the card at a time For complete instructions on loading data to the card using ReeferManager refer to manual 62 10889 Software may be downloaded by a Carrier Transicold dealer from the TransCentral site TIP Whenever performing a major operation to a microprocessor such as installing new operat ing software it is always a good idea to start the unit and give it a quick check over prior to per forming the operation NOTE Once the unit shuts down to begin the software install process the Compressor Suction Modu lation Valve closing process begins The soft ware installation processes will not begin until the CSMV is completely closed which will delay the actual process for about 45 seconds 5 5 CAUTION The display and MessageCenter may be have differently during the software loading process dependin
365. ents return air bulk head air chute cleanliness of evap coils Good Air Flow Return air not restricted Air chute in good condition No damage to evaporator fan motor assemblies Evap coil clean Evap fan rotation ok b Check airflow with unit running Even airflow through the entire coil No dead spots Visually Inspect Unit Visually inspect unit for damage to the liquid line causing a restriction or any signs of temperature drop at the filter drier All tubing from the receiver to the evaporator section is in good condition There is no temperature drop at the filter drier or anywhere on the liquid line Check Electronic Expansion Valve EVXV Check operation of EVXV Refer to Section 8 8 6 Check Thermal Expansion Valve s TXV Check operation and superheat adjustment of TXV s Refer to Section 8 8 11 Check Liquid Line Solenoid Valve s 2LSV Check operation of 2LSV s Refer to Section 8 8 10 62 11524 Alarm Cause Corrective Action 19 LOW FUEL SHUTDOWN Note This is an optional alarm This alarm will not occur in Standby Operation or if the Fuel Level Sensor Configur ation is NO DEVICE or if the Fuel Tank Size Configuration is OFF e TRIGGER ON The unit is operating in Engine Operation and the fuel level is 10 or less for more than 1 minute AND Alarm 126 Check Fuel Sensor Circuit is not active e UNIT CO
366. er 07 00375 00 connect the 4 pin test cable to the valve connector refer to Table 8 3 and the cable wires to the tester in accord ance with wire and terminal color Set the step rate to 200 steps per second and either open or close the valve Each red LED should light se quentially until all four are illuminated Any LED failing to illuminate indicates an open on that leg and a need to replace the piston and drive motor assembly To test with an ohmmeter check the winding resist ance between connector pin 1A amp 1B and then between 2A amp 2B see Figure 8 27 In normal ambi ent the resistance between the pins should be 72 to 84 ohms Also check each terminal to the coil casing ground If an out of tolerance or zero reading is ob served the piston and drive motor assembly is to be replaced WHITE 1B Figure 8 27 CSMV Coil Diagnostics Valve NOTE If the valve failed pretest and passed the pre ceding diagnostic testing this is an indication that the valve internal mechanism is damaged and the piston and motor assembly is to be re placed To test the valve internal mechanism install mani fold gauge set on the suction service valve and a stepper motor drive tester Start the unit set the step rate to 200 steps per second and close the valve while watching the suc tion pressure Within one minute the suction pressure should begin to fall Place the Main Power switch in the OFF position
367. er motor may be tested using a stepper motor drive tester or ohmmeter 1 To test with a stepper motor drive tester Carrier Transicold part number 07 00375 00 connect the 5 pin test cable to the valve connector and the cable wires to the tester in accordance with wire and termin al color if a 5 pin tester cable is required order Carri er Transicold part number 07 00375 11 2 Set the step rate to 50 steps per second and either open or close the valve Each red LED should light se quentially until all four are illuminated Any LED failing to illuminate indicates an open on that leg and a need to replace the drive 3 To test with an ohmmeter check the winding resist ance between connector 8 amp amp Eand then between amp In normal ambient the resist ance between the pins should be 46 ohms If an infin ite or zero reading is observed the piston and drive motor assembly is to be replaced Diagnostics Valve NOTE If the valve failed Pretrip and passed the pre ceding diagnostic testing this is an indication that the valve internal mechanism is damaged and the piston and motor assembly is to be re placed PIN A ORANGE PIN B RED COMMON 12VDC Connector Pin Wire Color Winding A ORANGE A B RED B YELLOW D BLACK B E GREY COM 12V 2 Set the voltmeter to the DCV scale Ensure the unit is disconnected from standby power and start
368. er switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Frontseat the discharge service valve to isolate compressor There should be very little refri gerant remaining in the compressor at this point If the compressor is not operational ensure the unit will not start automatically by disabling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source lockout tagout the receptacle and then front seat both the discharge and suction service valve to isolate the compressor 2 Connect a refrigerant recovery device and a clean re frigerant recovery cylinder to the suction and dis charge service valves and remove any remaining re frigerant from the compressor DO NOT bring the compressor pressure below 0 psig bar After making necessary repairs leak check and evacuate the compressor Refer to Sections 8 6 3 and 8 6 4 f Adjusting The Charge Level Adjustment of the charge level may be required when there has been a leak or the system was not correctly charged during a previous service 1 Check charge level by performing the procedures of the preceding step a 2 charge removal is required connect a clean evacu ated refrigerant recovery cylinder to the liquid line ser vice valve Open liquid valve on cylinder Midseat li quid line service valve and monitor the liquid refrigerant flow into the cylinder If the un
369. er test circuit from Step a above Use a megohmmeter to test Check Overload Ground Fault Device With the engine OFF and standby power disconnected start the unit in Engine Operation 7 67 Must have 12 VDC at HC19 and 2MP26 Refer to Section 8 9 4 for checking OGF 62 11524 Aarm Alarm Cause Corrective Action 101 C2 EVAP MOTOR OVERHEATED TRIGGER ON One or more of the 2EVM1 2 3 4 Internal Motor Protectors is open e UNIT CONTROL Engine and Standby Operation Compartment 2 shutdown only e RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Compartment 2 Evaporator Motor Contactor 2EVCON a Inspect the three contacts behind If the contactor buttons are blue due to chattering the top cover caused by a defective IP replace the contactor b Check tightness of the contactor Tighten and check for discoloration of wires wire connections Check Motor Operation Turn the unit ON Check current on each phase Refer to Section 2 12 for correct electrical values Check voltage on each phase must be at least 440
370. er the High Speed Pretrip Test 6 engine speed has NOT dropped back to the low speed range within 15 seconds as shown above Note This test will be skipped if the RPM sensor alarm A130 is active UNIT CONTROL Engine Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED Standby Operation This test is not made e RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Model Number Verify that the model number on the nameplate matches the model num ber shown in the microprocessor Un it Data Enter the correct number in Configurations Refer to Section 5 2 1 Check the fuel speed actuator Check FSA plunger Must move in and out freely Verify low speed operation See Note 5 page 7 2 a Set Functional Parameter LOW SPEED START for a high number 30 to 90 then start the unit Set Functional Parameter back to original setting after completing repairs LED 27 must be OFF b Check operation of Speed Relay LED LED 27 must be OFF c Check voltage to FSA Must be 0 VDC d Check for 12 VDC
371. er to Table 8 5 for complete resistance chart Check Sensor Wiring a Inspect harness amp control box con nector pins amp terminals 1MP amp see wiring schematic Sec tion 10 No physical damage to harness No damage moisture or corrosion in connectors Power up the microprocessor see Note 2 page 7 2 Disconnect sensor from harness Check for 2 5 VDC at harness plug between pins Voltage should be 2 5 VDC volts at harness plug be tween pins This verifies microprocessor output and wiring connections to the sensor Check remote sensor switch conne ctor c Locate and inspect 10 position connector OC for optional sensors and switches 7 89 Connector must have cap on No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 62 11524 AOT Steps Alarm Cause Corrective Action 7 9 PRETRIP ALARMS P141 PRETRIP STOPPED BY USER TRIGGER ON Pretrip cycle was stopped by user before the Pretrip cycle ended automatically e UNIT CONTROL Engine and Standby Operation Alarm Only RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back again NOTE Follow the steps below until a problem is found Once a repair or c
372. erro neous current readings Remove wire from fuse holder and gently pull through the current sensor g Remove the screws holding the sides of the micro processor into the control box Remove the single screw holding the top of the microprocessor in place h Pull the microprocessor back and twist it out of the control box i Install the new microprocessor by reversing the pre ceding steps 62 11524 5 7 3 Microprocessor Setup a Ensure that the replacement microprocessor is in place all wires connected and the negative battery cable is reconnected Power up the microprocessor by toggling the Main Power switch out of the OFF position The micropro cessor will immediately go into the Configuration mode Select the correct model family Vector and then enter the correct model number by using the UP or DOWN ARROW keys scroll through the list until the correct Model Number appears verify by reading the Model Serial Plate on the unit Press the key to enter the new model number Press the UP ARROW key again and the Unit Serial Number field will appear Press the key then the UP ARROW key You will see a blinking cursor in the field Using the UP or DOWN ARROW key scroll through the Number Letter list until the first letter of the serial number appears Press the key to enter that letter and advance the cursor to the next place Repeat this process until the entire Unit Serial Num ber is entered i
373. es Action Refer ence Section 9 4 1 Unit Will Not Cool Compressor contactor or relay defective Check Compressor malfunction Compressor defective 8 7 1 A defrost cycle did not terminate Check Compartment 8 9 10 DTT Refrigeration system Abnormal pressure 9 4 8 Check system for noncondensibles 8 6 2 9 4 2 Unit Runs But Has Insufficient Cooling Compressor Compressor internal damage 8 7 1 Unloader malfunction 8 7 6 Abnormal pressure 9 4 8 Unloader malfunction 8 7 6 Rofligaration system Expansion valve malfunction 9 4 11 9 4 12 No or restricted evaporator airflow 9 4 10 Suction Modulation Valve malfunction 8 8 5 Check system for noncondensibles 8 6 2 9 4 3 Unit Operates Long Or Continuously In Cooling Hot Load Allow time to pull down Defective or insufficient refrigerated compartment insula Correct tion or air leak Abnormal pressure 9 4 8 Refrigeration system Temperature sensor malfunction 8 9 10 Check system for noncondensibles 8 6 2 Compressor Defective 8 7 1 62 11524 9 4 Indication Trouble Possible Causes Action Refer ence Section 9 4 4 Unit Will Not Terminate Cooling Unit fails to stop cooling Temperature sensor malfunction 8 9 10 Contactor CCON stuck closed Check Check setpoint Check whether Microprocessor improperly set microprocessor is set at C o
374. ess nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Check Evaporator High Temperature Switch EVHTS Inspect for open EVHTS per wiring If open replace switch as required schematic Section 10 Additional steps on the next page 7 115 62 11524 Steps Alarm Cause Corrective Action CHECK HEATER 1 CIRCUIT Continued 6 Check Amp Draw of 1HTCON 1 Heater Circuit a With the unit running and calling for Heat in Compartment 1 use a clamp on ammeter to check the cur rent draw of all 3 legs Must be within range shown in Section 2 12 for all three legs b Check fuses for heater elements F10 F11 and 12 must not be blown c Check voltage at 1HTCON1 con tacts Must be within range shown in Section 2 12 for L1 L2 L1 L3 and 12 13 Must be within range shown in Section 2 12 for 1 2 T1 T3 and T2 T3 Check Heater Elements a rg heater elements with the unit ff No visual physical damage Remove and replace if damaged b Check heater element resistance Check from terminals on 1HTCON 1 contactor See section 2 12 for correct resistance Check Heater Element Connections a Inspect high voltage heater con nections at evaporator No corrosion water damage or burning discoloration Remove repair or replace if required b Disconnect heater element
375. essor Refer to Section 8 6 2 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Loosen the oil drain plug item 10 Figure 8 19 and allow oil to seep out and bring the level to 1 8 glass Tighten the plug securely back into the compressor Leak check the oil drain plug refer to Section 8 6 3 Start compressor and recheck oil level 8 7 6 Unloaders 9 m Unloader Checkout procedure Install a manifold gauge set on the compressor suc tion and discharge service valves and start unit in cooling with compartment temperatures at least 5 F 2 8 C below setpoint The compressor will be fully loaded both unloader coils de energized Note suc tion pressure Unplug both unloader coils Using cable included in the test kit Carrier Transicold part number 07 50006 00 energize the front un loader UL1 Note discharge and suction pressures A rise of approximately 3 psig 0 2 bar will be noted on the suction pressure gauge Discharge pressure should drop approximately 5 to 15 psig 0 4 to 1 0 bar Disconnect UL1 and note pressures Suction pres sure should drop and discharge pressure should rise by same amount as in step 3 above Repeat steps 3 amp 4 for the rear unloader UL2 At the end of the test reconnect both unloaders If p
376. essor is closed and all repairs complete 1 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Connect refrigerant system service equipment to the suction and discharge service valves if not already connected Refer to Figure 8 18 3 9 CAUTION Only a refrigerant cylinder containing R404A should be connected to this refriger ation unit in order to pressurize the system However dry nitrogen may be used to in crease pressure Any other gas or vapor will contaminate the system and require addi tional removal and evacuation CAUTION Do not vapor charge R404A Only liquid charging through the liquid line service valve is acceptable Pressurize the compressor to 5 to 10 psig 0 3 to 0 7 bar by opening the suction service valve for a few seconds then closing frontseating it again WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 psig 159 9 bar Do not use oxygen in or near a refrigerant system an explosion occur See Figure 8 30 Connect a cylinder of dry nitrogen Use the nitrogen to increase the compressor pressure to 20 to 150 psig 1 4 to 10 2 bar to detect the leak The larger the leak the less pressure is required The smaller the leak the greater
377. et surfaces and reinstall intake air heater and flange using new gaskets Torque flange bolts to 11 to 18 ft Ibs 15 to 24 nm The ENSCU is located on the air cleaner bracket see item 4 Figure 2 3 Figure 8 14 Electronic Speed Control Components 8 5 11 Speed Control System Engine speed is controlled by three components the engine speed control unit ENSCU the fuel speed actuator FSA and the engine speed sensor ENSSN The ENSSN provides the speed signal to the ENSCU The ENSCU starts stops and controls the speed of the engine by varying the position of the FSA rod It also provides a speed signal to the microprocessor The FSA combines the fuel shutoff solenoid and speed control solenoid into one component The ENSCU is fitted with an alarm LED which may be used to diagnose failures within the system Refer to Section 10 for wiring schematic and to Section 9 5 for Speed Control System Diagnostics 8 5 12 Cooling System a Cleaning and Flushing Air flows through the condenser and then the radiator The cooling surfaces of both must be clean and the interior of the radiator must be clean for 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 ra diator engine Never exceed more than a 60 concentration of anti freeze Use a low silicate anti freeze meeting speci
378. etween 28 F and 55 F 2 2 and 12 8 C Range 1 will be set for Continuous with a Minimum Temperature of 28 F 2 2 and a Maximum Temperature of 55 F 12 8 Should Continuous Operation ALWAYS also be required with setpoints between 22 and O F 30 and 17 8 then Range 2 will be set for Continuous with a Minimum Temperature of 22 F 30 C and a Maximum Temperature of O F 17 8 C Any setpoint outside of Range 1 or 2 will allow changes between Start Stop and Continuous 62 11524 1 amp 2 Range 2 is set for 0 to 22 F 17 8 to 30 23 3 17 8 12 2 Range 1 is set for 28 to 55 F 2 2 to 12 8 C Figure 4 4 Range Lock Settings Non Overlapping Range 1 always has priority when Range 1 amp 2 overlap Range 1 is set for 32 to 42 F 0 to 5 6 C Set for Continuous 23 3 17 8 12 2 Range 2 is set for 22 to 89 6 F 30 to 32 C Set for Start Stop Figure 4 5 Range Lock Settings Overlapping The primary time that it is important to determine which range is to be Range 1 and which is to be Range 2 is when the ranges overlap each other In example 2 see Figure 4 5 the ranges have been set to lock all setpoints into Start Stop except for a small range between 32 and 42 F 0 and 5 6 C where the unit will always operate in Continuous Range 62 11524 4 12 1 Minimum Temperature has been set for 32 F 0 C an
379. fication GM 6038M for standard life coolant or use Texaco Havoline extended life coolant or any other extended life coolant which is Dexcool approved and has 5 150 5 years 150 000 miles on the label 1 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle 2 Remove all foreign material from the condenser coil and radiator by reversing the normal air flow Air is pulled in through the front and discharges over the engine Compressed air or water may be used as a cleaning agent WARNING Do not remove the cap from a hot radiator or bottle if the cap must be removed do so very slowly in order to release the pressure without spray NOTE Draining the coolant from the engine petcock will leave approximately 1 quart 9 liters of coolant in the block 3 Drain coolant completely by removing radiator cap and then the lower radiator hose CAUTION NEVER POUR COLD WATER INTO A HOT ENGINE however hot water can always be added to a cold engine 4 Install hose and fill system with clean untreated wa ter 5 NOTE Only clean water should be used to flush the cooling system Do not use any radiator flush or detergents to clean the radiator Start the engine and drain system while warm Rinse system three times after it has cooled down Refill system wit
380. figuration s will be automatically set for default value RESET CONDITION Auto Reset when valid Configuration s are entered or alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Configurations Check Configurations All must be set for selectable values Check Software Version Check microprocessor software ver Upgrade to the latest version of software Newer ver sion sions of ReeferManager may contain configurations that were not present in older versions of micropro cessor software Reconfigure Microprocessor Send settings to microprocessor Using the latest version of ReeferManager and a Configuration PC Card write the desired configura tion file to the PC Card then load the file into the mi croprocessor Allow the microprocessor to reboot it self Reset Microprocessor a Place the Main Power switch in the Microprocessor powers up OK OFF position for 30 seconds then back to the desired position Check for valid Configuration set Values are set correctly for all parameters tings in Configuration List Alarm is cleared Disconnect positive battery cable Micr
381. flood back of liq uid refrigerant Correct this situation before perform ing step 3 Turn unit off to check the oil level The correct oil level range should be 1 8 to 1 2 glass If level is above 1 2 glass or below 1 8 glass continue with the following steps as required b Adding Oil With Compressor In System CAUTION Use only Carrier Transicold approved Poly ol Ester Oil POE Buy quantities of one gal lon or less When using this hygroscopic oil immediately reseal Do not leave con tainer of oil open or contamination will oc cur Two methods for adding oil are the oil pump method and closed system method Oil Pump Method One compressor oil pump that may be purchased is a Robinair part no 14388 This oil pump adapts to a one U S gallon 3 785 liters metal refrigeration oil container and pumps 2 1 2 ounces 0 0725 liters per stroke when connected to the oil fill Item 12 Figure 8 19 There is no need to remove pump from can after each use When the compressor is in operation the pump check valve prevents the loss of refrigerant while allowing the technician 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 oil fill Purge the oil hose at oil pump Add oil as necessary Closed System Method CAUTION Extreme care must be taken to ensure the hose is immersed in the oil at all times
382. for shorted circuit in harness and continuity through the harness Energize Circuit See Note 2 page 7 2 Check for voltage from SP5 through switch and SP15 to micro processor terminal 2MP29 Check HP1 Switch Check switch operation Test switch refer to Section 8 8 7 step b 62 11524 Alarm NO Corrective Action Alarm Cause 14 HIGH A C AMPS e TRIGGER ON AC Current Sensor 1 is greater than 40A or AC Current Sensor 2 is greater than 40A for 3 seconds e UNIT CONTROL Engine Operation Alarm will not activate Standby Operation Refrigeration system shutdown and alarm with PSCON still energized e RESET CONDITION Auto reset after 15 minutes if the AC current sensor reading is less than 38 amps or alarm may be manually reset via keypad or by turning unit off then back on NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Generator Voltage If Used When Alarm Occurred Check voltage at GENCON 11 12 L1 L3 L2 L3 Must be nominal 460 VAC Check Power Source Voltage If Used When Alarm Occurred Check voltage at PSCON 11 12 Must be nominal 460 VAC L1 L3 L2 L3 Check Voltage Output From Contactors a Check
383. g on the version of soft ware currently in the microprocessor DO NOT INTERRUPT THE SOFTWARE INSTAL LATION PROCESS ONCE IT HAS STARTED Also do not place the Main Power switch in the OFF position during the initial power up following a software upgrade To load software from the card into the microprocessor insert the card in accordance with the instructions provided in Figure 5 3 When loading new software the MessageCenter will display one of 3 different messages SAME SW TO LOAD T TO CANCEL The software loaded on the card is the same as the software presently in the microprocessor OLD SW TO LOAD T TO CANCEL The software loaded on the card is older than the software presently in the microprocessor NEW SW TO LOAD TO CANCEL The software loaded on the card is newer than the software presently in the microprocessor 62 11524 NOTE All units should have the microprocessor soft ware upgraded to the latest production soft ware provided for Carrier Transicold dealers on the TransCentral site except for those units that are listed in the Field Test Software sec tion For units listed in the Field Test Software section ensure the latest software for that unit is installed Press the key to load the software The MessageCenter will display ENGINE AND MICRO WILL STOP NOW and the unit will shutdown After about 45 seconds the MessageCenter backlight will dim and t
384. g two 6mm bolts and a puller remove the blade NOTE DO NOT use 6mm bolts to drive the fan off CAUTION A mica shim Carrier Transicold part num 19 Install the lifting tool Carrier Transicold part number ber 54 00630 25 must be installed before 07 60085 01 removal of the generator The generator is 225 to be removed piece with the shim in 20 the remaining stator bolts place DO NOT attempt to remove the rotor 21 Remove the generator with a sling DO NOT pry from the stator against the spacer between engine and generator 8 41 62 11524 c Generator Assembly Procedure 4 Locate two screw holes on the face of the crankshaft which are approximately 0 5 in 12 7mm apart See Figure 8 41 all other screw holes are approximately 0 75 in 19mm apart 5 Assemble two guide rods CTD P N 5671 into the two holes on the crankshaft located in the pre vious step Assemble the third rod across from the first two rods 6 Install the flywheel on the crankshaft using the guide rods to align properly Make sure the flywheel mates with the crankshaft with no rocking or side to side movement 7 Lift the generator using the lifting tool and hang it in front of the engine Make sure the generator leads 11 Figure 8 40 exit the stator winding on the side away from the engine 8 The mounting holes on the generator rotor Item 10 have two holes offset to match the ones in the crank shaft
385. ge must be within allowable range Refer to Section 2 12 for correct electrical values Alarm NO Alarm Cause Corrective Action 76 CONDENSER MOTOR OVERHEATED TRIGGER ON One or both of the condenser fan motor Internal Protectors IP CDM1 AND 2 cir cuit is open e UNIT CONTROL Engine Operation eng ine and unit shutdown and alarm Standby Operation refrigeration system shutdown and alarm with PSCON still energized RESET CONDITION Auto Reset when motor overload input is within limits or change to engine Operation or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Condenser Fan Blades for Free Operation Visually inspect condenser fan blades for any foreign material or damage or anything that will prevent the blade and motor from turning freely Fan blade must be in good condition No sticks or other material obstructing its movement No ice build up preventing blade rotation Check For 12 VDC At 4MP2 a If 12VDC Alarm should have cleared itself b If no power OVDC Continue with step 2 below Check IPC circuit a Check
386. gerant Overcharge Check refrigerant level in the receiv er Refer to Section 8 6 2 Perform Pretrip Check Clear Active Alarm list then run Pre trip amp check for any new alarms Any active alarms must be corrected and cleared be fore proceeding Check EVXV a Check wiring and connections to EVXV No physical damage to harness No damage or corrosion in connectors Connector tight on valve b Check operation of EVXV Refer to Section 8 8 6 Check Compressor 62 11524 a Perform Pump Down Test Refer to Section 8 7 1 Must hold a vacuum and not equalize in a short peri od of time b Cover condenser and build up discharge pressure Must be able to pump up to 400 psig 27 2 bar c Disassemble and inspect compressor valve plates reeds pistons etc Must be intact clean and in good working order Alarm Cause Corrective Action 28 CHECK REFRIGERATION SYSTEM TRIGGER ON The compressor is running and the discharge pressure is less than 5 psig 0 34 bar higher than suction pressure for more than 10 minutes e UNIT CONTROL Engine Operation alarm only or if configured for shutdown engine and unit shutdown and alarm Standby Operation alarm only or if configured for shutdown refrigeration system shutdown and alarm with PSCON still energized RESET CONDITION Auto reset when discharge pressure is more than 20 psig 1 36 bar
387. ges 4 3 3 4 3 VE E UE ROLE eas E Eo da dos 4 3 2203 2 12 Sepa kv RA e a pao nd dd cs d Uo 4 3 4220 dace exp ide Se Se duode 4 3 AA START STOP OPERATION 4 3 4 4 4452 4 4 4 5 4 6 4 6 45 ras 4 6 DEFROST RE RE 4 9 4 8 1 Deirost Initiation And 4 9 rc 4 9 4 9 47 USER SELECTED OVERRIDE OPERATION 4 10 7 gd te kg ied ics Abed Sie eli cla ible Wate das 4 10 ae Xa dana dd 4 10 Range Lock 162s ess X RAO PG Rd Rudd 4 11 4 8 PREPROGRAMMED SOFTWARE OVERRIDES 4 13 Cargo Protect MUR sisse proc d ddp 4 13 4 8 2 Compressor Minimum Operating 4 13 463 Engine Speed Overrides i e potiore da UE A RE ER UD A Mea iit Up 4 13 Unliader Control DVeti ecu eux esee reapse tac ist Re a Oe 4 14 405 Dorost oH DS
388. gine next to the injection pump This pump has a manual plunger for priming the fuel system when the fuel tank has been run dry To prime the fuel system use the following steps a Turn the bleed valve red counter clockwise until ful ly opened Turn the top of the manual plunger counter clockwise to unlock it S L O W L Y up down once per second pump the manual plunger until positive pressure re sistance is felt This may take up to 200 strokes This will indicate fuel flow b Continue to pump S L O W L Y up down once second approximately 100 more strokes to fill the fil ter and bleed the air out of the lines 62 11524 8 8 d Start engine It may be necessary to continue to pump until the engine starts CAUTION Running the engine for an extended period of time with the manual plunger up can cause a priming pump failure e Depress and turn the top of the manual plunger clock wise to lock in place f When engine is running smoothly turn bleed valve clockwise until fully closed 1 Mechanical Fuel Lift Pump 2 Manual Plunger 3 Bleed Screw 4 Injection Pump Figure 8 6 Fuel Bleed Components 8 5 3 Mechanical Fuel Pump Screen The fuel screen See Figure 8 7 may become plugged or restricted with foreign particles or wax as a result of using the wrong grade of fuel or untreated fuel in cold weather This will cause the engine to lose power The screen must
389. gine with control of temperature by alternate cooling and heating of the supply air evaporator outlet air The auto Start Stop feature is standard equipment The unit can be described as having three major sec tions the condensing section Figure 2 1 amp Figure 2 2 which includes the engine generator drive package Figure 2 3 the evaporator section Figure 2 4 e the controls Items 11 through 14 Figure 2 3 Figure 2 6 amp Figure 2 10 The remote evaporators Figure 2 5 are mounted in Compartments 2 amp 3 62 11524 Table 2 1 Model Chart Engine Speed High Low Model Compressor Engine NDP532 6JBP2 060 41 V2203 L DI E3B CTD 5 1800 1350 Three Compartment Configuration Remote Evaporator Location 1 MHS22 445 3A4 Z MHD22 445 3A4 Z MHS11 245 3A4 Z MHD11 245 3A4 Z MHS11 245 3A4 Z MHD11 245 3A4 Z MHD11 245 3A4 Z MHD11 245 3A4 Z MHS11 245 3A4 Z MHS11 245 3A4 Z MHS22 245 3A4 Z MHS11 245 3A4 Z MHD22 245 3A4 Z MHS11 245 3A4 Z MHS22 245 3A4 Z MHD11 245 3A4 Z MHD22 245 3A4 Z MHD11 245 3A4 Z Table 2 2 Additional Support Manuals Manual Number
390. h Configuration If the Door Remote Switch Configuration is set for low speed the engine will run in low speed when the door remote switch is open active 8 Start Stop Restart If the engine is restarted from a Start Stop off cycle for any reason except a Start Stop Parameter Override Temperature the engine will operate in low speed all conditions are met for another off cycle OR for the Minimum Run Time Functional Parameter value 9 Low Speed To High Speed Delay The compressor must operate for 2 minutes before transition to high speed is allowed The time value entered in the High Speed Delay Con figuration must be expired before transition to high speed is allowed 10 Low Speed Startup The time value entered in the Low Speed Startup Minutes Functional Parameter for Start Stop or Continuous must be expired before transition to high speed is allowed 62 11524 11 Frozen Setpoint Frozen Setpoint Override If the setpoint is a frozen setpoint below 10 4 F 12 C and the temperature is below setpoint the engine will operate in low speed 12 Low Suction Pressure The microprocessor monitors the signal provided by the Suction Pressure Transducer If the suction pressure falls below 2 0 14 bar for more than 20 seconds the engine will operate in low speed for a minimum of 5 minutes then remain in low speed until the suction pressure is greater than 2psig 0 14 bar 13
391. h water Run engine to operating temperature Drain system again and fill with 50 50 water anti freeze mixture see Caution Note at the beginning of this section b Radiator Replacement Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Drain coolant completely by removing radiator cap and then the lower radiator hose Remove condenser fans refer to Section 8 9 7 When removing the road side fan assembly remove the condenser to subcooler line support bracket com pletely to allow clearance for coil removal Remove the radiator frame assembly mounting bolts see Figure 8 15 and and remove the radiator frame assembly Remove top radiator mounting brackets and remove the radiator through the top of the unit Re assemble in reverse order of removal Flush and fill radiator with coolant Refer to section 8 5 12 Condenser coil not shown for clarity Radiator Frame Assembly Radiator Mounting Bracket Radiator Condenser Frame Assembly Radiator Frame Mounting Bolts o RON Figure 8 15 Condenser And Radiator Assemblies 62 11524 8 5 13 Water Pump V Belt WARNING Beware of moving poly V belt and belt driv en components WARNING When working with belts beware of pinch points Figure 8 16 Wate
392. harge ESD In certain cases the hu man body can have enough static electric ity to cause resultant damage to the compo nents by touch This is especially true of the integrated circuits found in the Advance mi croprocessor CAUTION Under no circumstances should a techni cian electrically probe the microprocessor at any point other than the connector termi nals where the harness attaches Micropro cessor components operate at different voltage levels and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could perma nently damage the microprocessor CAUTION Ensure the clock you are using is curate Also some customers are located in different time zones from the repair loca tion If you know the owners desired loca tion time enter that time If you don t enter the current time at your location CAUTION DO NOT leave the circuit energized for the full 5 minutes if full amperage is shown as the intake air heater element life will be greatly shortened CAUTION Unit uses R404A and POE oil The use of in ert gas brazing procedures is mandatory for all Carrier Transicold refrigeration units otherwise compressor failure will occur For more information Refer to Technical Procedure 98 50553 00 Inert Gas Brazing CAUTION Do not over torque display amp keypad head screws Torque all screws to 60 in Ibs 6 8 Nm
393. he 4 hex head 1 4 20 bolts holding the assembly to the unit see Figure 8 4 and lay the assembly on a clean work surface Re ground wrist strap at new work surface Loosen and remove the 4 pan head screws holding the display board to the keypad support Carefully separate the display board from the keypad support If additional disassembly is required remove the el even pan head screws eight screws around the peri meter and three in the center used to retain the keypad support keypad gaskets and window to the bezel DETENT NOTCH Display Board Keypad Support Keypad Latch Spring Bezel OoahWND 7 Condensate Drain 8 Door 9 Plug 10 Gasket Window to Bezel 11 Window 12 Gasket Keypad to Window Figure 8 4 Display and Keypad Assembly b Reassembly CAUTION Do not over torque display amp keypad pan head screws Torque all screws to 60 in Ibs 6 8 Nm NOTE All gaskets must be replaced any time the keypad support is removed from the bezel All replacement display bezel assembly kits are packaged with replacement gaskets 1 Clean all gasket surfaces and install keypad support keypad gaskets and window to the bezel in the cor rect order see Figure 8 4 Install the 11 mounting screws 2 Install the display board and reconnect wiring between the keypad amp display assembly and har ness 3 Reconnect negative battery cable and standby plug as required and run
394. he Advance microprocessor contains a_ built in DataLink data recorder with 512K of memory The re corded data can be downloaded from the DataLink data recorder using either ReeferManager or a Download PC card The DataLink data recorder reads the same input infor mation as the microprocessor Functional Parameters Configurations and Unit Data at all times The DataLink data recorder records events as they occur such as setpoint changes and defrost initiation and ter mination and also records all data values including tem perature sensors and pressure transducers in either av eraged or snapshot format The following intervals are available for sensor record ing 2 Minutes 30 Minutes 5 Minutes 1 Hour 10 Minutes 2 Hours 15 Minutes 4 Hours 3 18 1 Microprocessor Information The microprocessor information that may be recorded is as follows DataLink data recorder setup Logging Intervals Events and Sensors DataLink data recorder time clock date time Setpoints ID Number Unit Serial Number Unit Model Number Trailer ID Current System Mode Functional Parameters Microprocessor Configurations 3 18 2 Data Recording The DataLink data recorder data comes from four gen eral categories of information a Microprocessor Information as described in Section 3 18 1 above 3 27 b Sensor Data This information is recorded at pre determined inter vals as a snapshot of the sensor at the time of the re cordi
395. he calculation is 2 6 4 C lowest allowed supply air temperature Value to be used to calculate the lowest allowable supply air temperature when in Continuous Opera tion in accordance with the formula Setpoint this value coldest allowable supply air temperature For example Fahrenheit if the setpoint is 35 F and the Configur ation value is set at 10 F the calculation is 35 7 10 25 F lowest allowed supply air temperature Celsius if the setpoint is 2 C and the Configuration value is set at 6 C the calculation is 2 6 4 C lowest allowed supply air temperature YES The unit will remain in high speed 6 cylinder cooling until the compartment temperature has dropped to less than 0 36 F 0 2 C above setpoint NO Normal unit operation CONFIG COMPLETE Press the key to exit configurations 5 23 62 11524 SECTION 6 MESSAGECENTER PARAGRAPH NUMBER Page 6 1 MESSAGES 22 22 9 RR 6 1 62 11524 6 1 MESSAGECENTER MESSAGES SECTION 6 MESSAGECENTER The following table lists all of the messages which do not appear in other lists in this manual and a description of their meaning Refer to Section 7 for a list of Alarm messages Refer to Section 3 13 for a list of Unit Data messages Refer to Section 3 15 for a list of Functional Parameter messages Refer to Section 5 2 1 for a list of Configuration messages Mes
396. he compartment door has been opened Troubleshooting steps begin on the next page 62 11524 7 46 Alarm NO Alarm Cause Corrective Action 62 C2 TEMP OUT OF RANGE Continued NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Compartment Doors Inspect all trailer compartment doors Must be closed no air leakage Defrost Evaporator Initiate Manual Defrost Cycle Must terminate automatically All ice cleared from all evaporator coils Check For Any Shutdown Alarm s Check the Alarm List for any Shutdown Alarms Alarm conditions must be corrected and the alarm cleared to continue Check For Low Refrigerant Pressur e Alarm Check for alarm 18 Alarm conditions must be corrected and the alarm cleared to continue Check Refrigerant Level Visually check refrigerant level in receiver Must be at correct level Refer to Section 8 6 2 Check System Pressures Install manifold gauge set and check system pressures Suction amp Discharge Pressures must be in the nor mal range Suction amp Discharge Pressures must have the same reading on gauges amp on micro dis play Check Evaporator Airflow Alarm Check for
397. he engine generator air cleaner muffler coolant system fuel system oil filter system and engine sensors 2 3 1 Engine The engine is a four cylinder diesel which gives excellent fuel economy and has easy starting characteristics It is equipped with spin on lube oil and fuel oil filters for easier filter changes The fuel filter may also be equipped with a thermostatically controlled fuel heater The engine cooling system consists of the radiator which is mounted with the condenser coil and coolant overflow bottle The system is also fitted with an electronic battery charger which converts generator or standby alternating current to direct current for battery charging Refer to Section 2 9 for engine data 2 3 2 Engine Air System The air cleaner prolongs the life and performance of the engine by preventing dirt and grit from getting into the engine and causing excessive wear on all operating parts It is the responsibility of the operator to give the air cleaner equipment regular and constant attention in accordance with the instructions An optional air cleaner service indicator may be connected to the intake manifold Its function is to indicate when the air cleaner requires replacement Refer to section 8 5 9 2 3 3 Engine Controls a Engine Speed Control Unit ENSCU The ENSCU see Figure 2 7 is a microprocessor based unit which controls the fuel supply to and speed of the engine in accordance with the position of the
398. he message INSTALLING PROGRAM SOFTWARE will be displayed The microprocessor will continue and complete the software loading in accordance with the instructions provided in Figure 5 3 5 4 3 Configuration PC Card A configuration card may be loaded with Configuration or maintenance files for download to the microprocessor The card may contain either type of file however only one may be loaded to the card at a time NOTES 1 When loading Configuration or Maintenance files to the ReeferManager will provide instruction for loading of IntelliSet files Use of IntelliSets for the Vector 6600MT units is not recommended at this time There can be a single complete DataLink data recorder and microprocessor setup placed on the card for setting up reefers This is simply called creating a Configuration Card Unit specific and time sensitive data cannot be loaded to a configuration card This data includes model number serial number hour meter readings date time These configurations must be set using the keypad or ReeferManager There certain individual microprocessor settings placed on the card for maintenance purposes This is called creating a Maintenance Card To load a file from the card into the microprocessor insert the card in accordance with the instructions provided in Figure 5 3 Press the key to load the file The MessageCenter will display LOADING INFO while the
399. he unit off then back on again Check UL2 circuit refer to procedure for alarm 86 P166 C2 CHECK SUPPLY AIR SENSOR TRIGGER ON Supply Air Sensor is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip mode is started again or alarm may be manually reset via keypad or by turning the unit off then back on again Check Sensor refer to procedure for alarm 136 7 101 62 11524 Alarm Cause Corrective Action P167 C3 CHECK HEATER 2 CIRCUIT This device is checked twice Pretrip once in Test 2 and again in Test 8 TRIGGER ON TEST 2 Normal draw for the 3HTCON contactor coil is 05 to 5 0 D C Amps 12 VDC The circuit tests outside this range TRIGGER ON TEST 8 Normal draw for the SHTCON heaters is 1 0 to 7 0 A C Amps 460 VAC The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip mode is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the s
400. hematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors e Check resistance of FSA Refer to Section 2 13 for correct electrical values f Check operation of FSA Plunger must move in when energized g Check connections at points SP3 SP5 ans SP6 splice Connections must be good condition No loose or broken wires 62 11524 Additional steps on the next page Steps Alarm Cause Corrective Action ENGINE STALLED Continued 7 Check Engine Speed Sensor ENSSN Inspect harness amp control box connector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors Check Electrical System Amperage a Check the configuration setting for Diesel Max Gen Amps Must be set for 22 25 Amps b Check the configuration setting for Diesel Offset Max Amps Must be set for 4 Amps c With the unit operating check all 3 high voltage circuits for amperage Must be no more than 26 Amps Check engine air intake system a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check engine exhaust system Inspect the exhaust system Must be clear and unobstructed Check engine a Check Injection pump timing
401. hese features 4 4 START STOP OPERATION Start Stop is provided to reduce fuel or power consumption This feature allows full automatic control of the unit by monitoring compartment temperatures battery condition and when in Engine Operation engine coolant temperature The main function of Start Stop Operation is to shutdown the engine or compressor after certain conditions are met to provide an efficient temperature control system and to initiate a restart sequence after certain conditions met The Start Stop Continuous key is pressed to select between Continuous and Start Stop Operation The corresponding LED will be illuminated NOTE The microprocessor may be locked so that the unit will always operate Start Stop whenever the setpoint is within a specific range Refer to Range Lock Section 4 7 3 for additional infor mation 62 11524 4 4 1 Start Stop Configuration Microprocessor control of Start Stop Operation is dependent both Configuration and Functional Parameter settings The first setting to be considered is the START STOP PARAMETERS Configuration This setting determines control actions when in the Perishable Range or Frozen Range The available settings are TOGETHER and SEPARATE When SEPARATE is chosen the control action will be different depending on whether the setpoint is in the Perishable Range or in the Frozen Range refer to Section 4 3 2 When TOGETHER is chosen the same settings ap
402. hich ensures that the electric motors will run in the correct direction For safe reliable operation in Standby Operation it is important to consider the following guidelines e NEVER connect the unit to a high voltage power source unless the Main Power switch is in the OFF position 3 3 The microprocessor will then perform a Self Test refer to section 3 3 and start the unit automatically Ensure the 2nd Compartment Run C2 is in the ON position if operation is desired The power supply cable and circuit breaker must comply with local electrical code and unit specifica tions Refer to section 2 12 The power supply cable must be equipped with a ground connection Repairs or maintenance to the supply voltage circuit should only be performed by licensed authorized personnel 62 11524 3 3 SELF TEST MODE LIGHTS ALARM STRTSTOP CON TINUOU MAIN DISPLAY COOL DEFROST MessageCenter oL sg 00 NS RATURE TERE ENGINE O N TZ STANDBY SELF TEST When first powered up the microprocessor will run a self test consisting of the following steps All of the mode lights will illuminate All of the segme
403. ht Glass Or Fusible Plug Remove the refrigerant charge Refer to Section 8 6 2 b Loosen the sight glass or fusible plug to relieve any remaining pressure Remove and discard glass or plug c Wrap threads of new sight glass or plug with Teflon tape or spread sealing compound on pipe threads and install Torque the sight glass to 15 to 25 ft lbs 20 to 34 Nm Torque the fusible plug to 4 to 8 ft 16 5 to 11 62 11524 8 28 d Leak check evacuate and charge the system Refer to Sections 8 6 3 8 6 4 amp 8 6 2 8 8 5 Compressor Suction CSMV The purpose of the SMV is to maintain the compressor within its operating envelope and maximize unit capacity and fuel economy At initial startup the microprocessor will go through a self test When the test is complete the MessageCenter will display SMV CLOSING Then the MessageCenter will display SETTING SMV XX with actual percentage depending on ambient temperature and refrigerated compartment temperatures The unit will then go through its normal start procedure Modulation Valve 2 1 8 INCH NUT 4 PIN CONNECTOR STEPPER MOTOR Figure 8 26 Suction modulation valve CSMV If it is suspected that the SMV is malfunctioning the most efficient method of diagnosing the valve is to run a pretrip refer to Section 3 4 The pretrip steps will check the remainder of the system and the 11 test will check the SMV The valve will be brought to a preset
404. i tional removal and evacuation CAUTION Do not vapor charge R404A Only charging through the liquid line service valve is acceptable 3 Ensure that the microprocessor MessageCenter dis plays RECOVER LEAK CHK EVAC MODE during the pressurizing and leak checking procedures Re fer to Section 5 2 3 If the microprocessor switches to charge mode during the process switch it back to the RECOVER LEAK CHK EVAC MODE 62 11524 4 Pressurize the system to 5 to 10 psig 0 3 to 0 7 bar with refrigerant at the liquid line service valve WARNING Do not use nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 psig 159 9 bar Do not use oxygen in or near a refrigerant system as an explosion occur See Figure 8 30 Connect a cylinder of dry nitrogen Use the dry nitro gen to increase the pressure as necessary to 20 to 150 psig 1 4 to 10 2 bar to detect the leak The larger the leak the less pressure is required The smaller the leak the greater pressure is required The recommended procedure for finding leaks from a system is with an electronic leak detector Checking joints with soapsuds is satisfactory only for locating large leaks or pinpointing small leaks once a general area has been located Once leak checking is complete remove the refriger ant nitrogen vapor out of the system If no leaks are found the system is ready for evacu
405. i Refer to Section 2 11 for switch setting If switch fails to actuate at correct gauge reading adjust switch by turn ing adjusting screw clockwise to increase setting or counterclockwise to decrease setting j Repeat checkout procedure until switch actuates at correct gauge reading k After switch is adjusted place a small amount of paint or fingernail polish on the adjusting screw so that vibration will not change switch setting 8 8 10 Liquid Line Solenoid Valve 2LSV 3LSV a Checking Operation the LSV is used to control the flow of refrigerant to the compartment Generally when a compartment is enabled and the box temperature is above setpoint the microprocessor will be calling for that compartment to operate in Cool When the compartment is calling for Cool the LSV will be energized allowing liquid refrigerant to flow through the valve to the evaporator If time permits an easy method for checking an LSV is to first run the unit through a defrost cycle Then operate Compartment 1 only with the remote compartments turned off After 5 to 10 minutes visually inspect the remote evaporators The evaporator fan motors should not be running Inspect the condition of the evaporator coil There should be no frost If possible check the temperature of the suction line leaving the evaporator without damaging the insulation on the line Frost on either a remote compartment coil or a suction line that is colder than the compartme
406. icroprocessor calls for a change from low to high speed or when unit first starts UNIT CONTROL Engine Operation alarm only Standby Operation this alarm will not activate in standby Operation RESET CONDITION Auto Reset if microprocessor is set for high speed operation and the signal is between 1670 and 1930 for 60 seconds or change unit to standby Operation or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Model Number Verify that the model number on the nameplate matches the model number shown in the microprocessor Unit Data Enter the correct number in Configurations Refer to Section 5 2 1 Check for proper voltage to the Engine Speed Control Unit ENSCU pin 16 Check for proper voltage with unit running a Check ENSCU 16 12 VDC between ENSCU 16 and ENSCU19 b Check circuit from ENSCU 16 to microprocessor connection Must be 12 VDC at MPQC3 and ENSCU16 Check Fuel Speed Actuator FSA plunger Check plunger on fuel speed actuator Must move in and out freely Spring tension must hold rod firmly extended and in place Chec
407. id line solenoid valves When the valves are closed CHARGE MODE HOLD TO EXIT is displayed in the Mes sageCenter This action is taken to prevent refriger ant migration to the compressor during charging To exit Service Mode at any time press and hold the key for seconds EXITING SERVICE MODE will then display in the MessageCenter 62 11524 5 3 PC MODE PC Mode allows the technician to access the microprocessor without the engine running and without the refrigeration system running When in PC Mode the microprocessor is fully functional and all Operator Interfaces may be performed the operation of the microprocessor may be demonstrated and all PC functions may be performed again without the unit actually operating Insulated Jumper Download Port GREEN WIRE E MODE CONNECTOR P N 22 50180 01 Figure 5 2 PC Mode Connection To place the microprocessor in PC Mode a Place the Main Power switch in the OFF position b Locate the serial download port item 14 Figure 2 3 remove the protective plug to gain access to the wire terminals c Plug in a PC mode connector or install an insulated jumper Figure 5 2 WARNING Do not toggle the Main Power switch out of the OFF position when in PC Mode or the unit will start d The microprocessor will be energized but the engine and refrigeration system will not be started e When work is complete r
408. ier Transicold PC Cards The microprocessor automatically detects the presence and type of PC Card inserted and responds accordingly The different types of PC Cards are Download Card for copying unit data from DataLink data recorder Options PC Card for installing optional software programs Configuration PC Card for setting the Microprocessor Functions Configurations and DataLink data recorder Configurations Program PC Card for upgrading the microprocessor software There are three LEDs associated with the function of the PC card slot These are e A green Micro Status LED which will blink steadily once per second indicating that the microprocessor is operating and will blink every 0 5 seconds if there is no software or if it is loading software e A green PC Card Status LED which comes on when there is a PC card inserted in the slot This LED will Blink once per second when data is being trans ferred to or from the PC Card Will be on steady when the operation is complete indicating the PC Card may be removed 1 During Download after Card is read and identified card status LED blinks 2 seconds on and 2 seconds off until the key is pressed to start the programming from the card to the micro Once the data transfer to the micro begins the Card Status LED and the Micro Status LED will blink together 1 2 second on and 1 2 second off until the data transfer is complete then the Micro Status LED w
409. iguration is an option it other supplier QUALCOMM The microprocessor is set for communication from Qualcomm Trailer Tracs STANDARD STANDARD The microprocessor is set to control UNIT OPERATION RAIL trailer refrigeration operation RAIL Not recommended for Vector MT 21 6 to 0 F Value to be used to calculate the lowest allowable 12 to 0 C supply air temperature when in Start Stop Opera in 0 5 F or C in tion in accordance with the formula Setpoint this crements value coldest allowable supply air temperature DEFAULT 21 6 F For example SUPPLY AIR LIMIT FOR S S 12 C Applies to Compartment 1 Fahrenheit if the setpoint is 35 F and the Configur ation value is set at 10 F the calculation is 35 10 25 F lowest allowed supply air temperature Celsius if the setpoint is 2 C and the Configuration value is set at 6 C the calculation is 2 6 4 C lowest allowed supply air temperature 62 11524 5 22 Table 5 2 Microprocessor Configurations Continued Selections Descipion SUPPLY AIR LIMIT FOR CONT Applies to Compartment 1 C2 SUPPLY AIR LIMIT FOR S S Applies to Compartment 2 C2 SUPPLY AIR LIMIT FOR CONT Applies to Compartment 2 HIGH SPEED PULLDOWN Applies to operation with only Com partment 1 enabled 21 6 to 0 F 12 to 0 C in 0 5 F or C in crements DEFAULT 5 0 2 7 C NOT INSTALLED
410. il that may have migrated with refrigerant to other parts of the system during unit operation x Install components removed in step h Install blankoff plates and plugs in original compressor for shipment Remove any remaining old gasket material from the discharge and suction service valve sealing surfaces m Secure junction box to compressor 5 Install compressor in unit See Figure 8 19 for mounting bolt torque information Connect all wiring per wiring schematic Install junc tion box cover Install new gaskets and mounting bolts in service valves Torque discharge service valve mounting bolts 20 to 30 ft Ibs 27 to 40 7 Nm Torque suction service valve mounting bolts 55 to 80 ft 105 74 to 108 Nm q Leak check and evacuate the compressor Refer to Section 8 6 3 and Section 8 6 4 8 7 3 Cylinder Head and Valve Plate Service a Pumpdown the compressor Refer to Section 8 6 2 b Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle WARNING Do not unscrew cylinder head mounting capscrews all the way before breaking seal Entrapped pressure could result in injury Loosen cylinder head capscrews Tap the head lightly with a wooden or lead mallet to break the seal and re lieve any remaining pressure Be careful no
411. ill continue at the 1 2 second rate and the Card Status LED will come on solid and remain on solid until the card is removed from the slot e A red PC Card Fault LED blinks if there is a problem transferring data from the PC card that has been plugged into the PC card slot The red LED will continue to blink until the PC card is removed The LED will also blink if there is an error reading the card Check the MessageCenter for description of error RUN RELAY RR Board Relay K2 amp LED28 PC CARD FAULT LED RED 1MP WHITE IN OUTPUT CONNECTOR Bw PC CARD SLOT 2MP BLACK IN OUTPUT CONNECTOR PC CARD STATUS LED GREEN MICROPROCESSOR STATUS LED GREEN MICROPROCESSOR 3MP GREY IN OUTPUT CONNECTOR FET LEDs Refer to Table 5 1 N QC4 12V OUTPUT TO RR SPEED RELAY SR Board Relay K1 amp LED 27 12 OUTPUT TO SR m Figure 2 10 Control Module F2 10A RELAY POWER QC8 12 VDC DC CURRENT SENSOR CT1 LED30 LED31 SSR 6MP IN OUTPUT CONNECTOR 5MP IN OUTPUT CONNECTOR AMP IN OUTPUT The QC9 FET ARC PM SUPPRESSION QC2 GROUND FROM BATTERY 124 VDC FROM BATTERY F1 7 5A 62 11524 2 VAN ALTERNATE CONFIGURATION O COOL DEFROST ALARM STARTSTOP TINU
412. ill display in either English psig or Metric bar ECO MODE NO When in Continuous Operation control for maximum temperat ure protection YES When in Continuous Operation control for maximum fuel eco nomy RESET PM HOUR METERS STANDBY RUN HOURS TOTAL ENGINE HOURS TOTAL SWITCH ON HOURS PM 1 Thru 5 This Functional Parameter allows resetting of the PM maintenance alarm when an hour meter has timed out or when over 95 of the time out value has expired If a maintenance interval has not been configured for the alarm this parameter will not display Selecting RESET and pressing the key will de activate the alarm and reset the hour meter for the next maintenance interval The amount of time added back into the meter before the next alarm trig ger is determined by the maintenance interval entered in the meter Configuration If there are active maintenance hour meters and none have expired and turned the alarm on or none are within 9596 of the time out value the MessageCenter will display NO METERS TO RESET NOTE If a reset is required for a meter that has not timed out the meter must be configured with a 0 reset value to turn it off and then reconfigured with the desired reset interval Refer to Section 5 for Configuration instructions OUT OF RANGE ALARM Compartment 1 AND C2 OUT OF RANGE ALARM AND C3 OUT OF RANGE ALARM The value entered he
413. in Table 2 2 The unit model serial number plate is located inside the unit on the frame as shown in Figure 2 1 2 2 GENERAL DESCRIPTION The Vector 6600MT unit is a hybrid diesel electric fully charged pre wired refrigeration heating nosemount unit The unit is used on insulated refrigerated compart ments to maintain cargo temperatures within very close limits Electrical power is supplied to the unit from a power plug or by the A C generator which is driven by the engine The generator provides nominal 480V 3 60Hz power when the engine is in high speed and nominal 350V 3 45Hz power in low speed The control box includes manual switches micropro cessor fuses and associated wiring The unit can be equipped with an optional remote light bar which mounts separately on the front roadside corner of the trailer Temperature control is provided by the Carrier Transicold Advance microprocessor Refer to Section 2 6 Once the microprocessor is set at the desired tem perature 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 neces sary to maintain the desired temperature within the refri gerated compartments The auto Start Stop operation provides automatic cycl ing of the diesel engine which in turn offers an energy efficient alternative to continuous operation of the en
414. in the ON position SWITCH ON CONTACTS CLOSED The remote switch will be used as a remote control switch The switch contacts will be CLOSED whenever the switch is ON REMOTE PANEL C1 or C2 If set to this value the remote panel SYSTEM ON OFF key will be en abled The switch panel mounted Main Power switch must be toggled out of the OFF position and the remote panel SYSTEM ON OFF key must be pressed for the compartment to operate However if the Override Remote Switch 1 or 2 Functional Parameter is set to YES the remote panel is dis abled 62 11524 5 20 Table 5 2 Microprocessor Configurations Continued selections ALARM ONLY ALARM ONLY When the switch is activated a UNIT SHUTDOWN Warning alarm will be displayed in the Message Center FEED MINE UNIT SHUTDOWN When the switch is activated alarm will displayed in a UE enter and the compartment REMS1 Compart ONIS RECORDER ment 1 REMS2 Compartment 2 will shutdown LOW ENGINE SPEED When the switch is activ ated the engine will be forced to low speed DATA RECORDER ONLY The DataLink data re corder will record every time the the switch is activ ated There will be no alarms or messages dis played in the MessageCenter SET TIME Indicates to the microprocessor the time and date for the DataLink data recorder Real Time Clock STANDARD STANDARD When individual compartments ECONOMY reach setpoint and cycle off
415. ing to ground of more than 150 miliamps UNIT CONTROL Engine Operation eng ine and unit shutdown and alarm Standby Operation refrigeration system shutdown and alarm RESET CONDITION Auto Reset in Engine Operation Alarm may be manually reset via Keypad or alarm may be reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Overload Ground Fault Detector OGF LED Check status LED LED is On Ground Fault is detected Start with Step 3 below LED is Off Circuit Overload is detected Start with Step 2 below Check For Electrical Overload Check high voltage amp draw from GENCON if running in Engine Oper ation or if running in standby Operation Must be less than 40 Amps Check For High Voltage Short To G round a Check resistance between T1 T2 and for ALL High voltage contactors to ground Reading must be greater than 25 000 Ohms b Perform Megohmmeter test on all high voltage circuits See Section 8 9 Perform Pretrip Check a Clear Active Alarm list then run Pretrip amp check for any new alarms Note during which test Alarm 100 occurs b Furth
416. ins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 62 11524 7 124 Alarm Cause Corrective Action P208 CHECK GENERATOR CONT CIRC TRIGGER ON Normal draw for the GENCONR and GENCON coils is 0 0 to 1 0 Amps 12 VDC The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check GENCONR a Inspect GENCONR and GENCON No damage to coil contactor coils and wire connec No damage moisture or corrosion in connections tions b Check contactor coil resistance Refer to Section 2 13 Check GENCONR and GENCON Amp Draw a Check GENCONR and GENCON Use Component Test Mode Section 5 2 2 to test contactor coils amp draw Refer to Section 2 13 for amp values View current draw in Data List FET 3 On b Listen for GENCON to pull in If GENCON contactor pulls in GENCONR and GENCON are OK If GENCON contactor does not pull in check for 12 VDC at GENCON coil 12 VDC indic
417. installed FUEL TANK SIZE 50 Gallons Refer to Fuel Sensor Configuration for additional in 75 Gallons formation 100 Gallons 120 Gallons 25A Indicates to the microprocessor the maximum al 10 TO 35 lowable amperage in Diesel operation DIESEL MAX GEN AMPS 0 5A increments USE FACTORY DEFAULT SETTING ONLY DO NOT OPERATE UNIT WITH DIFFERENT SETTING 25A Indicates to the microprocessor the maximum al 10 TO 35 lowable amperage in Standby operation STANDBY MAX GEN AMPS 5 increments USE FACTORY DEFAULT SETTING ONLY DO NOT OPERATE UNIT WITH DIFFERENT SETTING 17A Indicates to the microprocessor the maximum al 10 TO 35 lowable amperage during start up STARTUP MAX GEN AMPS 0 5A increments USE FACTORY DEFAULT SETTING ONLY DO NOT OPERATE UNIT WITH DIFFERENT SETTING The maximum allowable amperage in low speed operation will be the configured MAX GEN AMPS in 0 5A increments or MAX STANDBY AMPS less this value USE FACTORY DEFAULT SETTING ONLY DO NOT OPERATE UNIT WITH DIFFERENT SETTING Indicates to the microprocessor the delay for this 5 Seconds unit when starting in standby STANDBY STARTUP DELAY D E This setting is used when multiple units are on the 2n 22 same line to stagger the occurrence of high inrush DIESEL OFFSET MAX AMPS current in situations such as restart after a power loss YES NO YES This hour meter will be displayed during the startup messaging sequence and will be in
418. ions can be loaded as released NO System OK Does the MessageCenter acknowledge a program card was nstalled by displaying Verify you are using a Program PC card and not UB OLD SOFTWARE NEW SOFTWARE another PC card Did you find and correct the or SAME SOFTWARE condition Once the unit shuts down to begin the software installation process the suction modulation valve closing process begins The YE software installation processes will not begin Can the card be read by the until the CSMV is completely closed which ReeferManager program will delay the actual process for about 45 seconds Did you find and correct the J YE a Place card back Possible condition NO into the micro and _ defective try again Did this PC card Retry solve the problem operation with another card Micro display will show ENGINE AND MICRO WILL STOP NOW and engine will stop Did you find and correct YES the condition Y System OK NO Y The display will show INSTALLING PROGRAM SOFTWARE Make sure you wait until the display shows INSTALLL COMPLETE before removing card Did you find and correct the condition Using the ReeferManager Y Program install Program Does MessageCenter display CARD DATA CORRUPT CANNOT LOAD
419. is displayed on the MessageCenter and that the START STOP light is illuminated The unit is now in Start Stop operation Start Stop is provided to reduce fuel or power sumption This feature allows full automatic control of the unit shutdown and restart by monitoring refrigerated compartment temperatures battery charging amps and engine coolant temperature Engine Operation only The main function of Start Stop Operation is to turn off the refrigeration system near setpoint to provide an effi cient temperature control system and to initiate a restart sequence after certain conditions are met The Start Stop Continuous key is pressed to select between Con tinuous Run and Start Stop Operation The corres ponding LED will be iluminated For refrigerated compartment 1 the microprocessor may be configured with Start Stop operation tied to the setpoint ranges for frozen and perishable loads The Start Stop Continuous key is locked out if START STOP LOCKED displays in the MessageCenter when the key is pressed and the unit is in Start Stop Opera tion or CONTINUOUS LOCKED displays in the Mes sageCenter when the key is pressed and the unit is in Continuous Run Operation Refer to Section 5 2 1 for Configuration information If the unit fails to start after three start attempts the A31 FAILED TO START AUTO alarm will be activated While running if the unit shuts down an internal counter keeps track of the shutdo
420. is parameter to SWITCH TO DIESEL will confirm the Configuration and the switch will be allowed SHUT UNIT DOWN If the NO AC POWER Configuration is set to the Switch To Engine setting this parameter to SHUT UNIT DOWN will override the Configuration setting and shut the unit down when power is lost The purpose of this setting is to temporarily override the Configuration setting in situations where switching to engine power is not desired OVERRIDE REMOTE SWITCH 1 SHUTDOWN REMS1 AND OVERRIDE REMOTE SWITCH 2 SHUTDOWN REMS2 AND OVERRIDE DOOR SWITCH SHUTDOWN DS If the Switch is configured Switch Not Installed this parameter will not display NO the microprocessor will respond to the switch as configured YES the configured action on activation of the switch will be overrid den and the action will be alarm only The purpose of this setting is to temporarily override the Configuration setting in situations where shut down or speed change is not desired LANGUAGE IDIOMAS LANGUE LINGUAGEM 62 11524 ENGLISH ENGLISH All information displayed in the MessageCenter will be dis played in English ESPANOL FRAN AIS All information displayed in the MessageCenter will be displayed in French FRANCAIS ESPANOL All information displayed in the MessageCenter will be dis played in Spanish PORTUGU S PORTUGUES All information displayed in the Mess
421. is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check wiring to DPT amp SPT a Verify that correct wires are con nected to each transducer Plugs to transducers are the same The correct wire plug must be connected to the proper transducer b Verify that correct transducer is be ing used in each position Mechanical connections to transducers are the same The Discharge Transducer should have a RED mark ing dot on it The Suction Transducer should have a BLUE mark ing dot on it Check for Check UL2 Alarm Check for alarm 86 or P164 Alarm conditions must be corrected and the alarm cleared to continue Check System Pressures Install manifold gauge set and check and compare compressor discharge amp suction pressures with those shown on the microprocessor dis play Suction and Evaporator Outlet pressures must be above 3 psig 0 2 bar Suction Evaporator Outlet amp Discharge Pressures must have the same reading on gauges amp on micro processor display NOTE Microprocessor Suction CSP and Evapo rator EVOP pressure readings have a maximum value of
422. ist to check amps at power wires b Check A C amps with compressor Must be greater than 5 Amps running c Compare A C Amp readings Maximum allowable difference is 10 Amps between L1 L2 L3 62 11524 7 80 Steps Alarm Cause Corrective Action 129 CHECK ENG COOLANT SENSOR TRIGGER ON Engine Coolant Temperature Sensor ENCT is not within the range of 58 to 266 F 50 to 130 C UNIT CONTROL Engine Operation Alarm Only Standby Operation This alarm does not activate in standby RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check sensor resistance See 10 000 Ohms 77 F 25 See Table 8 5 for Note 3 page 7 2 complete table of temperatures and resistance values Check Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins terminals gt damage moisture or corrosion in connectors see wiring schematic Section 10 Power up the micropr
423. it is operat ing close the cylinder valve and backseat the liquid line service valve when the ball in the upper sight glass drops to the bottom of the glass It the unit is not operating when approximately 5 16 2 3 kg have been removed close the cylinder valve and backseat the liquid line service valve Proceed to step 7 If charge is to be added place cylinder of refrigerant on a scale and connect a charging line and gauge from cylinder to liquid line service valve Start unit in Continuous Run Operation with all compartments op erating with setpoints lower than refrigerated com partment temperatures Wait until unit switches to high speed operation Run approximately ten minutes 4 Note weight of cylinder and refrigerant Frontseat the liquid line service valve turn clockwise and watch the pressure on the manifold gauge When the pressure falls below the pressure in the refriger ant cylinder or to 50 psig 3 4 bar open the cylinder valve and monitor the liquid refrigerant to flow into the unit When approximately 5 Ibs 2 3 kg have been added close the cylinder valve and backseat the liquid line service valve Recheck for the correct refrigerant charge Refer to preceding step a Repeat preceding steps as re quired When charge level adjustment is complete remove refrigerant service equipment Adding a Complete Charge Evacuate unit and leave in deep vacuum Refer to Section 8 6 4 Determine charg
424. itch High Pressure Service 8 31 Switch High Pressure 2 12 Switch Main Power 2 16 3 1 3 2 3 3 62 11524 Switch Remote 2 18 Switch START RUN OFF 2 17 T Technician Interface 5 1 Temperature Control 4 2 9 4 Temperature Determination 4 2 Temperature Range Lock 4 11 Transducer Compressor Suction Pressure 2 11 Transducer Discharge Pressure 2 11 Transducer Evaporator Outlet Pressure 2 12 Transducers Service 8 31 Trip Start 3 14 U Unit Data 3 17 Unloader Checkout procedure 8 25 62 11524 Unloader Coil Replacement 8 25 Unloader Replacing Internal Parts 8 26 Unloader Valve Replacement 8 26 Unloaders 2 9 V Valve Compressor Suction Modulation 2 12 8 28 Valve Electronic Expansion 2 12 8 29 Valve Liquid Line Service 8 32 Valve Liquid Line Solenoid 2 13 Valve Thermal Expansion 2 13 8 33 W Wiring Harness Plugs 10 1 10 7 Wiring Control Box Interior Splice Points 10 13 10 14 Wiring Display Test Points 10 15 Wiring Schematic 10 15 Index 4 TRANSICOLD m North America Central America rri e Carrier Transicold and Mexico 700 Olympic Drive Ejercito Nacional 253 Piso 5 Athens GA 30601 USA Colonia Anahuac Tel 1 706 357 7223 11320 Mexico D F Fax 1 706 355 5435 Tel 55315010 Fax 55315010 ext 1005 A member of the United Technologies Corporation family Stock symbol UTX 2011 Carrier Corporation Printed in U S A 0611
425. k Evaporator High Temperature Switch 5 Inspect for open 3EVHTS per wiring If open replace switch as required schematic Check Amp Draw of 3HTCON1 Heater Circuit Use a clamp on ammeter to check Must be within range shown in Section 2 12 for all the current draw of all 3 legs three legs Check Heater Elements Check heater elements No visual physical damage No blockage due to debris Remove and replace if required Check Heater Element Plugs And Connections Disconnect heater element plug No corrosion water damage or burning discoloration spect plugs plug seal and connec Remove and replace if required tors Verify Accuracy of AC Current Sensor With microprocessor in PC Mode Reading for AC1 amps and AC2 amps must both be refer to Section 5 3 check amper 0 age in the Unit Data refer to Section 3 13 Check Heater Wiring a Use a clamp on ammeter to check Compare to Unit Data the total current draw b If no fault was found in previous Remove and replace contactor tests P164 CHECK UL2 CIRCUIT TRIGGER ON Normal Amps for the Rear Unloader UL2 Circuit is 0 75 to 2 0 Amps The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail in test 2 and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning t
426. k FSA Harness a Inspect harness amp control box connector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors b Check resistance of fuel speed actuator Refer to Section 2 13 for correct electrical values Force High Speed Operation a Adjust setpoint for all compartments to at least 20 degrees away from compartment temperature If the unit does not immediately go into High Speed ensure the Silent Mode Functional Parameter is set to OFF and or the applicable High Speed Delay Configuration is set to OFF Reset following testing The microprocessor will call for High Speed opera tion b Check operation of Speed Relay LED LED 27 must be ON If LED 27 is not on the micro processor is not calling for High Speed operation Check Speed Overrides in Section 4 8 3 for more information c Check voltage on the engine speed control unit ENSCU pin 16 Must be 12 14 VDC Additional steps on the next page 7 29 62 11524 Steps Alarm Cause Corrective Action CHECK HIGH SPEED RPM Continued 6 Check Engine RPM a Check actual engine RPM using hand held tachometer Refer to Table 2 1 b Compare actual RPM with those shown on display Both readings within 50 RPM Check Engine Air Intake System a Check air filter indicator Flag must not
427. l 62 11524 5 16 Table 5 2 Microprocessor Configurations Continued selections PM 1 5 RESET INTERVAL Note This Configuration will not display for those meters that are con figured OFF RANGE 1 LOCK OR RANGE 2 LOCK Applies to Compartment 1 setpoint only however all compartments will be affected by the lock RANGE 1 or 2 MINIMUM TEMPERATURE RANGE 1 or 2 MAXIMUM TEMPERATURE OFF ENGINE PROTECT HOURS 0 or 50 TO 30 000 hours in 50 hour in crements SWITCH ON PROTECT HOURS 0 or 50 TO 30 000 hours in 50 hour in crements STANDBY HOURS 0 or 50 TO 30 000 hours in 50 hour in crements incre ments START CYCLES 0 or 1 000 TO 90 000 CYCLES in 1 000 cycle incre ments HIGH SPEED HOURS 0 or 50 TO 30 000 hours in 50 hour in crements COMPRESSOR RUN HOURS 0 OR 50 to 30 000 hours in 50 hour in crements MAINTENANCE DAYS 0 OR 10 to 990 days in 10 day in crements OFF START STOP CONTINUOUS 22 F TO 89 6 F 30 C to 32 C in 0 1 F or C in crements 22 F TO 89 6 F 30 C to 32 C in 0 1 F or C in crements The value to be entered here is the desired number of hours cycles or days between PM Maintenance Alarms for this meter When the meter is reset the value selected here will be added to the to the present meter reading to indicate to the microprocessor when the next ser vice interval alarm is to be activated
428. l be activated regardless if the refrigerated compartment temperature has been in range or not UNIT CONTROL Engine and standby Operation If the microprocessor is not configured for shutdown alarm only If the microprocessor is configured for shutdown the unit will shutdown and alarm RESET CONDITION Condition 1 Auto Reset If the unit is running in Pulldown Mode and the SAT is greater than 1 F 0 56 C below the RAT or if the unit is running in Pull Up Mode and the SAT is greater than the RAT Condition 2 amp 3 Auto Reset when the temperature is within 2 7 F 1 5 C for perishable setpoints or 2 7 F 1 5 for frozen setpoint For either Condition alarm may be manually reset via Keypad OR by turning the unit off then back on again NOTE The 30 or 45 minute timer is reset and starts again whenever eThe unit cycles off and restarts in Start Stop eThe unit goes into and comes out of Defrost NOTE This alarm does not go into the Inactive alarm List when it becomes inactive or is cleared NOTE This alarm will not be activated in Sleep Mode NOTE For Condition Two the temperature criteria for this alarm is reset and the refrigerated compartment temperature must again go In Range before this alarm can be activated if any of the following occur ePretrip is started eSetpoint is changed eA door switch or remote switch is installed and configured as a door switch and the switch is opened indicating that t
429. l display the Parameter selections available for that Function The MessageCenter will flash indicating that a change to the displayed parameter selection has not been entered into memory Continue pressing UP or DOWN ARROW key until the desired Parameter selection is displayed then press the key The MessageCenter will stop flashing The new Parameter selection is now in memory If the key is not pressed within 10 seconds the MessageCenter will display FUNCTION NOT CHANGED This will display for 5 seconds then return to the last Functional Parameter displayed If no further keys are pressed the default display will return in another 10 seconds NOTE The microprocessor may be configured with all of the Parameters locked or some individual Para meters locked Any Parameter that is displayed with a padlock symbol cannot be changed from the keypad 3 21 62 11524 FUNCTION PARAMETER SELECTIONS Table 3 2 Functional Parameters DESCRIPTION NOTES Selections in BOLD are the default settings Also Functional Parameter marked with an asterisk may not display in the list for this unit depending on how the microprocessor has been configured SILENT MODE ON OFF OFF Normal engine speed operation ON Forced low engine speed operation Used to disable high speed DEFROST IN TERVAL TIMER SET FOR 1 5HRS 3HRS 6HRS 12HRS The defrost timer will automatically put the unit into the defr
430. larm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check wiring to DPT SPT a Verify that correct wires are con nected to each transducer Plugs to transducers are the same The correct wire plug must be connected to the proper transducer b Verify that correct transducer is be ing used in each position Mechanical connections to transducers are the same The Discharge Transducer should have a RED mark ing dot on it The Suction Transducer should have a BLUE mark ing dot on it Check for Check UL1 Alarm Check for alarm 85 or P144 Alarm conditions must be corrected and the alarm cleared to continue Confirm Compressor Suction Pressure Transducer Is Working a Check transducer operation Refer to Section 8 8 8 b Check Schrader valve fitting under each transducer Must not be physically damaged depressor must fully open valve to allow pressure to transducer a Verify the correct Transducer is in place Verify by part number or colored dot that the correct Transducer is installed for the SPT Check System Pressures Install manifold gauge set and check and compare compressor discharge amp suction pressures with those shown on the microprocessor dis play Suction and Evaporator Outlet pressures must be above 3 psig 0 2 bar Suction Evaporator O
431. larm will not activate in standby Operation UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if glow plug amperage is between 4 to 55 amps for at least 14 seconds during the glow cycle or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Model Number Verify that the model number on the nameplate matches the model number shown in the microprocessor Unit Data Enter the correct number in Configurations Refer to Section 5 2 1 Check Glow Configuration Verify that the Glow configuration is set to INTAKE HEATER INTAKE HEATER must be the selection Refer to Section 5 2 1 for configuration settings Check Air Intake Heater circuit a Inspect relay amp socket No signs of discoloration from overheating No damage moisture or corrosion in socket b Check operation of intake air heater relay CAUTION DO NOT leave the circuit energized for the full 5 minutes if full amperage is shown as the intake air heater element life will be greatly shortened Using Component Test Mode refer to Section 5 2 2 energize the intake air heater relay LED 30 must be illumi
432. le ARCO 3 27 218 3 Basta DOW dii seii RE CIA 3 27 3 18 4 DataLink Data Recorder Power Up eee eee eee eek eee eee 3 27 OPTIONS Pr e nor rrr 3 28 I P 3 28 2182 Remote Control Panel 52 ace wal ae kaw 3 29 ENGINE STANDBY TEMPERATURE CONTROL 4 1 AT INTRODUCTION dE UE UR EXE SR ue does 4 1 42 ENGINESISNDBY OPERATION ose De oe Rot tn d 4 1 4 1 ENDISSE Ub inte ded 4 1 42a ansion TO HoN SpE traded EORR 4 2 TEMPERATURE CONTROL 52 3 d 44d ER 4 2 4 3 1 Temperature Determination uses ees xe ene x RR RR ROB don kp drago dons 4 2 4 3 2 Perishable And Frozen Setpoint Ranges 4 3 2253 4 3 zr PUSS rao e UT 4 3 40 o M Cru 4 3 cT pP prp 4 3 SIART STOF OF ERATION Ae a pii 4 3 Silat Spp 4 4 448 Slop PANOS 8 4
433. lief Valve Assembly 5 Idler 11 Pins 2 6 Shaft Drive 12 Thrust Washer Figure 8 23 Oil Pump e Install the pump end thrust washer on the two dowel pins located on the bearing head See Figure 8 22 CAUTION Ensure that thrust washer does not fall off dowel pins while installing oil pump Install the bearing head assembly with a new gasket on the compressor crankshaft Carefully push oil pump on by hand ensuring that the thrust washer re mains on the dowel pins the tang on the end of the drive engages the slot in the crankshaft and the oil inlet port on the pump is aligned with the oil pickup tube in the crankcase The oil pump should mount flush with the crankcase with the word TOP stamp on the pump oriented straight up Align the gasket and install the eight capscrews in the mounting flange Torque capscrews in a diagonal pattern 30 to 50 ft lbs 40 7 to 87 Nm Leak check and evacuate the compressor Refer to Sections 8 6 3 and 8 6 4 8 7 5 Compressor Oil Level a Checking Compressor Oil Level CAUTION An overcharge of oil will reduce system ca pacity and possibly cause internal com pressor damage 5 62 11524 8 24 1 Operate the unit in Cool Mode for at least 20 minutes Check the oil sight glass 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 opera tion check the refrigerant system for
434. ll be obvious once a visual inspection is performed For those cases where the cause of the problem is not obvious this troubleshooting guide will be of assistance Troubleshooting should begin with the first alarm that appears in the active alarm list The first alarm that appears is the last alarm that was recorded Other alarms in the list may have contributed to the occurrence of the first alarm The check items in the troubleshooting guide are listed in order of their likeliness of occurrence and ease of testing We recommend that you follow the order in which they are presented however there may be times when situations or experience lead a to the use of a different order For example if the trailer is loaded condensing unit checks should be done first even though some evaporator section checks may be listed before them When the cause of the problem is corrected it is not necessary to continue through the remainder of the steps Some active alarms will inactivate themselves automatically once the cause has been corrected Alarms that do not inactivate themselves automatically must be cleared manually See Note 1 page 7 2 When repairs are completed run the unit through a Pretrip cycle and verify that no further active alarms occur Also the inactive alarm list should be cleared so that there are no old alarms in memory when the unit leaves the repair facility If the message CHECK WIRES FROM MICRO TO KEYPAD app
435. ll be operated with the compart ment having a frozen setpoint given additional ca pacity e FROZEN PRIORITY TIME 5 to 60 minutes When Frozen Priority Cooling is active this is the 1 minute incre amount of time priority will be given to the compart ments ment with a frozen setpoint Default 5 minutes e NON PRIORITY TIME 5 to 60 minutes When Frozen Priority Cooling is active this is the 1 minute incre amount of time priority will be given to the compart ments ment with a perishable setpoint Default 5 minutes e PERISHABLE OVERRIDE OFF When temperature in the compartment rises above TEMPERATURE 3 6 to 27 F setpoint by this setting Priority Cooling shall be 2 to 15 C suspended YES NO YES Natural defrost will be allowed NO Natural defrost will not be allowed Refer to Section 4 6 for more information on natural defrost YES YES When the Main Power switch is placed the OFF position the DataLink data recorder will continue to record data for an additional 8 hours SHOU aoe NO When the Main Power switch is placed in the OFF position the DataLink data recorder will stop recording data 1 Minute HIGH SPEED DELAY O to 10 minutes Select the length of time unit remains in low speed 0 5 minute incre before transitioning to high speed ments OTHER OTHER The microprocessor is set for communic COMM E QUALCOMM ation from Qualcomm T2 Trailer Tracs 2 or any This Conf
436. ll return the user to the main microprocessor Configuration list BACK TO FUNC PARAMS Pressing the key with this message showing will return the user to the main Functional Parameter list BAD PC CARD OR CARD SLOT The microprocessor has detected a problem with either the PC card or the PC card slot BUZZER OFF IN X MINS The Buzzer circuit has been energized in Component Test Mode The Buzzer circuit will continue to be energized for the number of minutes shown CALIBRATION UNSUCCESSFUL An attempt to calibrate the discharge transducer failed CANNOT ENTER TRIP START Cannot enter Trip Start A problem has been detected within the DataLink data recorder CANNOT START DEFROST CYCLE Due to current unit conditions the defrost cycle cannot be started Refer to Defrost Sections 3 9 and 8 8 9 CANNOT START PRETRIP Due to current unit conditions a Pretrip test cannot be started Re fer to Pretrip Section 3 4 CANNOT DOWNLOAD BATTERY TOO LOW Data cannot be downloaded and software upgrades are prohibited when battery voltage is below 7 0 volts This message will be dis played until the serial cable is removed CARD FULL REMOVE CARD The PC Download Card is full There is no additional room to down load information from the microprocessor You may safely remove the PC Card from the slot 6 1 62 11524 MessageCenter MESSAGES Continued Message Description
437. lowing microprocessor connector CDP 1MP05 CSP 1MP29 EVOP 1 06 If voltage and signal wire are good replace the trans ducer The transducer may be removed by discon necting the connector and quickly backing it off the Schrader valve fitting 8 8 9 Defrost Air Switch NOTE If the DTT temperature is above 40 F 4 4 C defrost cannot be initiated and the Message Center will display CANNOT START DEFROST CYCLE a Check air switch tubing Red tube is to be connected to the high connection and routed below the coil Clear 62 11524 tube is to be connected to the low connection and routed above coil Check condition and mounting of air sensing fittings on the coil end of both tubes b To check the defrost air switch run unit in cooling and jumper across the air switch terminals This will start the defrost cycle as it simulates the action of the de frost air switch Bypassing the switch in this manner operates all components involved in defrost c Unit should remain in defrost until DTT in all compart ments reach 55 F 12 8 C for normal defrost or for 5 to 10 minutes in each compartment for natural defrost refer to Section 4 6 for more information on defrost At this point the defrost cycle will terminate and the unit will resume automatic operation d If the above test indicates satisfactory operation test DAS settings using a Magnehelic gauge Carrier Transicold part number 07 00177 or similar
438. ls 11 12 1MP23 SP12 3RAT 1MP04 3RAT 1 1MP21 SP43 3DTT Compartment 3 Door Switch SP5 Unused terminals D E G amp M o 62 11524 10 6 10 2 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED START RUN OFF 1MP NATURAL 1 24 12 35 Component Terminal REMSN1 REMSN E 3 14 CDP C 5 16 30 DP16 S 6 17 30 7 18 2DTT 2EVC k 8 CDT 9 20 CST 10 19 AAT 11 22 1RAT DP16 G 12 23 MAP A 13 28 30 REMSN1 REMSN F SP1 14 3 REMSN2 REMSN G SP1 14 33 1MP NATURAL Continued Component Terminal CSP A SP16 15 29 30 OGF OV HC 1 SP16 15 CDP A 16 5 30 EVOP A DP16 P 17 6 30 ENCT SP2 18 7 CST SP14 19 10 EVOT DP16 F SP14 19 32 CDT 20 9 1DTT DP16 B SP42 21 34 2EVC L SP42 21 8 2SAT 2SAT B SP42 21 31 AAT 22 11 1SAT DP16 D SP12 23 35 1RAT DP16 H SP12 23 2EVC H SP12 23 FLS C 26 MAP C 28 13 30 CSP C 29 15 30 CSP B SP7 30 15 29 ps SP7 30 5 16 EVOP B SP7 DP16 R 30 6 17 MAP B SP7 30
439. lues Check Engine Air intake System a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check For Correct Engine Oil Check for correct oil viscosity weight for conditions Refer to Section 2 9 Must be correct for ambient conditions Check Engine Exhaust System Inspect the exhaust system Must be clear and unobstructed Check Generator Check for proper maintenance and precautions preventative operating Refer to Section 8 9 9 Check Engine 62 11524 Check engine compression Refer to Engine Workshop manual Alarm NO Alarm Cause Corrective Action 34 ENGINE FAILED TO STOP TRIGGER ON When in Engine Operation engine is turning more than 500 RPM for 20 seconds after unit shutdown or cycled off or Oil Pressure Switch is closed longer than 20 seconds after unit shutdown or cycle off UNIT CONTROL again Engine Operation engine and unit shutdown and alarm Standby Operation this alarm will not activate in standby Operation RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back on NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm o
440. ly format such as MS Excel NOTE Beginning with ReeferManager version 03 08 00 USB to RS 232 adapter cables are supported for communication between the PC and the Download connector The USB RS232 program must be installed from the CD ROM and the instructions that are included with the CD ROM must be followed to success fully assign the USB driver to the correct USB port on the PC that will be used for the serial connection Refer to bulletin SERO9 033 for further information c Connecting Computer and Microprocessor To connect the microprocessor and computer a Locate the serial download port item 14 Figure 2 3 remove the protective plug to gain access to the wire terminals Plug a download cable into the download port and computer connection see Figure 5 4 Once the cable is connected to the download port the micro processor will power up and display PC MODE Start the ReeferManager amp Reports program by double clicking on the icon on your computer desktop For complete instructions on using ReeferManager amp Reports refer to manual 62 10889 When work is complete remove the download cable The microprocessor will return to normal operation DOWNLOAD CABLE P N 22 01737 00 6 LONG OR P N 22 01737 04 20 LONG Figure 5 4 ReeferManager amp Reports Connection 62 11524 5 6 MICROPROCESSOR DISPLAY DIAGNOSTICS Before replacing a microprocessor or display the follow
441. m NO Alarm Cause Corrective Action 17 HIGH COMP DISCHARGE TEMP TRIGGER ON Discharge sensor alarm not active AND Ambient temp below 120 F 48 9 C and discharge temp was between 310 and 349 F 154 4 to 176 7 C for minutes or Ambient temp above 120 F 48 9 C and discharge temp was between 340 and 349 F 171 1 and 176 7 C for 3 minutes or Discharge temp ever reaches 350 F 176 7 C UNIT CONTROL Engine Operation eng ine and unit shutdown and alarm Standby Operation refrigeration system shutdown and alarm with PSCON still energized RESET CONDITION Auto Reset after 15 minutes with Ambient temp below 120 F 48 9 C the discharge temp falls below 300 F 148 8 C or Auto Reset after 15 minutes with Ambient temp above 120 F 48 9 C the discharge temp falls below 330 F 165 4 C or alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check For Bad Compressor Discharge Temperature Sensor Check for Alarm 125 Alarm conditions must be corrected and the alarm cleared to continue Check Refrigerant Charge Check for undercharged system
442. may be reset for another 5 minutes anytime during the test by pressing the key The timer may only be reset once during each test After the 5 minute timer ex pires the MessageCenter will return to the Compo nent Test Mode Menu and display the last compo nent tested To retest the same component and circuit again press the key Press the UP or DOWN Arrow key to select another component To stop an individual component test press and hold the key for 6 seconds The microprocessor will still be in Component Test Mode and ready for another component to be selected To stop component testing and turn the microprocessor off place the Main Power switch in the OFF position To go to Configuration Mode or Service Mode select Main Menu and press the key The only keys that operate during Component Test Mode are the ALARM and SELECT keys The alarm list is available for review of any active or inactive alarms The SELECT key will only allow access to the data list Amp Draw information for the component that is currently being tested Table 5 1 Component Test Component Menu List MessageCenter Green Light LIGHT OFF IN X MINS Amber Light LIGHT OFF IN X MINS Defrost Light LIGHT OFF X MINS Front Unloader UL1 UL1 OFF IN X MINS Rear Unloader UL2 UL2 OFF IN X MINS Speed Relay SR SR OFF IN X MINS Buzzer B BUZZER OFF IN X MINS Glow Plug
443. may both be set from 5 to 60 minutes The factory default is 15 minutes The Perishable Priority Temperature Configuration may be set to OFF or from 3 6 to 27 F 2 to 15 C The factory default setting is OFF With the Frozen Priority Cooling Configuration set to ON once the temperature in a compartment with a frozen setting is less than 32 F 0 C the compartment s with a perishable setting will be 62 11524 operated with the fan operating and the liquid control valve pulsing on a 20 second cycle 8 seconds on and 12 seconds off for the duration of the Frozen Priority Time setting It will then operate with the fan on and the valve open for the duration of the Perishable Priority Time setting This operation will continue to cycle on the timers as long as both compartments are calling for cooling With the Frozen Priority Cooling Configuration set to HIGH CAPACITY once the temperature in a compartment with a frozen setting is less than 32 F 0 C the compartment s with a perishable setting will be operated with the fan and liquid control valve off for the duration of the Frozen Priority Time setting It will then operate with the fan pulsing on a 20 second cycle 8 seconds on and 12 seconds off for the duration of the Perishable Priority Time setting This operation will continue to cycle on the timers as long as compartments are calling for cooling If the Perishable Priority Temperature is not set to OFF the micropro
444. ment temperature drift this far above or below setpoint in the Perishable Range or above setpoint in the Frozen Range the unit will restart OVERRIDE TEMP 3 6 F 2 C TO 18 F 10 C 11 F 6 C in 0 5 F or C incre ments This selects the override temperature for the Minimum Off Time por tion of the Auto Start Stop Off Cycle During the Minimum Off Time should the compartment temperature drift this far above or below set point in the Perishable Range or above setpoint in the Frozen Range the microprocessor will override the Minimum Off Time and restart OFF 10MINS TO 255MINS in 1 minute incre ments OFF There is no maximum off time When a minute value is selected this is the longest amount of time the unit will remain off during a Perishable or Frozen or both Auto Start Stop Off Cycle When this time expires the unit will restart and run for the Minimum Run Time regardless of any temperature change inside the compartment e FROZEN SHUTDOWN OFFSET 62 11524 0 C 0 F TO 2 C 3 6 F in 0 5 F or C incre ments This only applies to Frozen setpoints Start Stop operation The system generally will allow an off cycle when the RAT is 0 5 F 0 3 C above setpoint This offset is the number of degrees below the 0 5 F 0 3 C value that the unit will run before cycling off This will al low for a lower average compartment temperature when considering temperat
445. motor contactor 1 circuit is shorted The contactor output from the microprocessor 4MP15 is negative so the circuit will not be shorted to ground but is shorted either within the contactor coil itself or to a positive wire UNIT CONTROL Alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 1EVCON Inspect evaporator fan contactor No damage to coil coil and terminals No damage or corrosion b Check coil resistance Cannot be opened infinite ohms Shorted Zero Ohms or shorted to ground c Check amp draw of coil Use ammeter Check 1EVCON Current Draw Use Component Test Mode to test actual current draw of the circuit Refer to Section 5 2 2 Refer to Section 2 13 for correct electrical values View current draw in Data List Check 1EVCON Wiring Inspect harness amp control box connector pins amp terminals See wir ing schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors 110 CHECK 2EVCON RELAY COIL TRIGGER ON Evaporator fan
446. mps and AC2 amps must both be 0 Check Heater Wiring a Use a clamp on ammeter to check the total current draw Compare to Unit Data b If no fault was found in previous tests Remove and replace contactor P151 CHECK GLOW PLUG CIRCUIT This applies to the Intake Air Heater TRIGGER ON Normal Amps for the Intake Air Heater Circuit is 23 to 75 Amps after 15 seconds The circuit tests outside this range UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again Check glow plug circuit refer to procedure for alarm 40 7 95 62 11524 Alarm Cause Corrective Action P152 CHECK FUEL SOLENOID CIRC Normal Amps for the Fuel Solenoid Hold Circuit is 0 2 to 4 5 Amps including possible electric fuel pump The circuit tests outside this range e UNIT CONTROL Alarm Only e RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for bad F2 or F3 fuse alarm Check for alarm 71 Alarm conditions must be c
447. ms 77 F 25 C Refer to Table 8 5 for complete table of temperatures and resistance val ues g Check voltage at harness connec tion to EVOT Must be 2 5 0 5 VDC This verifies microprocessor output and wiring connections to sensor h Verify accuracy of EVOT using in frared or other accurate temperat ure testing tool EVOT reading must be within 3 F 1 7 C of test temperature tool reading Check EVOP and CSP a Check operation of both trans ducers Refer to Section 8 8 8 b Check Schrader valve fitting under each transducer Must not be physically damaged depressor must fully open valve to allow pressure to transducer Check EVXV Check operation of EVXV Refer to Section 8 8 6 Check Liquid Line Solenoid Valves Operate with only Compartment 1 enabled Check condition of the suction line in Compartments 2 amp 3 the lines should not be sweating or frosting and should be close to compartment temperature Check heat exchanger With the unit running in high speed cool check temperature of suction line inlet and outlet at the heat ex changer Inlet line toward evaporator coil must be colder than outline toward compressor 62 11524 Alarm NO Steps Alarm Cause Corrective Action 23 A C CURRENT OVER LIMIT TRIGGER ON The high voltage amp draw is over the limit shown in the following table for more than 10 sec
448. n the Main Power switch is not in the OFF position CAUTION Under no circumstances should techni cian electrically probe the microprocessor at any point other than the connector termi nals where the harness attaches Micropro cessor components operate at different voltage levels and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could perma nently damage the microprocessor CAUTION Most electronic components are suscepti ble to damage caused by electrical static discharge ESD In certain cases the hu man body can have enough static electric ity to cause resultant damage to the compo nents by touch This is especially true of the integrated circuits found on the micropro cessor Automatic Start Stop Your refrigeration unit is equipped with auto start in both Start Stop and Continuous Operation The unit may start at any time the Main Power switch is not in the OFF position A buzzer will sound for 5 seconds before the unit is started When performing any check of the refrigeration unit e g checking the belt checking the oil make certain that the Main Power switch is in the OFF position Engine Coolant The engine is equipped with a pressurized cooling system including a pressurized coolant bottle Under normal operating conditions the coolant in the engine and radiator is under high pressure and is very hot Contact with hot coolant can
449. nal electric fuel pump FP if supplied During the start sequence the engine speed control unit ENSCU will hold the engine in low speed ENGINE RUNNING 0 180 Seconds following start 3to 10 Seconds SECOND AND THIRD ATTEMPTS 15 Seconds STOP ENGINE RUNNING 0 180 Seconds following start ATTEMPT Figure 4 1 Auto Start Sequence 62 11524 The engine start sequence consists of periods of time with the intake air heater relay IAHR and starter solenoid relay SSR energized and de energized for up to three start attempts See Figure 4 1 Energizing GPR closes its contacts to energize the intake air heater IAH the heating time will vary in duration based on engine coolant temperature refer to Table 4 1 Table 4 1 Intake Air Heat Time Heat Time in Seconds Preheat Post Heat 30 180 20 120 Engine Coolant Temperature Less than 33 F 1 0 C 33 F to 51 F 1 0 C to 11 C 51 F to 78 F 11 C to 26 C Greater than 78 F 26 C 10 60 0 0 If the A129 CHECK ENGINE COOLANT SENSOR alarm is active the microprocessor assumes temperature of less than 32 F 0 C for the heat timing During the last five seconds of Preheat OR for 5 seconds before a start attempt if no Preheat is required the buzzer B is energized then the starter solenoid relay SSR will be energized for a maximum of ten seconds while the engine condition is checked ea
450. nated Amperage must be correct refer to Section 2 9 for correct electrical values c Check voltage to Air Intake Heater Must be 11 VDC or higher Check Air Intake Heater circuit wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors b Check connection at Intake Air Heater 7 33 Ring terminal is tight on terminal No signs of overheating 62 11524 Alarm NO Alarm Cause Corrective Action 41 ENGINE STALLED TRIGGER ON The engine is running RPM sensor is good and engine speed is less than 10 RPM or the engine is running RPM sensor alarm is ON and the Oil Pressure switch contacts are open UNIT CONTROL Engine Operation Engi ne and unit shutdown and alarm Standby Operation This alarm will not activate in standby Operation RESET CONDITION Auto Restart after 15 minutes or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check For Alarm 130 Check RPM Sensor Check for alarm 130 When Alarms 130 and 41 occ
451. nd the unloaders will de energize load as required 4 Fan Motor Delay Whenever any fan motor has been energized there will be a 3 second delay before either unloader is allowed to de energize load 5 Four Cylinder Delay When the compressor suction pressure CSP is great er than 22 psig 1 5 bar AND the compressor is fully un loaded operating on 2 cylinders AND the conditions call for UL2 to be de energized loaded there will be a 20 second delay while the CSMV closes down by 2096 from the current setting After UL2 loads the CSMV will go back to normal control 6 Two Minute Delay When an unloader is energized unloaded due to a re frigeration system pressure override overrides 6 7 8 or 9 the unloader remains energized for a minimum of 2 minutes 7 Compressor Startup UL1 remains energized unloaded for a minimum of 10 seconds when the ambient is above 100 F 37 8 C or 5 seconds when the ambient is at or below 100 F 37 8 C after the compressor motor contactor is energized UL2 remains energized unloaded for a minimum of 60 seconds when the ambient is above 100 F 37 8 C or 30 seconds when the ambient is at or be low 100 F 37 8 C after the compressor motor con tactor is energized 8 High Evaporator Pressure UL2 will always be energized unloaded when the suction pressure is above the value shown Figure 4 6 for 1 minute according to the current ambient tempera
452. nd circuit on injection pump assembly for Did you find and correct loose screws or tampering the condition Are the screws loose NO YES Y Check for high resist Set proper high speed RPM between ENSCU ter Table 2 1 Lock screws in place and rewire minal 25 amp ENSSN 12V terminal Did you __veg Did you find and correct the find and correct the condition condition YES Y Remove new ENSCU System and re install old OK ENSCU back into unit ENSCU is not the fault i 5 222 Check for proper internal mechanical i your Super operation of injection pump assembl pump y 22 visor If necessary go to Using jumper wire check for 5 D and governor assembly Did you find the beginning of the tree and correct the condition VDC at ENSCU terminal 10 amp test agai Do you have 5 VDC at terminal 10 Review results of Replace ENSCU Did you above tests with your find and correct the condition supervisor If neces sary go to the begin ning of the tree amp test again v Check for open or high resist ance on circuit between Replace ENSSN Did you find ENSSN and ENSCU Did you and correct the condition find and correct the condition
453. nd dried several times can be very hard to remove Therefore several washings may be necessary a Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Remove rubber check valves Kazoo from drain lines of the evaporator s to be cleaned Spray with a mild detergent solution such as Oakite 164 or 202 or any good commercial grade au tomatic dish washer detergent such as Electrosol or Cascade and let the solution stand for a few minutes and 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 Re install check valves and run unit until defrost mode can be initiated to check for proper draining from drain pan Condenser Radiator Assembly Condenser Frame Condenser Coil Radiator Radiator Frame 8 8 2 Condenser a Cleaning Note Only Clean Water Should Be Used To Wash The Condenser Do Not Use Any Detergents To Clean The Condenser Remove all foreign material from the condenser coil by reversing the normal air flow Air is pulled in through the front and discharges over the engine Compressed air or water may be used as a cleaning agent Take care so that the fins aren t bent during this proce
454. nd start the pump Evacuate unit to 500 microns Close the vacuum pump valve and shut off the pump Wait a few minutes to be sure the vacuum holds below 2000 microns 62 11524 8 20 10 If vacuum holds below 2000 microns continue to step 12 If vacuum rises above 2000 microns contin ue to step 11 11 Repeat steps 6 through 9 until the vacuum stays be low 2000 microns 12 Once the system holds a good vacuum open the compressor discharge service valve and the liquid line service valve 13 Start unit and check the refrigerant charge Refer to Section 8 6 2 Evacuation of the Compressor Evacuate only after a compressor pressure leak check Refer to Section 8 6 3 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle If possible keep the temperature of the compressor above 60 F 15 6 C to speed evaporation of mois ture If the temperature is lower than 60 F 15 6 C ice might form before moisture removal is complete Heat lamps heat guns or alternate sources of heat may be used to raise compressor temperature Connect evacuation equipment to the compressor suction and discharge service valves See Figure 8 18 Start the vacuum pump Evacuate compressor to 500 microns Close the vacuum pump valve and shut off the pump Wait a few minutes to be su
455. ne Solenoid Valve Figure 8 18 Refrigerant System Service Equipment 8 6 2 Servicing The Refrigerant Charge Servicing of the refrigerant charge includes checking the charge level checking for noncondensibles removing the charge pumping down the low side pumping down the compressor adjusting the charge level and adding a complete charge Procedures for charge service are provided in the following sub paragraphs a Checking Charge Level Check the refrigerant charge before adding any refrigerant to the system Only add refrigerant if charge is low If charge is low leak checking must be performed Refer to Section 8 6 3 and all leaks repaired before adding refrigerant Install a manifold gauge set to allow reading of dis charge pressure See Figure 8 18 2 Start unit in Continuous Run Operation Adjust set points so that unit is running in high speed fully loaded and all compartments are operating in cooling Run approximately ten minutes until the refrigera tion system is warmed up and the refrigerated com partment temperatures are approaching setpoint 3 Partially block off air flow to condenser coil so dis charge pressure rises to 230 psig 15 7 bar 4 Check the receiver sight glasses to determine charge The system is correctly charged when the lower sight glass is not empty and the upper sight glass is not full 5 If the system appears to be overcharged or under charged adjust charge Refe
456. ne Manual Plugged fuel filter 8 5 5 Plugged inlet screen to mechanical pump 8 5 3 Plugged inlet screen to electric pump 8 5 4 Injector nozzle s defective Engine Manual Injection pump defective Engine Manual Air cleaner or hose restricted Safety device open 2 14 ESC defective 9 5 Electric fuel pump malfunction 8 5 4 Mechanical fuel pump malfunction Engine Manual Oil pressure switch defective Replace 9 1 3 Engine Will Not Shut Off Engine will not shut off ESC operation defective 9 5 9 1 4 Starter Motor Malfunction Battery insufficiently charged 9 2 Battery cable connections loose or oxidized Check Battery cables defective Replace Starter motor will not crank or turns slowly Starter brushes shorted out Engine Manual Starter brushes hang up or have no contact Engine Manual Starter solenoid damaged Engine Manual Incorrect grade of lubricating oil 2 9 Starter motor turns but pinion does not engage Pinion or ring gear obstructed or worn Clean both remove burrs or replace Starter motor does not disengage after engine starts Starter motor solenoid defective Engine Manual Defective starter Engine Manual 9 1 5 Malfunction In The Engine Starting Circuit No power to starter solenoid SS Battery defective Check Loose electrical connections Tighten ESC defective 9 5 No power to
457. nected and engine is not running in order to enter PC Mode PM DUE Preventative Maintenance is now due on the unit PRESS TJ VIEW DATA Press the UP or DOWN ARROW key to scroll through the Data List PRESS fl VIEW SETTINGS Press the UP or DOWN arrow key to scroll through Functional Pa rameter Settings PRESS TJ TO VIEW PRINT MENU Press the UP or DOWN arrow key to view the Strip Print setup menu PRESS TO MARK TRIP START Press the key to mark the start of the trip in the DataLink data recorder PRESS TO START PRETRIP Press the key to begin pretrip tests PRETRIP FAIL amp COMPLETED The Pretrip test is completed and some of the pretrip tests did not pass Check the Alarm List for pretrip alarms PRETRIP FAIL IN TEST XX Some of the pretrip tests did not pass and the pretrip was not com pleted Check the Alarm List for pretrip alarms PRETRIP PASS All of the pretrip tests were ok PRETRIP STOPPED BY USER Pretrip has been stopped by user READY TO INSTALL SOFTWARE The microprocessor has been forced into Program Install Mode If this message does not clear after loading the current version of software check for a shorted circuit between 5MP5 and 5MP6 RECOVER LEAK CHK EVAC MODE This message will be displayed when the unit is in Service Mode and the system is ready for recovery and leak testing 62 11524 6 4 MessageCenter ME
458. negative so the circuit will not be shorted to ground but is shorted either within the valve coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check LSV3 a Inspect coil and connector No damage to coil No damage moisture or corrosion in connector b Check coil resistance Cannot be opened infinite ohms Shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check LSV3 Current Draw Use Component Test Mode Refer to Refer to Section 2 13 for correct electrical values Section 5 2 2 to test actual current View current draw in Data List draw of the circuit Check LSV3 Wiring 62 11524 Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Alarm Cause Corrective Action 109 CHECK 1EVCON RELAY COIL TRIGGER ON Evaporator fan
459. nfigura tions are installed amp correct Did you find and correct the condition NO Use Pre Trip to check for any alarms Use the Component Test Mode Section 5 2 2 to verify operation Did you find and correct the condition Use this manual to check for correct operation Did you find and correct the condition Download DataLink data recorder amp review unit operation Did you find and correct the condition Remove new micro amp re install old micro back in the unit Micro is not the fault Review results of above tests with your supervisor If necessary go to beginning of tree amp test again Are you sure unit is not operating properly Operate the system Did you find and correct the condition MPR Code 5 Replace micro and operate system order to verify repair Did you find and correct the condition 9 15 Figure 9 6 Micro Diagnostic Tree Cond 2 Main Power Switch On Unit Operates But Not Properly 62 11524 START HERE Is the unit equipped with two way Place the Main Power switch in the OFF posi tion Does the engine There a problem with the re mote communication sys communication continue to run tem Repair as necessary gt YES YES Disconnect two
460. ng or an averaged reading of the sensor readings since the last recording The user can determine which sensor s will be recorded at what intervals and wheth er snapshot or averaged readings are preferred Snap shot readings of sensors are also taken at the time of a shutdown alarm All of the sensors and transducers that may be read un der Unit Data refer to Table 3 1 may be included or ex cluded form the recordings c Event Occurrences This information is any additional data that is recorded on a when it occurs basis Events are recorded by the recorder as they occur An Event is defined as some thing that happens and may include Setpoint change Defrost cycle start Main power on Pretrip start Pretrip end Unit mode Start Stop or Continuous Operation Control mode Heat Cool High Low speed etc Door and Remote switch activations Hour Meter readings Hour meters are recorded at midnight or the first time of day the Main Power switch is toggled out of the OFF position d User Area Data The User or service technician may enter a Comment into the DataLink data recorder using the ReeferMan ager program 3 18 3 Data Downloading The data within the DataLink data recorder can be downloaded using either the ReeferManager program with a download cable connected to the download port or with a Download PC card refer to Section 5 3 Ifa PC card is used the ReeferManager program is then used to extra
461. ng is below 77 F 25 C if the reading is below this temperature the fuel heater relay FHR should be energized If the relay does not energize check for power from micro processor terminal 4MP16 to the relay coil and ground from the coil connector Check for power from SP50 through fuse F19 the re lay contacts and HC16 to the fuel heater connector Check also for ground from the fuel heater connector to SP 6 If the fuel heater temperature is below 45 F 7 2 C replace the fuel heater If the fuel heater temperature is above 45 F 7 2 C the internal temperature switch may be open Retest at a temperature below the switch close point as soon as conditions allow 8 5 8 Engine Oil And Oil Filter a To Check The Engine Oil Level Warm up the engine and then stop it by placing the Main Power switch in the OFF position Ensure the unit will not start automatically by disabling any two way communication Disconnect the high voltage source and lockout tagout the receptacle Unscrew the cap dipstick see Figure 8 10 Wipe the dipstick clean and insert the cap into the oil fill tube without threading into tube Remove the dipstick again and check oil level DO NOT add oil if the level is in the safe range If need ed add oil as indicated by markings on dipstick until level is in the safe range After checking or adding oil as necessary ensure cap is threaded back onto oil fill tube Cap Dipsti
462. ng schematic Section 10 Power up the microprocessor see Voltage should be 2 5 VDC volts at harness plug be Note 2 page 7 2 Disconnect tween pins This verifies microprocessor output and sensor from harness Check for wiring connections to sensor 2 5 VDC at harness plug between pins 128 LOW UNBALANCED A C AMPS TRIGGER ON The compressor is on and AC Current Sensor 1 or 2 is less than 5 amps for 10 seconds OR If the difference between AC Current 1 and AC Current 2 is greater than 10 amps for 10 seconds UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Change unit to Standby Operation when AC Current Sensor 1 and 2 is great er than 7 amps for 5 minutes AND difference between AC Current 1 and AC Current 2 is less than 7 amps for 5 minutes OR alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Perform Pretrip Check Clear Active Alarm list then run Pre Any active alarms must be corrected and cleared trip amp check for any new alarms before proceeding Check Current Draw Use a clamp around A C ammeter Must be 1 0 Amp of reading in Data L
463. nge Suction amp Discharge Pressures must have the same reading on gauges amp on micro dis play Check Evaporator Motor or Contactor Alarm Check for alarm 77 101 102 109 110 Must be corrected and cleared to continue or 111 Verify accuracy of RAT amp SAT sensors Verify accuracy of RAT amp SAT using RAT amp SAT readings must be within 3 F 1 7 C of infrared or other accurate temperat test temperature tool reading ure testing tool Perform Pretrip Check Clear Active Alarm list then run active alarms must be corrected and cleared Pretrip amp check for any new alarms before proceeding Check For Low Delta T Read Delta T from Unit Data In Cool the Delta T must be greater than cooling more than 1 F 0 56 In Heat the Delta T must be greater than 0 1SAT must be higher than 1RAT 62 11524 7 38 Alarm NO Alarm Cause Corrective Action 54 DEFROST NOT COMPLETE TRIGGER ON Defrost cycle did not complete within 45 minutes UNIT CONTROL Engine and standby Operation alarm only While this alarm is active the Defrost Timer will be set to initiate a defrost cycle 90 minutes 1 5 hours of unit running time after the alarm comes on RESET CONDITION Auto Reset when defrost cycle is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is fo
464. nit Data Refer to Section 3 13 PRESS TO VIEW AND CHANGE SETTINGS Displays unit Functional Parameter settings Refer to Section 3 15 PRESS TO MARK TRIP START This menu selection is used to record a Trip Start event which is logged in the DataLink data recorder This records the time and date of the beginning of the trip Data can then be downloaded and reviewed by trip making data review much easier Refer to Section 3 10 PRESS TO VIEW PRINT MENU Configures the microprocessor for use with the hand held Strip Print Il printer kit P N 12 50150 10 Refer to manual 62 90476 Strip Print or 62 11338 Strip Print II 62 11524 2 7 ELECTRONIC MODULES 2 7 1 Overload Ground Fault Module OGF Figure 2 12 OGF Module The OGF see Figure 2 12 is located in the control box see Figure 2 6 The module has two electrical safety features which are active in both Engine and Standby Operation 1 Overload protection 2 Ground Fault Leakage In each case the A100 OVERLOAD GROUND FAULT alarm is activated and the unit shuts down When ground leakage is detected the red LED on the OGF module will be on continuously 2 7 2 Phase Reversal Module PRM Figure 2 13 PRM Module The PRM Figure 2 13 is located in the control box see Figure 2 6 In Standby Operation the phase reversal module checks the electrical phase and reverses if necessary 2 8 OPTIONS 2 8 1 Light Bar Th
465. nsion valve is accompanied by a drop in temperature so the low pressure low temperature fluid that flows into the evaporator tubes is colder than the air that is circulated over the tubes by the evaporator fan The evaporator tubes have aluminum fins to increase heat transfer therefore heat is removed from the air circulated over the evaporator This cold air is circulated throughout the refrigerated compartments to maintain the cargo at the desired temperature The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize This low temperature low pressure vapor passes through the evaporator outlet The vapor then passes through the heat exchanger where it absorbs more heat from the high pressure high temperature liquid and then returns to the compressor through the compressor suction modulation valve CSMV The CSMV controls the compressor suction pressure thereby matching the compressor capacity to the load 2 16 REFRIGERANT CIRCUIT HEATING AND DE FROSTING The compressor is turned off for all heating and defrost cycles In heat the coil mounted heaters and evaporator fan s are energized Air flowing over the warm heater elements is circulated through the compartment to maintain the cargo at the desired temperature Defrost may be accomplished using either electric heaters or re turn air refer to Section 4 6 62 11524 EXTERNAL EQUALIZER COMPARTMENT 3 EVAPORATOR3 EXTERNA
466. nt temperature indicates that the LSV for that compartment is leaking refrigerant into the coil Another method of checking these components is to follow these steps 1 Install a manifold gauge set on the compressor dis charge and suction service valves 2 Pump down the low side of the system refer to Sec tion 8 6 2 3 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle 4 After the unit has been shut off verify that the pres sures do not equalize and the suction pressure does not rise above 5 psig If the suction pressure rises above 5 psig repeat the pump down procedure Using Unit Data refer to Section 3 13 check to en sure the EVXV is 0 open slowly open the liquid line service valve The suction pressure should not rise If the suction pressure rises the leakage possibilities are the EVXV 2LSV or 3LSV Go into each compart ment and listen for any internal system leakage NOTE When the suction pressure remains at 0 to 5 psig with the liquid line service valve open 2LSV and EVXV have been tested for holding and passed Open the compartment LSV in question using Com ponent Test Mode Refer to Section 5 2 2 Monitor the suction pressure when the Micropro cessor key is pressed to energize the LSV The suction pressure sho
467. nts on the main display will turn on All of the liquid crystal diodes LCDs of the Messa geCenter will turn on to verify their operation The main display will then display the setpoint tem perature in the left two characters and a compart ment BOX temperature in the right two characters The character just to the right of the box temperature indicates the temperature units as C Centigrade or F Fahrenheit The last character indicates which compartment temperature is being displayed The MessageCenter will then display MICRO SELF TEST IN PROGRESS for several seconds If one or more Inactive alarms are stored INAC TIVE ALARMS IN MEMORY will be displayed and the Alarm LED will flash for 5 seconds then turn off 62 11524 Refer to Section 3 12 for information on viewing in active alarms If the microprocessor has been configured to display the hour meters the Total Engine Hours Standby Run Hours and or Total Switch On Hours will be displayed If there are one or more active alarms the Mes sageCenter will display UNIT SHUTDOWN SEE ALARM LIST Any active alarms must be corrected and cleared before the unit can start Refer to Sec tion 3 11 for information on active alarms The microprocessor will then display SMV CLOS ING while the CSMV and the EVXV are brought to unit starting positions In engine operation the intake air heater will ener gize as required the buzzer will sound an
468. o Day j Using the same key presses as in step g continue to enter the correct numerical value for the Day Year Hour and Minute Hours are displayed and entered as a 24 hour clock 0 to 12 is AM 13 to 24 is PM When you are finished the MessageCenter will dis play PRESS TO SAVE TIME CHANGES NOTE If you do not press the key the time changes you just made will not be saved Press the UP ARROW key to go to SET NEW HOURS Press the key then the Up Arrow key to enter that menu The first hour meter is Engine Protect Hours Press the key to select this meter The cursor will be blink ing on the ten thousands place Press the UP or DOWN ARROW key to select the correct value then press the key If the correct number in any of the locations is O zero just press the key to enter 0 as the value and move the cursor to the next place For example if you are entering 567 hours you will press the key twice to leave a 0 for the first two numbers then use the UP and DOWN ARROW key to scroll through the numbers to enter the correct hours When the correct hours for Engine Protect Hours has been entered press the key to advance to the next hour meter If an invalid number is entered a warning message will flash in the MessageCenter For example you can not enter a higher number of hours for Engine Protect than the number of Switch On Hours NOTE None of the Total hour meters are listed When the hour
469. o Section 4 8 1 WRONG UNIT TYPE REMOVE CARD A configuration PC card has been inserted into the PC Card slot The unit model family type on the PC card is not in the same unit family type as the microprocessor The card may be safely re moved from the microprocessor 62 11524 6 6 SECTION 7 ALARM TROUBLESHOOTING PARAGRAPH NUMBER Page 7 1 INTRODUCTION E Roper 7 1 Xu NOTES 7 2 TO DRIVERS OFEBATOR ALARMS 7 3 7A SHUTDOWN ALARMS 7 4 BE 7 ENGINE ALARMS 7 22 WARNING STATUS ALARMS decies doc ci Geop tabiii ein h 7 36 34 ELECTRICAL ALARMS iU id d 9513 dod ORA ed aad 7 50 L8 SENSOR ALARMS 7 75 7 8 PRETRIP ALARMS EROR RO 7 90 7 10 MAINTENANCE ALARMS E EXE s 7 129 MICROPROCESSOR ALARMS 7 133 62 11524 SECTION 7 ALARM TROUBLESHOOTING WARNING Advance microprocessor equipped units may start automatically at any time the Main Power switch is not in the OFF position Also the unit may be fitted with two w
470. o ground Check 2HTCON2 Amp Draw Check 2HTCON2 amp draw Use Component Test Mode Section 5 2 2 to test Refer to Section 2 13 for correct electrical values View current draw in Data List Check 2 2 Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Additional steps on the next page 62 11524 7 94 Steps Alarm Cause Corrective Action C2 CHECK HEATER 2 CIRCUIT Continued 5 Check Evaporator High Temperature Switch 2EVHTS Inspect for open 2EVHTS per wiring schematic If open replace switch as required Check Amp Draw of 2HTCON2 Heater Circuit Use a clamp on ammeter to check the current draw of all 3 legs Must be within range shown in Section 2 12 for all three legs Check Heater Elements Check heater elements No visual physical damage No blockage due to debris Remove and replace if required Check Heater Element Plugs And Connections Disconnect heater element plug In spect plugs plug seal and connec tors No corrosion water damage or burning discoloration Remove and replace if required Verify Accuracy of AC Current Sensor With microprocessor in PC Mode refer to Section 5 3 check amper age in the Unit Data List refer to Section 3 13 Reading for AC1 a
471. ocedure for alarm 16 for low voltage condition 7 97 62 11524 Alarm Cause Corrective Action P157 CHECK BATTERY CURRENT e TRIGGER ON With all circuits off current flow of more than 1 5 amps is detected in the 12 VDC electrical circuits NOTE If this alarm occurs Pretrip Test 2 will not be performed You will need to run pretrip again e UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check No Load Current Draw Energize circuit refer to Note 2 Reading is less than 1 5 Amps page 7 2 Observe current draw on microprocessor display Disconnect F5 wire and remove Without wire in sensor reading should be 0 1 from inside DC current sensor see amp Figure 2 10 page 2 15 NOTE Ensure wire is rerouted through sensor prior Reconnect at F5 and power the to returning unit to service microprocessor by toggling the Main Power switch out of the OFF position Check Individual Circuits Isolate individual circuits and te
472. ocessor see Voltage should be 2 5 VDC volts at harness plug be Note 2 page 7 2 Disconnect tween pins This verifies microprocessor output and sensor from harness Check for wiring connections to sensor 2 5 VDC at harness plug between pins Check remote sensor switch connector c Locate and inspect 10 position Connector must have cap on connector OC for optional No corrosion or moisture inside connector sensors and switches If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 7 81 62 11524 Alarm Cause Corrective Action 130 CHECK ENGINE RPM SENSOR TRIGGER ON When in Engine Operation only If ambient temperature is above 32 F 0 C and this is the second or third start attempt and the engine oil pressure switch is closed oil pressure good and engine RPM is sensed at less than 1000 OR if ambient is below 32 F 0 C and the DC amp draw is more than 2 amps and this is the second or third start attempt and engine RPM is sensed at less than 1000 UNIT CONTROL Alarm Only and engine will be considered running RESET CONDITION Auto Reset in Auto Start when engine speed is greater than 1 000 RPM or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem
473. of the piston for damage Check for debris burned and carbonized oil sludge or mechanical failure Inspect cylinder bores for excessive wear Excessive wear for cylinder bores is defined as heavy and un even scratches gouges or chipping of the internal wall of the cylinder with a depth greater than 0 025 inch which are caused by foreign objects other than a normal reciprocating movement of the pistons and piston rings If cylinder s are damaged compressor replacement is required Discard valves and gaskets Use only new valves and gaskets when assembling cylinder head and valve plate assemblies If required install the discharge valves and discharge valve stops with capscrews and lock washers onto the valve plates Torque the capscrews to 12 to 16 ft lbs 16 3 to 21 7 Nm i Turn the valve plate over j Install the suction valve spring on the dowel pins with the spring ends bearing away from the cylinder head See Figure 8 20 Place suction valve on dowel pins Place the valve plate and new valve plate gasket with flat side toward cylinder deck on cylinder deck ensuring that the valve plate is properly positioned on the four dowel pins m Using a small screwdriver operate the suction valves to ensure that the valve tips are not being held by the valve plate gasket See Figure 8 21 Figure 8 21 Checking Suction Valve n Install capscrews cylinder head and new cylinder head gasket with
474. oimimoou Component Terminal SP64 1 2 2HTCON2 14 2bEVCON A2 2HTCON 1 A1 2 1 2bEVCON A1 Unused terminals H 10 11 62 11524 10 2 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED START RUN OFF Continued 2C10 22 01997 20 Component Terminal 2HTCON1 T1 1 2HTCON1 T2 2HTCON1 T3 2HTCON2 T1 2HTCON2 T2 2HTCON2 TS3 2EVCON T1 2EVCON T2 2EVCON T3 PE Plate Unused terminals 11 12 Oi OIN 62 11524 10 12 10 3 CONTROL BOX INTERIOR SPLICE POINTS FOR UNITS WITH A MAIN POWER SWITCH LABELED ENGINE OFF STANDBY Splice Point No Component Splice Point No Component F5 A 19 IAHR 30 F6 A SSR 30 F9 A BUZZER 5 1 OGF 12V RCR 1 FHR 1 HC 15 MPQC 2 PRM OV CCON A2 GENCONR 3 LOW VOLT GND 3RSA 3 compartment only SSR 86 HC 18 MPQC 9 F9 B CCONR 3 PSCONR 3 8 SP59 RCR 5 EVM 4 EVHTS A SP52 SP62 CT BLUE 4MP 10 4 1 CCONR 1 HC 11 OGF BLUE CT BROWN 4 8 OGF BROWN HC 19 OGF S 1 PSCONR 1 4 4 1 2 1HTCON2 A2 SP52 SP59 CDM2 4 SP6
475. om harness Check for wiring connections to sensor 2 5 VDC at harness plug between pins IF A SENSOR IS NOT INSTALLED Check remote sensor switch connector Locate and inspect 10 position Connector must have connector for optional sensors and No corrosion or moisture inside connector switches see wiring schematic If there is a problem with the connector and there are Section 10 no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 62 11524 7 84 Alarm Cause Corrective Action 136 C2 CHECK SUPPLY AIR SENSOR TRIGGER ON Supply Air Temp Sensor 2 2SAT is not within the range of 53 to 158 F 47 to 70 C NOTE 2SAT is an optional sensor that may not be present If the configuration is set to INSTALLED and the sensor is not connected this alarm will be active UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset when sensor is in range or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Senso
476. on 4 Plunger Spring 8 Body Figure 8 32 Liquid line Solenoid Valve Pump down the low side of the system refer to Sec tion 8 6 2 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Remove coil retainer and coil assembly from valve refer to preceding step b Remove enclosing tube assembly and related items Check for foreign material in valve body Install new parts Tighten enclosing tube assembly to 250 in Ibs 28 Nm Install coil assembly and retainer refer to preceding step b Leak check and evacuate the low side Refer to Sec tions 8 6 3 and 8 6 4 8 8 11 Thermal Expansion Valve a Check Superheat NOTE For evaporators with two thermal expansion valves thermocouple is only required on one valve However when making adjustments make an equal adjustment to both valves for each required change Loosen the insulation at one end of the expansion valve bulb Loosen one TXV bulb clamp and make sure the area where the bulb contacts the line is clean 62 11524 3 Place a thermocouple parallel to the TXV bulb and then secure loosened clamp making sure the ther mocouple and bulb are both firmly secured to suction line as shown in Figure 8 33 Use insulation to com pletely cover both Suction Line TXV Bulb Clam
477. on for 2 consecutive defrost cycles The air switch contacts were closed continuously for 15 seconds before the defrost cycle was started UNIT CONTROL Engine and standby Operation alarm only While this alarm is active the defrost air switch will NOT be used to initiate a defrost cycle however the Defrost Timer will initiate a defrost cycle 90 minutes after the alarm comes on and the manual defrost switch will remain operative RESET CONDITION Auto Reset when defrost cycle terminates correctly and the air switch does not call for a defrost cycle within the 8 minutes following defrost termination or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Condition Of Refrigerated mpartment amp Load a Check condition of refrigerated compartment doors amp seals Doors must be closed and door seals must seal and prevent entrance of outside air b Check condition of evaporator Check for blockage sufficient to cause an air pres sure differential across the coil great enough to close the contacts of the defrost air switch Coil must be free of ice following defrost c Check
478. onds CONDITION Compartment 1 Compartments Enabled 1 amp 2 Enabled Engine High Low Speed Standby Cool or Pretrip 30A 30A Engine High Speed Heat 18A 24A Engine Low Speed or Standby Heat 14A 20A Engine High Speed Defrost With heaters energized 16A 22A Engine Low Speed or Standby Heat Defrost 12A 18A Engine High Low Speed or Null 8A 10A Engine High Low Speed Standby 8A N A Natural Defrost when heaters are de energized e UNIT CONTROL Engine Operation refrigeration system shutdown and alarm Standby Operation refrigeration system shutdown and alarm with PSCON still energized e RESET CONDITION Auto reset after 15 minutes or alarm may be manually reset via keypad or by turning the unit OFF then back ON NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Perform Pretrip Clear Active Alarm list then run Pre trip amp check for any new alarms Any active alarms must be corrected and cleared be fore proceeding 2 Check Configurations for Correct Maximum Amps Settings a Check DIESEL MAX GEN AMPS Setting should be 24 25 Amps Maximum recom configuration setting mended setting is 25 Amps Minimum recommended
479. onger battery life The engine will restart from a Start Stop Off cycle or a Sleep Mode Off cycle when the engine coolant temperature drops to this value 62 11524 Table 5 2 Microprocessor Configurations Continued selections Description YES When the A51 ALTERNATOR CHARGING alarm is activated the alarm light will ALTERNATOR CHECK illuminate and the unit will shutdown SHUTDOWN NO When the A51 ALTERNATOR NOT CHAR alarm is activated the alarm light will illumin ate and the unit will continue to run BATT CHARGER NO TEMP NO TEMP SENSOR Use this setting when the Applicable to unit not lift gate SENSOR battery charger does not have the temperature battery charger only sensor wire WITH TEMP WITH TEMP SENSOR Use this setting when the SENSOR battery charger does have the temperature sensor wire connected to the battery positive post ENGINE OIL LEVEL SWITCH YES NO YES An Engine Oil Level Switch is installed NO An Engine Oil Level Switch is not installed ENGINE OIL LEVEL SHUTDOWN YES NO YES When the 2 LOW ENGINE OIL LEVEL alarm is activated the alarm light will illuminate and the unit will shutdown NO When the 2 LOW ENGINE OIL LEVEL alarm is activated the alarm light will illuminate and the unit will continue to run LOW COOLANT LEVEL YES YES A Coolant Level Sensor is installed A Coolant Level Sensor is not installed
480. ons at evaporator No corrosion water damage or burning discoloration Remove and replace if required Verify Accuracy of AC Current Sensor With microprocessor in PC Mode refer to Section 5 3 page 54 check amperage in the Unit Data refer to Section 3 13 Reading for AC1 amps and AC2 amps must both be 0 Check Compartment 3 evaporator fan motor wiring 62 11524 a Use a clamp on ammeter to check the total current draw Compare to Unit Data b If no fault was found in previous tests Remove and replace contactor 7 114 Steps Alarm Cause Corrective Action P186 CHECK EVAP OUTLET TEMP TRIGGER ON Evaporator Outlet Temperature Sensor EVOT is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again Check Sensor refer to procedure for alarm 131 P187 CHECK HEATER 1 CIRCUIT This device is checked twice in Pretrip once in Test 2 and again in Test 8 TRIGGER ON TEST 2 unit not running Normal draw for the 1HTCON1 relay coil is 0 05 to 1 0 Amps 12 VDC The circuit tests outside this range TRIGGER ON TEST 8 unit running Normal draw for the 1HTCON 1 heaters is 1 0 to 3 5 Amps 460 VAC The circuit tests outside this range
481. ontacts to allow power from the power plug while the engine is shutdown and power from the generator is locked out With the switch in the ENGINE position the generator contactor relay GENCONR is energized Energizing GENCONR reverses its contacts to allow the engine and generator to operate while power from the power plug is locked out Once the Main Power switch is toggled from the OFF position the compressor suction modulating valve CSMV and evaporator expansion valve EVXV will both open to a predetermined position to equalize system pressure and then close 096 open before the unit starts NOTE The unit will not restart for at least 30 seconds following a shutdown 4 2 1 Standby Start Up On command to perform a Start Up in Standby Operation the microprocessor will energize the buzzer for five seconds The refrigeration system or heaters will then operate in the mode s required for temperature control 4 2 2 Engine Start Up On command to perform a Start up in Engine Operation the microprocessor will enter the engine start sequence to start the engine and direct connected generator Following start the refrigeration system or heaters will then operate in the mode s required for temperature control At the beginning of the start sequence the microprocessor will close the run relay RR contacts to signal the engine speed control unit ENSCU that engine operation is required and to provide power to the optio
482. ontrol box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Additional steps on the next page 62 11524 7 92 Steps Alarm Cause Corrective Action C2 CHECK HEATER 1 CIRCUIT Continued 5 Check Evaporator High Temperature Switch 2EVHTS Inspect for open 2EVHTS per wiring If open replace switch as required schematic Check Amp Draw of 2HTCON 1 Heater Circuit Use a clamp on ammeter to check Must be within range shown in Section 2 12 for all the current draw of all 3 legs three legs Check Heater Elements Check heater elements No visual physical damage No blockage due to debris Remove and replace if required Check Heater Element Plugs And Connections Disconnect heater element plug In No corrosion water damage or burning discoloration spect plugs plug seal and connec Remove and replace if required tors Verify Accuracy of AC Current Sensor With microprocessor in PC Mode Reading for AC1 amps and AC2 amps must both be refer to Section 5 3 check amper 0 age in the Unit Data refer to Section 3 13 Check Heater Wiring a Use a clamp on ammeter to check Compare to Unit Data the total current draw b If no fault was found in previous Remove and replace contactor tests 7 93 62 11524 Alarm Cause Corrective Action P147 C2 CHECK HEATE
483. oprocessor powers up OK from the battery wait 30 seconds then reconnect and place the Main Power switch in the desired posi tion Check for valid Configuration Values are set correctly for all parameters settings in Configuration List Alarm is cleared Valid Configurations not Download and replace microprocessor Refer to entered and alarm remains active Section 5 7 7 135 62 11524 Alarm Cause Corrective Action 242 DIS PRESS CALIBRATE ERROR TRIGGER ON There is an error in the Compressor Discharge Pressure Sensor Calibration value stored in memory UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when the Discharge Pressure Sensor is calibrated successfully or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Discharge Pressure Reading Check Discharge Pressure Reading Must read valid data Calibrate Discharge Pressure Sensor a Calibrate Discharge Pressure Calibration successful Sensor b Discharge Pressure Sensor can not Download and replace microprocessor Refer to be successfully calibrated and Section 5 7 alarm remains ac
484. optional No corrosion or moisture inside connector sensors and switches If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink Steps Alarm Cause Corrective Action 138 C3 CHECK RETURN AIR SENSOR TRIGGER ON Return Air Sensor 3 8RAT is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and standby If setpoint is in the perishable range compartment 3 will shutdown If setpoint is in the frozen range compartment 3 will run in reduced capacity cool RESET CONDITION Auto Reset when sensor is in range or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check sensor resistance See Note 3 page 7 2 10 000 Ohms 77 F 25 C Refer to Table 8 5 for complete resistance chart Check Sensor Wiring a Inspect harness amp control box con nector pins amp
485. or No physical damage to harness No damage moisture or corrosion in connectors b Check Return Air Sensor resistance 10 000 Ohms 77 F 25 C See Note 3 page 7 2 Refer to Table 8 5 for complete resistance chart Check Compartment 2 Defrost Sensor Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Check Remote Sensor Connector 2 Compartment Units Only Locate and inspect remote sensor Cap is in place connector No physical damage No moisture or corrosion 7 127 62 11524 Alarm Cause Corrective Action P212 CHECK DEFROST SENSOR 3DTT TRIGGER ON Defrost Sensor for Compartment 3 is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip mode is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Compartment 3 Defrost Sensor a Inspect sensor amp connector No physical damage
486. or corrosion in connections b Check contactor coil resistance Refer to Section 2 13 for resistance values Check PSCONR PSCON and PSCON2 Amp Draw PSCONR PSCON and PSCON contactor coils amp draw Use Component Test Mode Section 5 2 2 to test Refer to Section 2 13 for amp values View current draw in Data List FET 19 On b Listen for PSCON or PSCON to pull in If PSCON or PSCON contactor pulls in PSCONR and PSCON or PSCON are OK If PSCON or PSCON contactor does not pull in check for 12 VDC at Phase Reversal Module PRM N terminal 12 VDC indicates defective PSCON or PSCON coil No voltage check PSCONR and PRM Check PSCONR PSCON PSCON2 and PRM Wiring 62 11524 Inspect harness amp control box con nector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors 7 126 Alarm Cause Corrective Action P210 C3 CHECK RETURN AIR SENSOR TRIGGER ON Compartment 3 Return Air Sensor is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip mode is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correc
487. orrected and the alarm cleared to continue Check fuel and speed actuator FSA a Check resistance of FSA Refer to Section 2 13 b Check amp draw between MPQC4 Use Component Test Mode Section 5 2 2 to test amp terminal 13 of the ENSCU Refer to Section 2 13 for amp values Check FSA amp circuits a Inspect FSA and wiring No physical damage to harness No damaged or corroded pins No damage to component b Check operation of Run Relay With microprocessor powered see Note 2 LED 28 must be ON c Check voltage to FSA With microprocessor powered see Note 2 OR component test mode 12 VDC between engine speed control unit ENSCU pins 13 and 19 With Main Power switch not in the OFF position 12 VDC between ENSCU pins 24 and 19 62 11524 7 96 Alarm Cause Corrective Action P153 CHECK RETURN AIR SENSOR TRIGGER ON Return Air Temperature Sensor 1RAT is not within the range of 53 to 158 F 47 to 70 C e UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again Check Sensor refer to procedure for alarm 122 P154 CHECK SUPPLY AIR SENSOR TRIGGER ON Supply Air Temperature Sensor 1SAT is not within the range of 53 to 158 F 47 to 70 C UNIT CON
488. orrection has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check For Any Pretrip Alarms Scroll the alarm list for any Active Alarm conditions must be corrected and the alarm Pretrip alarms cleared to continue Rerun Pretrip Check If Desired a Clear Active Alarm List then run Unit is in Pretrip Check for any new alarms Pretrip amp check for any new alarms b Allow to terminate automatically Pretrip cycle operates normally P144 CHECK UL1 CIRCUIT TRIGGER ON Normal Amps for the Front Unloader UL1 Circuit is 0 75 to 2 0 Amps The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail in test 2 and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again Check UL1 circuit refer to procedure for alarm 85 62 11524 7 90 Alarm Cause Corrective Action P145 CHECK SPEED SOL CIRCUIT TRIGGER ON Normal Amps for the Speed Solenoid Circuit is 0 to 1 0 Amps The circuit tests out sidethis range UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again 1 Check For Bad F2 O
489. ost cycle at the interval selected if a DTT is below 40 F 4 4 C Shorter times are generally used for warm humid products like pro duce Longer times can be used for dry and frozen products NOTE the the timer increments time toward the next defrost only when the DTT is below 40 F and the unit is running Set Start Stop Parameters Time and Temperature values that control Start Stop Operation are set in this section The microprocessor may be configured so that 1 the same settings apply to any setpoint Together or 2 the set tings are different depending on whether the setpoint is in the perishable range or in the frozen range Separate elf together is configured there will be six settings with only the sixth applicable to just frozen range elf Separate is configured there will be eleven settings five labeled perishable and six labeled frozen MIN RUN TIME 4MINS TO 60MINS in 1 minute incre ments This determines the minimum length of time the unit will run every time the unit starts in Start Stop Operation MIN OFF TIME 10MINS TO 90MINS 20MINS in 1 minute incre ments This determines the minimum length of time the unit will remain off whenever the unit cycles off in Auto Start Stop Operation RESTART TEMPERATURE 0 5 F 2 C TO 18 F 10 C 5 5 F 3 C in 0 5 F or C incre ments Following the Minimum Off Time should a compart
490. oubleshooting 91 ENGINE NOTE Indication Trouble Possible Causes Action Refer ence Section Refer to section 9 5 for electronic speed control system diagnoses NOTE 9 1 1 Engine Will Not Start Starter motor will not crank or low cranking speed Battery insufficiently charged 9 2 Battery terminal post dirty or defective Check Bad electrical connections at starter Check Starter motor malfunctions 9 1 4 Starter motor solenoid defective Engine Manual Open starting circuit 9 1 5 Incorrect grade of lubricating oil 2 9 Internal generator damage 8 9 9 No fuel in tank Check Air in fuel system 8 5 2 Water in fuel system Drain Sump amp 8 5 5 Starter motor cranks Plugged fuel filter 85 5 but engine fails to start Plugged inlet screen to mechanical pump 8 5 3 Plugged inlet screen to electric pump 8 5 4 Plugged fuel lines to injector s Check ESC defective 9 5 Intake air heater defective 8 5 10 Starter cranks engages Incorrect grade of lubricating oil 2 9 but dies after a few seconds Voltage drop in battery cable s Check ESC defective 9 5 62 11524 Indication Trouble Possible Causes Action Refer ence Section 9 1 2 Engine Starts Then Stops Engine stops after several rotations Fuel supply restricted Check No fuel in tank Check Leak in fuel system Check Faulty fuel control operation Engi
491. our Meters and DataLink data recorder Setup NOTE Specific configurations may be found on the TransCentral Website Authorized Carrier Transicold Dealers only 7 43 62 11524 Alarm NO Alarm Cause Corrective Action 60 DATALOGGER DataLink data recorder TIME WRONG TRIGGER ON The real time clock in the Data Recorder does not contain a valid date UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset when the DataLink data recorder real time clock is reset or alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Real Time Clock Check Real Time Clock in the Data List or using ReeferManager Must show correct date and time Change as needed Configuration List Reset Microprocessor a Place the Main Power switch in the OFF position for 30 seconds and then return it to the desired position Microprocessor powers up OK b Check for valid Real Time Clock reading in Data List Valid date and time in memory Alarm is cleared automatically c Real Time Clock can not be changed Replace microprocessor
492. p Nut and Bolt Clamp Thermocouple TXV Bulb Figure 8 33 Thermostatic Expansion Valve Bulb and Thermocouple 6 Connect accurate gauge to the 1 4 port on the suction line If the valve s have not been adjusted previously preliminary adjustment may be made by turning the adjustment fully clockwise to bring the valve to the closed position and then turning the adjustment screw counter clockwise three complete turns of 360 Set Compartment 2 at O F 18 C to keep the unit running in high speed Adjust the bulkhead or open the compartment door slightly to maintain Compart ment 2 temperature as close to 32 F 0 C as pos sible Keep in mind that running the unit with the door open will frost the evaporator coil making the super heat measurements unstable Take at least ten readings of pressure and temperat ure 10 seconds apart and average readings 10 From the temperature pressure chart refer to Table 8 7 determine the saturation temperature corresponding to the average suction pressure 1 Subtract the average saturation temperature from the average bulb temperature The difference is the evaporator superheat Evaporator superheat should be 15 to 17 F 8 3 to 9 4 C If required adjust valve One complete turn will change the reading by about 7 F 3 8 C Turn clockwise to increase or counter clockwise to decrease superheat Repeat adjust ment as required to bring superh
493. p hole Bearings tight and quiet Impeller firmly attached to shaft d Check cooling system for scale sludge rust etc Coolant must be clean amp clear No foreign particles or substances in it Flush amp clean the coolant system as necessary e Check water pump bypass hose to thermostat housing for internal blockage 7 6 Must be clear and open Alarm NO Alarm Cause Corrective Action 13 HIGH DISCHARGE PRESSURE ALARM 75 WILL ALSO ACTIVATE TRIGGER ON Compressor discharge pressure switch HP1 contacts are open HP1 contacts open when the discharge pressure rises to 465 psig 31 6 bar UNIT CONTROL Engine Operation Engine and unit shutdown and alarm Standby Operation Refrigeration system shutdown and alarm with PSCON still energized RESET CONDITION Auto Reset after 15 minutes if the compressor discharge pressure falls below 350 psig 23 8 bar or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check System Pressures Install manifold gauge set and check and compare compressor discharge amp suction pressures with those shown on th
494. partments Check defrost air switch setting and hoses Refer to Section 8 8 9 Check for restricted bulkhead or air chute installation Perform Pretrip Check Clear Active Alarm list then run Pre Any active alarms must be corrected and cleared trip amp check for any new alarms before proceeding Check Compressor Suction Temperature CST and Evaporator Outlet Temperature EVOT sensors a Inspect CST amp connector No damage to sensor No damage moisture or corrosion in connector b Check CST resistance 10 000 Ohms 77 F 25 C Refer to Table 8 5 for See Note 3 page 7 2 complete table of temperatures and resistance val ues c Check voltage at harness connec Must be 2 5 0 5 VDC This verifies microprocessor tion to CST output and wiring connections to sensor d Verify accuracy of CST using in CST reading must be within 3 F 1 7 C of test frared or other accurate temperat temperature tool reading ure testing tool Additional steps on the next page 62 11524 7 16 Steps Alarm Cause Corrective Action LOW SUCTION SUPERHEAT Continued 5 Cont d Check Compressor Suction Temperature CST and Evaporator Outlet Temperature EVOT sensors Continued e Inspect EVOT amp connector No damage to sensor No damage moisture or corrosion in connector f Check EVOT resistance See Note 3 page Note 3 10 000 Oh
495. perage of added on components amp accessories Total current draw including the actual unit current draw and all add on components amp accessories must be less than battery charger rating Perform Pretrip Check 62 11524 Clear Active Alarm list then run Pretrip amp check for any new alarms Any active alarms must be corrected and cleared before proceeding am Alarm Cause Corrective Action 53 BOX TEMP OUT OF RANGE Compartment 1 TRIGGER ON Condition One If the unit is running in Pulldown Mode and the SAT is not greater than 1 F 0 56 C below the RAT or if the unit is running in Pull Up Mode and the SAT is not above the RAT the configured action Alarm only after 30 minutes or Alarm and Shutdown after 45 minutes will be activated NOTE If the Out Of Range Alarm Functional Parameter is set to OFF the following conditions will not trigger an alarm or shutdown Condition Two If the refrigerated compartment temperature has been within 2 7 F 1 5 for perishable setpoints or 2 7 F 1 5 C for frozen of setpoint at least once since the unit was started and is now further away from setpoint than the limit set in the Out Of Range Alarm Functional Parameter 4 5 or 7 F 2 3 or 4 C the configured action Alarm only after 30 minutes or Alarm and Shutdown after 45 minutes will be activated Condition Three If a shutdown alarm occurs and the RAT is further away from se
496. physical damage to harness No damage moisture or corrosion in connectors Check CCONR Current Draw 62 11524 Use Component Test Mode to test actual current draw of the circuit Refer to Section 5 2 2 Refer to Section 2 13 for correct electrical values View current draw in Data List num Alarm Cause Corrective Action 95 CHECK CDCON RELAY COIL TRIGGER ON Condenser fan motor contactor CDCON circuit is shorted The contactor output from the microprocessor 4MP6 is negative so the circuit will not be shorted to ground but is shorted either within the contactor coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check CDCON a Inspect condenser fan contactor No damage to coil coil and terminals No damage or corrosion b Check contactor coil resistance Refer to Section 2 13 for correct electrical values Cannot be opened infinite ohms shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical
497. pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 Additional steps on the next page 7 111 62 11524 Steps Alarm Cause Corrective Action C2 CHECK EVAP FAN MOTOR Continued 5 Check Amp Draw of Compartment 2 evaporator fan motor 2EVCON circuit Use a clamp on ammeter to check the current draw of all 3 legs Must be within range shown in Section 2 12 for all three legs Check Compartment 2 evaporator fan motors a With the unit off visually check fan motors and blower wheels No visual physical damage No blockage due to debris Blower wheels spin freely Remove and replace if required b With the unit off check resistance of the evaporator fan motor windings No open windings phase to phase No continuity from any high voltage lead to ground Check Compartment 2 evaporator fan motor connections Inspect high voltage fan motor con nections at evaporator No corrosion water damage or burning discoloration Remove and replace if required Verify Accuracy of AC Current Sensor With microprocessor in PC Mode refer to Section 5 3 page 54 check amperage in the Unit Data refer to Section 3 13 Reading for AC1 amps and AC2 amps must both be 0 Check Compartment 2 evaporator fan motor wiring 62 11524 a Use a clamp on ammeter to check the total current draw Compare to Unit Data
498. pplicable Check battery cables and terminals Check evaporator coils for cleanliness Check bulkheads and return air screens Check all defrost water drains Place in continuous run and start unit IMMEDIATELY AFTER STARTING ENGINE OK ADJUST Check fuel lines and filter for leaks Check oil lines and filter for leaks Check coolant hoses for leaks Check exhaust system for leaks L L Check condenser fan for proper airflow Check evaporator fans for proper airflow Check for unusual noises MICROPROCESSOR PRETRIP PASS FAIL Initiate Pretrip L LI List Alarms occurring during Pretrip AFTER OPERATING UNIT FOR 15 MINUTES OR MORE OK ADJUST Check refrigerant level Check compressor oil level Check for proper temperature control Check Start Stop Operation Initiate defrost and allow to terminate Check engine speeds 62 11524 8 4 Table 8 2 Pre Trip Inspection Continued OPERATE UNIT IN HIGH SPEED COOL AND RECORD From Microprocessor Unit Data Suction Pressure Suction line Temp Unit Serial Di
499. pre set the setpoints for the oth er compartments 2 Press Carrier logo and the lock light will illuminate 3 31 62 11524 e Removing Pre Set Setpoints With Remote Control Panel 1 Place the unit switch panel mounted Main Power switch in the de sired position and the Compartment Switches in the ON position TEMPERATURE H 4 22 A B COMPARTMENT 1 TEMPERATURE g8 3 Press UP ARROW for the de BB sired compartment for 10 sec COMPARTMENT 2 9 onds P1 will be displayed 4 Set temperature to lowest pre set setpoint and OFF will be displayed Bg COMPARTMENT 3 9 5 Repeat steps 3 8 4 to remove the pre set setpoints for the oth T gt i 8 er compartments SYSTEM MAN DEFROST vector 2 Press Carrier logo and the lock light will illuminate 62 11524 3 32 SECTION 4 ENGINE STANDBY TEMPERATURE CONTROL PARAGRAPH NUMBER Page S INTRODUCTION anda T A 4 1 42 ENGINE STANDBY 55 556 5 555 4 1 4 1 22 p Pm 4 1 423 Transition TO High BOB seals 4 2 42 TEMPERATURE CONTROL 35325 4 2 43 1 Temperature Determination 4 2 4 3 2 Perishable And Frozen Setpoint Ran
500. pressure required The recommended procedure for finding leaks from a compressor is with an electronic leak detector Checking joints with soapsuds is satisfactory only for locating large leaks or pinpointing small leaks once a general area has been located Once leak checking is complete remove the refriger ant nitrogen vapor from the compressor If no leaks are found the compressor is ready for evacuation Skip to Step 10 If any leaks are found they must be repaired before proceeding Repeat steps 4 thru 9 as necessary 10 Disconnect the nitrogen cylinder Evacuate the compressor after all leaks are repaired Refer to Sec tion 8 6 4 8 6 4 Evacuation And Dehydration Moisture is detrimental to refrigerant systems The presence of moisture in a refrigeration system can have many undesirable effects such as copper plating acid sludge formation freeze up of the expansion valves and formation of acids resulting in metal corrosion Proper evacuation of the system will remove any moisture from inside the system 5 1 Essential tools to properly evacuate system include a good vacuum pump 5 cfm 8m3H volume displacement Carrier Transicold part number 07 00176 11 anda good vacuum indicator such as a thermocouple vacuum gauge micrometer Carrier Transicold part number 07 0041 4 00 2 The use of a compound gauge is not recommended for use in determining when the evacuation process
501. priate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 2HTCON1 a Inspect heater contactor coil and terminals No damage to coil No damage or corrosion b Check contactor coil resistance Cannot be opened infinite ohms Shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check 2HTCON1 Current Draw Use Component Test Mode Refer to Section 5 2 2 to test actual current draw of the circuit Refer to Section 2 13 for correct electrical values View current draw in Data List Check 2HTCON1 Wiring Inspect harness amp control box con nector pins amp terminals See wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors 104 CHECK 2 2 RELAY COIL TRIGGER ON Remote heater contactor 2 2HTCON2 circuit is shorted The contactor output from the microprocessor 8MP06 is negative so the circuit will not be shorted to ground but is shorted either within the contactor coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm
502. ptional sensors and switches Connector must have cap on No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink Alarm Cause Corrective Action 140 C3 CHECK DEFROST SENSOR TRIGGER ON Defrost Termination Temperature Sensor for Compartment 8DTT is not within the range of 53 to 158 F 47 to 70 C e UNIT CONTROL Engine and Standby Operation If Alarm 138 is not active alarm and initiate defrost if is below 45 F 7 2 C and defrost will end after 10 minutes If both alarm 140 and 138 are active alarm and defrost is not allowed for compartment 3 RESET CONDITION Auto Reset when sensor is in range or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check sensor resistance Note 3 page 7 2 see 10 000 Ohms 77 F 25 C Ref
503. r a Inspect sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check sensor resistance See 10 000 Ohms 9 77 F 25 C Note 3 page 7 2 Refer to Table 8 5 for complete resistance chart Check Sensor Wiring a Inspect harness amp control box con No physical damage to harness nector pins amp terminals 1MP see No damage moisture or corrosion in connectors wiring schematic Section 10 Power up the microprocessor see Voltage should be 2 5 VDC volts at harness plug be Note 2 page 7 2 Disconnect tween pins This verifies microprocessor output and sensor from harness Check for wiring connections to the sensor 2 5 VDC at harness plug between pins Check remote sensor switch connector c Locate and inspect 10 position Connector must have cap on connector for optional sensors and No corrosion or moisture inside connector switches If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 7 85 62 11524 Steps Alarm Cause Corrective Action 137 C2 CHECK RETURN AIR SENSOR TRIGGER ON Return Air Sensor 2 2RAT is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and standby If setpoint is in the perishable range compartment 2 will
504. r F 9 4 5 Unit Will Not Heat Or Has Insufficient Heating Heater s defective 8 9 5 Heater contactors or coil defective Replace Defective wiring connectors Replace Unit will not heat or has insuffi Loose terminal connections Tighten cient heat Low voltage 9 3 No or restricted air flow 9 4 10 Temperature sensor malfunction 8 9 10 Compressor contactor stuck closed Check 9 4 6 Unit Will Not Terminate Heating Microprocessor temperature improperly set Reset Unit fails to stop heating Microprocessor malfunction 9 6 Temperature sensor malfunction 8 9 10 9 4 7 Defrost Cycle Malfunction Defrost timer has not expired Check Reset Will not initiate defrost Defrost air switch DAS malfunction 8 8 9 automatically A Compartment DTT is above 40 F 4 4 C Cool Down Loose terminal connections DAS Tighten Keypad defective 8 4 4 Loose terminal connections between keypad and micro Tighten Will not initiate defrost manually Processor A compartment DTT is above 40 F 4 4 C Cool Down Unit has been running less than 15 seconds Try again Heater contactor or coil defective Replace Initiates but does not defrost Heater s burned out 8 9 5 Evaporator fan contactor stuck closed Check Defrost air switch DAS out of adjustment 8 8 9 Frequent defrost Wet load Normal Does not terminate or Defrost air switch DAS out of adjustment 8 8
505. r housing clean inspect element and replace if re quired e Wipe inside of the cover and re install f Re secure 2 clips on air cleaner housing g Reset air cleaner service indicator 8 5 10 Intake Air Heater The circuit amp draw for the air heater circuit is checked during a Pretrip cycle Refer to Section 2 13 for amperage and resistance values a Troubleshooting The Intake Air Heater IAH 1 Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Disconnect the lead Measure the resistance between the terminal and the heater body 4 the resistance is infinite or zero the intake air heater is faulty and must be replaced Figure 8 13 Intake Air Heater Replacing The Intake Air Heater Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle 2 Remove the inlet hose 3 Disconnect the lead 4 Remove the flange intake air heater and gaskets NOTE To avoid short circuiting the heater ensure that the heater and the heater elements are vertical when assembling to the intake manifold The plus terminal is to be mounted towards the front of the unit 62 11524 5 Clean gask
506. r C increments The factory default is 5 5 F 326 5 Compartment temperature has exceeded the Override Functional Parameter value During MINIMUM OFF TIME the microprocessor continually monitors the refrigerated compartment temperatures If the temperature in one of the compartments should drift outside the START STOP OVERRIDE TEMPERATURE Functional Parameter value the unit will be restarted The value may be set from 3 6 to 18 F 2 to 10 C in 0 5 increments The factory default setting is 11 F 6 C Whenever the unit restarts temperature control will be in the PullDown or Pull Up mode refer to Section 4 3 3 62 11524 4 5 CONTINUOUS OPERATION 4 5 1 Introduction In Continuous Operation the unit will not shutdown except in response to a shutdown alarm Temperature control in the compartments will operate under Pulldown Pull Up Cooling Heating or Null Continuous Operation is normally used for fresh produce and other sensitive product loads The Start Stop Continuous key is pressed to switch between Continuous Operation and Start Stop Operation The corresponding LED will be illuminated NOTE The microprocessor may be locked so that the unit will always operate in Start Stop or in Con tinuous whenever the setpoint is within a specif ic range Refer to Range Lock Section 4 7 3 for additional information 4 5 2 Continuous Operation Refer to Figure 4 2 and Figure 4 3 for the Switch Point temperatures
507. r F3 Fuse Alarm Check for Alarm 71 Alarm conditions must be corrected and the alarm cleared to continue Check Speed Circuit To ENSCU And FSA a Check voltage to ENSCU and amp Use Component Test mode to energize the Speed draw of engine speed control circuit Relay Section 5 2 2 ENSCU pin 16 and on the Refer to Section 2 13 for amp values microprocessor View current draw in the Unit Data Refer to Section 3 13 Check voltage at ENSCU16 and ground Must be 11 VDC or higher b Check operation of Speed Relay LED 27 must be ON when the Speed Relay is ON in LED component Test Mode Check Engine Speed Control Unit ENSCU a Check resistance of FSA Refer to Section 2 13 With FSA unplugged ohm spec is to 4 ohms 10 b Inspect ENSCU and wiring No physical damage to harness No damage moisture or corrosion in connectors No damage to ENSCU Check ENSCU Circuit Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic 7 91 62 11524 Alarm Cause Corrective Action P146 C2 CHECK HEATER 1 CIRCUIT This device is checked twice Pretrip once in Test 2 and again in Test 8 TRIGGER ON TEST 2 Normal current draw for the 2 1 contactor coil is 05 to 2 0 D C Amps 12 VDC The circuit tests outside this range TRIGGER ON TEST 8
508. r Head Loaded 2 11 Figure 2 10 Control Moule ERR dad pde 2 15 Figure 2 11 Display And Keypad Assembly 2 16 boob pate dcc od 2 18 Figure 2 15 PRM MOWIE o E edd deb bebe rob prob Addc aped 2 18 Fur DHL Bol pbi 2 18 Figure 2 15 Pelriosrant Grol iu pisa ic dd hg od pad i ra iik qr 2 24 Figure 4 1 Auto Start Segausrcas arg ae OE Qa dor Ree be a 4 1 Figure 4 2 Continuous Operation Switch Points with Eco Mode setto 4 7 Figure 4 3 Continuous Operation Switch Points with Eco Mode set to YES 4 8 Figure 4 4 Range Lock Settings Non Overlapping 4 12 Figure 4 5 Range Lock Settings Overlapping cii siani ec 4 12 Figure 4 8 Evaporator Pressure Char 4 15 Figure 5 1 Technicians Interiace Connection 5 1 CODO Gd atic atin 5 4 Sa CA cuir MT P c r 5 5 Figure 5 4 ReeferManager amp Reports Connection 5 7 Figure 5 5 Connector GMP 5 8 Figure 5 6 Di
509. r Pump V Belt The water pump v belt is driven by a sheave on the engine crankshaft Frayed cracked or worn belts must be replaced This belt is a one time use only type and requires no tension adjustment To replace the poly V belt perform the following steps a Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle b Using the proper size socket slowly rotate the crank by turning the crank pulley nut At the same time use a flat blunt object to guide the belt off the crank pulley Be careful not to damage grooves on the pulley Replace the poly V Belt by positioning the belt on the water pump pulley and while rotating the engine as 62 11524 in step 1 use a flat blunt object to guide the belt onto the crank pulley Be careful not to damage grooves on the pulley or belt 8 5 14 Crankcase Breather The engine uses a closed type breather with the breather line attached to the cylinder head cover See Figure 8 17 The breather assembly should be cleaned once a year or at every 2000 hours maintenance interval whichever comes first See Table 8 1 Screw Breather Cover Breather Valve Breather Tube Figure 8 17 Engine Crankcase Breather 8 6 REFRIGERANT SYSTEM SERVICE Service of the refrigerant system includes connection of refrigerant
510. r to following step f b Checking For Noncondensibles To check for noncondensibles proceed as follows 1 Install a manifold gauge set to allow reading of suction and discharge pressure See Figure 8 18 Stabilize system to equalize pressure between the suction and discharge side of the system The gerant system needs to be off for several hours 3 Measure temperature at the copper tubing leaving the condenser not the subcooler gt Record compressor discharge pressure 5 Determine saturation pressure as it corresponds to the condenser temperature using the temperature pressure chart Table 8 7 6 If gauge reading is not close to the calculated satura tion pressure in step 5 noncondensibles or mixed re frigerants are present 7 Remove refrigerant Refer to following step c 8 Leak check evacuate and recharge the system c Removing Charge To remove the refrigerant charge proceed as follows 1 If the system is in operating condition it will be quicker to remove the charge by continuing with step 2 If the system is not in operating condition skip steps 2 through 5 and continue with step 6 2 Install a manifold gauge set to allow reading of suction and discharge pressure See Figure 8 18 CAUTION Only a refrigerant cylinder that has previ ously been used with R404A should be con nected to this refrigeration unit 3 Connect a clean evacuated refrigerant cylinder to th
511. rant and forces it into the condenser channels The condenser fans circulate surrounding air over the outside of the channels The channels have fins designed to improve the transfer of heat from the refrig erant gas to the air This removal of heat causes the re frigerant to liquify Liquid refrigerant leaves the condens er and flows to the receiver The receiver stores the additional charge necessary for low ambient operation The receiver is equipped with a fusible plug which melts on occurrence of very high tem perature to relieve the refrigerant pressure The refrigerant leaves the receiver and flows through the liquid line service valve to the subcooler The sub cooler occupies a portion of the main condensing coil surface and gives off further heat to the passing air The refrigerant then flows through a filter drier where an absorbent keeps the refrigerant clean and dry The refrigerant flows to the suction line heat exchanger Here the liquid is further reduced in temperature by giv ing off some of its heat to the suction gas The liquid then flows to an electronic expansion valve compartment 1 and through a liquid line solenoid valve and thermal expansion valve compartment s 2 and or 3 if active which reduces the pressure of the liquid and 2 23 meters the flow of liquid refrigerant to the evaporator to obtain maximum use of the evaporator heat transfer surface The refrigerant pressure drop caused by the expa
512. re is the number of degrees away from setpoint the compartment temperature may drift before the Compartment is considered Out Of Range and the configured alarm or alarm and shutdown action will be activated Refer to Alarm A53 BOX TEMPERATURE OUT OF RANGE A63 C2 BOX TEMPERATURE OUT OF RANGE or A63 BOX TEMPERATURE OUT OF RANGE Section 7 for more information 3 23 62 11524 FUNCTION Table 3 2 Functional Parameters Continued PARAMETER SELECTIONS DESCRIPTION Low Speed Startup Minutes Allows user to set the number of minutes the unit will run in low speed every time the engine starts Press to access menu CONTINUOUS OFF 1 TO 255MINS 1 MINUTE Allows user to set the number of minutes the unit will run in low speed every time the engine starts in Continuous operation START STOP OFF 1 TO 255MINS 10 MINUTES Allows user to set the number of minutes the unit will run in low speed every time the engine starts in Start Stop Operation SLEEP MODE SETTINGS For complete instructions on entering and setting parameters for Sleep Mode refer to Section 3 8 Press to access menu NO S B POWER SWITCH TO DIESEL SHUT UNIT DOWN the AC POWER Configuration is set to Alarm amp Shutdown this parameter will not display SWITCH TO DIESEL If the NO AC POWER Configuration is set to the Switch To Engine on power loss setting th
513. re the vacuum holds This checks for residual moisture and or leaks Once the compressor holds a good vacuum open the compressor suction and discharge service valve to allow refrigerant to enter the compressor Start unit and check the refrigerant charge Refer to Section 8 6 2 8 7 COMPRESSOR AND UNLOADER SERVICE 8 7 1 Repair or Replacement Determination 7 Certain operating conditions or refrigeration system components may be misdiagnosed and subsequently lead to the determination that the compressor requires replacement These conditions or components should be checked prior to replacing a compressor and after a replacement compressor is installed to prevent replacement compressor damage To determine if compressor replacement or repair is required do the following a If the compressor is operational check the refrigerant charge refer to Section 8 6 2 b If the compressor is operational check operation of the unloaders refer to Section 8 7 6 c If the compressor is operational check the system components as follows Install gauges to allow reading of receiver suction and discharge pressure See Figure 8 18 2 Start the unit with at least one compartment in cool ing so that compressor operates 1 Frontseat the liquid line service valve Shut down the unit when the suction pressure drops to 2 psig 0 2 bar Monitor the gauges If the receiver pressure drops rapidly and the suction and dis
514. rect water or steam into the gener ator openings Do not allow any soap and water solutions to enter the generator NOTE Always test suspect generators with a megohmmeter Refer to Section 8 9 1 WARNING Generators of this type should not be flashed Operation with external voltage source or momentary shorting of leads will damage the generator and may cause in jury Costly repairs and down time can usually be prevented by operating electrical equipment under conditions which are compatible with those at which the equipment was designed Follow the instructions outlined below to ensure maximum efficiency of the electrical equipment Drying the Generator Windings Generators that have been in transit recently steam cleaned or in storage for long periods may be subjected to extreme temperature and moisture changes This can cause excessive condensation and the generator windings should be thoroughly dried out before bringing the generator up to full nameplate voltage If this precaution is not taken serious damage to the generator can result Always test suspect motors or generators described above with a megohmmeter Refer to Section 8 9 1 Do not set voltage higher than rating on wiring insulation in order not to prevent insulation breakdown during testing Test each winding to ground looking for very high megohmmeter readings Also test each phase to phase winding looking for a low ohm reading but with
515. ree legs b Check fuses for heater elements F10 F11 and 12 must not be blown c Check voltage at 1HTCON2 con tacts Must be within range shown Section2 12for 11 12 L1 L3 and L2 L3 Must be within range shown in Section 2 12 for T1 T2 T1 T3 and T2 T3 Check Heater Elements a rg heater elements with the unit ff No visual physical damage Remove and replace if damaged b Check heater element resistance Check from T terminals on HTCON contactor See section 2 12 for correct resistance Check Heater Element Connections Inspect high voltage heater connec tions at evaporator No corrosion water damage or burning discoloration Remove repair or replace if required Verify Accuracy of AC Current Sensor 62 11524 Put microprocessor in PC Mode Re fer to Section 5 3 page 5 4 Must have 0 AC1 Amps and 0 AC2 Amps in Unit Data 7 118 Alarm Cause Corrective Action P189 CHECK EVAPORATOR FAN MOTOR This device is checked twice Pretrip once in Test 2 and again in Test 8 TRIGGER ON TEST 2 unit not running Normal draw for the 1EVCON contactor coil is 0 05 to 2 0 Amps 12 VDC The circuit tests outside this range TRIGGER ON TEST 9 unit running Normal draw for the Evaporator Fan motor is 0 7 to 3 5 Amps 460 VAC The circuit tests outside this range UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP
516. ressure switch set tings refer to Section 2 11 Close valve on cylinder and open bleed off valve Open cylinder valve Slowly close bleed off valve and increase pressure until the switch opens If light is used light will go out and if an ohmmeter is used the meter will indicate open Close cylinder valve Slowly open bleed off valve to decrease pressure until switch closes light will illuminate or ohmmeter will in dicate open 8 8 8 Pressure Transducers The Compressor Discharge Pressure Transducer CDP has a range of 0 to 500 PSIG 0 to 34 0 bar while the Compressor Suction Pressure Transducer CSP and Evaporator Pressure Transducer EVOP have a range of 14 7 to100 PSIG 1 to 6 8 bar To test the transducers do the following NOTE The Compressor Discharge Pressure on the microprocessor Data List will never read less than 0 bar psig even if it is exposed to a vacuum such as when evacuating the system Also the compressor suction pressure and evaporator pressure transducers will never read higher than 100 psig even if the actual pressure is higher a Verify that the wiring to the transducer is correct b Power up the transducer circuit Place the unit in PC mode refer to Section 5 3 Check Voltage to trans ducer connector Voltage reading between B posi tive and A negative should be 5 0 VDC To check the signal wiring check continuity between the transducer connector C terminal and the fol
517. ressures do not change as indicated check the unloader coil resistance refer to Section 2 13 Replace if coil is open or shorted If either unloader coil energizes and the suction and dis charge pressures do not change the unloader assembly must be checked Unloader Coil Replacement NOTE The coil may be removed while the compressor is under pressure Disconnect leads and lift coil see Figure 8 24 off en closing tube Verify replacement coil is the correct type voltage and frequency Place new coil over enclosing tube With wiring facing in the desired direction ensure roll pin is fitted in one of the detents in the bottom of the coil mounting Coll is to snap into place with bottom in contact with the enclosing tube nut Connect wiring Check operation refer to preceding step a 1 Coil Assembly 8 Gasket 2 Pin Roll 9 Valve Body 3 Enclosing Tube Nut 10 O Ring 4 Enclosing Tube 11 Plunger 5 Bolts Valve Body 3 12 Plunger Spring 6 Washers 3 13 Installation Removal 7 Piston Tool Figure 8 24 Unloader Coil 62 11524 1 N gt a Replacing Unloader Valve Internal Parts Pump down the compressor Refer to Section 8 6 2 step e Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Disconnect
518. rical there is an alignment hole in the sensor alignment holes and index dimples in the gaskets and an align ment notch in the focus tube flange to assist in align ing the components Install mounting screws and washers in all mounting holes and bring to finger tight Tighten in accordance with the instructions provided in the preceding CAUTION g With the fuel tank empty the output reading should be approximately 0 25 VDC h With the fuel tank full the output reading should be approximately 4 75 VDC i Start unit and check for leaks 8 5 7 Fuel Heater The optional fuel heater itemNO TAG Figure 8 5 applies heat to fuel in the fuel filter Heating the fuel dissolves prevents paraffin wax crystals and ice that form when diesel fuel is chilled thus enabling the water separator to work more efficiently and to prevent the filter from plugging with wax and or ice crystals When the ambient air sensor is reading 77 F 25 C or higher the microprocessor will not enable this circuit Also the heater is fitted with an internal temperature switch FHTS see schematic diagrams Section 10 which will close on a temperature fall to energize the heater element at temperatures below 45 F 7 2 C and open on a temperature rise to de energize the heater element at 75 F 23 9 C 62 11524 To test the fuel heater do the following a Using Unit Data refer to Section 3 13 check to en sure the Ambient Air Temperature readi
519. rnesses for the Check Wiring for high ing OK micro and display resistance or an open now the cable from the Did you find and Smicro to the back of correct the condition YES the display the 1 cable from the back NO of the display to the YES Y System OK display itself and the Check voltage Re install two ribbon cable from between 5MPA1 amp way the keypad to the QC2 Voltage nication if dis board Did you find Did the loading should read 11 connected and correct the of the software volts or higher Is earlier condition correct the voltage problem within range NO MPR Code 2 Review the results of Check Wiring for high Replace micro and operate above tests with your resistance or an open NO 34 system in order to verify repair E supervisor If necessary Did you find and MPR Code 1 Did you find and correct the go to the beginning of the correct the condition condition tree amp test again Y NO Go To Condition 8 Program ming Problems with PC Cards if using a PC Card to upgrade software Did the software load correctly NO NO System OK Remove new micro and re install old micro re install wo Way COMMUNICA back into the unit Micro is not the fault tions if disconnected earlier Review results of abo
520. roblems with this circuit Review steps for Alarm 13 and correct if necessary Check For 12 VDC At 4MP1 a If 12VDC Alarm should have cleared itself b If no power OVDC Continue with step 3 Check IPC circuit a Use Component Test Mode to ener gize CCON circuit Refer to Section 5 2 2 FET 2 will be on b Check IPC harness to microproces sor 12 VDC on terminals 8 amp 9 at the compressor white wires Check SP 15 There should be 12 VDC from HP1 to SP15 to IPC d Test continuity through IPC Should be 0 Ohms If compressor body is extremely warm allow it to cool off then recheck IPC continuity e Test IP circuit from compressor mo tor to microprocessor 12 VDC at 4MP1 Check Compressor Motor Contacto r a Inspect the wire connections to the contactor See wiring schematic Section 10 No signs of overheating of the contactor Wiring is routed correctly to the contactor b Check tightness of the contactor wire connections Tighten with screwdriver and check for discoloration of wires Perform Pretrip Clear Active Alarm list then run Pre trip amp check for any new alarms Any active alarms must be corrected and cleared be fore proceeding Check Compressor Motor Operation 62 11524 Turn the unit ON in Engine or Stand by Operation Check voltage and current on each phase voltage and ampera
521. rogram If Re eferManager can communicate with the micropro cessor the unit wiring and microprocessor are perform ing normally and any communication problem is with the provider s equipment 3 19 2 Remote Control Panel TEMPERATURE COMPARTMENT 1 w 3 SYSTEM TRANSICOLD DEFROST SETPOINT DISPLAY Control panel power on LED System ON OFF key Reset Button Manual defrost key Control panel lock LED HEAT mode LED COOL mode LED Setpoint display Up and down arrow keys OTemperature display WAITING FOR COMMUNICATION WITH MICROPROCESSOR UNIT WAS TURNED OFF VIA REMOTE CONTROL UNIT IN DEFROST MODE TEMPERATURE SENSOR MALFUNCTION DISPLAYED WHEN SETTING PRE SET SETPOINTS TEMPERATURE DISPLAY C OR F IS DEPENDENT ON MICROPROCESSOR CONFIGURATION The unit may be fitted with an optional remote control panel The panel displays compartment setpoints compartment temperatures and operating modes heat cool or defrost The setpoint may be set and the unit may be started and stopped using the remote panel This compact panels can be mounted to suit the individual operator s preferences in the cab on the front bulkhead or in the compartment including in the wall itself 3 29 The remote control panel be used to Turn the unit on or off Check compartment temperatures Check and change setpoints Initiate manual defrost
522. rom the slot NO ACTIVE ALARMS There are no active alarms in the microprocessor Alarm List NO DATA ON CARD REMOVE CARD A Program or Configuration PC Card has been inserted into the PC Card slot and no valid data is present on the PC Card The PC Card may safely be removed from the unit NO DATA TO COPY REMOVE CARD A Download PC Card has been inserted into the PC Card slot and there is no valid data in the DataLink data recorder to copy onto the PC Card The PC Card may safely be removed from the unit NO INACTIVE ALARMS There are no inactive alarms in the Alarm List NO INSTALLS LEFT REMOVE CARD An Option PC Card has been inserted into the PC Card slot and all install options have been used The PC Card may safely be re moved from the unit OLD SW CANNOT LOAD REMOVE CARD A Program PC Card has been inserted into the PC Card slot and the major version of the program on the PC Card is an older vers ion than what is already loaded in the microprocessor Software with older major versions can not be loaded into the micropro cessor Remove the PC Card OLD SW TO LOAD TO CANCEL A Program PC Card has been inserted into the PC Card slot and the minor version of the program on the PC Card is an older ver sion than what is already loaded in the microprocessor Press the key to load the older program PC MODE The Main Power switch is in the OFF position the PC Mode Jump er is con
523. rrier Transicold part number 07 00223 00 compress the unloader ring while in serting the unloader into the compressor head One valve body mounting hole is offset to assist in correctly aligning the valve body and gasket Insert mounting bolts align with gasket holes and mounting holes in head Start bolts by hand and then toque mounting bolts 12 to16 ft lbs 1 3 to 1 8 Nm Leak check and evacuate the compressor Refer to Sections 8 6 3 and 8 6 4 8 Check operation refer to preceding step a 8 8 REFRIGERANT SYSTEM COMPONENT SERVICE 8 8 1 Evaporator Coils The use of recycled cardboard cartons is increasing across the country The recycled cardboard cartons create much more fiber dust during transport than new cartons The fiber dust and particles are drawn into the evaporators where they lodge between the coil 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 Clean the evaporator coils on a regular basis not only to remove cardboard dust but to remove any grease or oil film which sometimes coats the fins and prevents water from draining into the drain pan Cardboard fiber particles after being wetted a
524. rs Continue with the steps below as necessary IF A SWITCH IS INSTALLED Determine what REMS 1 is controlle d by REMS1 may be connected to a com partment door or some other device and used to remotely control the compartment Locate the device used as REMS1 Check To See If REMS1 Has Activat ed Inspect device used to activate 51 For example Compartment door must be closed and switch must be de activated Check REMS1 Remote Switch 1 Configuration Verify that Configuration is set for the type of switch being used i e when Switch is activated switch contacts are closed etc Configuration must agree with switch type Refer to REMS1 Remote Switch 1 Configuration Table 5 2 Check Wiring a Visually inspect wiring to Remote Switch 1 Wiring must be connected b Visually inspect condition of switch Must not be damaged wet corroded etc c Check circuit See wiring schemat ic Section 10 With the switch contacts closed check for 12 VDC through the wiring and switch to the correct micropro cessor terminal refer to applicable wiring schematic Section 10 Temporary Solution Tip In the event of a defective switch that can not be repaired or replaced and the switch is forcing the unit into a Shutdown this alarm may be tem porarily overridden by setting the correct Functional Parameter In the Functional Parameter li
525. ry close limits 2 6 1 Multiple Languages Messages in the MessageCenter can be displayed in English French Spanish or Portuguese Press and hold the Select Key for 6 seconds to view or change the current language selection Refer to Section 3 15 for more information on language selection 2 6 2 Automatic Start Stop Standard equipment includes an auto start stop feature This feature provides automatic cycling of the diesel engine which in turn offers an energy efficient alternative to continuous operation of the engine with control of temperature by alternate cooling and heating of the supply air evaporator outlet air 62 11524 2 6 3 Special Features The following additional special features incorporated into the Carrier Transicold Advance Microprocessor An LCD display MessageCenter which clearly dis plays all information in dot matrix form Unit Operation amp Alarms are displayed in text not in codes Unit Data and Functional Parameters Programmable Maintenance Hour Meters resettable from the Keypad Bright LED Alarm amp Indicator Lights Fully Automated Pretrip Automated Microprocessor Self test DataLink data recorder date amp time can be set from the Keypad Trip Start to record date time of trip in DataLink data recorder memory PC card functionality for downloading data upgrad ing operational software and Configuration set up FET Field Effect Transistor indicating LE
526. s The overrides will be allowed in Cargo Protect Mode only if the override does not use the return or supply temperature There is a minimum delay of 20 seconds between LOADING and UNLOADING cylinders under all operat ing conditions except when the engine is starting When the Compressor is Off the Unloaders are always de energized NOTE In all of the following instances UL1 refers to the Front Unloader and UL2 refers to the Rear Un loader 62 11524 1 Low Generator Amp Draw When the A128 LOW AC AMPS is activated the compressor will only operate on 2 or 4 cylinders 2 High Discharge Pressure Or High Generator Amp Draw The microprocessor will not allow additional cylinders to load whenever the compressor discharge pressure is above 415 psig 28 3 bar OR when the compressor amp draw is within 1 Amp of the maximum allowable generator current Maximum Allowable Generator Cur rent is a Configuration Setting Refer to 5 2 1 However if the CDT is above 284 F 140 C for more than 30 seconds at the same conditions loading of one cylinder bank is allowed 3 Compressor Restart The microprocessor will force the compressor to run in 2 cylinders for 10 minutes when the compressor restarts unless the compressor is restarting following a defrost cycle If the compressor discharge temperature CDT becomes greater than 284 F 140 C or the system re turns to Pulldown mode 10 minute will be overridden a
527. s MessageCenter 6 1 Microprocessor 3 27 Microprocessor Diagnostics 9 13 Microprocessor Display Diagnostics 5 8 Microprocessor Replacement amp Setup 5 8 Model Chart 2 2 Module Control 2 14 Module Overload Ground Fault 2 18 Module Phase Reversal 2 18 8 35 N Noncondensibles 8 15 O oil capacity 2 19 Oil Engine 8 10 Operation Continuous 3 10 4 6 Operation Engine Standby 4 1 Operation Start Stop 3 9 4 3 Options 2 18 3 28 Overload Ground Fault 8 36 Overrides 4 3 Overrides Compressor Minimum Operating Time 4 13 Overrides Default Mode 4 15 Overrides Engine Speed 4 13 Overrides Preprogrammed 4 13 Overrides Unloader Control 4 14 Overrides User Selected 4 10 Index 2 INDEX Continued Parameters Functional 3 21 Parameters Re Start 4 5 Parameters Stop 4 4 PC Cards 5 4 PC Cards Configuration 5 6 PC Cards Download 5 6 PC Cards Handling 5 4 PC Cards Option 5 6 PC Cards Program 5 5 PC Mode 5 4 Perishabe Range 4 3 Pre Trip Inspection 8 1 Pretrip 3 5 Priming The Fuel System 8 8 Priority Cooling 4 10 Pull Down 4 3 Pull Up 4 3 Pulse Cool 4 3 Pumping Down Compressor 8 16 Pumping Down Low Side 8 16 R Radiator 8 13 Receiver 2 12 Receiver Sight Glass 8 28 ReeferManager 5 6 Refrigerant 1 1 Refrigerant Circuit Cooling 2 23 Refrigerant Circuit Heating amp Defrosting 2 23 refrigerant charge 2 2 Refrigera
528. s than 1200 rpm or greater than 1500 rpm for more than 60 seconds 120 seconds when the microprocessor calls for a change from high to low speed or when unit first starts UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if microprocessor is set for low engine speed operation and signal is Between 1220 to 1480 RPM for 60 seconds or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Model Number Verify that the model number on the nameplate matches the model number shown in the microprocessor Unit Data Enter the correct number in Configurations Refer to Section 5 2 1 Check For Proper Voltage To The E ngine Speed Control Unit ENSCU Pin 16 Check For Proper Voltage With Unit Running Check ENSCU 16 0 VDC between ENSCU 16 and ENSCU 19 GND Check Fuel Speed Actuator FSA Check fuel speed actuator Plunger must move in and out freely Refer to Engine Manual Force Low Speed operation a Using Functional Parameters set the Low Speed Start Up Delay to 10 minutes Unit will run in low speed RPM must be within range shown above for each specifi
529. s available Normal Defrost and Natural Defrost NOTE When the unit is in defrost and in Engine opera tion the condenser fan will operate to supply air for the radiator e engine will operate in high speed when the heaters are energized to supply power for the heaters e engine will operate in low speed when the heaters are de energized e three compartments are operating in defrost only one bank of heaters may operate in each compartment a Normal Defrost Mode Normal Defrost Mode will be entered if RAT is less than 39 2 F 4 0 C and SAT is less than 45 0 F 7 2 C Defrost will be accomplished by shutting down the refrigeration system including the evaporator fan motors while the heaters are energized If three compartments are enabled the two compartments with the coldest DTT readings will defrost first When one of these compartments exits defrost the final compartment will begin it s defrost cycle b Natural Defrost Mode Natural Defrost Mode uses a combination of the heat from the product and the electric heaters to melt any ice Natural defrost is available when e only the front compartment is enabled all other compartments are off and the Natural Defrost microprocessor Configuration is set to YES and e defrost is initiated by closing of the DAS contacts with RAT greater than or equal to 39 2 F 4 0 C and e at least one normal defrost has been performed since power
530. s for all the hour meters are en tered the microprocessor will add the correct hours together and calculate the Total Engine Hours Total Standby Run Hours and Total Switch On Hours When the end of the list is reached PRESS TO SAVE HOURS will be displayed Pressing the key will save the hours and return you to the configuration list If you do not press the key none of the time hours or cycles you just entered will be saved Hour meters may be changed for 60 minutes following the initial hour entry If an error has been made be certain to correct it within the 60 minute time period Following that time the hour meters will count the appropriate hours because the unit switch is on and the unit is op erating and no further manual changes will be allowed NOTES If a Configuration card will be used to setup the remainder of the microprocessor settings proceed to Section 5 7 7 after the settings are entered After the unit specific and time sensitive configuration settings are complete use the UP or DOWN ARROW keys until CONFIGS COMPLETE TO EXIT is displayed in the MessageCenter Press the key to save If the Configurations Functional Parameters and DataLink data recorder setup will be set from the keypad and or ReeferManager continue with following steps 5 7 4 Configurations Via Keypad a Refer to Section 5 2 for a list of available micropro cessor Configurations Refer to Section 5 2 1 for in s
531. sageCenter MESSAGES Message Description TL TO SCROLL THEN TO LOCK This message is used when viewing Unit Data Use the UP and DOWN arrow keys to move through the Data list Press the key to lock a Data item in the MessageCenter 14 TO SCROLL THEN TO SAVE Press the UP or DOWN arrow key to scroll through menu selec tions available in this mode When you reach the desired selection press the key to store new value in microprocessor s memory Tl TO SCROLL THEN TO SELECT Press the UP or DOWN arrow key to scroll through menu selec tions available in this mode When you reach the desired selection press the key to select it TO INSTALL INSTALLS LEFT XX An Option PC Card has been inserted into the PC Card slot Press the key to install the option into the microprocessor The number of installs remaining on the PC Card will be shown ACTIVE ALARM LIST CLEARED The list of active alarms in the microprocessor has been erased This does not remove alarms from the DataLink data recorder ALL ALARMS CLEARED The list of active and inactive alarms in the microprocessor alarm lists have been erased This does not remove alarms from the DataLink data recorder ALL INFO LOADED REMOVE CARD All data has been loaded into the microprocessor from the PC Card The card may be safely removed from the microprocessor BACK TO CONFIGS Pressing the key with this message showing wi
532. scharge Pressure Evap Outlet Temp Unit Model Evaporator Pressure Compr Disch Temp C2 Evaporator Engine Coolant Temp Battery Voltage C3 Evaporator Return Air Temp Current Draw DC Fuel Level C2 Return Air Temp Engine RPM Hrs to Engine Maint C3 Return Air Temp Unit AC Current 1 Hrs to S B Motor Maint Supply Air Temp Unit AC Current 2 Hrs to Unit Maint C2 Supply Air Temp CSMV Time Left to PM1 Delta T EVXV Time Left to PM2 Ambient Air Temp Software Rev Time Left to PM3 Defrost Term Temp Display Software Rev Time Left to PM4 C2 Defrost Term Temp Controller Serial Time Left to PM5 C3 Defrost Term Trailer Vehicle Car ID Datalogger DataLink Temp data recorder Date Time Display is optional record if displayed FINAL OK ADJUST Review Functional Parameters Download DataLink data recorder if required Enter Trip Start In Microprocessor 8 4 EXTERNAL SURFACE SERVICE Procedures for servicing or maintaining the grille surround doors door latches and display amp keypad assembly are provided in the following sub paragraphs 8 41 Grille Insert Removal To remove the grille insert do the following NOTE If difficulty is experienced when attempting to remove the grille mounting bolts the grille may be removed with the surroun
533. setting is 22 Amps b Check STANDBY MAX GEN AMPS Setting should be 22 25 Amps Maximum recom configuration setting mended setting is 25 Amps Minimum recommended setting is 22 Amps c Check STARTUP MAX AMPS Setting should be 15 19 Amps Maximum recom figuration setting mended setting is 19 Amps d Check DIESEL OFFSET MAX Setting should be 4 6 Amps Maximum recom AMPS configuration setting mended setting is 6 Amps 3 Check For Electrical Failure In System a Check electrical motors Visually inspect condenser fans and evaporator fans in all compartments for damage to motor or fan blade or for foreign material obstructing the move ment of the fan Listen for noise caused by failed bearing or motor obstruction b Check for defective wiring Check for discolored wiring at contactors and loose connections c Check for defective contactor Remove and replace any suspected contactor s Additional steps on the next page 62 11524 Steps Alarm Cause Corrective Action A C CURRENT OVER LIMIT Continued 4 Check High Voltage Components Amp Draw a Check condenser fan amp draw on all legs CDCON These checks must be made with the unit operating b Check evaporator fan motor amp draw for compartments 1EVCON 2EVCON amp 3EVCON if applicable WARNING Caution and good electrical practices must be used when working around and with
534. slot and information from the card is being loaded into the micropro cessor DO NOT REMOVE THE CARD WHILE THIS MESSAGE IS BEING DISPLAYED MAIN MENU Consists of Configuration Mode Component Test and Service Modes MAX SETPOINT HAS BEEN REACHED Maximum setpoint allowed by configuration settings has been reached MICRO WILL RESET amp RESTART NOW The microprocessor Program software has just been changed or a new configuration has been programmed into the microprocessor The microprocessor will turn itself off then on again similar to a computer reboot in order for the changes to be effective MICRO WILL STOP IN XXX SECONDS The Main Power switch has been placed in the OFF position and the system valves are closing The display will turn off when the count down reaches zero 6 3 62 11524 MessageCenter MESSAGES Continued Message Description MIN SETPOINT HAS BEEN REACHED Minimum setpoint allowed by configuration settings has been reached NEW SW TO LOAD CANCEL A Program PC Card has been inserted into the PC Card slot and the program on the PC Card is a newer version than what is al ready loaded in the microprocessor Press the key to load the program NO ACTION TAKEN REMOVE CARD A Program PC Card has been inserted into the PC Card slot and no key presses have been made to install the program into the mi croprocessor The PC Card may be safely removed f
535. sor is between 11 14 VDC or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check For Alarm 51 Check for Alternator Not Charging Alarm conditions must be corrected and the alarm Alarm Note The A51 name is car cleared to continue ried over from unit models with alter nators For the Vector Model Alarm 51 indicates that the solid state bat tery charger is not performing cor rectly Check Battery Voltage a Inspect battery cable ends and Must be clean and tight posts b Test voltage at battery with unit off Must be above 11 VDC C Test voltage at battery with unit Must be above 11 VDC running d Test specific gravity of battery Check for battery specifications e Perform load test on battery Check for battery specifications Follow battery manufacturer s procedure Check Voltage At Microprocessor a Check voltage reading at Must be above 11 VDC microprocessor input MPQC1 to MPQC2 b Check voltage reading on Must be within 0 5 VDC of reading obtained at QC 1 microprocessor display 62 11524 7 10 Alar
536. splay TeSt PRA ODER EG 5 8 Figure 8 1 Grille Insert Removal And Door Latch Maintenance 8 5 Figure 8 2 Suron RembgVal 8 6 Figure 8 3 Door Lateh Cable Removal 8 6 Figure 8 4 Display and Keypad Assembly 8 7 Figure 8 5 Fuel System OG RE I HERE REA GRAF ei aie 8 8 Figure 8 8 Fuel Blood Comporbhls rere uen Rem REAGAN Ed RA A 8 8 Figure 8 7 Mechanical Fuel eR IR doritor ERROR 8 8 Figure B B Elect Fuel PUMPS 8 9 Figure 8 9 Fuel Level SENSO RE CE I SEE 8 10 Figure 8 10 Engine OILLEyEl PR EUM 8 11 Figure 8 11 Engine Oil Flow Diagram 325p den REG 8 11 6 12 Dil Drain CHI 8 11 Figure 9 19 Intake Akr HOOF COP IPAE CREE 8 12 Figure 8 14 Electronic Speed Control Components 8 12 Figure 8 15 Condenser And Radiator Assemblies 8 13 xiii 62 11524 LIST OF ILLUSTRATIONS Continued FIGURE NUMBER Page Figure 6 1
537. ss Valve Bleed Orifice ONDI WD 4 5 6 9 Strainer 10 Suction Manifold 11 Cylinder Discharge Valve 12 Valve Plate 13 Cylinder Suction Valve 14 Discharge Check Valve Assembly 15 Discharge Manifold Figure 2 8 Compressor Cylinder Head Unloaded b Unloaded Operation Pressure from the discharge manifold item 15 Figure 2 8 passes through the strainer 9 and bleed orifice 8 to the back of the bypass valve piston 6 Un less bled away this pressure would tend to close the pis ton against the spring 5 pressure and load the cylin ders in that head With the solenoid valve 1 energized the solenoid valve stem 2 will open the gas bypass port 3 Discharge pressure will be bled to the suction manifold 10 through the opened gas bypass port A reduction in pressure on the bypass piston valve will take place be cause the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice 8 62 11524 When the pressure behind the piston has been reduced sufficiently the valve spring will force the piston back opening the gas bypass from the discharge manifold to the suction manifold Discharge pressure in the discharge manifold will close the discharge piston check valve assembly 14 isolat ing the compressor discharge manifold from the individ ual cylinder bank manifold The unloaded cylinder bank will continue to operate fully unloaded until the solenoid valve is
538. st Must be in range Refer to Section 2 13 for correct amp draw electrical values Check for parasitic loads Check for electrical loads that are Check for non factory installed devices such as lift drawing current with all circuits OFF gates inside lights satellite systems etc These devices must be wired so as to not draw current during Pretrip testing P158 CHECK AMBIENT AIR SENSOR TRIGGER ON Ambient Air Temperature Sensor AAT is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again Check Sensor refer to procedure for alarm 121 62 11524 7 98 Alarm Cause Corrective Action P159 CHECK DEFROST TERM 1 SENSOR TRIGGER ON Defrost Termination Temperature Sensor 1DTT Compartment 1 is not within the range of 53 to 158 F 47 to 70 0 UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again Check Sensor refer to procedure for alarm 124 P160 CHECK DISCHARGE TEMP SENSOR TRIGGER ON Compressor Discharge Temperature Sensor CD
539. st set OVERRIDE REMS1 SHUTDOWN to YES IF A SWITCH IS NOT INSTALLED Locate and inspect 10 position con nector for optional sensors and switches see wiring schematic Sec tion 10 Connector must have cap on No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the con nector may be removed and each individual wire sep arated from the others terminated and insulated with heat shrink 7 41 62 11524 ALARM CAUSE CORRECTIVE ACTION 58 CHECK REMOTE SWITCH 2 REMS2 TRIGGER ON Remote Switch 2 is set to activate an alarm if the switch is activated opened closed depending on switch type for more than five seconds UNIT CONTROL May be configured as alarm only alarm and force low engine speed or alarm and shutdown Compartment 2 RESET CONDITION Alarm Only Auto Reset after the switch has de activated for more than five seconds Shutdown Auto Reset after three minutes minimum off time for door open condition and the switch has de activated for more than five seconds NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary IF A SWITCH IS INSTALLED De
540. suction service valve so that the approxi mate temperature OR current limit is maintained For perishable loads it is recommended that the ad justment be made so that the available capacity is slightly larger than the load the unit will cycle OFF and ON Once repair parts become available repair as re quired 8 8 6 Electronic Expansion Valve The electronic expansion valve EVXV see Figure 8 28 is a microprocessor driven device which meters the flow of refrigerant into the coil The flow control provides a response to match the evaporator load and b prevention of liquid refrigerant return to the compressor Unless the valve is defective it seldom requires any maintenance 9 As preliminary check ensure the EVXV coil is snapped down fully and the coil retention tab is properly seated in one of the valve body dimples 62 11524 FLOW DIRECTION 1 Electronic Expansion 3 Coil Valve 4 Five Pin 2 Coil Boot Connector Figure 8 28 Electronic expansion valve a Diagnostics Microprocessor or Wiring 1 Locate the wires on the engine harness side of the EVXV connector labeled EXVA EXVB EXVC EXVD and EXVE These will correlate to the connec tor pins labeled D and Refer to Table 8 4 Table 8 4 EVXV Connections good continuity before replacing the micropro cessor b Diagnostics Stepper Motor The valve stepp
541. system equipment servicing the refrigerant charge leak checking and evacuation Procedures for refrigerant system service are provided in the following sub paragraphs 8 6 1 Refrigerant System Service Connections To service the refrigerant system service equipment is connected to the system at the compressor discharge service valve compressor suction service valve and or the liquid line service valve When connecting to a valve backseat the valve turn counterclockwise to close off gauge connection and attach service line to the valve Open valve 1 4 to 1 2 turn clockwise and then purge the service line See Figure 8 18 for an example of a full service connection setup NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing refrigerant from a refrigeration system When working with refrigerants you must comply with all local government environmental laws U S A EPA section 608 1 Refrigerant Cylinder Valve 13 Thermal Expansion 2 Refrigerant Recovery Unit 14 Electronic Expansion Valve 3 Manifold Gauge 15 Receiver Set 16 Liquid Line Service 4 Valve 5 Vacuum Indicator 17 Subcooler 6 Vacuum Pump 18 Filter Drier 7 Discharge Service 19 Condenser boda 20 Suction Servi 8 Compressor uction Service 9 Heat Exchanger Valve 10 Compartment 1 21 Compressor Evaporator Suction 11 Compartment 2 Modulation Valve Evaporator CSMV 12 Liquid Li
542. t 1 gt gt t 27 1 9 62 11524 SECTION 2 UNIT DESCRIPTION PARAGRAPH NUMBER Page 2d INTRODUCTION 2 1 22 GENERAL DESCRIPTION 2 1 23 CONDENSING SECTION 2 9 oom 2 9 254 Engl site eri dp Maes 2 9 Enone COMTO 2 9 GeO OEN emer 2 9 eo 2 9 2 9 2 3 7 Compressor Switches Transducers and Sensors 2 11 dB Gandane EE REUS 2 12 2 3 9 Ambient Air Temperature Sensor 2 12 rrr 2 12 MECH 2 12 24 COMPARTMENT 1 EVAPORATOR SECTION 2 12 55 44 ee A ree er eee 2 12 24 2 Electronic Expansion Valve EVAV 2 12 ENA 2 12 2 4 4 Compressor Suction Modulation Valve CSMV 2 12 245 Compartment 1 Evaporator Switches Transducers and Sensors 2 12 25 REMOTE EVAPORATOR 2 13 Sl
543. t and the refrigerated compartment temperature must again go In Range before this alarm can be activated if any of the following occur ePretrip is started eSetpoint is changed eA door switch or remote switch is installed and configured as a door switch and the switch is opened indicating that the compartment door has been opened Troubleshooting steps begin on the next page 62 11524 7 48 Alarm NO Alarm Cause Corrective Action 63 BOX TEMP OUT OF RANGE Continued NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Compartment Doors Inspect all trailer compartment doors Must be closed no air leakage Defrost Evaporator Initiate Manual Defrost Cycle Must terminate automatically All ice cleared from all evaporator coils Check For Any Shutdown Alarm s Check the Alarm List for any Shutdown Alarms Alarm conditions must be corrected and the alarm cleared to continue Check For Low Refrigerant Pressur e Alarm Check for alarm 18 Alarm conditions must be corrected and the alarm cleared to continue Check Refrigerant Level Visually check refrigerant level in receiver Must be at correct level Refer to Section 8 6 2
544. t 10 amps supply contactors Excessive current draw by Compartment 1 Fuse F10 F11 12 Opens at 12 amps evaporator heater Excessive current draw by remote evaporator Fuse F13 F14 15 Opens at 12 amps heater or fan motor Excessive current draw by Compartment 2 Fuse F16 Opens at 5 amps remote drain heater Excessive current draw by Compartment 3 Fuse F17 Opens at 5 amps remote drain heater Excessive current draw by Fuel Heater Circuit Fuse F19 Opens at 20 amps CR AND current draw by Fuel Level Sensor Fuse FLS Opens at 3 amps ircuit Excessive current draw by Compartment 1 Fuse F26 F27 F28 Opens at 12 amps evaporator or condenser fan motor Excessive condenser fan motor winding Internal protector Auto reset temperature Excessive compressor motor winding Internal protector Auto reset temperature Excessive evaporator motor winding Internal protector Auto reset temperature NOTE When a second 20 amp charger is used to charge a lift gate battery the higher rated fuse is installed 62 11524 2 22 2 15 REFRIGERANT CIRCUIT DURING COOLING When cooling See Figure 2 15 the unit operates as a vapor compression refrigeration system The main components of the system are the 1 reciprocating compressor 2 air cooled condenser 3 expansion valves and 4 direct expansion evaporators The compressor raises the pressure and the tempera ture of the refrige
545. t is the approved software for this model The preferred method for setup of the microprocessor is to use PC cards All required changes except unit specific and time sensitive data may be performed using the cards If cards are not available the microprocessor may be setup using ReeferManager ReeferManager allows entry of all required data If neither PC Cards or ReeferManager are available the microprocessor may be setup for immediate use using the keypad Changes to the default DataLink data recorder settings may not be entered using the keypad if the microprocessor is setup using the keypad this feature will need to be loaded at a later date 5 7 1 Pre Replacement Steps NOTE For diagnoses of problems with the micropro cessor DataLink data recorder downloading file analysis using Reports or use of PC cards refer to Section 9 6 Before the unit can be started using the replacement microprocessor certain unit specific and time sensitive data must be known That information includes Unit Serial Number Unit Model Number Engine Protect Hours Switch On Protect Hours Engine Sleep Hours e Standby Hours Switch On Sleep Hours High Speed Hours e Start Cycles Date and Time D Number a If possible power the original microprocessor up by entering PC Mode or by toggling the Main Power switch out of the OFF position b Insert a Download PC Card into the PC Card slot and download all da
546. t maintenance TIME LEFT TO PM 1 5 This is only displayed when one or more of the meters is configured ON Number of hours until the next programmed maintenance May display user programmed identification RANGE 1 LOCK This is only displayed when Range Lock 1 is configured ON Displays Range Lock 1 setting OFF Temperature Range 1 Lock is turned off CONTINUOUS When the setpoint is set between Range 1 Minimum amp Maximum Temperatures the unit is set to operate only in Continuous START STOP When the setpoint is set between Range 1 Minimum amp Maximum Temperatures the unit is set to operate only in Start Stop RANGE 1 MINIMUM TEMP Displays minimum temperature setting for Range 1 Will only be dis played if Range Lock 1 is ON RANGE 1 MAXIMUM TEMP Displays maximum temperature setting for Range 1 Will only be dis played if Range Lock 1 is ON RANGE 2 LOCK This is only displayed when Range Lock 1 is configured ON Displays Range Lock 1 setting OFF Temperature Range 2 Lock is turned off CONTINUOUS When the setpoint is set between Range 2 Minimum amp Maximum Temperatures the unit is set to operate only in Continuous Run START STOP When the setpoint is set between Range 2 Minimum amp Maximum Temperatures the unit is set to operate only in Start Stop RANGE 2 MIN TEMP Displays minimum temperature setting for Range 2 Will only be dis played if Range Lock 2 is ON RANGE 2 MAX
547. t to drop the head or damage the gasket sealing surface Remove cylinder head capscrews and gasket See Figure 8 20 d If removing the center head remove the discharge valve mounting hardware required free the valve plates from the cylinder deck by using the discharge valve capscrews without washers as jackscrews through the outermost tapped holes in the valve plate after the valve stops and valves have been removed Remove the valve plate gasket Capscrew Cylinder Head Cylinder Head Gasket Capscrew Lockwasher Discharge Valve Backer 7 Discharge Valve 8 Valve Plate 9 Valve Plate Gasket 10 Suction Valve 11 Suction Valve Spring 12 Dowel Pin Figure 8 20 Cylinder Head amp Valve Plate 62 11524 Inspect the parts of the cylinder head and or the valve plate Inspect cylinder head gaskets for proper alignment and center web blow out Inspect the discharge valves for loose or damaged valve stops or any debris that may affect the proper operation of the valves Inspect for broken cracked or chipped discharge valves Inspect the side valve plate discharge check valves to ensure the pistons move and contact the plates Inspect for broken cracked or chipped suction valves Inspect the valve plate and the cylinder head for cracks Inspect valve plate gaskets for damage and wear Remove any oil on top of the pistons Inspect the top
548. t triggered an alarm s either PRETRIP amp COMPLETE if the entire Pretrip cycle was completed or PRETRIP FAIL IN TEST if the Pretrip cycle was aborted by an alarm before it was completed will be displayed 62 11524 3 5 CHANGING SETPOINT HEAT COOL DEFROST 20 SETPOINT SETPOINT CHANGED MANUAL ALARM LIST DEFROST si 34 F BOX TEMPERATURE START STOP CONTINUOUS 1 Watch the dis 1 M play until the re frigerated com partment num ber for which the setpoint is being changed is dis played SELECT CONTINUOU EN 2 With the correct refrigerated compartment number displayed press the UP ARROW or DOWN ARROW key to change the setpoint to the de sired value The MessageCenter will display TO SCROLL THEN TO SAVE 3 Press the key to save the new setpoint By default setpoints of 22 F to 89 F 30 C to 32 C may be entered via the keypad The micropro cessor always retains the last entered setpoints in memory The setpoints will change 1 one full degree for each press and release of the UP ARROW or DOWN ARROW key NOTES 1 Setpoint for Compartment 2 or Compartment 3 cannot be changed unless the switch for that compartment is in the ON position 2 The microprocessor may be configured with a minimum and or maximum setpoint other than the default values listed above MAX SETPOINT HAS BEEN REACHED or MIN SETPOINT H
549. t will terminate after 10 minutes NOTE Defrost uses a Defrost Duration Timer that al lows for a maximum of 45 minutes in defrost If defrost is not terminated during the 45 minutes the microprocessor will end the defrost cycle and activate the A54 DEFROST COM PLETE alarm When this occurs the Defrost Interval Timer is set for 1 5 hours at which time the unit will go into defrost again 4 7 USER SELECTED OVERRIDE OPERATION Three optional software override programs are avail able to the user These programs include Priority Cool ing Supply Air Limit Control and Temperature Range Lock Information on how the unit operates under these programs is provided in the following sub paragraphs 4 7 1 Priority Cooling Priority cooling applies when the unit is operating with more than one compartment enabled and if one compartment has a frozen setpoint and the other s a perishable setpoint refer to Section 4 3 2 In priority cooling priority is assigned to the compartment with a frozen setpoint or the compartment with a perishable setpoint in accordance with four configuration settings These settings include Frozen Priority Cooling Frozen Priority Time Perishable Priority Time and Perishable Priority Temperature The Frozen Priority Cooling Configuration may be set to OFF ON or HIGH CAPACITY The factory default setting is OFF The Frozen Priority Time Configuration and Perishable Priority Time Configuration
550. ta from the DataLink data recorder If a Download Card is not available data may also be downloaded using the ReeferManager PC Program Scroll through the data list and hour meter readings and make note of the unit specific data listed above If the original microprocessor will not power up gath er the unit specific data from the model serial num ber nameplate and estimate hour meter readings form the unit maintenance records If PC Cards will be used to setup the replacement microprocessor write the required data to the cards Also if the cur rent configuration file is available for this customer from the TransCentral site it should be downloaded and written onto the card prior to beginning work 5 7 2 Microprocessor Replacement a Power down the microprocessor by removing the PC Mode connector and or placing the Main Power switch in the OFF position b Remove negative battery cable from battery c Remove Connectors 1MP 2MP amp 3MP from the out side of the Control Box d Open the control box door e Remove Connectors 4MP 5MP amp 6MP inside the Control Box Remove all wires from the Micropro cessor f Locate wire to 80A fuse that runs through the current sensor Note the orientation of the wire through the current sensor to be certain that the wire is rein stalled through the new current sensor in the same direction Inserting the wire through the current sensor in the opposite direction will result in
551. take Air Heater Circuit 0 3 to 0 5 Ohms 38 46 Amps Starter Motor Less than 1 Ohm but more than 0 270 380 amps Fuel Heater 1 4 Ohms 10 10 7 amps 10 62 11524 2 14 SAFETY DEVICES The system is protected from high pressure conditions which may occur when exposed to very high temperatures such as a fire by a fusible plug mounted in the receiver Under very high temperature conditions refer to Section 2 11 the plug will melt releasing the refrigerant pressure System components are protected from damage caused by unsafe operating conditions by automatic shut down of the unit when such conditions occur This is accomplished by the safety devices listed in the following table Unsafe Conditions Safety Device Device Setting Excessive operating pressure High Pressure Switch Refer to Section 2 11 Excessive current draw by microprocessor Opens at 7 5 amps Excessive current draw by speed relay Opens at 10 amps Excessive current draw by run relay Opens at 7 5 amps Excessive current draw by battery output Opens at 80 amps Excessive current draw by control circuit Opens at 15 amps Excessive current draw by battery charger in Opens at 3 amps single charger OR put 20 amp chargers opens at 6 amps dual chargers See note Excessive current draw by battery charger Fuse F7 F8 F29 Opens at 5 amps timed put 40 amp charger Excessive current draw by generator power Fuse F9 Opens a
552. tdown Configuration is are set to YES and either Alarm 11 Low Engine Oil Pressure or Alarm 12 High Coolant Temperature has become active and shut the unit down three times within the past 2 hours e UNIT CONTROL Engine Operation engine and unit shutdown and alarm Standby Operation This alarm will not activate in Standby Operation e RESET CONDITION Reset from inactive alarm list only Can not be reset by turning switch OFF and then ON again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Alarm Caused This Alarm To Be Active a Check active alarm list for One or more of these alarms will be present Alarm s 11 or 12 b Follow the steps for the alarm s All alarms condition must be corrected found above and correct the alarm condition Reset Alarm Reset all alarms from the inactive All alarms must be cleared to start unit alarm list 7 15 62 11524 ANI Alarm Cause Corrective Action 22 LOW SUCTION SUPERHEAT TRIGGER ON Compressor suction superheat Compressor Suction Temperature CST minus satu rated temperature for Compressor Suction Pressure CSP refer to Table 8 7 is less than 9 F 5 C for more than 2 minutes
553. te for a period with no oil supplied to the bearings 3 Lightly oil gasket on new filter before installing Tight en 3 4 to 1 turn after the seal makes contact 4 Start unit and check for leaks 8 5 9 Air Cleaner The air cleaner should be inspected regularly for leaks A damaged air cleaner or hose can seriously affect the performance and life of the engine The air cleaner is de signed to effectively remove contaminants from the air stream entering the engine An excessive accumulation of these contaminants in the air cleaner will impair its op eration therefore a service schedule must be set up and followed An air cleaner service indicator is connected to the in take manifold Its function is to indicate when the air cleaner requires replacement During operation when a plugged air cleaner causes the intake manifold pressure to drop to 20 500 mm WG the indicator will move to the red line The air cleaner should then be replaced and the indicator reset by pressing the reset button a Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle 62 11524 b Check all connections for mechanical tightness Be sure filter outlet pipe is not fractured c Release 2 clips on air cleaner housing and remove the cover d Remove filter element wipe inside of air cleane
554. te intervals The factory default setting is 4 minutes If only one compartment is operating and it is not in Pulldown or Pull Up that compartment will remain in operation with the compressor and heaters off and the evaporator fan s running The compartment will remain in this condition until this stop parameter has been met OR cooling heating is required in any compartment and the Minimum Off Time Functional Parameter has been met 2 The engine coolant temperature has warmed Each time the unit is started in Engine Operation it must continue to run until the coolant temperature rises to 122 F 50 C to ensure it has fully warmed up before shutdown is allowed If only one compartment is operating and it is not in Pulldown or Pull Up that compartment will remain in operation with the compressor and heaters off and the evaporator fan s running The compartment will remain in this condition until this stop parameter has been met OR cooling is required in any compartment and the Minimum Off Time Functional Parameter has been met OR any compartment requires heat 3 The battery is fully charged Voltage A good battery is defined as having 13 4 VDC at 77 F 25 C The microprocessor will calculate the equivalent voltage based on the ambient temperature and shutdown will be allowed when battery voltage is at or above the calculated value TIP When the microprocessor is powered up the status of the unit battery can be readily che
555. ted it will continue to run until the conditions de scribed above are met While the unit is cycled off in Sleep Mode SLEEP MODE OFF ON TO will be displayed in the MessageCenter The display backlight will turn off after 5 minutes While in Sleep Mode Unit Data and Alarm Lists may be viewed and Functional Parameters may be viewed and changed as necessary However Start Stop Continu ous Run selections and setpoint can not be changed Manual Defrost and Pretrip can be initiated The unit will restart when engine coolant temperature drops below the configured restart temperature value or if the battery voltage drops below the configured battery restart value refer to Table 5 2 NOTE FOR ENGINE OPERATION ONLY In the event that the Engine Coolant Tempera ture sensor fails Sleep Mode will operate as fol lows In ambients above 32 F 0 C the unit will run as above and will monitor battery voltage and charging amps only according to the Configur ation setting In ambients below 32 F 0 C the unit will run for 20 minutes minimum run time then restart every 60 minutes maximum off time Battery voltage and amperage will be monitored nor mally 3 9 MANUAL DEFROST DEFROST LIGHT HEAT COOL DEFROST START STOP CONTINUOUS 34 dF SETPOINT BOX TEMPERATURE DEFROST CYCLE STARTED Press the MANUAL DEFROST key The DEFROST light will come on and the Messa geCenter will display DE
556. temperature fall at 100 7 F 37 8 3 9 C Opens on temperature rise at 120 5 F 38 5 E 2 7 C Closes on temperature fall at 80 10 F 26 7 5 5 C 15 to 17 F 35 F Compartment Temperature 10 to 12 F 20 F Compartment Temperature Compartment 1 Evaporator High Temperature Switch EVHTS Remote Evaporator High Temperature Switch 2 5 3EVHTS Remote Evaporator Thermal Expan sion Valve Superheat Setting Fusible Plug Melting Point 430 F 221 C High Pressure Switch HP1 Opens on pressure rise 465 10 psig 34 0 7 bar Closes on pressure fall at 350 10 psig 24 0 7 bar Host Unit Dry Weight Less Battery 2045 pounds 928 KG Battery 50 pounds 23 KG Remote Evaporator Weight 2 12 ELECTRICAL DATA MHS1100 106 Ibs 48 1 kg MHD1100 117 Ibs 65 1 kg MHS2200 207 Ibs 98 0 kg MHD2200 225 Ibs 102 1 kg Full Load Amps FLA 17 5 amps 460 VAC Compressor Motor Locked Rotor Amps 99 0 amps 460 VAC Winding Resistance Approximately 2 ohms phase to phase Full Load Amps FLA 1 9 amps 460 vac 60 hz 1 1 hp 820 watts at 60 hz 1700 rpm 60 Hz Factory lubricated additional grease not required Clockwise when viewed from shaft end Horsepower Condenser Fan Speed Motors Each Bearing lubrication Rotation Resistance 20 to 21 ohms Compartment 1
557. teps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during Test 3 by holding Key for 6 seconds d Review active alarm list for Alarm If alarm is present follow steps 2 thru 4 If alarm is 167 not present follow steps 5 thru 10 Check 3HTCON2 a Inspect heater contactor coil and No damage to coil wire connections No damage or corrosion b Check contactor coil resistance Cannot be opened infinite ohms Shorted Zero Ohms or shorted to ground Check 3HTCON2 Amp Draw Check 2HTCON1 amp draw Use Component Test Mode Section 5 2 2 to test Refer to Section 2 13 for correct electrical values View current draw in Data List Check 2 Wiring Inspect harness amp control box con No physical damage to harness nector pins terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 62 11524 7 102 Steps Alarm Cause Corrective Action C3 CHECK HEATER 2 CIRCUIT Continued 5 Check Evaporator High Temperature Switch 3EVHTS Inspect for open 3EVHTS per wiring If open replace switch as required schematic Check Amp Draw of 2 Heater Circuit Use a clamp on ammeter to check Must be within range shown in Section 2 12 for all the current draw of all 3 legs
558. ter EVHTS opens when the temperature of the evaporator becomes very high Refer to Section 2 11 For example if the heaters are on when the fan is not running If the temperature of the evaporator section is very warm hot it will have to cool down before the EVHTS closes Check High Temperature Thermostat EVHTS Inspect thermostat and connector See wiring schematic Section 10 No damage to thermostat No damage or corrosion in connector Check High Temperature Contacts a Contacts must be closed when temperature is normal Unplug EVHTS and check for continuity Must be 0 zero Ohms Cannot be opened infinite ohms or shorted to ground b Check for 12VDC on 7 65 12 VDC at MPQC9 Unplug EVHTS and check for 12 VDC at EVHTS pin A harness connector Visually inspect and repair wiring as needed 62 11524 Alarm Cause Corrective Action 99 CHECK STANDBY CONTACTOR TRIGGER ON Standby motor contactor relay PSCONR circuit is shorted The relay output from the microprocessor 5MP7 is negative so the circuit will not be shorted to ground but is shorted either within the relay coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only In engine Operation the unit will con tinue to operate In Standby the refrigeration system will not operate RESET CONDITION Auto Reset when the PSCONR Coil current amp draw is normal or alarm
559. ter 5 for the next service interval Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 7 132 ANS Alarm Cause Corrective Action 7 11 MICROPROCESSOR ALARMS 232 SETPOINT ERROR TRIGGER ON There is an error in the setpoint that is stored in the microprocessor memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when a valid setpoint is entered or alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Setpoint a Check setpoint setting b Enter new setpoint Must be between 22 and 89 6 30 and 32 C Reset Microprocessor a Place the Main Power switch in the OFF position for 30 seconds then back to the desired position The microprocessor powers up OK and the latest setpoint appears in the display b Valid setpoint can not be entered and alarm 232 remains active Download and replace microprocessor Refer to Section 5 7 233 MODEL ERROR TRIGGER ON There is an error in the Model Number that is stored in the microprocessor memory e UNIT CONTROL Unit Sh
560. termine what REMS2 is controlle d by REMS2 may be connected to a com partment door or some other device and used to remotely control the compartment Locate the device used as REMS2 Check To See If REMS2 Has Activat ed Inspect device used to activate REMS2 For example Compartment door must be closed and switch must be de activated Check REMS2 Remote Switch 2 Configuration Verify that Configuration is set for the type of switch being used i e when Switch is activated switch contacts are closed etc Configuration must agree with switch type Refer to REMS2 Remote Switch 2 Configuration Table 5 2 Check Wiring a Visually inspect wiring to Remote Switch 2 Wiring must be connected b Visually inspect condition of switch Must not be damaged wet corroded etc c Check circuit See wiring schemat ic Section 10 With the switch contacts closed check for voltage from microprocessor terminal 2MP13 through the 10 position connector OC through the 2EVC connect or and through the switch to ground at SP6 Temporary Solution Tip In the event of a defective switch that can not be repaired or replaced and the switch is forcing the unit into a Shutdown this alarm may be tem porarily overridden by setting the correct Functional Parameter In the Functional Parameter list set OVERRIDE REMS2 SHUTDOWN to YES IF A SWITCH IS NOT INSTALLED
561. tes of engine crank Bad cell in battery Test battery for defect accord ing to battery manufacturer s instructions Charger does not charge Defective charger Replace Open F7 or F8or F29 if applicable Replace Charger is not receiving AC input 8 9 8 Charger output is not connected to 12 volt battery Check output wiring connec tions to battery across charger output charger output with no battery connected Defective charger Replace Battery not connected to charger It is Check charging Low output voltage measured normal to measure 12 volts or less across leads from charger to bat tery 9 3 62 11524 9 3 GENERATOR Indication Trouble Possible Causes Action Refer ence Section Damaged harness Check No voltage with engine running GENCON damaged Check Open or short in stator windings Check Low engine speed Correct Low voltage Excessive load Check High resistance connections connections Clean and warm or hot Tighten Fluctuating speed 9 5 Fluctuating voltage Irregular speed of engine 9 5 Loose terminal or load connections Tighten High voltage Excessive engine speed 9 5 Generator overloaded Check Clogged ventilation openings Clean Overeating Insufficient circulation Check Fan Unbalanced load Balance Mechanical Noise Loose laminations 8 9 9 9 4 REFRIGERATION TEMPERATURE CONTROL Indication Trouble Possible Caus
562. the microprocessor see Voltage should be 2 5 VDC volts at harness plug be Note 2 page 7 2 Disconnect tween pins This verifies microprocessor output and sensor from harness Check for wiring connections to the sensor 2 5 VDC at harness plug between pins Check remote sensor switch connector c Locate and inspect 10 position Connector must have cap on connector OC for optional No corrosion or moisture inside connector sensors and switches If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 126 CHECK FUEL SENSOR CIRCUIT TRIGGER ON The fuel level sensor is configured as a 0 5VDC or 0 25 4 75VDC sensor and the reading in the data list is less than 296 for 30 seconds UNIT CONTROL Engine Operation Alarm Only Standby Operation This alarm does not activate in standby RESET CONDITION Auto Reset when fuel level is sensed above 4 for 30 seconds or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Che
563. this condition until this stop parameter has been met OR cooling heating is required in any compartment and the Minimum Off Time Functional Parameter has been met 4 4 3 Re Start Parameters While the unit is in a Start Stop OFF Cycle restart will be initiated when one of the following conditions occurs 1 Engine coolant temperature drops below selec ted microprocessor Configuration value If in Engine Operation the microprocessor will monitor coolant temperature If coolant temperature drops below the ENGINE TEMPERATURE FOR RESTART Configuration value the engine will be started The Configuration value may be set from 10 to 32 F 12 2 to 0 C in 0 5 C or F increments The factory default setting is 32 F 0 C 2 Battery voltage falls below selected micropro cessor Configuration value The microprocessor will monitor battery voltage If battery voltage is at or below the VOLTAGE FOR START STOP RESTART Configuration value the engine will be started or when in a Standby Operation OFF Cycle a PSCON relay will be energized to supply power to the battery charger The value may be set from 12 0 to 12 8 volts The factory default setting is 12 2 volts TIP When the microprocessor is powered up the status of the unit battery can be readily checked by reading the Battery Voltage in the Data List If OK appears after the voltage reading bat tery voltage is sufficient to allow the unit to cycle off 3 The Maximum
564. three legs Check Heater Elements Check heater elements No visual physical damage No blockage due to debris Remove and replace if required Check Heater Element Plugs And Connections Disconnect heater element plug No corrosion water damage or burning discoloration spect plugs plug seal and connec Remove and replace if required tors Verify Accuracy of AC Current Sensor With microprocessor in PC Mode Reading for AC1 amps and AC2 amps must both be refer to Section 5 3 check amper 0 age in the Unit Data List refer to Section 3 13 Check Heater Wiring a Use a clamp on ammeter to check Compare to Unit Data the total current draw b If no fault was found in previous Remove and replace contactor tests 7 103 62 11524 Alarm Cause Corrective Action P168 C2 CHECK LSV VALVE TRIGGER ON In Test 2 Compartment 2 Liquid Solenoid Valve 2LSV current is outside the range of 0 75A to 2 0A OR In Test 14 The suction pressure did not rise as expected when the 2LSV was energized opened e UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset when Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See
565. tic Section 10 Once the PRM is activated it will provide a 12VDC power signal to the microprocessor at terminal 5MPO4 to signal the microprocessor that Standby Operation has been selected and high voltage has been detected at the ou o APRONS 62 11524 power plug The PRM has two output contacts PRM IN 1 and PRM IN 2 If incoming power is correct the PRM IN S1 contact is closed energizing PSCON to supply power to the motors If any two incoming power wires are reversed the PRM IN S2 contact are closed energizing to supply power to the motors Both PSCON and PSCON2 have a set of normally closed auxiliary contacts wired in series with the other contactor to prevent energizing of both contactors at the same time To test the PRM a Check for 460 VAC power from the power plug to the PRM If required correct wiring or power source Check for 12 VDC to the 12V from the switch If re quired correct wiring Check for ground at the PRM OV terminal If required correct wiring Check for a 12 VDC signal from the PRM to micropro cessor terminal 5MP04 If required correct wiring from PRM to the microprocessor If all wiring and voltage readings are correct replace PRM LIGHT BAR SIDE CON
566. tinued 7 Check Low Speed Engine RPM a Check actual engine RPM using hand held tachometer Refer to Table 2 1 b Compare actual RPM with those shown on display Both readings within 50 RPM Force High Speed Operation a Place unit in continuous run and adjust setpoint to at least 15 degrees away from refrigerated compartment temperature and temperature greater than 20 F 5 6 C If the unit does not immediately go into High Speed set the AIRFLOW Functional Parameter to HIGH The microprocessor will call for High Speed opera tion b Check operation of Speed Relay LED LED 27 must be ON If LED 27 is not on the micro processor is not calling for high speed operation Check Speed Overrides in Section 4 8 3 for more information Check high speed engine RPM 62 11524 a Check actual engine RPM using hand held tachometer Refer to Table 2 1 b Compare actual RPM with those shown on display Both readings within 50 RPM Alarm NO Alarm Cause Corrective Action 40 CHECK GLOW PLUGS This alarm applies to the Intake Air Heater TRIGGER ON Engine Operation Intake Air Heater amperage is less than 25 Amps or greater than 70 Amps after 14 seconds of glow time NOTE This can only occur when the Engine Coolant Temperature is below 50 F 11 C due to the glow time allowed Refer to Table 4 1 for glow times Standby Operation This a
567. tion Parameters List Alarm List etc EQUAL Key ENTER The EQUAL key is used for many things including entering a setpoint changing a Functional Parameter clearing alarms and locking the data menu MANUAL DEFROST Key MANUAL DEFROST rre The MANUAL DEFROST key may be used to initiate a defrost cycle when the required conditions are met TUIS ALARM LIST Key The ALARM LIST key allows viewing of the alarms stored in the microprocessor The alarm list displayed the MessageCenter Pressing the ALARM LIST key once displays the active alarm list Each successive press advances through the list to the end To view the inactive alarm list Refer to Section 3 12 START STOP CONTINUOUS Key AN 5 Pressing this key toggles between Start Stop and Continuous Run operation SELECT Key SELECT kA Press the SELECT key to scroll through the menu selections One of the five standard menu selections will appear in the MessageCenter when the SELECT key is pressed Repeated pressing of the SELECT key will sequence the menu through these selections The menu wraps around Press the SELECT key until the desired menu selection appears in the MessageCenter The selections are PRESS TO VIEW HOUR METERS Displays the hours for individual hour meters Refer to Section 3 14 PRESS 1 TO START PRETRIP Used to initiate a pretrip Refer to Section 3 4 PRESS TO VIEW DATA Displays U
568. tion System Data 2 20 Remote Control Panel 2 19 3 29 Reports 5 6 Resistance Component 2 21 S Safety Devices 2 22 Safety Precautions 1 1 Scheduled Maintenance 8 1 Index 3 Self Test 3 4 Sensor Ambient Air Temperature 2 12 Sensor Compressor Discharge Temperature 2 11 Sensor Compressor Suction Temperature 2 12 Sensor Defrost Termination Temperature 2 12 2 13 Sensor Engine Coolant Temperature 2 9 Sensor Engine Speed 2 9 Sensor Evaporator Outlet Temperature 2 12 Sensor Fuel Level 8 9 Sensor Remote Temperature 2 19 Sensor Return Air Temperature 2 12 2 13 Sensor Supply Air Temperature 2 13 Sensors Service 8 43 Service Mode 5 3 Setpoint Changing 3 8 Setpoint Changing with Remote Control Panel 3 30 Sleep Mode 3 11 Speed Control System 8 12 9 8 speed engine 2 2 Speed Transition to High 4 2 Standby Power 1 1 Start Stop Automatic 1 1 2 13 Start up Engine Operation 4 1 Start Up Standby Operation 4 1 Starting Engine Operation 3 1 Starting Standby Operation 3 2 Starting with Remote Control Panel 3 30 Stopping 3 26 superheat checking 8 33 Supply Air Limit Control 4 10 Surround 8 6 Switch Board 2 17 Switch 2nd Compartment Run 2 17 Switch 3rd Compartment Run 2 17 Switch Defrost Air 8 31 Switch Diesel Electric 2 17 Switch Diesel Off Engine Standby 2 17 Switch Engine Oil Pressure 2 9 Switch Evaporator High Temperature 2 12 2 13 Sw
569. tion has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Return Air Sensor a Inspect sensor amp connector No physical damage to harness No damage moisture or corrosion in connectors b Check Return Air Sensor resistance 10 000 Ohms 9 77 F 25 C See Note 3 page 7 2 Refer to Table 8 5 for complete resistance chart Check Return Air Sensor Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 P211 CHECK DEFROST SENSOR 2DTT TRIGGER ON Defrost Sensor for Compartment 2 is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND COMPLETED RESET CONDITION Auto Reset if Pretrip mode is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Compartment 2 Defrost Sensor a Inspect sensor amp connect
570. tion until this stop parameter has been met OR cooling heating is required in any compartment and the Minimum Off Time Functional Parameter has been met If in Standby Operation and all Start Stop parameters required to enter a Start Stop Off cycle have been met except this parameter the unit will enter the Off cycle In the Off cycle the PSCON relay remains energized supplying power to the battery charger The battery charger will continue to charge the battery if required 5 The compartment temperature requirement is satisfied In Start Stop Operation the refrigeration system will operate in Pulldown or Pull Up Mode in order to reach the shutdown condition as quickly as possible Shutdown will be allowed when the temperature in all compartments is within 0 5 F 0 3 C of setpoint for operation in the Perishable Range In the Frozen Range shutdown will be allowed when the temperature in all compartments is calculated to be within 0 5 F 0 3 C minus the FROZEN shutdown OFFSET of setpoint The FROZEN shutdown OFFSET Functional Parameter may be set from 0 to 3 6 F 0 to 2 C in 0 5 C or F increments The factory default setting is 0 F 0 If the temperature requirements for all compartments have been satisfied while one of the other shutdown requirements has not been met the last compartment will remain in operation with the compressor and heaters off and the evaporator fan s running The compartment will remain in
571. tive 62 11524 7 136 Alarm Cause Corrective Action 243 SUCTION EVAP CALIBRATE ERROR TRIGGER ON There is an error in either or both of the Suction Pressure CSP or Evaporator Pressure EVOP Sensor Calibration values stored in the microprocessor memory Note that neither of these transducers can be calibrated manually This is an error in the microprocessor UNIT CONTROL Alarm only RESET CONDITION Auto Reset when both Suction and Evaporator Pressure transducers are reading correctly or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Suction Pressure CSP and Evaporator Pressure Readings a Check Suction and Evaporator Pressure Readings in the Unit Data Must read valid data b Install manifold gauge set and check and compare compressor suction amp evaporator pressures with those shown on the microprocessor display Suction and Evaporator Outlet Pressures must have the same reading on gauges amp on microprocessor display NOTE Microprocessor Suction CSP and Evap orator EVOP pressure readings have a maxi mum value of 1
572. to continue 62 11524 7 22 Alarm NO Alarm Cause Corrective Action 31 FAILED TO START AUTO MODE TRIGGER ON Engine has tried to start three times unsuccessfully in the auto start mode e UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back on again If the Unit Operation configuration is set to Rail Mode this alarm will reset after 4 hours NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check For Flash Code on Engine Speed Control Unit ENSCU Check for flash codes on the ENSCU Refer to ENSCU LED Fault Chart Section 9 5 must be no LED alarm codes occurring to continue Check Fuel Level in Tank Check fuel gauge on tank Fill tank as needed Check For Alarms Check for the following alarms 71 Check for Bad F2 or F3 Fuse alarm 40 Check Glow Plug alarm 35 Check Starter Circuit alarm Alarm conditions must be corrected and the alarm cleared to continue Check ENSCU Power a Check run relay Using Component Test Mode refer to Section 5 2 2 energize run relay b Check Run Relay LED Must be ON c Check voltage to ENSCU Must have 12 VDC
573. tor Note mo tor is assembled to allow routing of the wiring down the lower right hand leg of the welded support See Figure 8 39 Remove the condenser fan assembly mounting bolts and slide the assembly out of unit If required the di vider may be removed by removing the upper and lower mounting bolts Disassemble the fan and motor assembly from the mounting and then disassemble the fan from the mo tor as required Complete the assembly in reverse order of removal When mounting fan amp motor assembly assemble so wire connector is in line with lower right welded sup port leg see in Figure 8 39 Torque Fan to motor bolts 4 to 6 ft lbs 5 5 to 6 8 Nm Fan amp motor as 5 to 6 ft lbs 6 8 to 8 1 Nm sembly to welded support bolts Welded support to frame bolts 7 to 8 ft Ibs 9 5 to 10 8 Nm Shroud to frame and frame to unit bolts 6 to 7 ft lbs 8 1 to 9 5 Nm Condenser Fan Assembly Divider Shroud Frame Fan amp Motor Assembly Figure 8 39 Condenser Fan Assembly Ord OI 62 11524 Fan Motor Welded Support Wire Routing 8 9 8 Battery Charger BTYC NOTE A battery of known good condition must be con nected to the charger before doing the following test Run the unit with the battery charger connected to the battery as usual Using clamp on ammeter take a reading of the am perage on both output wires of the battery
574. tor 2 1 2 circuit is shorted The contactor output from the microprocessor 4MP14 is negative so the circuit will not be shorted to ground but is shorted either within the contactor coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 1HTCON2 a Inspect heater contactor coil and damage to coil terminals No damage or corrosion b Check contactor coil resistance Refer to Section 2 13 for correct electrical values Cannot be opened infinite ohms shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check 1 2 Current Draw Use Component Test Mode to test Refer to Section 2 13 for correct electrical values actual current draw of the circuit View current draw in Data List Refer to Section 5 2 2 Check 1HTCON 2 Wiring Inspect harness amp control box con No physical damage to harness pins amp terminals See wiring No damage moisture or
575. tor is to be in operation This switch is placed in the ON position to signal the microprocessor that the compartment 2 evaporator is to be in operation Diesel Off Engine Standby Switch DOES O When placed in the ENGINE or STANDBY position this switch provides power the microprocessor The microprocessor performs a self test segments of display are illuminated Then setpoint and compartment temperatures are displayed and the unit is started in Engine Operation or Standby Operation To stop the unit place the DOES switch in the OFF position EN Era STANDBY Diesel Electric Switch DES This switch is used to select either Engine Operation or Standby Operation When this switch is placed in standby position the microprocessor will not energize the power source contactors until the engine oil pressure switch ENOPS opens START RUN OFF Switch SROS aar When placed in the START RUN position this switch provides power to the microprocessor The microprocessor performs self test al segments of display are illuminated Then setpoint and compartment temperatures are displayed To stop the unit or remove power from the microprocessor place the SROS in the OFF position Keypad UP ARROW and DOWN ARROW Keys These keys allow changing of the setpoints or other displayed data of the system They also allow scrolling through the Unit Data Func
576. tpoint than the limit set in the Out Of Range Alarm Functional Parameter 4 5 or 7 F 2 3 or 4 C the configured action Alarm only after 30 minutes or Alarm and Shutdown after 45 minutes will be activated regardless if the refrigerated compartment temperature has been in range or not UNIT CONTROL Engine and standby Operation If the microprocessor is not configured for shutdown alarm only If the microprocessor is configured for shutdown the unit will shutdown and alarm RESET CONDITION Condition 1 Auto Reset If the unit is running in Pulldown Mode and the SAT is greater than 1 F 0 56 C below the RAT or if the unit is running in Pull Up Mode and the SAT is greater than the RAT Condition 2 amp 3 Auto Reset when the temperature is within 2 7 F 1 5 C for perishable setpoints or 2 7 F 1 5 for frozen setpoint For either Condition alarm may be manually reset via Keypad OR by turning the unit off then back on again NOTE The 30 or 45 minute timer is reset and starts again whenever eThe unit cycles off and restarts in Start Stop eThe unit goes into and comes out of Defrost NOTE This alarm does not go into the Inactive alarm List when it becomes inactive or is cleared NOTE This alarm will not be activated in Sleep Mode NOTE For Condition Two the temperature criteria for this alarm is reset and the refrigerated compartment temperature must again go In Range before this alarm can be acti
577. trical values Cannot be opened infinite ohms shorted Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 for correct electrical values Use ammeter Check GENCONR Current Draw Use Component Test Mode to test Refer to Section 2 13 for correct electrical values actual current draw of the circuit View current draw in Data List Refer to Section 5 2 2 Check GENCONR Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 62 11524 7 64 Alarm NO Alarm Cause Corrective Action 98 CHECK HIGH TEMP THERMOSTAT TRIGGER ON With the Main Power switch toggled out of the OFF position the 1EVHTS circuit is open UNIT CONTROL Alarm AND no heat allowed in any compartment RESET CONDITION Auto Reset when the 1EVHTS circuit is okay for 15 minutes or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Evaporator Area For High Temperature Check Evaporator temperature using a test thermome
578. tructions on how to access them 5 7 5 Functional Parameters Via Keypad a Refer to Section 3 15 for list of available Micropro cessor Functional Parameters and for directions on how to access them Leave the microprocessor powered up as you con tinue with the next section 5 7 6 DataLink Data Recorder Via ReeferManager NOTE If the factory settings are used you can skip this section Refer to Section 3 18 for list of DataLink data record er setups Connect your computer to the download port of the unit and start the ReeferManager program refer to Section 5 5 step c You will need ReeferManager version 03 08 00 or higher NOTE ReeferManager 03 08 00 is REQUIRED in or der to view change and send new features to and from the microprocessor In ReeferManager go to the Serial Operations Tab and then click on Data Recorder Microprocessor setup button Select the Sensors to be recorded and whether you wish averaged or snapshot recordings averaged is recommended for all temperature sensors snap shot is recommended for voltage amperage amp RPM When the setup is correct press the Send button to send the new settings to the microprocessor From the Confirm Send Information Pop Up check the data you want to send and un check the data you don t want to send Click the OK button g Verify that the settings were sent by waiting for the confirmation pop up message NOTE If the DataLink d
579. ture For example at an ambient temperature of 100 F 37 8 C UL2 will be energized when the suction pressure rises to approximately 75 psig 5 bar UL2 can load as soon as the pressure is 5 psig 0 3 bar less than the value in the chart 100 110 120 130 Ambient Temperature F Figure 4 6 Evaporator Pressure Chart 9 High Discharge Pressure f the compressor discharge pressure reaches 435 psig 29 6 bar at some point soon after engine start up for more than 1 minute UL2 will energize unload and remain energized until the compressor discharge pressure drops below 415 psig 29 6 bar If both unloaders are energized unloaded and the discharge pressure drops below 430 psig 29 3 bar UL1 will be de energized loaded 10 Low Suction Pressure If suction pressure falls below 2 psig or 4 in Hg 0 14 bar for more than 20 seconds UL2 will be energized unloaded After 20 seconds if suction pressure is still less than 2 psig or 4 in Hg 0 14 bar UL1 will be energized unloaded OR Once the suction pressure rises above 5 psig 0 3 bar UL2 will be de energized loaded after the 2 Minute Delay mentioned above If both unloaders are energized unloaded AND 20 seconds has elapsed since energizing unloading UL1 AND the suction pressure rises above 5 psig 0 3 bar UL1 will be de energized loaded 11 High CDT If the compressor is operating with both unloaders energized
580. turn Air Sensor is in range or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connectors No damage to sensor No damage moisture or corrosion in connectors b Check sensor resistance Note 3 page 7 2 See 10 000 Ohms 77 F 25 C Refer to Table 8 5 for complete table of temperatures and resistance values Check Sensor Wiring a Inspect harness amp control box connector pins amp terminals 1MP amp DP16 see wiring schematic Section 10 No physical damage to harness No damage moisture or corrosion in connectors Power up the microprocessor see Note 2 page 7 2 Disconnect sensor from harness Check for 2 5 VDC at harness plug between pins Voltage should be 2 5 VDC volts at harness plug be tween pins This verifies microprocessor output and wiring connections to the sensor Check remote sensor switch conne ctor 62 11524 c Locate and inspect 10 position connector OC for optional sensors and switches Connector must have cap on No corrosion or moisture inside connector If there is
581. ue to an override or Configura tion Setting when Start Stop Operation and the compartment temperature Stop Parameter for all compartments have been satisfied while one or more of the other Stop Parameters has not f in Continuous Operation perishable and the High Speed Pulldown Configuration is OFF and the tem perature is in the required range Pulldown Mode ends f in Continuous Operation perishable and the High Speed Pulldown Configuration is ON when the tem perature is equal to or less than 0 36 F 0 2 C above setpoint 4 3 4 Pulse Cool Pulse cool may be entered if one or more compartment s have a frozen setting and one or morea perishable setting Whenever the compartment with the frozen setting is in cooling and the compartment s with a perishable setting is are calling for low speed pulse cooling begins in that compartment During pulse cooling the liquid control valve EVXV in Compartment 1 or LSV in Compartments 2 amp 3 will operate on a 30 second cycle During the 30 second cycle It will be opened for 4 seconds and closed for 26 seconds 4 3 5 Defrost Refer to Section 4 6 for a description of defrost 4 3 6 Overrides With the complex control systems in use with the Advance microprocessor there are many user selected and preprogrammed software overrides and Configuration settings which may change the operation of the unit Refer to Sections 4 7 amp 4 8 for complete descriptions of t
582. uld rapidly rise indicating that the valve opened If pressure does not rise check FET voltage at plug and coil resistance If required replace coil Refer to following step b If valve leakage is detected during the low side pump down or the valve fails to open valve repair is re quired Refer to following step c b Replacing the Coil CAUTION Ensure all parts are assembled into the solenoid valve enclosing tube in proper se quence to avoid premature coil burnout Do not over tighten or damage the enclosing tube assembly NOTE The coil may be replaced without removing the refrigerant or pumping the unit down Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle Note direction of coil wiring Unplug coil from wiring harness remove coil retainer see Figure 8 32 and coil assembly Verify coil type voltage and frequency Place new coil over enclosing tube With wiring fa cing in the direction noted in the preceding step en sure roll pin is fitted in one of the detents in the bot tom of the coil mounting Ensure bottom of coil housing is in contact with the enclosing tube nut In stall snap clip and connect wiring c Replacing internal parts 8 33 oc Ff 9 1 Coil Retainer 5 Plunger 2 Coil 6 Gasket 3 Enclosing Tube 7 Pist
583. ule unit into service facility for maintenance Must be done soon Perform Maintenance Perform appropriate engine amp unit maintenance Follow instructions on proper maintenance form Reset Maintenance Hour Meter 2 a Check that Maintenance Hour Meter 2 interval is set for your requirements Reset configured Interval if required b Reset Maintenance Hour Meter 2 for the next service interval Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 228 SERVICE SOON PM 3 DUE TRIGGER ON The Maintenance Hour Meter 3 time has expired e UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad 1 Check Unit Maintenance Records Schedule unit into service facility for maintenance Must be done soon Perform Maintenance Perform appropriate engine amp unit maintenance Follow instructions on proper maintenance form Reset Maintenance Hour Meter 3 a Check that Maintenance Hour Meter 3 interval is set for your requirements Reset configured Interval if required b Reset Maintenance Hour Meter 3 for the next service interval 7 131 Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 62 11524 Alarm Cause Corrective Action 229 SERVICE SOON PM 4 DUE TRI
584. unctional Parameter which can be set to OFF or ON and the Supply Air Limit for Start Stop Operation Configuration or Supply Air Limit for Continuous Operation Configuration for each compartment which be set from 0 to 21 6 F 0 to 129 NOTE These values are all negative except for 0 therefore when the value is added to the set point the result will be a temperature that is less than the setpoint When the Perish Sensitive Product Functional Parameter is set to OFF the supply air temperature for either or both compartments will be the coldest temperature of 32 F 0 C OR the calculated value of setpoint minus the configured Supply Air Limit value When the Perishable Sensitive Product Functional Parameter is set to ON the supply air temperature for either or both compartments will be the calculated value of setpoint minus the configured Supply Air Limit value Supply Air Limit controls the temperature of the supply air as it leaves the evaporator so that it does not go colder than the configured Supply Air Limit value below setpoint NOTE The 9 F value used in the following examples is not necessarily a recommend setting but is only used to show how the Supply Air Temper ature Limit is calculated EXAMPLE 1 Perishable Sensitive Product Functional Parameter OFF Supply Air coldest temperature limit is the colder temperature of 32 F OR Setpoint minus configuration value for Supply Air Limit
585. und Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Perform Pretrip Check Clear Active Alarm list then run Pretrip amp check for any new alarms Any active alarms must be corrected and cleared before proceeding Check For Defective Defrost Senso r Location Correct Installation Has sensor fallen from location Must be corrected to continue Check Evaporator Fan Contactors Check that contactors are energized and that the contacts are not stuck closed in defrost Must de energize evaporator fan in each enabled compartment during defrost Check Evaporator Heater Current D raw a Check Compartment 1 Heater amp draw for 1HTCON1 amp 1HTCON2 b Check Compartment 2 Heater amp draw for 2HTCON1 amp 2HTCON2 These checks must be made with the unit operating Verify that all three actual amperage readings for each component are within 1096 of each other and c Check Compartment 3 Heater amp draw for SHTCON1 amp 2 7 39 are within the values shown in section 2 12 62 11524 Alarm NO Alarm Cause Corrective Action 55 CHECK DEFROST AIR SWITCH TRIGGER ON The defrost air switch has called for a defrost cycle within 8 minutes of a defrost terminati
586. up When a natural defrost is initiated the unit will operate for the first five minutes with the evaporator fan and 2 de energized and only HTCON1 energized After 5 minutes the evaporator fan is energized while both HTCON1 amp HTCON2 are de energized Only 3 consecutive natural defrosts cycles are allowed After there have been 3 consecutive natural defrost cycles the next defrost will be a normal deforst 4 6 3 Defrost Termination When in normal defrost mode defrost will terminate in each compartment when the compartment DTT rises to 55 F 12 8 62 11524 When operating in natural defrost defrost will continue in that compartment for a minimum of 5 minutes a maximum of 10 minutes or until the SAT is equal to or higher than the RAT When the last compartment exits defrost the engine will go to low speed dF will continue to be displayed in place of compartment temperature and the COOL LED will come on when the compressor starts The EVXV or LSV will open and the evaporator coil will begin to cool down The evaporator fans will not come on right away so that warm air is not blown into the refrigerated compartment but will wait for the evaporator to cool down up to a maximum of 8 minutes Once the last evaporator fan has started dF will no longer be displayed and refrigerated compartment temperature will again be shown in the main display lf a DTT sensor alarm has been activated defros
587. ur at the same time generally the engine has run out or is running out of fuel This causes the engine RPM to surge and drop Check fuel tank and add fuel as necessary Check fuel lines between the fuel tank and the fuel pump inlet for drawing air in Check For Flash Code On Engine Speed Conirol Unit ENSCU Check for flash codes on the ENSCU Refer to ENSCU LED Fault Chart Section 9 5 must be no LED alarm codes occurring to continue Was Engine Shut Off Manually Check for external cause Correct problem Check For Bad F2 Or F3 Fuse Alarm Check for alarm 71 Alarm conditions must be corrected and the alarm cleared to continue Check Fuel System a Check for Alarm 1 Fill tank as needed b Check fuel flow Unrestricted fuel flow through system Fuel not gelled c Check fuel system prime No air in fuel system d Check fuel system check valve from filter to injection pump Check valve must hold fuel and not leak back Check Fuel Speed Actuator FSA a Check Run Relay LED LED 28 must be ON b Check voltage to ENSCU Use Component Test Mode to energize Run Relay Refer to Section 5 2 2 Must have 12 0 VDC or higher reading between ENSCU 13 and 19 c Inspect ENSCU connector pins amp terminals No damage moisture or corrosion in connector d Inspect harness amp control box connector pins amp terminals See wiring sc
588. ure rises during off cycles 3 22 FUNCTION Table 3 2 Functional Parameters Continued PARAMETER SELECTIONS DESCRIPTION PERISHABLE SENSITIVE PRODUCT OFF Supply air temperature will be limited to the colder temperature of 32 F 0 C or setpoint less the Supply Air Limit Configuration value ON Supply air temperature will be limited to setpoint less the Supply Air Limit Configuration value Refer to Section 4 7 2 for complete information on Perishable Sensit ive Product and Supply Air Configuration interaction TEMP CONTROL Compartment 1 RETURN AIR SUPPLY AIR The compartment 1 evaporator has both a Return Air Sensor and a Supply Air Sensor RETURN AIR only the return air sensor reading will be used for cal culating control actions Return is generally selected for most products SUPPLY AIR the microprocessor will switch to the supply air sensor when operating with a perishable setpoint 10 4 F 12 C or above Supply will control within a narrower temperature band DISPLAY TEMPS IN FAHRENHEIT CELCIUS The compartment temperature will display in either English F using a decimal point to display tenths of a degree OR or Metric C using a comma to display tenths of a degree NOTE Temperature setting values displayed in the MessageCenter will continue to use a decimal for both F and C DISPLAY PRES SURES IN Pressures w
589. use the keypad c Check Configurations All settings must be valid Send desired settings to microprocessor using the latest version of ReeferManager or a PC Card Do NOT use the keypad Reset microprocessor a Place the Main Power switch in the Microprocessor powers up OK OFF position for 30 seconds then back to the desired position b Alarm 248 remains active Download and replace microprocessor Refer to Section 5 7 7 139 62 11524 Alarm Cause Corrective Action 249 MICROPROCESSOR ERROR TRIGGER ON Microprocessor Input Conversion Error e UNIT CONTROL Shutdown and alarm e RESET CONDITION Auto Reset when input conversions are valid or Alarm may be manually reset by turning the unit off then back on again Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Software Revision Check microprocessor software revi Upgrade to the latest revision of software sion Check Microprocessor a Check Temperature Sensor Data Must be valid reading for RAT SAT AAT etc b Check for any Active Sensor Must all be cleared Alarms Check Microprocessor amp Unit Wiring Check Wiring to Micro and at input Must not be miss wired to allow 12 VDC on any
590. ustomer specified message will display 6 To lock an hour meter in the MessageCenter for continuous viewing press the key The Data item will flash continuously to indicate it is locked 7 Pressing any key on the keypad will unlock the item Pressing the UP or DOWN ARROW key will move to the next hour meter Hour meters available when OTHER METERS AND COUNTERS is chosen are Meters listed in Step 3 above and up to 5 User Engine Sleep Hours Configurable meters including Switch On Sleep Hours e Switch On Standby Hours Compressor Run Hours Engine Protect Hours High Speed Hours Switch On Protect Hours Start cycles 62 11524 3 20 3 15 FUNCTIONAL PARAMETERS HEAT COOL DEFROST ALARM START STOP CONTINUOUS 20 34 1 SETPOINT BOX TEMPERATURE PRESS J TO VIEW SETTINGS MANUAL List SELECT DEFROST elit j 1 Press the SELECT key until the MessageCenter displays PRESS TL TO VIEW SETTINGS 2 By pressing the UP ARROW key you will move through the Functional Parameter list beginning at the top or by pressing the DOWN ARROW key you will move through the list beginning at the bottom 3 To change one of the Parameters bring the Parameter you wish to change into the MessageCenter and press key T TO SCROLL THEN TO SAVE will display in the MessageCenter Pressing either UP or DOWN ARROW key wil
591. utdown amp Alarm e RESET CONDITION Auto Reset only when a valid Model number is entered NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Model Number a Check Model microprocessor Number in b Enter correct Model Number Check Model Number on Nameplate Select the correct model number in the MODEL NUMBER Configuration If correct model number is not found Install or have Carrier Transicold dealer install latest software revision Reset Microprocessor a Place the Main Power switch in the OFF position for 30 seconds then back to the desired position Microprocessor powers up OK b Check for valid Model number in Data List Valid number is present Alarm is cleared c Valid model number can not be entered and alarm remains active 7 133 Download and replace microprocessor Refer to Section 5 7 62 11524 Alarm Cause Corrective Action 237 FUNCTION PARAMETERS ERROR TRIGGER ON There is an error in one or more of the Functional Parameters that are stored in the microprocessor memory UNIT CONTROL Incorrect Functional Parameter s will be automatically set for default value RESET CONDITION Auto Reset
592. utlet amp Discharge Pressures must have the same reading on gauges amp on micro processor display NOTE Microprocessor Suction CSP and Evapo rator EVOP pressure readings have a maximum value of 100 psig 7 5 bar The actual pressure must be lower than 100 psig in order to perform this test Check Front Unloader UL1 Operat See Note 5 page 7 2 ion Unit must be running Check operation of Front Unloader UL1 7 109 See Section 8 7 6 Unloader must load and unload properly 62 11524 Alarm Cause Corrective Action P180 CHECK SUCTION MOD VALVE TRIGGER ON With the unit running in Pretrip Test 11 after the microprocessor attempts to close the suction pressure fails to drop below 4in Hg 0 14 bar UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL IN TEST 11 RESET CONDITION Auto Reset if Pretrip is started again or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Software Revision Level Upgrade software Install or have Carrier Transicold dealer install latest revision Check wiring to DPT amp S
593. values Use ammeter Check CDCON Current Draw Use Component Test Mode to test Refer to Section 2 13 for correct electrical values actual current draw of the circuit View current draw in Data List Refer to Section 5 2 2 Check CDCON Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 7 63 62 11524 ANI Alarm Cause Corrective Action 96 CHECK GENCONR RELAY COIL TRIGGER ON Generator contactor relay GENCONR circuit is shorted The relay output from the microprocessor 4MP7 is negative so the circuit will not be shorted to ground but is shorted either within the relay coil itself or to a positive wire UNIT CONTROL Engine and Standby Operation alarm only RESET CONDITION Auto Reset or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check GENCONR a Inspect generator contactor relay No damage to coil coil and terminals No damage or corrosion b Check contactor coil resistance Refer to Section 2 13 for correct elec
594. vated if any of the following occur ePretrip is started eSetpoint is changed eA door switch or remote switch is installed and configured as a door switch and the switch is opened indicating that the compartment door has been opened Troubleshooting steps begin on the next page 7 37 62 11524 Aam Alarm Cause Corrective Action 53 BOX TEMP OUT OF RANGE Continued NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Compartment Doors Inspect all trailer compartment doors Must be closed no air leakage Defrost Evaporator Initiate Manual Defrost Cycle Must terminate automatically All ice cleared from all evaporator coils Check For Any Shutdown Alarm s Check the Alarm List for Alarm conditions must be corrected and the alarm Shutdown Alarms cleared to continue Check For Low Refrigerant Pressure Alarm Check for alarm 18 Alarm conditions must be corrected and the alarm cleared to continue Check Refrigerant Level Visually check refrigerant level in Must be at correct level Refer to Section 8 6 2 receiver E Check System Pressures Install manifold gauge set and check Suction amp Discharge Pressures must be in the nor system pressures mal ra
595. ve tests with your supervisor If necessary go to the beginning of the tree amp test again System OK re install two way communica tions if disconnected earlier Figure 9 5 Micro Diagnostic Tree Cond 1 Main Power Switch On Unit Does Not Operate 62 11524 9 14 Wrong Chart See Condition 1 START HERE The unit starts amp runs Micro may not be configured properly Verify correct model number is selected Unit may be running on old software Upgrade software to current version Did the software load correctly v Go To Condition 8 Programming Problems with PC Cards if using a in the micro via Unit Data Did you find and correct the condition Did the loading of the software correct the problem Check ground connectors the battery starter engine block and inside the control box Did you find and correct the condition T NO Check for active amp inactive alarms PC Card to upgrade software Did the software load correctly NO Y Review the results of above tests with your supervisor If necessary go to the begin ning of the tree amp test again Refer to Section 7 for troubleshooting alarms Did you find and correct the condition NO Verify Functional Parameters and Co
596. way communications from Is unit equipped unit and install J1 jumper This will eliminate with two way com remote communication from the system munications NO Is Micro Status NO waking YE LED blinking S Check the F1 fuse Check Micro Status YES Is the fuse blown LED blink rate Replace the fuse Bent Did you find and ot correct the this Micro Status LED Micro Status LED is blinking condition NO is blinking at 1 at 1 2 second ON amp 1 2 second ON amp 1 second OFF second OFF i Check ground Inspect and repair poor connectors at the connections at the micro battery starter and display Did you find engine block and and correct the condition inside the control box Did you find and NO B correct 0 e condition Ensure the operator is waiting NO long enough by turning the Load current version Main Power switch ON of software from http Check voltage waiting 2minutes for the display www transcentral between QC1 amp QC2 to come on Did you find and carrier com Did the Voltage should read correct the condition current version of 11 volts or higher NO software load correctly Is voltage within range v y 5 the Inspect and repair NO system he 3 wiring NO Y operat ha
597. ween 11 and 14 VDC or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Battery Voltage a Test voltage at battery with unit Must be between 11 16 VDC off b Test voltage at battery with unit Must be between 12 16 VDC running Check Battery Charger Voltage Test voltage at battery charger Must be between 11 16 VDC output terminal with unit off b Test voltage at battery charger Must be between 12 16 VDC output terminal with unit running Check Voltage At Microprocessor a Check voltage reading at Energize circuit See Note 2 page 7 2 microprocessor input QC 1 to Must be between 11 16 VDC QC2 b Check voltage reading on Must be within 0 5 VDC of reading obtained at QC 1 microprocessor display 7 9 62 11524 Alarm Cause Corrective Action 16 BATTERY VOLTAGE TOO LOW TRIGGER ON Voltage at the microprocessor is less than 10 VDC except when the engine starter is engaged UNIT CONTROL Unit Shutdown amp Alarm Alarm condition only if activated while starting unit RESET CONDITION Auto Reset after 15 minutes when the voltage at the microproces
598. wiring is correct cable shield is prop erly grounded and condition of connectors No dam age to sensor no damage moisture or corrosion in connectors Energize sensor circuit refer to Note 2 page 7 2 Check power approximately 12 VDC from SP5 9 Figure 8 9 through to connector 13 Check ground from SP6 8 through connector 12 Check signal greater than 0 24 VDC and less than 5VDC at mi croprocessor 1 26 If checks in the preceding step are OK remove the fuel level sensor focus tube and gaskets With the trailer level verify that the fuel level sensor flange is within one half bubble of level using a 24 inch level Adjust tank mounting as required CAUTION Torque fuel level sensor mounting screws to 15 to 18 inch pounds DO NOT over tight en as little as 20 inch pounds will damage the sensor 62 11524 Fuel Level Sensor Gasket Focus Tube Sensor Flange Fuel Level Sensor Flange Fuel Tank Wire 1MP26 FLSC Connection Wire SP6 FLSB Connection Wire SP5 FLSA Connection Fuse FLS White Wire Connection Black Wire Connection B Red Wire Connection A Ground Shield Yellow Wire Connection C Black Wire Connection B Red Wire Connection A Wires From Sensor Figure 8 9 Fuel Level Sensor f Using new gaskets reinstall fuel level sensor com ponents The mounting holes are not symmet
599. wns Should the unit shutdown three consecutive times without running a minimum of 15 minutes between shutdowns the A31 FAILED TO RUN MINIMUM TIME alarm will be activated The shut down counter is cleared when the unit has run for 15 mi nutes NOTE In Standby Operation the unit will stop for a minimum of 5 minutes instead of 15 minutes Refer to Section 4 4 for more detailed information on Start Stop Operation 3 9 62 11524 3 7 CONTINUOUS OPERATION ALARM 34 20 SETPOINT COOL DEFROST CONTINUOUS OPERATION LIGHT START STOP CONTINUOUS 1 BOX TEMPERATURE CONTINUOUS RUN MODE SELECTED Press the START STOP CONTINU OUS key until the CONTINUOUS OPERATION Light on the micropro cessor illuminates 2 Verify that CONTINUOUS RUN MODE SELECTED is dis played on the MessageCenter and that the CONTINUOUS OPERATION light is illuminated The unit is now in Continu ous Operation In the Continuous Operation the unit will not shutdown except in response to a shutdown alarm Refer to Sec tion 4 5 for more detailed information on Continuous Op eration The microprocessor may be configured with Start Stop operation tied to the setpoint ranges for frozen and per ishable loads The START STOP CONTINUOUS key is locked out if START STOP LOCKED displays in the MessageCenter when the key is pressed and the unit is in Start Stop Operation or CONTINUOUS LOCKED
600. x con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 62 11524 7 74 ANS Alarm Cause Corrective Action 7 8 SENSOR ALARMS 121 CHECK AMBIENT AIR SENSOR TRIGGER ON Ambient Air Temperature Sensor AAT is not within the range of 53 to 158 F 47 to 70 C UNIT CONTROL Engine and Standby Operation A value of 122 F 50 C will be used for any calculations RESET CONDITION Auto Reset when Ambient Air Sensor is in range or alarm may be manually resetvia keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check sensor resistance See 10 000 Ohms 77 F 25 See Table 8 5 for Note 3 page 7 2 complete table of temperatures and resistance values Check Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals 1MP No damage moisture or corrosion in connectors See wiring schematic Section 10 Power up
601. y If suction pressure doesn t change as expected with CSMV closed then the P180 CHECK SUCTION MOD VALVE alarm will be activated This test may take several minutes Test 12 Electronic Expansion Valve EVXV This test checks the operation of the EVXV If valve doesn t test properly the P177 CHECK EVAP SU alarm will be activated Test 13 Unloaders This test checks the operation of the unloaders If suc tion and discharge pressures do not change when UL1 and 012 are energized and de energized the P178 CHECK or P191 CHECK UL2 alarm will be ac tivated Test 14 Liquid Line Solenoid Valve This test checks the operation of LSV2 and then LSV3 If suction pressure does not change when a valve is en ergized and de energized the P168 C2 CHECK LSV VALVE or P176 CHECK LSV VALVE alarm will be activated Test 15 Check For Other Alarms The alarm list is checked for any non pretrip alarms that may have occurred during the Pretrip test If any operational alarms occurred Pretrip will display FAIL and the technician will need to review the Alarm List and take necessary and appropriate action to clear them Test 15 will last about five seconds Pretrip Termination When the Pretrip cycle is completed the unit will return to normal temperature control operation PRETRIP PASS will be displayed until the operator presses any key In the event that the Pretrip tes
602. y be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during Test 3 by holding Key for 6 seconds d Review active alarm list for Alarm If alarm is present follow steps 2 thru 4 If alarm is 163 not present follow steps 5 thru 10 Check 1 Inspect heater contactor coil and No damage to coil wire connections No damage or corrosion b Check contactor coil resistance Refer to Section 2 13 for correct electrical values Check 3HTCON1 Amp Draw Check 1 amp draw Use Component Test Mode Section 5 2 2 to test Refer to Section 2 13 for correct electrical values View current draw in Data List Check 3HTCON1 Wiring Inspect harness amp control box con No physical damage to harness nector pins amp terminals See wiring No damage moisture or corrosion in connectors schematic Section 10 62 11524 7 100 Steps Alarm Cause Corrective Action C3 CHECK HEATER 1 CIRCUIT Continued 5 Chec
603. y shorting of leads will damage the generator and may cause in jury CAUTION Under no circumstances should anyone tempt to repair the keypad display or in ternal control module components Should a problem develop with these components contact your nearest Carrier Transicold dealer for replacement 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 ra diator engine Never exceed more than a 60 concentration of anti freeze Use a low silicate anti freeze meeting GM specifica tions GM 6038M for standard life coolant or use Texaco Havoline extended life coolant or any other extended life coolant which is Dexcool approved and has 5 150 5 years 150 000 miles on the label CAUTION Service Mode MUST be used whenever moving refrigerant charge refrigerant leak checking or evacuating CAUTION The display and MessageCenter may be have differently during the software loading process depending on the version of soft ware currently in the microprocessor DO NOT INTERRUPT THE SOFTWARE INSTAL LATION PROCESS ONCE IT HAS STARTED Also do not place the Main Power switch in the OFF position during the initial power up following a software upgrade 62 11524 CAUTION Most electronic components are suscepti ble to damage caused by electrical static disc
604. zes HTCON1 and 2 The microprocessor verifies that engine speed is in high speed range If the engine is not operating within the high speed range the P175 CHECK HIGH SPEED RPM alarm will be activated Test 7 Engine Low Speed 2 The engine switches back to low speed and heaters turn off The microprocessor verifies that engine speed is in low speed range If the engine is not operating within the low speed range the P174 CHECK LOW SPEED RPM alarm will be activated Test 8 Electric Heater Amperage Check Each heater will be energized individually and checked for proper current draw An alarm will be activated for any heater not drawing amperage in the expected range Test 8 is repeated for Compartment 2 and if ap plicable Compartment 3 Test 9 Evaporator Fan Motor Amperage Check The evaporator motor contactor will be energized and checked for proper current draw An alarm will be activ ated if the evaporator fan motor is not drawing amper age in the expected range Test 9 is repeated for Com partment 2 and if applicable Compartment 3 Test 10 Condenser Fan Motors Amperage Check The condenser fan motor contactor will be energized and checked for proper current draw An alarm will be activated if the condenser fan motors are not drawing amperage in the expected range Test 11 Check Compressor Suction Modulation Valve CSMV This test ensures that the CSMV is opening and closing properl

OPERATION & SERVICE MANUAL VECTOR 6600MT

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OPERATION &amp; SERVICE MANUAL VECTOR 6600MT

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OPERATION & SERVICE MANUAL VECTOR 6600MT