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Genesis TM900 and TM1000 Service Manual

1. 10 22001 29 B C D E E 6 H l J K L M N Q R 5 T U V W X Y ZONE SYMBOL DESCRIPTION K2 A AMMETER RS RER TO 0CJ1J HC he 39 pcez 411 L3 ALT ALTERNATOR TA STOP Ji FON 2 5A B LB ARL AUTO RESTART LIGHT LIGHT BARD E 4 ef M HCK gt TO 38830 BTY Le TO MICRO Y2 DATA J F9 ARR AUTO RESTART RELAY ES Trpo DUKE SWITCHED 1272 SP34 36 V
2. B C D E F 6 H l J K L M N Q R T V W X Y ZONE DESCRIPTION K2 AMMETER RS FE gt All L2 ALT ALTERNATOR TS STOP 1 7 7 5A ALF8 B L8 ARL AUTO RESTART LIGHT LIGHT BARD ee f gt 2 TO 3RR30 BTY LTO MICRO YD DATA J F9 ARR AUTO RESTART RELAY 2 DEKE SWITCHED 12V Spaa 10A 39 36 5 RECORDER 89 ATS TEMPERATURE SENSOR UN DEOS Ie 55 ses ROWND
3. B C D E E 6 H 1 K L M N Q R 5 T U V W X id E War ZONE SEO DESCRIPTION K2 AMMETER RS STOP OCJIK PINDA DKB SWITCHED 120 L3 ALT ALTERNATOR L5 RCR see DATA LINK dA aK Heka TO SP37 Bm pre 18 c ARL AUTO RESTART LIGHT LIGHT BAR AU A LAY S e 3 Ks Ha SHurDOWN ON lt 2 ses S gt GROUND Ag ATS AMBIENT TEMPERATURE SENSOR OPTIONS Si Hd Ene N2 B BUZZER ROW B 38 7 35 gg CHS To SPK15 NI BTY BATTERY 2 3 gt ECC To 5926 3 DKF Ato CDT COMPRESSOR DISCHARGE TEMPERATURE SENSOR 15 5
4. 8 D E F 6 H 1 J L M N 0 R 5 1 v x Y B ZONE gren DESCRIPTION _ RS STOP Hee HCE2 m K2 AMMETER TO OCJIK DKB gt SWITCHED 120 B Fe Le TO 5937 BTY m L5 ALT ALTERNATOR 1 RCR EI SPK DATA LINK 15A DATA LB ARL AUTO RESTART LIGHT LIGHT BAR Kaos d COR E 39 36 45 LINK J7 F9 ARR RESTART RELAY 23 5 51 SHUTDOWN p GROUND Ag ATS AMBIENT TEMPERATURE SENSOR OPTIONS rr EE LI PS2 SSC 5 5 NI BTY BATTERY RUN B 38 7 35 10 CDT COMPRESSOR DISCHARGE TEMPERATURE SENSOR 1 L L LIGHT LIGHT BAR 5 Rd L dis sis COOL LIGHT REMOTE LIGHT 15 L13 01 73CL COOL LIGHT REMOTE LIGHT f 58 r CLH CLUTCH SLP op m MAX FUSE 8620 J13 K13 04 09 2CR B COOL RELAY 2ND COMPARTMENT PS1 SPK1 N13 P13 011 R4 L LAY MPARTMENT RED 95 SPKI6 i RUPI3 01
5. ZONE SYMBOL DESCRIPTION 0 62 66 Flo FUSE 20 A rig S 22 4 KDa 63 67 FH FUSE 20 A HIGH VOLTAGE CIRCUITS F123 2 5 6 3 nvr 61 65 F12 FUSE 2 FAN 3 2A 3 FAN 5A 4 FAN 6 3A gt 2HT SEE NOTE 5 63 68 F13 FUSE 2 FAN 3 2A FAN 5 4 FAN 6 RED b EXAMPLE 4 FAN MOTORS G5 F14 FUSE 2 FAN 3 2A n 8 1HVR br 68 F15 FUSE 2 FAN 3 2A UT gt L2 L7 N2 N7 2EFM EVAPORATOR FAN MOTOR 2ND COMPARTMENT BLUE F1I0 SPS 2 22 07 07 3EFM EVAPORATOR FAN MOTOR COMPARTMENT WHITE 92 05 BROWN DEFR EVAPORATOR FAN RELAY 2ND COMPARTMENT _GREEN YELLOW 7 BROWN 1HE 2HE H5 H8 EVAPORATOR FAN RELAY COMPARTMENT 92 M Hc HIGH CURRENT AF 611 HC2 HIGH CURRENT BLACK 02 BLUE Fi 20 2012 2 7 GEN GENERATOR n 2EFR J2 J IHE HEATER ELEMENT 2 jenes Uie Ge S GS DNA P F1 8 K HI HEA LEMENT FIG 1 REND 12 16 J2 THT HIGH TEMP THERMOSTAT 1 J6 K2 2HT HIGH TEMP THERMOSTAT 2 APPLICABLE TO ALL R2
6. C7 EXTERNAL EQUALIZER lt a EXPANSION 1 H RHG VALVEBULB i BY PAS __ RECEIVER CHECK SUCTION LINE EVAPORATOR VALVE V LIQUID LINE lt Y 7 QUENCH J HOT GA LIQUID BYPASS SOLENOID VIBRASORBER LINE VALVE SV Ah QUENC HOT H CHARGE HP A gt CSI AU iN VALVE P EINE VALVE SUBCOOLER DRIER B SUCTION SERVICE BOT OSS 1 VALVE FA NOID SH 9 AS 3 SOLE Y SV MC DISCHARGE i CHECK f A L DISCHARGE LINE VIBRA SORB ER CONDENSER oe CONTROL SOLENOID Figure 1 20 R 22 Refrigerant Circuit Heating and Defrosting HOT GAS EXTERNAL EQUALIZER EXPANSION VAL BY PASS LINE EXPANSION x VALVE FUSIBLEE bulb A 2 RECEIVER EVAPORATOR ee d BY PASS C gt A CHECK Y HEAT EXCHANGER gt VALVE lt 9 LIQUID LINE LIQUID VIBRASORBER HOT GAS wee SOLENOID EINE s lt VALVE SV2 DISCHARGE Y A FIL Pe SUCTION DNE 2 SERVICE Y SUBCOOLER TER VALVE HOT GAS 27 iil a
7. SUCTION LINE CHECK VALVE EXPANSION VALVE LIQUID SOLE REMOTE EVAPORATOR S NOID VALVE S LSV EXTERNAL EQUALIZER EXPANSION VALV gt rugs e E EXPANSION hh ATENO VALVE BULB s VALVEBUI 4 BY Pass __ RECEIVER CHECK y SUCT ON LINE EVAPORATOR VALVE V LIQUID LINE UENCH VALVE HOT LIQUID 9 BYPASS SOLENOID a LINE VALVE SV 2 VIBRASORBER Ms UENC HOT h DISCHARGE GAS eae VALVE HP 24p LINE SUT OFE DRIER Bi SERVIGE Y VALVE SUBCOOLER SERVICE 1 amr VALVE M SOLE NOID um 51 OJT IGA 5 m SOLE gt NOW DISCHARGE 4 NC CHECK VALVE YS A CONDENSER gt CONDENS DISCHARGE LINE 9 VIBRASORBER ER PRESSURE CONTROL SOLENOID SV1 NO 62 10022 01 Figure 1 19 R 22 Refrigerant Circuit Cooling 1 30 1 17 REFRIGERANT CIRCUIT DURING HEATING AND DEFROSTING See Figure 1 20 orFigure 1 21 The unit will only hot gas heat when the controller is set above 10 122 as the heat relays electronically loc
8. lt SUCTION LINE CHECK VALVE EXPANSION 1 VALVE LIQUID lt SOLE REMOTE EVAPORATOR S OID Y VALVE S LSV gt J HEAT EX lt CHAN Glee HOT GAS EXTERNAL EQUALIZER EXPANSION VA BYPASSLINE yc EXPANSION lt assasi S lt VALVE i lt BULE A 2 RECEIVER EVAPORATOR Sur 22 BYPASS gt CHECK HEAT EXCHANGER VALVE lt lt LIQUID LINE LIQUID VIBRASORBER SHU TOER SOLEN OI D HOT GAS VALVE VALVE SV2 NG LINE LO am DISCHARGE Y FIL SUCTION LUE SERVICE Y SUBCOOLER TER EE ik H VALVE HOT GAS IER a ld SOLENOIBY SV3 NC T Y Bl POLEN UID CONDENSER 5V4 NC gt PRESSURE m CONTROL SOLENOID COMPRESSOR DISCHARGE SV1 NO CHECK VALVE A sme CONDENSER gt VIBRASORBER Figure 1 18 R 404A Refrigerant Circuit Cooling 1 29 62 10022 01 3
9. 8 D E F 6 H 1 J K M N R E U v x Y ZONE ameo DESCRIPTION HC2V Ag f 2 Hil K2 AMME TER RS F9 7 DKB SWITCHED 120 QB BTY zs RO 72 L2 ALT ALTERNATOR To STOP spky DATA LINK 10 Shot Q MICRO YO DATA 8 ARL AUTO RESTART LIGHT LIGHT BAR on K TEI 15 39 35 SM LINK J7 F9 ARR AUTO RESTART RELAY 55 RUN SHUTDOWN T gt GROUND ATS AMBIENT TEMPERATURE SENSOR u OPTIONS SLP oP r Ps2 SSC ss NI BTY BATTERY B o AF eX 39135 AS CDT COMPRESSOR DISCHARGE TEMPERATURE SENSOR pe SPK6 gt FE 10 936 DKF COOL LIGHT LIGHT BAR Poder zu 15A FI es 2RR30 SPK6 K12 P12 2 3CL COOL LIGHT REMOTE LIGHT idi SP12 ee Cre HC 00 Schya COOL RELAY 2ND COMPARTMENT P E MAXI FUSE pne 13 1 4 L LAY O O PS1 SPK1 BER BE2GI JP S5 MP Q11 R4 269 8 COOL RELAY GRD COMPARTMENT oj 7 2 cH JH UD 5p35 DO 30576 13 7 K16 P16 010 012 00 DIODE CARD 2571 69 RR TO 3815 N3 F DER _ DIESEL ELECTRIC RELAY e 2515 9 DER JUNI 2 30FT DEFROST TIMER 2ND 3RD COMPARTMENT 25A He
10. 70 SYMBOL DESCRIPTION C4 C8 F10 FUSE 20 HIGH VOLTAGE CIRCUITS 65 69 11 FUSE 20 C3 C F12 FUSE 2 FAN 3 24 3 FAN 5A 4 FAN 6 3A BROWN C5 C10 F13 FUSE 2 FAN 3 240 3 FAN 5A 4 FAN 6 34 C 14 FUSE 2 FAN 3 2 AUF C11 F15 FUSE 2 FAN 3 2 5 15 19 5 2EFM EVAPORATOR FAN MOTOR 2ND COMPARTMENT 9 L K3 L 3EFM EVAPORATOR FAN MOTOR 3RD COMPARTMENT E3 E5 E7 E10 2EFR EVAPORATOR FAN RELAY COMPARTMENT FIG 1 E7 E11 3EFR EVAPORATOR FAN RELAY 3RD COMPARTMENT B4 B9 GEN GENERATOR APPLICABLE TO ALL 25 29 1HE HEATER ELEMENT VFM AND EFM MOTORS 65 69 2HE HEATER ELEMENT 2ND COMPARTMENT Ha 3HE HEATER ELEMENT 3RD COMPARTMENT B E4 F4 E9 1HT HIGH TEMP THERMOSTAT 1 q f gt GH H2 2617 64 68 2HT HIGH TEMP THERMOSTAT 2 F12 3 26 6 3 H8 SHT HIGH TEMP THERMOSTAT 3 HNR 2HT SEE NOTE 5 E4 E8 THVR HIGH VOLTAGE RELAY 5 7 208 i 4 FAN MOTORS E4 E8 2HVR HIGH VOLTAGE RELAY 2ND COMPARTMENT 1HVR THECTBE Eur EB 3HVR HIGH VOLTAGE RELAY C3RD COMPARTMENT KO 7 D4 D5 08 09 SP SPLICE POINT 15 9 71 CAPACITOR C4uF J5 K9 22 CAPACITOR 4bF L5 L9 73 CAPACITOR C4uF 2HE M5 M9 74 CAPACITOR 4uF ED NOTES SEER 1 UNIT SHOWN IN OFF POSITION B 2 WIRE IDENTIFICATION SYSTEM 8 2019 COLOR WHITE DC CONTROL CIRCUITS SP F13 BLACK GROUNDS GREEN W YELL
11. 42 PrimingtheFuel System 43 EngineService and Components 43 CoolingSystemi eee pUPRERUEELRCHISUOEDPUUPR dee A 43 2 bube OiL Filters ttn e hehe eee 43 3 Engine Air Cleaner 434 Engine Breather 4 3 5 43 6 Servicing Glow Plugs 44 Servicingand Adjusting V Belts 441 Belt Tension Gauge 442 Water Pump V Belt 443 Alternator V Belt 44 4 Driveshaft to Clutch G earbox and Clutch G earbox to E vaporator Condenser 5 45 Pumping The Unit Down or Removing The Refrigerant Charge 46 Refrigerant Leak TABLE OF CONTENTS CONT D 62 10022 01 ii 4 5 4 6 4 6 TABLE OF CONTENTS CONT D Section Page 4 Inns n nn 4 1 47 Evacuation and Dehydration 4 7 ALL General eh ___________ 4 7 4 12 iBreparation zs ss eei PAYA U
12. this test FAULT Off Load On Load No Output Incorrect Voltage No Output Incorrect Voltage Over Voltage Voltage Unstable Voltage Voltage Unstable heating Check Check Check Check Load Check Check Over Residual Speed Engine for Short Speed Engine Load Voltage Governing Circuit Governing Inlet or Check all Check Outlet Stator Connections Opening Resistances Obstructed Check Hot Engine Capacitor or Generator HOS Air Circulating Check Rotor Resistances Check Rotating Diodes Figure 4 24 Generator Fault Finding Guide 62 10022 01 Beveled Edge 4 35 GEARBOX CLUTCH Air Gap Coil Assembly Retaining Ring Rotor Pulley Assembly Retainer Nut Shims Pulley Assembly Key Washer Nut 52 09 OY UT OU PEE Figure 4 25 Gearbox Clutch Clutch Removal Disconnect electrical input Remove armature pulley assembly Figure 4 25 6 a Remove shaft nut 9 and washer 8 b Using a standard 2 or 3 jaw gear puller pull the armature 6 off the shaft Apply the puller jaws to the pulley hub not the rim of the pulley NOTE The armature pulley has been loctited to the shaft c Remove the shaft key 7 and shims 5 Remove rotor pulley assembly 3 a Remove bearing retainer nut 4 using removal tool b Slide rotor pulley assembly 3 from gearbox housing Remove the field coil assembly 1 a Remove field coil assembly retaining ring 2 b Remove field coil assembly 1 from gearbox Clutc
13. 2 5 5 F11 7 OR QUT OF RANGE RELAY DIC wes GAOB V o sn 8 9 REA l 3PL POWER LIGHT C2ND MPARTM Cms EHE eas OLA G9 8369 SPK11 86 TO 28286 T0 3RRB6 12 82 PS POWER STUD BE 3CR BS 10 MPP3 A7 RAS RETURN AIR SENSOR 2 3 HCFT All 12 2 3RAS RETURN AIR SENSOR 2ND 3RD COMPARTMENT o ero wo M 85 RUN STOP SWITCH F6 J3 RI UN LAY EHEHE OEN 2MDS 2DFT SPKI2 5 15 J12 N12 09 011 2 3RR RUN RELAY 2ND 3RD COMPARTMENT 305 hy HG AB SAS SUPPLY AIR SENSOR OPTIONAL p2 L AL SHAE 2 O 63 63 2RR 1 312 19 5 SM STARTER MOTOR SPKS 30 oe 5P SPLICE POINT ery 209 o TO BTY SES l HCHS SPLICE PACK sores Ber 51 SPT BUCTION PRESSURE TRANSDUCER SP24 M4 LEN INDICATES SOLDERED SPLICE POINT PL 0 Gers UNIT SHOWN IN OFF POSITION 2 1 9 20 o NI SSC STARTER SOLENOID CONTACTOR o INDICATES A SPLICE PACK CONNECTION 21 WIRE IDENTIFICATION SYSTEM AA I F7 J4 55R _ STARTER SOLENOID RELAY LIGHT LINES INDICATE SYSTEM WIRES COLOR WHITE DG CONTROL CIRCUITS SPK14 L ER egeo 87357 START SIOP SWITCH OO VALVE LACK Vi ND URE CON 0 NORMALLY CLOSED CONTACTS BED CIRCUITS oj 854 Hs 5 85 6 P4 5 2 119010 SOLENOID VALVE NC NORMALLY OPEN CONTACTS GREEN W YELLOW AC GROUN 15 V3 HOT GAS SOLENOID VALVE N C 3 ADDRESS
14. M A oues de ONT x EGG 2 12 90H RM HRA HEAT RELAY 4 epee 20 357 Oe ean ieu 018 NI6 010 011 2 3HR HEAT RELAY CIND 3RD COMPARTMENT 3 ie 3 SITE FT 508 5915 5020 SRK6 SPK8 d 8 kis 2HVR HIGH VOLTAGE RELAY 2ND COMPARTMENT CDT 5 2 a ENGINE io emo 8 TOF To mesi 016 3HVR HIGH VOLTAGE RELAY 3RD COMPARTMENT gun in 2 1 Spis Dl 1 _ JUMPER SHUT DOWN OPTIONS MGC Eu K12 012 373LSv LIQUID SOLENOID VALVE COND 3RD COMP T0 2RR86 Kl J11 N11 2 3MDS MANUAL DEFROST SWITCH 2ND 3RD COMP Sp20 SPK4 3s ME oe 219 MGC MANUAL GLOW CRANK 9 ool LE ae 8379 Ocs1 OPTION CONNECTOR JUMPER WAY 13 14 1 BR RB 62 FT 2 UG T Hero SPK16 gt 08 OIL PRESSURE SAFETY SWITCH X EE 2MD5 2DFT SP36 S TO 3DR086 ses 112 U AN LAY 55565 5 7 ORL OUT OF RANGE LIGHT LIGHT ze amp Oum CRIS K Subs 3DFT SFO 2 3PL POWER LIGHT OND 3RD COMPARTMENT 2 2RR SPK11 8 RAS _ RETURN AIR SENSOR 24 19 62 nom D cen GS on 88 30 BCS E Kl 89 6 965 weP3 11 12 2 3RAS RETURN AIR SENSOR 2ND 3RD COMPARTMENT SPES OIO 28 43 SPK12 C1 2 RCR REMOTE CONTROL RELAY e o N2 RES RESISTOR scale Ora OORE a lza G9GRGS To RS STOP SWITCH ea I irn SE lsp27 Bi SEE 09 0 Brann RUN RELAY 2ND 3
15. aos 1 16 1 5 UnitData Codes sic eis Lhe EUN bee oda puasa 1 17 1 6 Alarm Display deest cte tell iy e Nb 1 19 1 7 Battery Voltages ssec e uer Ede dad E e RR RR ade c gna 1 23 1 8 Stages for Defrost with Greater Than 100 F 37 8 C or 80 F 26 7 C Ambient with Software 3 14 OE EIGHT ser ASA u ua t La LM e at Meda DA Ced ad 1 29 2 1 Manual Glow n ER E ME DERE ia RE ER DEG ERE Us 2 2 2 2 Two Compartment M ulti Temp Logic Control 2 5 2 3 Three Compartment M ulti Temp Logic ne 2 6 4 1 Belt Tension y u aa s Ede ERR ku wll aati eek e reu 4 4 4 2 Evaporator Electrical lt 4 18 4 3 Connection Point Voltage hh 4 19 4 4 Microprocessor Configuration 4 20 4 5 Sensor Resistance ATS CDT RAS SAS amp 5 nnn 4 21 4 6 Suction Pressure Transducer Voltage 4 21 4 7 Generator Voltage Outputs 2 w sua Ee bre ier VR ER dad dee kupa REIN ga 4 23 4 8 R 22 Pressure Temperature Chart nn 4 26 4 9 R 404A Temperature Pressure Chart 4 27 6 1 M odel GClhiart ener tete reden co ben AM beer reed 6 1 V 62 10022 01 SECTION 1 DESCRIPTION 1 1 INTRODUCTION
16. FALLING TEMPERATURE RISING TEMPERATURE 2 3 6_F 1 1 8 F 0 5 C SET POINT E 1_C 1 8_F NULL FAN ONLY NULL FAN ONLY il 3 C 54 4 C 7 2_F 5 C 9 F 6 C 108 Figure 2 5 Frozen Range Temperature Controller Operating Sequence Controller Set Point Below 12_C 10 2 5 62 10022 01 2 6 6 Defrost Refer to sections 1 11 10and 1 17 for the heat and defrost cyde The defrost mode may be initiated by three different ways if the evaporator coil isbelow 35 F 1 7 C Refer to section 1 4 Method one to initiate defrost is by pressing the MANUAL DEFROST key M ethod two isthat defrost may be initiated automatically at preset intervals by the defrost timer in the microprocessor Refer to section 1 11 2 The manual defrost key and defrost timer are part of the microprocessor and are not shown on the schematic Onthe host unit a third means of defrost initiation is by the defrost air switch DA The switch isan air pressure differential switch which measures air pressure differential across the evaporator coil and initiates the defrost cycle when the air pressure differential increases enough to close the DA contacts such as would happen when excessive frost builds up on the evaporator coil surface When the defrost air switch contacts close there is a 12 vdc potential to terminal K 1 on the microprocessor The microprocessor looks for voltage at terminal K 2 Voltage a
17. P HEZO DEKT 14 010 ZER 2ND ENABLE RELAY D x E xi ONO Jo OB LW oh ge B EDD D 0 H oj 9 4 30 Hen COT oj s E ME IL D SP4 HPI UFR c HR SP SPKB 18 F1 F5 F9 FUSE 07 5 AMPERE SPKE aX Oras gt a Em Deer Re Wir HIT Ere Fuse Go etin Kk ps 2 lum VS aa ENE EUM FS HR SP7 ju ACD MOOO H A B a FHT FUEL HEATER THERMOSTAT OPTIONAL ius B8B Te mc 25 m PK3 SA BJ CL A bis GE 6569 89 HCE o SE 67 mE Ie SE F12 FR FAULT RELAY 5 2 DR Pi m 02 FP FUEL PUMP OPTIONAL HC2CHBJORLJAH9 3 5 SPK13 P2 FS FUEL SOLENOID BR 6365868 Ig ofS 810 4 19 4 i ES RAS ARR SPK13 1 DR SPK4 F4 12 K1 9 03 8 HC HIGH CURRENT BOX PLUG AH X2 FT 34 Go HL HEAT LIGHT LICHT BAR zc E xr c EG E te k EIL Ee optem E UR BOE Bone lt gt e Bo uc H nd 594 HED ECG 1 9 Go Hen HCJS reo F10 N8 HRT HEAT RELAY 1 E i E gt ve m 2 3 a T mov o d EN K IHC 2L PK2 ps HI HEA LAY H15 010 2HR HEAT RELAY C2RD COMPARTMENT ATS Spk5 RECORDER LKA TO 86IJPRRI85 H ol T0 OCJIG L15 011 3HR HEAT RELAY 3RD_COMPARTMENT EL F2 FHR FH apie enone 221 1 sekn do mo THT HIGH TEMPERAT
18. c Su n ooo 9 9 2 9 ORS SEE NOTE 4 4A c 53 w N m mmm XO CO AJ Ss UT UT UT NOTES SYMBOL DESCRIPTION C1 CAPACITOR 2502 C2 CAPACITOR 25uF C3 CAPACITOR 2502 0 FUSE 8 AMP 2 COMPT 1 FUSE 8 AMP 2 COMPT 2 FUSE 8 AMP 2 COMPT 3 FUSE 8 AMP 2 COMPT 4 FUSE 8 AMP 2 AMP 5 FUSE 8 AMP 5 COMPT 5 3 FUSE 4 AMP COMPT ONLY FUSE 4 AMP COMPT ONLYO F18 FUSE 4 AMP 3 COMPT ONLYO FLR FLASH RELAY HEATER ELEMENT 3 3 3 3 3 3 COMPT COMPT COMPT COMPT COPTIONAL COPTIONAL COPTIONAL 2HE HEATER ELEMENT 2ND COMPARTMENT 3HE HEATER ELEMENT 3RD COMPARTMENT HVR HIGH VOLTAGE RELAY MC1 MOTOR CONTACTOR MOL MOTOR OVERLOADER OL OVERLOAD PROTECTOR PSR POWER SUPPLY RECEPTACLE SBM STANDBY MOTOR SH SHUNT 5 OHM 25 WATT SP SPLICE POINT SPK SPLICE PACK 1 UNIT SHOWN IN OFF POSITION 2 WIRE IDENTIFICATION SYSTEM COLOR WHITE DC CONTROL CIRCUITS BLACK GROUNDS RED AC CIRCUITS GREEN AC GROUNDS 3 ADDRESS SYSTEM EXAMPLE HCD2 MPW2 NDICATES A WIRE BETWEEN PLUG HC PIN D2 amp MICROPROCESSOR MP PIN 2 4 COILS FOR CONTACTS ARE SHOWN ON HE CONTROL SCHEMATIC LOCATED ON THE 2 HIGH CURRENT BOX
19. NDICATES A SOLDERED SPLICE POINT NDICATES A SPLICE PACK CONNECTION LIGHT LINES INDICATE SYSTEM WIRES NORMALLY CLOSED CONTACTS NORMALLY OPEN CONTACTS NDICATES CONNECTION MULTIPLE PLUG CONNECTION NUMBER COMPONENT CONNECTION NUMBER OR LETTER NDICATES MOMENTARY CONTACTS NDICATES A WIRE GROUND NDICATES A CHASSIS GROUND NO WIRE NDICATES STANDARD OPTIONS NDICATES A CONNECTION WIRE LUG ETC DECAL NO REV 62 03923 00 B NDM84 HIGH VOLTAGE R22 ETO 2 3 COMPARTMENT Figure 6 7 Electrical Schematic Wiring Diagram Dwg No 62 03923 NDM o
20. 15 SARI ANCA an Sekt SP19 10 MPG3 Ra wen UE ESADER REAR RELAY MANUAL UBLE SHI NI URE P15 SPK SPK12 W4 s THIS LIRE NOT PRESENT ON SRD COMPARTMENT 1 COMPONENT CONNECTION NUMBER OR LETTER XX e 0501 46 WIS WATER TEMPERATURE SENSOR E PANE YOU MUST REMOVE 06y U O INDICATES MOMENTARY CONTACTS TEED AQ 18 5915 2 82 30H87 KIO 3 Gn 4G 19 SP15 HD GH INDICATES A WIRE GROUND 5 11 K mE PM GHK 3 COMPARTMENT H K12 DIODE 15 IN DIODE BLOCK DBD 7 INDICATES A CHASSIS GROUND NO WIRE 3 HRA 8 Code spe THE CATHODE 2AND AINE INDICATES STANDARD OPTIONS 592281 2 12 DECAL NO REV sou 8 5 TO 287 TO URR87 COT 7 x p ANODE ON RINGS Or THESBLOCKSEOR o INDICATES CONNECTION WIRE LUG ETC so L 52210135206 E E K COMPARTMENT NDA93 REVERSIBLE MULTI TEMP Figure 5 5 Electrical Schematic Wiring Diagram Dwg No 62 10135 NDA with R404A Sheet 1 of 2 A B C D E F 6 H 1 K L M N Q R 5 T U V W X Y o
21. Out of Range Tolerance The out of range temperature tolerance selection is displayed with the description T RANGE or codeFN11 The selection are A B or C 2 3 or 4 C 3 6 5 4 or 7 2 F respectively When the out of range temperature is configured ON the controller indicates out of range when the temperature has been within the tolerance band at least once and then goes outside the tolerance band for 45 minutes Also the unit will shut down When the out of range temperature is configured OFF the controller indicates out of range when the temperature has been within the tolerance band at least once and then goes outside the tolerance band for 15 minutes Also the unit will continue to operate For set points below 10 12 2 C frozen range the unit is only considered out of range for temperatures above set point 1 11 6 UNIT DATA The UNIT DATA key can be used to display the unit operating data values The data values will be displayed for 5 seconds and then the display will revert back to the normal display if no further action istaken T hefollowing sections describe the list of data which can be displayed via the keypad The description of the data will be displayed on the left side with the actual data on the right side Theunit data list can be scrolled through by pressing the UNIT DATA key With each successive key push the list will be advanced one If the UNIT DATA UP or DOWN Arrow key is held for one secon
22. 85 19 16 211 HEAT RELAY 3 mi n D CDI 65 Gg o 4 F11 N4 HR4 HEAT RELAY 4 x F2 P EUM i 3 seen 2 HIS 010 2HR HEAT RELAY ORD COMPARTMENT was C zi o WU T NISUS OH Ges T nes ee H 8i DERE E03 2 M mean H H TO 5 gt TO 3DROBG De c MPR OERE i3 p d TIE sis CXR NEAT er BE ag A SHUT DOWN OPTIONS fes OW Oe ae TO 3CRA8S 89 SR 66 K12 c 2 ro 9 HZ 10 CKE ro MPS1 111 2MDS MANUAL DEFROST SWITCH 2ND COMPARTMENT 2 MGC SPK11 L11 3MDS MANUAL DEFROST SWITCH 3RD COMPARTMENT 4348483 o Bo o HE 6968369 19 ga MANUAL GLOW CRANK ane 2 g g CAS OO Qi ais p22 MP MICROPROCESSOR B 2 5 35r MPR2 2 dE OIL PRESSURE BEEN DTch N 0 D Ben O 8 GHz TO MPJ3 321 29 5 2 11 OR _ 001 OF RANGE RELA 85 2288 Da 89 288 2 L SRL OUT OF RANGE 1691 IGHT BA 83 8469 A CORE B PL POWER LIGHT LIGHT BAR AND DOOR D E ONLY Casu NB hh 2 NOTES apie 273 POWER LIGHT REMOTE LIGHT SPKS 2 T SH OFF POSITION E MS 2566 5666 REN np p Mis RENI senson J84 spl SPK12 COLOR WHITE DC CONTROL CIRCUITS 11 2RAS RETURN AIR SENSOR C2ND COMPARTMENT BLACK GROUNDS A12 SRAS RETURN AIR SENSOR SRD COMPARTMENT r 2 8 83 n2 H sra RED AC CIRCUITS M RS RUN STOP SWITCH K SPK11 TO GREEN AC GROU
23. AC GROUNDS M RES RUN STOP SWITCH TO BTY lt Lo 3 ADDRESS SYSTEM EXAMPLE HCD2 MPW2 DCN BER RUN RELAY 2ND COMPARTMENT SPKS INDICATES A WIRE BETWEEN PLUG HC L4 010 RUN RELAY C3RD COMPARTMENT PIN D2 amp MICROPROCESSOR MP amp PIN W2 AB SAS SUPPLY AIR SENSOR OPTIONAL 4 VOLTAGE BELOW 12V REFER TO OWNERS 15 565 SPEED CONTROL SOLENOID m MANUAL FOR TROUBLE SHOOTING PROCEDURE 03 SLP SERIAL PORT xx DATA RECORDER SPEED PICKUP SM STARTER MOTOR To 1 THIS WIRE NOT PRESENT COMPARTMENT ap BPLICE POINT 00310 SPK11 5 15 INDICATES A SOLDERED SPLICE POINT 6 Sb B CIT N PRESSURE TRANSDUCER To 2511 6 HENS 50 INDICATES A SPLICE PACK CONNECTION 5 R SPEED RELAY 10 3571 F LIGHT LINES INDICATE SYSTEM WIRES M4 A TO E TO MPK3 WIRES FOR DIESEL ELECTRIC ONLY 55c STARTER SOLENOID CONTACTOR 2ERB 2 D TO OCJIE 252 DHR ECTR F7 J4 558 STARTER SOLENOID RELAY SPKE TN ONE SPK12 9 Soe TO MPH3 NORMALLY CLOSED CONTACTS od 55 SELECTOR SWITCH D D E ONLY i R MPpJ3 Z o 3011 NORMALLY OPEN CONTACTS SVI COND PRESSURE CONTROL VALVE N O s E 5 INDICATES CONNECTION te SVS WT aS SOLENOID VALVE SPK8 SPK19 2311 219 S gt 9 5 SPK11 MULTIPLE PLUG CONNECTION NUMBER fe Bet OT PRE VALVE N C 2 19 45715 COMPONENT CONNECTION NUMBER OR LETTER F8 J6 UFR UNLOADER FRONT RELAY N4 NS FB UR UNLOADER
24. unit shall default to unloaded 2 cylinder if a loss of control bad sensor is detected When in perishable range setpoint above 10 the unit shall shut down The proper alarm indication shall be displayed when this mode is active 1 11 10 DEFROST CYCLE Defrost is an independent cycle overriding cooling and heating functions to de ice the evaporator as required The controller displays D F during defrost mode on right hand temperature display T he left hand display will continue to display the setpoint a Defrost Timer Initiation A defrost timer initiation is a keyboard selection R efer to Section 1 11 5 The defrost timer is reset to zero gt En 62 10022 01 whenever a defrost cycleisinitiated The controller holds in memory the last entered defrost interval b Defrost Air Switch Initiation An external defrost signal DA may be supplied as a set of normally open switch contacts closing to initiate the defrost cycle c Manual Defrost Initiation The defrost cycle may be initiated by pushing the MANUAL DEFROST key d Defrost Function The defrost mode is initiated upon expiration of the defrost timing interval with the presence of a signal from the defrost termination thermostat D TT It may also be initiated by the presence of amomentary manual defrost signal Defrost may also be initiated by an external defrost signal from a device such as an air switch The defrost mode termin
25. 10 22001 29 CS
26. NDA Prior to S N FAC90391017 nnn 5 2 5 2 Electrical Schematic Wiring Diagram D wg N o 62 03998 NDA Prior to S N FAC90391017 IH 5 3 5 3 Electrical Schematic Wiring Diagram D wg N o 62 04003 NDA Starting with S N FAC90391017 5 4 5 4 Electrical Schematic Wiring Diagram D wg 62 04004 NDA Starting with S N FAF90396511 5 6 5 5 Electrical Schematic Wiring Diagram D wg No 62 04014 with RAOLA cR eee CNRC ENG S SC Aaa 5 8 6 1 Remote Evaporator ioci wd cer Re eee epe meh E er y ee d adem eoa a 6 2 6 2 High Voltage Control Box iesms n a a a a hn 6 3 6 3 Speed C ntrol S l n id ere Urn RE eR a HR SR 6 3 6 4 Removing V Belt from Clutch HH Hm 6 4 6 5 Standby Clutch Assembly I HH 6 4 6 6 Electrical Schematic Wiring Diagram D wg No 62 03922 6 5 6 7 Electrical Schematic Wiring Diagram D wg No 62 03923 6 6 6 8 Electrical Schematic Wiring Diagram D wg No 62 04014 NDM with Buzzer 6 7 LIST OF TABLES Table Page 1 1 Model Chart expe p ERR EP i es 1 1 1 2 Safety Devices ette ek icis ea poa eel lat oa pa apte cs i CU gra ua 1 10 1 3 Unloading in Temperature Mode 1 11 1 4 Function
27. Remove bracket then replace drier b Check refrigerant level Refer to section 4 9 b 4 15 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCH 4 15 1 Replacing High Pressure Switch a Pump down the unit Refer to section 4 5 a Frontseat both suction and discharge service valves to isolate compressor b Slowly release compressor pressure through the service valve gauge ports c Disconnect wiring from defective switch The high pressure switches are located on the top cylinder head See Figure 4 12 d Install new cutout switch after verifying switch settings Refer to section 4 15 2 e Evacuate and dehydrate the compressor Refer to section 4 10 p through 4 10 w 62 10022 01 4 15 2 Checking High Pressure Switch HP 1 or HP 2 WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 psi 165 kg cm Do not use oxygen in or near a refrigerant system as an explosion may occur See Figure 4 15 1 Cylinder Valve and Gauge Pressure Regulator Nitrogen Cylinder Pressure Gauge 0 to 400 psig 0 to 28 kg cm Bleed Off Valve 1 4 inch Connection TUN exon Figure 4 15 Typical Setup for Testing High Pressure Switch Remove switch as outlined in section 4 15 1 Connect ohmmeter or continuity light across switch terminals Ohmmeter will indicate resistance and continuity light will be lighted if switch closed after relieving pressure Conne
28. The Code displayis CD 12 Software Revision The Eprom software revision number is displayed with the description REV or CD13 on the left and Eprom software revision number on the right side Pressing the ENTER 3secondswill display REV U 2ontheleft and the board mounted software revision number on the right side Serial Number Low The low serial number of the unit is displayed with the description SERL or CD 14 The data isthe lower 3 digits of the serial number burned in to the E prom i e SERL 504 or CD 14 504 Serial Number Upper The upper serial number of the unit is displayed with the description SERU or CD 15 The dataisthe upper 3digits of the serial number burned in to the E prom i e SERH 001 or CD 15 001 Compartment 2 Air Temperature The air temperature for the second compartment will be displayed with the abbreviated description 2RA on the left hand side The code display isCD 16 T he data will be displayed with one decimal place and the proper unit designator D egree C or Degree F i e 2RA 85 0F Compartment 3 Air Temperature The air temperature for the second compartment will be displayed with the abbreviated description 3RA on the left hand side T he code displayisCD 17 The data will be displayed with one decimal place and the proper unit designator Degree C or Degree F i e 85 0F Maintenance Hour Meter 1 The maintenance hour meter 1 setting is displayed with the desc
29. Turn unit off and recheck belt tension o 62 10022 01 BELT STANDBY BELTS BN J ENGINE e COMPRESSOR ATTACHING SCREWS FLYWHEEL Figure A NEW BELT CLUTCH FLANGE ENGINE COMPRESSOR 25 FLYWHEEL CLUTCH SHEAVE SLIDE CLUTCH FLANGE Figure B Figure 6 4 Removing V Belt from Clutch NDM 6 5 SERVICING STANDBY CLUTCH NDM The clutch must be inspected if the clutch slips or grabs The clutch automatically engages clutch engagement 550 50 rpm during starting cycle of the engine as the engine accelerates to low speed The clutch does not engage during standby motor operation a b gt on Unplug unit from external electrical outlet and disconnect battery Remove the two rear compressor bracket mounting bolts compressor shockmount end Block up engine Remove clutch V belts as outlined in section 6 4 Pump down the unit Remove suction and discharge service valve Attach sling or other device to the compressor Slide compressor enough to remove clutch Remove 6 5 16 18 capscrews from rotor assembly Item 2 Figure 6 5 62 10022 01 j k O 1 gt QQ N F3 U sing 3 of the capscrews as jacking screws remove the center section of the clutch housing T his will expose the snap ring holdi
30. nee te section 4 11 4 Pressing the AUTO S S CONTINUOUS key 5 Observe any signs of lube or fuel oil leaks changes the operation of the unit between automatic 6 Check radiator hoses for leaks start stop unit will automatically start and stop in response to changing boxtemperature or automatic 7 Check refrigerant level Refer to section 4 8 f start continuous run unit will operate continuously 8 Feelfilter drier E xcessive temperature drop across after starting drier indicates restriction Refer to section 4 14 b Stopping Instructions 9 Check clutch gearbox for excessive noise Place RU N STOP switch in the STOP position to stop 10 Start microprocessor Pre trip Inspection Refer to unit Section 1 11 8 2 2 STARTING AND STOPPING INSTRUCTIONS 2 2 2 MANUAL STARTING a Starting Instructions Manual Starting 1 Tostartthe unit manually place Run Stop Switch to RUN position 2 Press the AUTO S S CONTINUOUS key if necessary to erase START STOP from the display 2 1 62 10022 01 3 Pressthe FUNCTION CHANGE key until AUTO OPor MAN OP appears on the display a IFAUTO OP appears 1 Pressthe ENTER key 2 Press the UP or DOWN arrow key to make MAN OP appear on the display 3 PresstheENTER key TheunitisinMANUAL START mode b IFMAN OP appears theunitisinMANUAL START mode Usethe M anual Glow Crank switch to start the unit referto Table 2 1 Do not crank the engine longer than 30 seco
31. next page 2 7 62 10022 Table 2 3 Three Compartment Multi Temp Logic Control Compartment CompartmentNeed Unleaders Re Re Host UR PEE Cool Coo eclesie erexit fe e RR 8 0 o x Heat x x o x mw x x fw mw x e De Heat x x wu x x E Nut o o o eene o o x X Outputis ON Energized Sean Su HS Ee UI higher Control both suction pressure and temperature demand re IS ICE o s EAM Engine Speed is 1700 RPM single speed have UltraFreeze refer to section 1 14 Under Under setpoint with setpoint at or below 10 12 C 62 10022 01 2 8 SECTION 3 TROUBLESHOOTING CAUTION Under no circumstances should anyone attempt to service the microprocessor see section 4 27 Should a problem develop with the microprocessor contact your nearest Carrier Transicold dealer for replacement INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 3 1 DIESEL ENGINE 311 Engine Will Not Start Starter motor will not Battery insufficiently charged crank or low cranking speed Battery terminal post dirty or defective Ba
32. temperature the unit will shift to unloaded heat For setpoints below 10 F 12 C hot gas heating is locked out Electric heat may be allowed depending on remote status Therefore it is possible for the box temperature to fall below setpoint in the frozen range U nit will remain in various stages of heating until the box temperature increases enough to place the unit in the unloaded cool mode A sthe box temperature increases the unit will shift to loaded cool 2 6 3 Pulsed Cooling The liquid solenoid valves 2 3L SV for compartments 2 and 3 are opened and closed to pulse cool according to the timing diagram See Figure 2 3 There is no pulsed cooling for the main compartment When any compartment isin cool band 1 3 C above set point regardless of setpoint and any remote compartment with a perishable setpoint isin the pulsed cool band it will use pulsed cooing See Figure 2 4 2 6 4 Ultrafreeze With software 3 11 or higher for frozen setpoint under mode has been replaced by U Itrafreeze R efer to section 1 14 for U Itrafreeze In Ultrafreeze mode anytime the main compartment is in null or heat band and a remote compartment requires cooling the main compartment will shut down by energizing HR 4 and de energizing HR 1 HR2 and HR 3 D uringthis period the U Itrafreeze control algorithm will continue to operate so that the main compartment is turned back on it will continue from the appropriate control
33. when disconnecting the harness at the condensing section end for testing purposes always leave the separate earth cable connected A seventeen core cable is provided with a multi pin connector on one end to connect directly to the condensing section The other end of the cable is color coded to allow easy connection in the evaporator When there are two wires of the same color they will be numbered i e yellow 1 yellow 2 brown 1 brown 2 Table 4 2 Evaporator Electrical Connections tow we Defrost termination sensor 25A 20A 26B 21B 24A 22B 1C 23B 3C 16C 17B 7C 9C 4 27 MICROPROCESSOR CONTROLLER NOTE The erasable programmable read only memory EPROM chip component U3 on the microprocessor logic board has a window on it which is covered with a label listing the revision level of the software The window isused to erase the chip s memory with the use of ultraviolet light the label prevents light from entering the chip and erasing the memory Under NO circumstances should this label be removed CAUTION Under no circumstances should a technician electrically probe the processor at any point other than the connector terminals where the harness attaches Microprocessor components operate at differentvoltage levels and atextremely low current levels Improper use of voltmeters jumper wires continuity testers etc could permanently damage the processor As mentioned above some micr
34. 0 2 kg cm rise on the suction gauge will be noted Compressor is now fully unloaded and only the top bank is loaded two cylinders Reverse the above procedure to check out compressor loading Suction pressure will drop with this test NOTE If either unloader coil energizes and the suction pressure doesnot change the unloader assembly must be checked Solenoid Coil Replacement NOTE The coil may be removed without pumping the unit down Disconnect leads Remove retainer Lift off coil See Figure 4 13 Verify coil type voltage and frequency of old and new coil This information appears on the coil housing Place new coil over enclosing tube retainer and connect wiring LU Nhe Retainer 8 Plunger Assembly Coil Assembly 9 Gasket Installation Removal 10 Valve Body Tool 11 Gasket Enclosing Tube 12 Bolt Collar 13 Gasket Bolt O Ring 14 Piston Ring Enclosing Tube Plunger Spring Figure 4 13 Unloader Solenoid Valve Replacing Solenoid Valve Internal Parts See Figure 4 13 Pump down the unit Frontseat both service valvesto isolate the compressor Remove coil retainer and coil Remove enclosing tube collar item 4 Figure 4 13 using installation removal tool supplied with repair kit item 3 Check plunger for restriction due to a Corroded or worn parts b Foreign material lodged in valve c Bent or dented enclosing tube Install new parts D o not overti
35. 000 20 67 46300 463000 3o i1 34500 345 000 3 of 3270 32700 40 44 26200 262 000 50 100 19900 199000 60 156 15300 153 000 119 000 7 25 1000 100 000 80 267 930 93000 90 322 7 300 73000 58 000 47 000 38 000 194 212 100 130 0 7 1 1 1 194 9 150 212 6 800 266 3 010 3 1 860 7 7 0 1 2 9 1 6 2 3 5 9j i 680 3m 4 30 SUCTION PRESSURE TRANSDUCER Before installing a new suction pressure transducer it must be calibrated The calibration will not be performed if the run relay is energized This prevents the operator from calibrating the unit with the sensor in the system T he reading of the sensor must be at atmospheric pressure 0 psig or 14 7 psi If the sensor readingis greater than 20 psig 34 7 psi or lessthan 6 7 psig 8 psi itcan not be calibrated O nce the micro is calibrated the display will readout the actual value 1 Turn power off and remove starter solenoid wire then let unit fail to start This will de energize run relay 2 Connect wiring to new suction pressure transducer Before installing suction pressure transducer into compressor display the suction pressure via the unit status display While the suction pressure is being displayed press ENTER key for 3 seconds the display should read 0 If display reads 0 install suction pressure transducer into compressor Psig Voltage Psig Vol
36. 231 2 ap 259 2 9 27312 i 28902 7 e Ww Mo Eo N A gt o Ui N NIN aol oe w N N I NJ O CO O 32 50 70 1 15 1 24 45 321 3 37 3 54 3 72 3 90 08 N N N Temperate Pressure C Psig Bar 2 O 725 s10 5 00 a 4 55 601 590 a 6 830 626 614 r 925 __650 638 e 962 676 663 o 999 7 02 689 eo 16 1251 887 8 69 es 18 137 4 966 947 776 21 484 1050 10130 715 24 1621 1140 iLi8 27 255 12 34 1210 29 189 1333 1307 90 32 2045 1438 1410 os 35 2202 1548 1518 100 38 2368 16 65 1633 105 a 2542 1787 1753 2724 1935 1878 2916 2030 2011 E3118 2192 2150 3323 2341 22 95 355 0 2496 2448 3781 2658 2607 4023 2628 2774 427 6 3006 29 48 454 0 3192 3130 110 43 115 46 120 49 125 52 130 54 135 57 140 60 145 63 150 66 62 10022 01 SECTION 5 ELECTRICAL SCHEMATIC WIRING DIAGRAM 5 1 INTRODUCTION This section contains Electrical Schematic Wiring Diagram covering the M odels listed in Table 1 1 The following supplement the specific warnings and cautions appearing elsewhere in this manual T hey are recommended precautions that must be understood and applied during operat
37. 24 AC Terminal 3 10 24 Ground Screw 4 1 4 20 Positive Output Cable Figure 1 17 Alternator and Regulator P N 30 00409 1 15 2 Integral Voltage Regulator Operation 12 volts dc The regulator is an all electronic transistorized device No mechanical contacts or relays are used to perform the voltage regulation of the alternator system The electronic circuitry should never require adjustment and the solid state active elements used have proved reliable enough to warrant a sealed unit The system is temperature compensated to permit the ideal charging rate at all temperatures The regulator is an electronic switching device It senses the system voltage level and switches the voltage applied to the field in order to maintain proper system voltage 1 15 3 Alternator Service The alternator brushes regulator and bearings may be replaced if necessary 62 10022 01 1 16 REFRIGERANT CIRCUIT DURING COOLING See Figure 1 18 or Figure 1 19 When cooling the unit operates as a vapor compression refrigeration system T hemain componentsof the system are the 1 reciprocating compressor 2 air cooled condenser 3 expansion valve and 4 direct expansion evaporator The compressor raisesthe pressure and the temperature of the refrigerant and forces it into the condenser tubes The condenser fan circulates surrounding air over the outside of the condenser tubes The tubes have fins designed to improve the transfer of heat from t
38. 240 VAC 60 HZ HEATER CIRCUITS KS 3HT HIGH TEMP THERMOSTAT 3 EFM MOTORS H2 H6 HIGH VOLTAGE RELAY H2 H6 2HVR HIGH VOLTAGE RELAY 2ND COMPARTMENT 3EFR HS SHVR HIGH VOLTAGE RELAY COMPARTMENT C3 c13 M rag SCT7 H227 SP SPLICE POINT F14 3 2A N2 M7 71 CAPACITOR k A 2EFR N2 N7 22 CAPACITOR Lie f 38 4 2017 P2 P7 23 CAPACITOR 4uF 12 43 2 GHVR m 02 07 74 CAPACITOR 4pF ca 2HVR 2HT RED 28 E 8 THVR 1HT Ul f We F10 20 5 WHITE BROWN 2HE 3HE NOTES G sero 1HE 1 UNIT SHOWN IN OFF POSITION n 5 2 2 WIRE IDENTIFICATION SYSTEM J COLOR WHITE DC CONTROL CIRCUITS Fi 204 2012 BLACK GROUNDS 3212 RED AC CIRCUITS 2EFR GREEN W YELLOW STRIP AC GROUNDS SP B ADDRESS SYSTEM EXAMPLE HCD2 MPW2 INDICATES A WIRE AT GEN ge fe HEH 2513 BETWEEN PLUG HC PIN D2 amp MICROPROCESSOR PIN W2 F13 3 24 4 COILS FOR HVR CONTACTS ARE SHOWN ON THE CONTROL SCHEMATIC h 3EFR LOCATED ON THE HIGH CURRENT BOX KH 5 TH NUMBER OF FANS DEPENDS ON YOUR COMPARTMENT F1S 3 2A CONFIGURATION Ci e 2 3 4 FANS 5 EVAPORATOR CONNECTOR LABELS EXAMPLE 2012 INDICATES 2 R3 240 VAC HZ HEATER CIRCUITS 7 THE NUMBER OF HEATERS DEPENDS ON YOUR APPLICATION 2 COMPARTMENT 4 HEATERS 3 COMPARTMENT 2 HEATERS CONNECTOR MP s a gt 1 ep CONNECTOR HC CONNECTOR HC2 3 22 f LI MN 2C 3C EVAPORATOR CONNECTO
39. 61 Model NDM Units With Standby 6 1 6 2 Electrical Data ex et EU RR IR o CAR Ee NAR Ad d 6 1 6 3 Servicing Speed Control Solenoid And 1 6 3 6 4 Standby M otor V Belts NDM ccc cece cece Hm 6 3 65 Servicing Standby mn 6 4 INDEX fect ann aa qh casera ham dab Norte nta Q awa Panos BT Index 1 iii 62 10022 01 Figure 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 1 18 1 19 1 20 1 21 2 1 2 2 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 14 4 15 4 16 4 17 4 18 4 19 4 20 4 21 4 22 LIST OF ILLUSTRATIONS Page Compartment Control BOX hes 1 2 1 3 gale erat eee Sahl 0 1 4 Roadside en EROR tede a SCR 1 4 Front 1 5 Evaporator Section Panels and Grille Removed 1 6 Control BOX DOOL pem eth ee dead hua tado di Aen 1 6 High Voltage Control BOX mms 1 7 Relay Module a meant Lee TS usica eh VE 1 7 System Diagram ieran scis SERE ke Ra ed ER RS 1 11 E ube Oil Elow ened x e REI e PER e nies 1 11 Compressor Cylinder H ea
40. Alarm W hen no communications exist between the main board and the display board for 8 seconds the display alarm description is DISPLAY or AL 17 Maintenance Hour Meter 1 Alarm The maintenance hour meter alarm 1 is displayed with the description SERVICE 1 or AL18 This alarm is generated when the designated hour meter is greater than maintenance hour meter 1 Maintenance Hour Meter 2 Alarm The maintenance hour meter alarm 2 is displayed with the description SERVICE 2 or AL19 This alarm is generated when the designated hour meter is greater than maintenance hour meter 2 Out of Range Alarm The out of range alarm is displayed with the description OUT RANGE or 1 20 This alarm is generated when the main compartment is out of range refer to section 1 11 5 The fault light FL isturned on Remote Compartment 2 Out of range Alarm The Code display isAL21 This alarm is generated when the remote compartment 2 is out of range refer to section 1 11 5 The fault light FL is turned on Remote Compartment 3 Out of range Alarm The Code display 15 AL 22 This alarm is generated when the remote compartment 3 is out of range refer to section 1 11 5 The fault light FL is turned on 62 10022 01 1 11 8 PRE TRIP The PRETRIP key is for checking unit operation and evaluating operation of all modes and indicating failure when detected The following details the sequence a Unit operating and box temperature is below 40 F 4
41. CONTACTOR 1 UNIT SHOWN IN OFF POSITION Que INDICATES A ISOLOERED 165 POINT up ska up sake IO 2811 6 08 310 37351 START STOP SMITH 2 WIRE IDENTIFICATION SYSTEM INDICATESCATSPEIEE PACK SCONNECTION 30 He 0102 30 D OO fo TO 3574 F PB SVi COND PRESSURE CONTROL VALVE N 0 COLOR WHITE DC CONTROL CIRCUITS LIGHT LINES INDICATE SYSTEM WIRES 5 50 SP50 10 2EROD SOLENO METUS BLACK GROUNDS NORMALLY NTACTS L V H LEN VALVE N C RED AC CIRCUITS ORHAL EY CLOSED CONTACTS 2DNR 30 SPKE 96 5 4 GAS SOLENOID VALVE N C 5 GREEN W YELLOW STRIPE AC GROUNDS NORMALLY OPEN CONTACTS 2011 Ra 1 Sc Ar 1 Ls d Ur UNLOADER FERONT RELAY Al Y M EXAMPLE H INDICATES A WIRE BETWEEN PLUG HC INDICATES CONNECTION Sano 5 UNLOADER REAR PIN D2 amp MICROPROCESSOR MP amp PIN M2 65 0222 50 Her 221 652 SPKB SPKIS FB N4 5 URR UNLOADER REAR RELAY 4 MT Or REFER TO OWNERS HC2F MULTIPLE PLUG CONNECTION NUMBER G Tis OTG 9 B5 WTS WATER TEMPERATURE SENSOR MANUAL UBLE SHI NI URE gt S THIS WIRE NOT PRESENT ON CONPARTHENT 0 COMPONENT CONNECTION NUMBER OR LETTER ras FE S o H USIN HI NAL PANEL YOU MUST REMOVE OCJ1 S INDICATES MOMENTARY CONTACTS A EN BE see 50 INDICATES A WIRE GROUND 42 13 5 562 395 TO MPK3 DIODE 15 IN DIODE BLOCK 081 7 INDICATES A CHASSIS GROUND N
42. Connection 4 7 Compressor Drive 5 4 9 Pressure Switches 1 and HP 2 4 9 Oil Eevelan Sight Glass eR ee dank iii ee ates te edes 4 9 COmIpresSsor z se cade DETTE tes 4 10 U nloader Solenoid Valve 4 11 Check Valve Serviceable Type 4 11 Typical Setup for Testing High Pressure Switch 4 12 Solenoid Valves ACO nose bert gate eda e aged r ACE een oa 4 13 Solenoid Valves Sporlan ree DEUM v DESEE Gand wae eee eae 4 13 Defrost Air Switch Test Setup 4 14 E vaporator Condenser Fan Shaft Assembly 4 16 Thermostatic Expansion Valve 4 17 Thermostatic Expansion Valve Bulb and Thermocouple 4 17 U nidrive Torque Requirements 4 22 62 10022 01 iv LIST OF ILLUSTRATIONS CONT D Figure Page 4 23 Generator es p d uo eade ett sett doen eee tte 4 23 4 24 Generator Fault Finding Guide 4 24 4 25 Gearbox Uber zi edi aa a edu achat ot ed HP RT ERE EPI dane 4 25 5 1 Electrical Schematic Wiring Diagram D wg N o 62 03997
43. ETC q m lt DECAL NO REV LP 62 04003 00 A NDA REVERSIBLE MULTI TEMP Figure 5 3 Electrical Schematic Wiring Diagram Dwg No 62 04003 NDA Starting with S N FAC90391017 Sheet 2 of 2 10 22001 29
44. Fluctuating suction Improper bulb location or installation 4 24 pressure Low superheat setting 4 24 High superheat Broken capillary 4 24 3 3 11 Solenoid Valve Malfunction Solenoid valve does not function properly Solenoid valve closes but refrigerant continues to flow 3 4 5 kw GENERATOR No power to valve Improper wiring or loose connections Coil defective Valve improperly assembled Coil or coil sleeve improperly assembled Movement of plunger restricted due to a Corroded or worn parts b Foreign material lodged in valve c Bentor dented enclosing tub Foreign material lodged under seat Clean Defective seat Replace Electric heaters and fans do not 5 kw generator malfunction 4 34 function properly 62 10022 01 3 6 SECTION 4 SERVICE WARNING Beware of V belts and belt driven components as the unit may start automatically Before servicing unit make sure the Run Stop switch is in the STOP position Also disconnect the negative battery cable CAUTION Unit with R404A and POE oil the use of inertgas brazing procedures is mandatory otherwise compressor failure will occur NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing refrigerant W hen working with refrigerants you must comply with all local government environmental laws U S A EPA section 608 4 1 MAINTENANCE SCHEDULE UNIT ON OFF SEE a Daily Maintenance l Pre Trip Inspection bef
45. Gi COMPRESSOR DISCHARGE TEMPERATURE SENSOR o HC2N Lq ps2 o 39 735 Spee CL COOL LIGHT LIGHT BAR B SLP 2528 CB J14 M14 2 30 COOL LIGHT REMOTE To 1 A SPK6 DB gt TO 28830 Gn UTCH SPK13 r vL eru 10 wa P J13 09 2CRA B COOL RELAY 2ND COMPARTMENT 2 3 s Ge SPA SPB SPC 3 28 5912 SPK1 DER SPK6 FE NI3 P10 SCRA B COOL RELAY 3RD COMPARTMENT L gt cS DB d MAXI EUSE 39 G70 Gri FS DA DEFROST AIR SWITCH J14 2DA DEFROST AIR SWITCH 2ND COMPARTMENT BOO 63 6 9 PORC Sp32 S N ps3 ce TO EE E OOO MI SDA DEFROST AIR SWITCH GND COMPARTMENT X RX SX ro 2515 Herz FE To P sa N3 7 ER DIESEL ELECTRIC RELAY 10 3s1i 53 NE ij 9 JH D Sort DEFROST TIMER COND AND COMPARTMENT 25A a I 5 SDAR DEFROST HEAT RESISTANCE 2ND EVAPORATOR tel ra ege wa e eme FF AE aL i d 0 0 Go 67 TO 3571 G3 39 7731 SSR Av J15 NI5 2 30L DEFROST LIGHT REMOTE LIGHT 5 455 1709 05 0 BLK DATA LINK OPTIONAL T P16 4 M2 HCC4 TI A 3 ls Z AP spk2 HRA SEE NOTE R 113 115 12 20R DEFROST RELAY 2ND COMPARTMENT 6 30 F6 CDS 12 2 M15 308 DEFROST RELAY 3RD COMPARTMENT TO SP19 63 son AU SP8 SP7 SPK8 F4 DIT DEFROST THERMOSTAT GH 3 114 207 DEFROST THERMOSTAT 2ND C
46. Indicator Ambient Temperature Sensor ATS Figure 1 5 Front View 62 10022 01 1 Evaporator Fan 3 Defrost Termination Thermostats 2 Expansion Valve 4 Return Air Sensor Figure 1 6 Evaporator Section Panels and Grille Removed SN f V A A 6 5 4 l FaultLight 4 Selector Switch SSW Model NDM 2 Standby Power Light PL Model NDM 5 Keypad Door 3 Run Stop Switch 6 Microprocessor Control Panel See Figure 1 14 Figure 1 7 Control Box Door 62 10022 01 1 6 B 3HCR EIUS 121 Evaporator Fan Relay High Voltage Relay Fuse FIN Fuse 20 amps oe Heat Control Rel R404A Units R22 Units Figure 1 8 High Voltage Control Box 9 Q VES 2 LZ QJ NJ eit 5 B G
47. Theair cleaner should bereplaced and the indicator reset by pressing the reset button Service Procedure Dry Type 1 Stopthe engine remove air cleaner Install new air cleaner d Service Procedure Oil Type 1 Air Inlet Hood 4 Inner Cup Oil bath 2 Air Cleaner Body 5 Oil or Dust Cup 3 Clamp Figure 4 1 AirFilter CAUTION Always cover the engine inlettube while the air cleaner is being serviced l Oil Cups When to Service Remove the oil cup at regular intervals Initially inspect daily or as often as conditions require N ever allow more than 1 2 inch 12 7 mm of dirt deposit in either cup M ore than 1 2 inch accumulation could result in oil and dirt to carry over into the engine causing accelerated engine wear H eavily contaminated oil will not allow the air cleaner to function properly How to Service Stop the engine and remove the oil cup from the air cleaner Dump the oil from the oil cups Remove the inner cup from the oil cup and clean both cups of sludge Reassemble and fill both oil cups to the indicated level with SAE 10 oil for temperatures below freezing or SA E 30 for temperatures above freezing It is generally a recommended practice to use the same oil as required in the engine crankcase Refer to section 1 2 CAUTION Do not underfill or overfill the cups Overfilling of cups means loss of capacity and underfilling means lack of efficiency 2 BodyAssembly When to Service Th
48. close suction service valve and the refrigerant will be trapped between the compressor suction service valve and the manual shutoff K ing valve 5 Before opening up any part of the system a slight positive pressure should be indicated on the pressure gauge 6 When opening up the refrigerant system certain parts may frost Allow the part to warm to ambient temperature before dismantling This avoids internal condensation which puts moisture in the system 7 Open backseat King valve and midseat suction service valve 8 Leak check connections with a leak detector R efer to section 4 6 9 Start the unit in noncondensibles 10 Check the refrigerant charge R efer to section 4 8 f NOTE Store the refrigerant charge in an evacuated container if the system must be opened between the compressor discharge valve and receiver Whenever the system is opened it must be evacuated and dehydrated Refer to section 4 7 b Removing the Refrigerant C harge Connect a refrigerant recovery system to the unit to remove refrigerant charge R efer to instruction provided by the manufacture of the refrigerant recovery system cooling and check for 4 6 REFRIGERANT LEAK CHECKING a If system was opened and repairs completed leak check the unit b The recommended procedure for finding leaks in a system is with a halide torch or electronic leak detector Testing joints with soapsuds is satisfactory only for locating larg
49. emergency situations the test board may be used to keep a unit running and prevent a critical load from spoiling Sincethe microprocessor istotally disconnected from the unit it cannot monitor the engine s safety switches for oil pressure and coolant temperature Since the engine is running unprotected when the test board is used it isimperative that should a problem develop with the microprocessor it be replaced immediately The test board is intended to be a trouble shooting tool only When using the test board to troubleshoot the unit should be started in low speed unloaded cool in the same way asthe processor would start the unit G ood judgment should also be used when cycling any unit with the test board Rapid cycling should be avoided When welding is required on the unit frame or on the front area of the trailer ALL wiring to the microprocessor M UST be disconnected When welding is performed on other areas of the trailer the welder ground connection M UST be in close proximity to the area being welded It is also a good practice to remove both battery cables before welding on either the unit frame or the trailer to prevent possible damage to other components such asthe alternator and voltage regulator a Replacing Key Board Should damage to the K ey Board of the microprocessor occur it is possible to replace only the K ey Board All replacement key boards are packaged with replacement O Ring The recommended torque fo
50. filters are notprimed the engine may operate fora period with no oil supplied to the bearings Replace filter s and add lube oil Refer to section 1 2 Warm up engine and check for leaks 4 3 3 Engine Air Cleaner a Inspection The dry type or oil bath air cleaner should be inspected regularly for leaks A damaged air cleaner or hose can seriously affect the performance and life of the engine The air cleaner is designed to effectively remove contaminants from the air stream entering the engine A excessive accumulation of these contaminants in the air cleaner will impair its operation therefore a service schedule must be set up and followed Remember that the air cleaner cleans the air but the air cleaner requires cleaning The following simple service steps are easily made while the engine is being serviced in the field The simple inspection steps are as follows 1 Check all connections for mechanical tightness Be sure cleaner outlet pipe is not fractured 2 Incase of leakage and if adjustment does not correct the trouble replace necessary parts or gaskets Swelled or distorted gaskets must always be replaced b Air Cleaner Service Indicator The air cleaner indicator is connected to the engine air intake manifold and its function is to indicate when the air cleaner requires replacing In operation When a plugged air cleaner decreases intake manifold pressure to 20 500 mm WG the indicator movesto the red line
51. is the responsibility of the operator to give the air cleaner equipment regular and constant attention in accordance with the instructions Refer to section 4 3 3 Clean air issupplied to the engine through the air cleaner See Figure 1 4 The air is necessary for complete combustion and scavenging of the exhaust gases As the engine piston goes through the intake stroke the piston draws clean fresh air down into the cylinder for the compression and power strokes As the engine goes through its exhaust stroke the upward movement of the piston forces the hot exhaust gases out of the cylinders through the exhaust valves and the exhaust manifold If the air filter is allowed to become dirty the operation of the engine would be impaired 1 8 SAFETY DEVICES System components are protected from damage caused by unsafe operating conditions by automatically shutting down the unit when such conditions occur This is accomplished by the safety devices listed in Table 1 2 The quench valve R 22 Only opens as required to maintain a 265 to 285 F 129 to 141 C discharge temperature Should this valve fail the compressor discharge temperature sensor CDT will shut the unit down if center compressor head discharge temperature reaches 310 F 154 C for 3 minutesor 350 F 177 C If ambient temperature sensor AT S isat 120 F 49 C orhigher theCDT limitsareincreasedto 340 171 C for 3 minutes 62 10022 01 Table 1 2 Safety Devices Un
52. operation Refer to section 2 4 18 SOLENOID VALVE SV 1 CHECKOUT PROCEDURE To obtain proper heating and defrost the normally open N O SV 1 solenoid valve must energize and close tightly duringthe heat and defrost cycles If the valve does not close tightly due to physical damage foreign material or wear refrigerant leakage through the valve can reduce heating capacity a During normal heat or defrost cycles the following conditions will be observed when the valve is operating properly 1 Receiver refrigerant level will drop quickly at initiation of heating or defrost mode 2 Suction pressure will rise slowly to 90 100 psig 6 3 to 7 0 kg cm 62 10022 01 3 Discharge pressure will drop quickly but begin to rise to a minimum of 250 psig 17 5 kg cmQ within 15 to 20 minutes b If suction and discharge pressures remain low and the receiver level does not drop the valve may be inoperative and can be checked by the following method 1 Verifythe solenoid coil has proper voltage and is energized in heating and defrosting 2 Connect a discharge pressure gauge to the com pressor discharge service valve and connect a gauge to theliquid line valve king valve leavingthe receiv er tank 3 With the trailer temperature at 35 F 1 7 C or lower operate the unit in high speed cool and re move or disconnect the hot wire leading to the SV 1 coil 4 With a separate 12 vdc positive voltage en
53. or remove power from the microprocessor move the run stop switch to the STOP position 2 Manual Glow Crank Switch M GC The manual glow crank switch when held in the GLOW position energizes approximately 7 5 amps per plug at 12 vdc the glow plugs in the engine to pre heat the combustion chamber The CRANK position of the switch is used to manually engage the engine starter 3 Selector Switch SSW M odel NDM This switch is used to select mode of operation either engine drive or standby electric motor drive When this Switch is placed in standby position the electric motor will not start until the oil pressure safety switch OP opens 1 12 3 Location of Engine Safety Devices a Oil Pressure Safety Switch OP This switch set to open below 15 3psig 1 0 0 2 kg cm will automatically stop the engine upon loss of oil pressure See Figure 1 5 for location b Water Temperature Sensor WTS This sensor senses engine water temperature The microprocessor will stop the unit when this temperature exceeds 230 F 110 C If ambient temperature sensor ATS is at 120 F 49 C or higher the WTS limits are increased to 230 to 240 F for 5 minutes or immediately over 240 F 116 C The sensor is located near the thermostat housing in the cylinder head 1 13 ULTRAFRESH 2 TEMPERATURE CONTROL NOTE UltraFresh 2 can operate when only one compartment is being controlled U ItraFresh 2 temperature control algorithm is a metho
54. point Compartment 2 10 seconds No Refrigerant Flow 15 seconds No Refrigerant Flow Compartment 3 5 Seconds Refrigerant Flow 2 6 5 Heating NOTES 1 SV 3 will open after a 60 second delay if the difference between ambient and discharge temperatures exceeds 100 F 55 5 C If the difference between ambient and discharge temperatures goes below 50 F 27 8 C SV 3 will close 2 Whenever the unit shifts to heat defrost HR 1 and HR2 energize simultaneously When switching from heat or defrost to cool HR1 de energizes 2 seconds before H R 2 Thisallows time for SV 1to open and clear the condenser of liquid before SV 4 closes This will eliminate any high pressure buildup which could occur D uring thistime only on the remote light bar the heat and cool lights will be on together T he heat and cool display on the control panel change immediately 3 Loaded H eat is locked out for 5 minutes after switching from cool to heat Refer to section 1 17 for description on heating cycle The unit will only hot gas heat when the controller is set above 10 F 12 C as the heat relays are electronically locked out with set points at or below 10 12 Electric heat may be allowed depending on remote status The controller automatically selects the mode s necessary to maintain box temperature at set point The heating modes are as follows with descending temperatures a U nloaded H eating b Loaded H ea
55. ro 3512 SN RECORDER 88 ATS AMBIENT TEMPERATURE SENSOR ifi RCR OPTIONS sek DATA RECORDER Ris gt gt GROUND 2 u b BUE creme od ONE we a C E Kom TES A OP SPKE DB SUA HCKTI TO 28830 DLKF LE d gc COOL LIGHT REMOTE o r 29 B Dz OO e b Ji3 P4 010 CRA B COOL RELAY 2ND COMPARTMENT gn oe T ux CN DB 212 80A MAXI F Go as HCZN 13 011 84 BGRA B COOL RELAY RD COMPARTMENT m ole63 5 Ka 67 07 To I SESS D DER u GBIF HANES 011 DIESEL ELECTRIC RELA at D 1X RX A P XB RR TO 2ER30 Lez FE To Pl spka SPKI JI MIT D Bort DEFROST TIMER oND RD COMPARTMENT PEEN G e ao He oun 13 Pk I HS SOIR DEFROST HEAT RESISTANCE C2ND EVAPORATOR eS 25 I 115 SDHR DEFROST HEAT RESISTANCE SRD EVAPORATOR Lp big eb pm om 5 eso Benz D DOSE us TO 385 H3 mv 9 H6 AU 25 0 3 DATA EINE 30 Hen CLT 58 115 15 J12 DOR DEFROST RELAY 2 COMPARTMENT To 5P16 2 HCC4 ls Z28 7 77 5PK2 _ HR4 SEE NOTERA E18 12 16 SDR DEFROST RELAY 3RD COMPARTMENT 7 HI 0 4 HERMI 19 63 orn GPR 30 AM COS erg sPkgo 114 207 DEFROST THERMOSTAT 2ND COMPARTMENT Hen ACLS M14 SDT DEFROST THERMOSTAT SRD COMPARTMENT WIS os HI2 L12 R EVAPORATOR FAN RELAY P62 x
56. switch is in the STOP position Also disconnect the negative battery cable b Model NDA The unit is a one piece self contained fully charged pre wired refrigeration heating nosemount diesel powered unit for use on insulated trailers to maintain cargo temperatures within very close limits The Number of Fans model serial number plate is located inside of the unit on the rear frame as shown in Figure 1 3 The evaporator fits into a rectangular opening in the upper portion of the trailer front wall When installed the evaporator section is located inside the trailer and the condensing section is outside and on the front of the trailer The condensing unit consists of an engine compressor drive package condenser fan condenser coil radiator coil control panel relay module refrigerant controls piping wiring defrost air switch and associated components The evaporator assembly consists of an evaporator coil evaporator fan expansion valve two defrost thermostats termination switches and 2 high temperature safety switches The location of the thermostats are shown in Figure 1 6 The return air sensor is also shown in Figure 1 6 H eating for the nosement is accomplished by circulating hot gas directly from the compressor to the evaporator coil Four electric solenoid valves control the refrigerant circuit to operate the heating cooling system Also heating can be accomplished by electric heat 2 kw of hea
57. the operation of the unit The processor board also controls the operation of the relay board through plug connections The relay module which contains plug in interchangeable relays provides the microprocessor with a means for switching the unit components to achieve a desired operating mode 2 6 2 Cooling Therearetwo control ranges Frozen and Perishable T he Frozen range is active with set points at or below 10 12 C and the Perishable range is active at set points above 10 12 C The controller automatically selects the mode necessary to maintain boxtemperature at set point See Figure 2 4 or Figure 2 5 When the unit is running in loaded cool and with the evaporator coil temperature below 40 F 4 4 C to close at least one defrost termination thermostat a pre trip may be initiated by depressing the PRETRIP key The 62 10022 01 operator now may verifythe pre trip sequence R efer to Section 1 11 8 Asthe trailer temperature falls closer to set point the controller will shift the operation from loaded cool to unloaded cool to further reduce cooling capacity To do this the microprocessor will pull terminals X2 or X2 amp X3 low completing the ground path for the unloader relays UFR amp URR The coils energizes to close the UFR amp URR contacts One or both unloaders U F and UR may energize to unload the compressor Refer to Section 1 10 For setpoints above 10 F 12 C and with decreasing
58. to the evaporators and number of compartments see Figure 1 2 The evaporator is constructed with aluminium profiles designed to meet the specific requirements of the transport industry T he bottom section of the evaporator is hinged to allow easy access to both the electrical and refrigeration hardware 62 10022 01 1 2 Inside the evaporator housing are one or more of the following 240 Volt Single phase backward curved impeller which supplies high air volumes at low noise levels expansion valve check valve 12V liquid line solenoid 12V water drain heater electrical heater element sensor defrost termination sensor safety heating thermostats d Compartment Control Box Optional The compartments of the M ulti Temp system maybe equipped with remote mounted control box see Figure 1 1 This control box has a system on off button and compartment on off buttons The remote mounted control box displays current compartment temperature and setpoint Set setpoint by pressing the up or down arrows as required The control box can be locked no buttons active by pushingthe Carrier oval once T his will activate the LED next to the lock picture To unlock the control box press the Carrier oval for 10 seconds When the compartment control box is locked the temperature setting and manual defrost can still be altered with microprocessor panel Figure 1 1 Compartment Control Box SINGLE DISCHARGE DOUBLE DISCHARGE C
59. 0 9 49715 COMPONENT CONNECTION NUMBER OR LETTER PS 08 UNLQADER REAR DOR J811 AEM2 AND THE N4 NS F8 URR UNLOADER REAR REL ES SEFR2 ANODE ON INDICATES MOMENTARY CONTACTS B5 WIS MATER TEMPERATURE SENSOR 4 Sn 894 Her 02 9 PIN 9 INDICATES A WIRE GROUND THE BLOCK INDICATES A CHASSIS GROUND NO WIRE FOR ALL I L INDICATES STANDARD OPTIONS 62 03922 00 D DIODES o INDICATES A CONNECTION WIRE LUG ETC NDMS4 REVERSIBLE MULTI TEMP Figure 6 6 Electrical Schematic Wiring Diagram Dwg No 62 03922 10 22001 29 CIRCUITS FOR DIESEL ELECTRIC 380V 50HZ 3e TO MPJ2 0 MOL PI P2 FROM DER 87 5 L1 TI L L2 T2 L2 TO MGC2 HCC2 CQO L3 13 C L3 MC1 OL A B 75 P 21077 4A B m 7 C2 gt 71 F11 BA A B 1HE SPK8 A ENG GRD TO SPK10 CHK Cm 4A B COE 5H P F12 4 A B 5 P F1377 4A B c fou Ui F14 B PC 2HE F15 BA 4A 53 w gt e 4
60. 0 AMPERE UFR SPk19 SPKB 18 F2 FUSE 20 AMPERE OPTIONAL 894 Hen mope SPK1 HR2 SPK19 SPKB 13 F3 FUSE 25 AMPERE 32 An 9I 30 Hen TEG e 9 15 F4 FUSE 15 D 218 15 F5 FUSE 7 5 AMPERE C K QO E B DE GARG 30 Her 022 9 R P er G ceu 18 11 F8 FUSE 15 AMPERE 5 5 ca o X L H UEL HEATER NAL 0 357 35 Ler cz BONITA ss e id J8 R3 FUEL HEATER RELAY OPTIONAL E Gem Ges c m ur s a L8 t AULT LIGHT LIGH AR ANI Md ARR HCCT 3 3 He Hc2FHB A F12 J8 FR FAULT RELAY o H P2 FF FUEL PUMP Glar La 0 ET cf PKI Sek8 03 FS FUEL SOLENOID ms 665 Z EJsPk13 67 NEH cG i B GO RE E x OOOO F6 FR 25 Io FLA COW PLUG RELAY 5 5 Ae S Po He zn En HC2U SPKL HRI SPKI9 SpK8 F3 R16 U16 Kor HERT CONTROL RELAY S te 62 x OOOO SA A o Her TAE 015 018 1 016 2 SHCR HEAT CONTROL RELAY 2ND 3RD COMPARTMENT SAS Cau Se 5020 ae 1 6 N16 Puan HEAT LIGHT CONQ ORD COMPARTMENT i 3HL HEAT LIGHT 2ND MPARTMENT A 3 x Fa UNSWITCHED I HPI HIGH PRESSURE CUT OUT SWITCH N C gt 120 2 2ST Hero SPK16 M HP2 HIGH PRESSURE CUT OUT CONTROL N C 8 63 x FL 935 573 epis 519 88 HR HEAT RELAY 1 Ga m DOE
61. 0022 01 Engine Coolant Temperature Glow Time Glow Time in Seconds For 15 Coolant Temperature EIN 10 4 06 second and third start attempts have a glow time that 155 seconds greater than the table amount The glowtime can be manually overridden through the function parameters If the coolant temperature sensor is defective the control assume a temperature of less than 32 F 0 C for the glow timing g Minimum On Time Theengineisallowed to turn off only after a minimum of 4or 7 minutesof run time with software revision lessthan 3 11 With software revision 3 11 or higher the on time is 4 minutes The unit will not cycle off if the engine coolant temperature is less than 122 F 50 C or the battery is not good If the unit can not cycle off it will operate normally in continuous mode If all temperature probes fail and the setpointis10 12 or less the unit will not shut down The unit will shut down when the main compartment is within 0 5 F 1 0 3 C of setpoint for setpoints in Perishable range or 0 5 0 3 above setpoint for setpoints in Frozen range and the remote compartments arewithin 1 C ofsetpointin Perishablerangeor 1 C of setpoint in Frozen range h Minimum Off Time Keypad provision is provided to select the minimum off time of 10 20 30 45 or 90 minutes After the minimum off time the unit will restart for temperatures
62. 1 U nit D ata 1 17 U nloader 1 11 4 10 V V Belt 4 23 V Belts 4 4 W Water temperature Sensor 1 10 Wiring Diagram 5 1 Index 2
63. 1 9 Evacuation 4 7 Evaporator Coil 4 16 Expansion Valve 1 8 4 17 F Fan Shaft 4 15 Filter Drier 4 11 Fuel Flow Diagram 1 11 Fuel Pump 4 3 Functional Parameters 1 15 Fuse 1 10 G G earbox Clutch 4 25 Generator 1 9 4 23 Generator Belt 4 23 H H ead Pressure Control Switch 1 9 H eat M ode 1 20 H eating 2 4 eating Cycle 4 14 High Pressure Switch 1 9 4 11 Introduction 1 1 Index 1 62 10022 01 Index K Keypad 1 14 L Liquid Solenoid Valve 4 23 Lube Oil Diagram 1 11 Lube Oil Filter 4 2 M M aintenance Schedule 4 1 M anual Starting 2 1 M icroprocessor Controller 1 14 4 19 Oil Pressure Safety Switch 1 10 1 20 PreTrip Inspection 2 1 Priming Fuel System 4 2 Pumping U nit Down 4 6 R Receiver Sight G lass 4 12 Refrigerant Charge 4 6 4 8 Refrigerant Circuit Cooling 1 26 Refrigerant Circuit H eating amp D efrosting 1 29 Refrigerant L eak Checking 4 6 Refrigeration System D ata 1 8 62 10022 01 S Safety D evices 1 9 Schematic Wiring Diagram 5 1 6 5 Sensor 4 21 Setpoint 1 15 Solenoid Valves 4 12 Speed Control Solenoid 6 3 Standby Clutch 6 4 Standby M otor V Belts 6 3 Starting Instructions 2 1 Stopping Instructions 2 1 Suction Pressure Transducer 4 21 Switches 1 23 T Thermostatic E xpansion Valve 4 17 Troubleshooting 3 1 U U ItraFresh 2 1 23 U nidrive Torque R equirements 4 2
64. 1 R ba BERORI AIR Su re TENT KI oi 3o A78 A B C xit SPK6 z7 071 AT 13 7 K16 P16 010 012 0 DIODE CARD KG ben NOM ines comparten PKI 11 11 MER 63 69 07 CWE cM 25A l 5 99 05 R2 DK OPTIONAL Y BY LA p414 ger OL DEFROST LIGHT LIGHT BAR hr RT KIs PIS 2730 DEFROST LIGHT REMOTE LIGHT 2En8s SSR FS R DEFROST RELAY fO s Rc 595 Av 2 DEFROST RELAY ANDARD COMPAR THEN 1S KI Ll NI 11 rd i TO SERED FS DTI DEFROST _THERMOSTA GPR 5 1 HRA 15 15 Dip BEEROST THERMOSTAT C2ND 3RD COMPARTMENT To SP182 124 Kl4 DDWR DRAIN WATER HEATER ND COMPARTMENT e Go Gu wy GH 12 24 14 DRAIN WATER HEATER RD COMPARTMENT Kl4 EVAPORATOR FAN RELAY COND COMPARTMENT 5218 63 5 1 014 SEFR EVAPORATOR FAN RELAY RD COMPARTMENT F4 46220 DKC 09 516 2ER 2ND COMPARTMENT ENABLE RELAY MTS O AQ 8 V feki unn 011 516 SER COMPARTMENT ENABLE RELAY 15 SPK6 L2 Fi FUSE MAXI FUSE 80 AMPERE VV 3 ISI 30 H Hc21 o I3 F2 FUSE 20 AMPERE OPTIONAL 42 x UFR SPk19 SPKB 13 F3 FUSE 25 AMPERE 894 HEZK gt e SPK1 HR2 SPK19 SPKB I5 F4 FUSE 15 AMPERE um 2 E GEI 4 GA CS KEN OIO 88 1 3 n 5 BEDS 7 HI o SRT x 5 Go He 2 E gres 01
65. 10 Suction Manifold Figure 1 13 Compressor Cylinder Head Loaded Hot Gas Bypass 62 10022 01 111 MICROPROCESSOR CONTROLLER COOL HEAT ap aa 11 1 p DEFROST SETPOINT FUNCTION CHANGE START STOP IN RANGE HI AIR hane gt 1 ap ap ap A LI TEMPERATURE ENTER UNIT PRETRIP AUTO S S MANUAL DATA CHECK CONTINUOUS DEFROST Figure 1 14 Microprocessor Control Panel 1 11 1 INTRODUCTION The microprocessor controller is housed in the control panel on the lower roadside corner of the unit This controller consistsof 2 control boards and a relay module 1 The Processor Board includes the microprocessor program memory and necessary input output circuitry to interface with the unit 2 The Display Board is mounted in the same control box as the processor board The display board includes the LCD display keypad and keypad interface 3 TheRelayM odulecontainsreplaceable relays diode blocks and fuses along with the wiring harness The microprocessor istotally self contained and doesnot contain any serviceable components CAUTION Under no circumstances should anyone attempt to repair the Logic or Display Boards see section 4 27 Should a problem develop with these component contact your nearest Carrier Transicold dealer for replacement The Carrier Transicold microprocessor controller incorporates the following features a Control supply or return air temperature to tigh
66. 10 2 Suction Pressure Operation The microprocessor will monitor suction pressure of the refrigeration system and control the unloaders to maintain a maximum operating pressure A suction pressure transducer is used to signal the microprocessor when to load or unload the compressor When the compressor is fully loaded it is operating on 6 cylinders When the front unloader UL1 is unloaded energized the unit operates on 4 cylinders When U 11 and the rear unloader U L2 are unloaded energized the unit operates on 2 cylinders The front unloader UL1 always unloades before the rear unloader UL2 During the diesel heating and defrosting cycles the rear unloader is locked out loaded forcing the compressor to always operate with at least four cylinders loaded a R 22 Refrigeration System Atambient temperatures of 90 32 2 C or below W hen the suction pressure is greater than 53 psig both unloaders are unloaded As the suction pressure drops below 52 psig the UL 2 unloader is loaded If the suction pressure drops below 26 psig the U L 1unloader isloaded Atambient temperatures of 90 F 32 2 C orhigher Atambienttemperaturesof90 or higher the unloading suction pressure settings relative to ambient temperatures are a straight line Refer to chart below R 22 REFRIGERATION SYSTEM DIESEL OPERATION SUCTION PRESSURES UNLOADING 60 45 40 SUCTION 35 PRESSURE PSIG 30 110 AMBIENT TEMPERATURE F 120
67. 130 UL1 FRONT UNLOADER UL2 REAR UNLOADER ABOVE THE LINE UNLOADED BELOW THE LINE LOADED 62 10022 01 b R 404A Refrigeration System Atambienttemperatures of 90 F 32 2 C orbelow When the suction pressure is greater than 64 psig both unloaders are unloaded As the suction pressure drops below 64 psig unloader UL2 is loaded If the suction pressure drops below 33 psig unloader UL1 is loaded Atambient temperatures of 90 F 32 2 C or higher Atambient temperatures of 90 or higher the unloading suction pressure settings relative to ambient temperatures are a straight line R efer to chart below R 404A REFRIGERATION SYSTEM DIESEL OPERATION SUCTION PRESSURES UNLOADING 70 SUCTION E 30 E NR NET E AMBIENT TEMPERATURE F UL1 FRONT UNLOADER UL2 REAR UNLOADER ABOVE THE LINE UNLOADED BELOW THE LINE LOADED 1 10 3 Unloading During 4 kw Heating R404A Only The HCR relays see Figure 1 8 energize the rear unloader during all 4 kw heating situations which do not also require hot gas heating 4 kw heating occurs when one compartment callsfor heating in a two compartment system and when two compartments call for heating in a three compartment system If all compartments call for heating then the host will heat using hot gas and the rear unloader will remain de energized of these possible different operating modes are shown in Table 2 2 and Table 2 3 Change 03 0
68. 140 to 150 kg cm 1991 to 2133 psi Firing Order Glow Plug Amperage Valve Clearance Cold Intake and Exhaust 1 3 4 2 a Lubrication System Oil Pressure 40 to 60 psig 2 8 to 4 2 kg cm 9 Oil Pressure Safety Switch Setting Closes 15 3 psig 1 05 kg cm Lube Oil Viscosity Fahrenheit Centigrade Winter Diesel No 1 Summer Diesel No 2 1 3 4 2 7 0 amps per plug at 10 5 vdc nominal 0 0071 to 0 0087 inch 0 18 to 0 22 mm 1 3 COMPRESSOR DATA Compresso Mod 086 _ Wo Cylinders 6 APPROVED COMPRESSOR OIL Refigerant um R 22 Zerol 150 synthetic P N 07 00274 R 404A Mobil Arctic EAL 68 Over 77 F Over 25 30W 15W40 Oil Change Intervals First 400 hours thereafter as listed below CAUTION The maximum oil change interval is 1 year for either approved oil The only approved synthetic lube oil is Mobil Delvac 1 The normal oil change intervals listed below should be reduced if the equipment is operated under extreme conditions suchas in dirty environments API MOBIL Class CD DELVAC 1 Hours Hours TV 1500 3000 or 20 40 62 10022 01 1 4 REFRIGERATION SYSTEM DATA a Defrost Air Switch Initiates D efrost 1 40 07 inch 35 1 8 mm WG b Defrost Timer Microprocessor 1 1 2 3 6 or 12 hours H ost U nit 1 1 2 hours R emote E vaporator c Defrost Thermostats Opens 50 5 10 3 Closes 40 5 F 4 4 3 d
69. 2 F 0 to 5 5 C the unit is locked into continuous run Start Stop Continuous key is disabled in this setpoint range With software revision 3 15 or higher when configurations CNF5 is OFF then and Ultrafreeze are turned off The evaporator pump down cycles used for standby heat and standby defrost are de activated In diesel mode the high ambient defrost algorithm is not used TV OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF CNF13 EE OFF CNF14 OFF 4 29 CONTROLLER SENSOR CHECKOUT An accurate ohmmeter must be used to check resistance values shown in Table 4 5 Due to variations and inaccuracies in ohmmeters thermometers or other test equipment a reading within 296 of the chart value would indicate a good sensor If a sensor is bad the resistance reading will usually be much higher or lower than the resistance values given in Table 4 5 Atleastonelead fromthe sensor RAS terminals D 1and Elor SAS terminals D 2 and E 2 must be disconnected from the unit electrical system before any reading is taken Not doing so will result in a false reading Two preferred methods of determining the actual test temperature at the sensor isan bath 32 F 0 a calibrated temperature tester Table 4 5 Sensor Resistance ATS CDT RAS SAS amp WTS ATS RAS SAS amp CDT WTS Resistance Resistance FE de In Ohms In Ohms 1 653 000 1 178 000 0 178 85500 855000 10 122 62400 624
70. 300 psig 21 1 kg cm Switch H P 2 opensto de energize the liquid line solenoid valve SV 2 and the valve closes to stop the flow of refrigerant to the expansion valve When the compressor discharge pressure falls to cut in setting refer to section 1 4 pressure switch H P 2 closes and in turn energizes the normally closed liquid solenoid valve SV 2 which opens allowing refrigerant from the receiver to enter the evaporator through the expansion valve When in engine operation and the discharge pressure exceeds pressure settings detailed in section 1 4 pressure cutout switch H P 1 opens to de energize the run relay coil RR When the RR coil is de energized the RR contacts open stopping the engine The function of the hot gas bypass line is to raise the receiver pressure when the ambient temperature is low below 0 F 17 8 C so that refrigerant flows from the receiver to the evaporator when needed 1 17 2 Defrost with Greater Than 100 37 8 C Ambient with Software less than 3 14 or 80 F 26 7 C with Software 3 14 or higher If the ambient is greater than 100 F 37 8 C or 80 F 26 7 C with Software 3 14 or higher the following stages are performed for defrost Refer to Table 1 8 The first stage Pump Down runs for a minimum of thirty seconds and then checks the suction pressure When the suction pressure is less than 10 PSIG it will continueto stage 2 Thetotaltimein stageone be greater than 330 sec
71. 4 1 10 4 Hot Gas Bypass Unloader a Major Working Parts 1 Solenoid and valve system 2 Springloaded piston type bypass control valve 3 Springloaded discharge check valve b Unloaded Operation Pressure from the discharge manifold Figure 1 12 item 15 passes through the strainer 9 and bleed orifice 8 to the back of the piston bypass valve 7 U nless bled away this pressure would tend to close the piston 6 against the piston spring 5 pressure With the solenoid valve 1 energized the solenoid valve stem 2 will open the gas bypass port 3 Refrigerant pressure will be bled to the suction manifold 10 through the opened gas bypass port A reduction in pressure on the piston bypass valve will take place because the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice 8 When the pressure behind the piston has been reduced sufficiently the valve spring will force the piston bypass valve back opening the gas bypass from the discharge manifold to the suction manifold Discharge pressure in the discharge manifold will close the discharge piston check valve assembly 14 isolating the compressor discharge manifold from the individual cylinder bank manifold The unloaded cylinder bank will continue to operate fully unloaded until the solenoid valve control device is de energized and the gas bypass port is closed Al SS Bur 1 Solenoid Valve 11 Cylinde
72. 4 C O perator presses the PRETRIP key If the defrost thermostat DTT is closed the controller will display PPPP If DTT isopen no response end of test Controller displays PPPP Pre trip mode isstarted After 30 secondsin cool unit cycles to loaded cool After 30 seconds unit cycles to unloaded cool After 30 seconds unit cycles to unloaded heat After 30 seconds unit cycles to loaded heat After 30 seconds unit cycles to heat and displays coolant temperature After 30 seconds unit cycles to cool and displays defrost interval selected for 30 seconds then unit cycles to defrost if DTT is closed j After standard defrost cycle Pre trip is terminated and unit returns to normal operation 1 11 9 HEAT COOL MODE There aretwo control ranges Frozen and Perishable T he Frozen range is active with set points at or below 10 12 C and the Perishable range is active at set points above 10 12 C The system is configured for cooling mode for engine start and during the oil pressure delay Hot gas heating is applied by energizing the HR 1 and HR2 relays which will energize the hot gas solenoids These relays will also control the remote heat and cool lights Hot gas heating is locked out of operation at setpoint temperatures less than 10 12 C except during defrost E lectric heat is available if remotes are not in full heat Default Mode When in frozen range setpoint at or below 10
73. 6 P COOL LIGHT LIGHT BAR S E EE Head 113 013 d ac COOL LIGHT REMOTE LIGHT E LH LU Ay OP gg CAT SPK1 E J 213 13 04 09 2CR B COOL RELAY COMPARTMENT i c n spk6 SPK16 TO B F THCB2H A HLS CHo Nia Pia 013 RA BR COOL RELAY 3RD COHPARIMENT SOG ROO ER T Am DE ee ic cert TO 0CJID SPK18 A 884 Hs TO 2ER30 sisse oo 99999Qoe OC Ox u Lee UN sed a E TIMER QU 9 SPK1 __ URR P DL DEFROST LIGHT LIGHT BAR ENS 558 K15 P1S 2 30L DEFROST LIGHT REMOTE LIGHT ies end rim BI 20 670 Ec25 F9 N7 R DEFROST RELAY E O 28 yn A J14 15 N14 15 2 308 DEFROST RELAY C2ND 3RD COMPARTMENT 315 kil NIS 011 2 368 DEFROST RELAY 2ND 3RD COMPARTMENT EPR 5 1 HR4 FS TI DEFROST _THERMOSTA x nou E 30 1 87 CLS S soy e CDS 15 15 8 THERNOSTAT COND 3RD COMPARTMENT 10 SP16 69 HECA GP Ax 2DWR DRAIN WATER HEATER 2ND COMPARTMENT TN PKI 14 3DWR DRAIN WATER HEATER 3RD COMPARTMENT To SP19 A DTT B SPK K14 2EFR EVAPORATOR FAN RELAY 2ND COMPARTMENT eae a FA 5 PS o 46220 DKC TO 2 3HCR6 014 SEFR EVAPORATOR PAN RELAY RD COMPARTMENT DTT A3 NI LAY Pp x we BPKT URR 5 6 011 SER COMPARTMENT ENABLE RELAY VV 3 ISI 30 H HC21 o L2 FUSE MAXI FUSE 8
74. 8 ft Ib 3 87 mkg Place V belt on the Clutch Gearbox sheave and adjust belt tension as indicated in Table 4 1 Install V belt guard DO NOT START UNIT UNTIL V BELT GUARD ISINSTALLED Start unit and run for 10 minutes to allow for belt stretch Turn unit off and recheck belt tension 62 10022 01 f ATTACHING SCREWS FLYWHEEL Figure A NEW BELT FLYWHEEL SLIDE ADAPTER Figure B Figure 4 7 Removing V Belt from Engine Adapter Drive Sheave 4 5 PUMPING THE UNIT DOWN OR REMOVING THE REFRIGERANT CHARGE NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing refrigerant When working with refrigerants you must comply with all local government environmental laws U S A EPA section 608 a Pumping the Unit Down To service the filter drier liquid line solenoid valve SV 2 expansion valve quench valve or evaporator coil pump most of refrigerant into condenser coil and receiver as follows 1 Backseat suction and discharge service valve turn counterclockwise to close off gauge connection and attach manifold gauges to valves 2 Open valves two turns clockwise Purge gauge line 3 Close the receiver outlet king valve by turning clockwise Start unit and run in high speed cooling Place Run stop switch in the STOP position when unit reaches 1 psig 0 1 kg cm 62 10022 01 4 Frontseat
75. Col nu 0 X o 0 X Electric wm Col 9 UnderFrzem Heat 0 Under Frozen Defrost 0 X Outputis ON Energized O Outputis OFF De energized C Cycling X X X M Control both suction pressure and temperature demand Engine Speed is 1700 RPM single speed m uU m i nm lt NOTE With software 3 14 or higher there is no Under mode These unit have Ultra Freeze refer to section 1 14 Under Under setpoint with setpoint at or below 10_F 12 C 62 10022 01 Table 2 3 Three Compartment Multi Temp Logic Control CompartmentNeed CompartmentNeed Unladers Re Re Host 1HVR 2CR 3CR EE CI E Cool EHR1 LSV1 LSV2 R404 Cos ced Cool 9 X Lew o Dx ox 9 Nu 0 X 9 9 o 9 X co Coo Heat Het 0 wet Coo Nul Het 0 too Nui 0 Cod Nul 0 X Lies ei ferre o X 0 L Nur coor cool Nul Coo Heat 0 Nur Cool Nu 0 Nur Heat Cod 0 Nul Nui Cod 0 2 Conder Nui 0 Under Nul Heat Electre X Conder Nui Nui fecic X x Under Nul Defost Elecic X X Under Defost Nul X X This Table is on
76. E 2 FAN 3 2A FAN SA 4 FAN 5 3 RED 268 EXAMPLE 4 FAN MOTORS 65 14 FUSE 2 FAN 3 200 ue THT 2HT ER 68 15 FUSE 2 FAN 3 2 A Ul f 3 9 y L2 L7 N2 N7 2EFM EVAPORATOR FAN MOTOR 2ND COMPARTMENT BLUE FIG 204 SPE O1 m 07 07 3EFM EVAPORATOR FAN MOTOR 3RD COMPARTMENT WHITE 02 BROWN EO Gee H1 8 2EFR EVAPORATOR FAN RELAY C2ND COMPARTMENT BROWN 1HE 2HE 71 72 73 74 HS H8 3EFR EVAPORATOR FAN RELAY 3RD COMPARTMENT A 3R2 02 1 02 03 I Mii HC HIGH CURRENT IF w Ae S gt 9 611 HC2 HIGH CURRENT BLACK 2 Fir 3 26 8 3 2212 E2 E7 GEN GENERATOR BLUE i E gEFR J2 J7 HEATER ELEMENT gf gt GH KH 26195 KLET 2HE HEATER ELEMENT 2ND COMPARTMENT FIG 1 SP F13 BA 4 K7 3HE HEATER ELEMENT COMPARTMENT 2 5 AT GEN 12 16 J2 1HT HIGH TEMP THERMOSTAT 1 2HT HIGH TEMP THERMOSTAT 2 APPLICABLE TO ALL R2 240 VAC 60 HZ HEATER CIRCUITS KS 3HT HIGH TEMP THERMOSTAT 3 VFM AND EFM MOTORS H2 H6 1HVR HIGH VOLTAGE RELAY H2 H6 2HVR HIGH VOLTAGE RELAY 2ND COMPARTMENT SEE HS 3HVR HIGH VOLTAGE RELAY 3RD COMPARTMENT A 8 C9 C13 MICRO PROCESSOR 38 KRH SP SPLICE PO NT M2 M7 71 CAPACITOR 4uF N2 N7 22 CAPACITOR 4uF 217 P2 P7 73 CAPACITOR 02 07 74 CAPACITOR 4uP 3HT 2HT 208 2 NOTES 1HE 1 UNIT SHOWN IN OFF POSITION 2 WIRE IDENTIFICATION SYSTEM J COLOR WHITE DC C
77. EPTACLE F14 4A F2 SBM STANDBY MOTOR Spk8 X E SH SHUNT 5 OHM 25 LJ de E 2N i5 B12 13 C12 13 SP SPLICE POINT J813 74 ENG F25 nsun SS C6 L2 SPK SPLICE PACK GRD FLR fh A HOF AQ 89 F16 4A O de 3 4 Tm FIT 4A 8 a lt Sf gt O DES NOTES CIRCUITS FOR DIESEL ELECTRIC 4A 2 WIRE IDENTIFICATION SYSTEM 380V 50HZ 3e s NOTE 4 COLOR WHITE DC CONTROL CIRCUITS 2 LACK UNI 2C 3C EVAPORATOR CONNECTOR RED AC CIRCUITS GREEN W YELLOW STRIPE AC GROUNDS 3 ADDRESS SYSTEM EXAMPLE HCD2 MPW2 INDICATES A WIRE BETWEEN PLUG HC PIN D2 amp MICROPROCESSOR MP amp PIN W2 4 COILS FOR HVR CONTACTS ARE SHOWN ON THE CONTROL SCHEMATIC LOCATED ON THE HIGH CURRENT BOX 9 CONNECTOR HC MPM2 AF19 FOLO 2 7 229 222 NB10 My f SP34 SP32 F20 B IAN N TO P512 0 GH Al rot gers RE g2 83 291223 F21SB gt 5 329 21 85 GD c2 c3 ca LZE 20 CONNECTOR HC2 9 INDICATES A SOLDERED SPLICE POINT MPM2 A F22 B 35 D1 D2 D3 D4 DS Se a eee oj INDICATES A SPLICE PACK CONNECTION 229 322 y Go ie LIGHT LINES INDICATE SYSTEM WIRES wl 3EFR1 E2 NORMALLY CLOSED CONTACTS TO PSI m GH 0 F2 NORMALLY OPEN CONTACTS 3EFR2 62 INDICATES CONNECTION 35297 23 Me OG c 20
78. Engine Hours The number of diesel engine hours are displayed with the description ENG or CD2 T he data isdisplayed with units designator H i e ENG 5040H OR CD2 5040H The display range is 0 to 99999 Engine Temperature The coolant temperature is displayed with the description WT or CD3 The data is displayed with the proper unit designator Degree C or Degree F i e WT 185F or CD3 185F The display range is 10 F to 266 F 12 C to 130 C Return Air Temperature The return air temperature is displayed with the description RAS or CD4 The data is displayed with one decimal place and the proper unit designator D egree C or DegreeF i e RAS 85 0F Thedisplayrangeis 36 to 158 F 38 C to 70 C Supply Air Temperature The supply air temperature is displayed with the description SAS or CD5 The data is displayed with one decimal place and the proper unit designator D egree C or Degree F i e SAS 85 0F display range is 36 to 158 F 38 C to 70 C This unit data will be displayed only if the SUP PROBE is selected in the controlling probe functional parameter Remote Air Temperature The remote air temperature is displayed with the description REM or CD 6 The data is displayed with one decimal place and the proper unit designator D egree C or Degree F i e REM 85 0F The display range is 36 F to 158 F 38 C to 70 C Thisunit data will be displayed only if the REM PROBE 15 selected in the cont
79. Expansion Valve Superheat Setting at 0 17 8 C box temperature 8to 10 F 44to 5 6 C e Fusible Plug Setting 208to 220 F 97 8 to 104 4 C f Head Pressure Control Switch HP 2 Cutout 300 10psig 21 1 0 7 kg cm Cutin 200 100 89 14 1 0 7 kg cm g High Pressure Switch HP 1 Cutout 465 10psig 32 7 0 7 Cutin 350 10psig 24 6 0 7 h Refrigeration Charge Refer to Table 1 1 i Weights Approximate Unit 1710 Ib 776 kg Battery Dry 35 16 16 kg Wet 50 Ib 22 7 kg L5 ELECTRICAL DATA a b Generator 5kw Wattage 5000 Watts Volts 240 v ac Phase 1 Speed 3600 rpm at 60 hz Rotation either direction Remote Evaporator Fan Motors Volts 230 v ac Horsepower 1 5 hp Speed 2250 rpm Amps 15 Remote Evaporator Heaters 1 Two Compartments Number 4 Voltage 240 v ac 1 ph 60hz Wattage 1000 watts each 2 Three Compartments N umber 2 Voltage 240 v ac 1 ph 60hz Wattage 1000 watts each Host Unit Evaporator Heaters 1 Two Compartments Number 2 Voltage 240 v ac 1 ph 60hz Wattage 2000 watts each 2 Three Compartments Number 2 Voltage 240 v ac 1 ph 60hz Wattage 1000 watts each 1 9 1 6 ENGINE SCREW THREADS All threads used on the diesel engine are metric 1 7 ENGINE AIR SYSTEM The air cleaner is put on the engine to prolongits life and performance by preventing dirt and grit from gettinginto the engine causing excessive wear on all operating parts H owever it
80. F9 FUSE 5 AMPERE E E x HR2 L9 FH FUEL HEATER OPTIONAL J9 R3 FHR FUEL HEATER RELAY OPTIONAL O 0 39 33 Har cz Bon uos e Ga ig FHT FUEL HEATER THERMOSTAT OPTIONAL Spgo SPK3 Olan GONE PKS Ao 21 DR 89 EL FAULT LIGHT LIGHT BAR AND DOOR 125 AULT RELAY ARR HCCI 91 43 He HC2F BIDA p2 EP FUEL PUMP OPTIONAL sper GG cem Buc a riu ws Ax SPK13 2804 iC2U o HcCi Hg F J4 GPR GLOW PLUG RELAY mL F FR A l HC HIGH CURRENT BOX PLUG EN MP u I ee Econ rele TL pU Lr H HEAT LIGHT LIGHT BAR SPKS 23 SPK19 SPKB J16 N16 2 3HL HEAT LIGHT 2ND 3RD COMPARTMENT 85502 x OOOO 5A SI 30 HC33 5 5 HPl HIGH PRESSURE CUT OUT SWITCH N C SAS 5 SP20 Ais R4 HP2 HIGH PRESSURE CUT OUT CONTROL N C Uae x QA sreo GO fa 80 1 m BIEN 12V DATA 0 BST een sae 11 6 HR3 HEAT RELAY 3 HG TO 208 F11 HR4 HEAT RELAY 4 EHO x QES H FH 9 e 34 707208088 ua 216 Ni6 010 011 2 3HR HEAT RELAY 2ND 3RD COMPARTMENT SPKS A_F2 ves SP15 TO 2RR30 19 10 0cJ16 91 THVR HIGH VOLTAGE RELAY THES x EGG 2 _ kis 2HVR HIGH VOLTAGE RELAY 2ND COMPARTMENT Eur 20A 381 TO MPR3 3 HIGH VOLTAGE RELAY GRD COMPARTMENT 3 sp37 gt 3 1 1 JUMPER SHUT DOWN NS BHEN N2 HECH3 oe oj 93 SPK13 SPK8 SP15 SP20 Spk6 SPKB 2 d O K12 012 2 3LSV
81. J812 MULTIPLE PLUG CONNECTION NUMBER 3EFR3 H1 n2 HS D COMPONENT CONNECTION NUMBER OR LETTER Ji T2 Tos INDICATES MOMENTARY CONTACTS pe Kt Lk2 INDICATES A WIRE GROUND 12 th J INDICATES A CHASSIS GROUND NO WIRE CIRCUITS FOR EVAPORATOR MOTORS Y 2 INDICATES STANDARD OPTIONS 12V DC o INDICATES A CONNECTION WIRE LUG ETC DECAL NO REV 62 04014 00 E NDM REVERSIBLE MULTI TEMP Figure 6 8 Electrical Schematic Wiring Diagram Dwg No 62 04014 with Buzzer A Air Switch 1 8 4 14 Alarm Display 1 19 Alternator 1 25 Auto Start Stop 1 21 Automatic Start 2 1 Belt Tension G auge 4 4 C Check Valve 4 11 Compartment O peration 2 2 Compressor 4 8 Compressor D ata 1 8 Compressor Discharge Temperature Sensor 1 10 Compressor Oil L evel 4 9 Compressor U nloader 1 11 4 10 Condenser Coil 4 16 Configuration of M icroprocessor 4 20 Control Circuit O peration 2 3 Controller 1 14 4 19 Controller Sensor 4 21 Cool M ode 1 20 Cooling 2 3 Cooling System 4 2 D D efrost 2 4 D efrost Air Switch 1 8 4 14 D efrost Cycle 1 20 4 14 Defrost Thermostats 1 8 Dehydration 4 7 Digital Display 1 15 Index Electrical D ata 1 9 6 1 Electrical Schematic 5 1 Engine Air Cleaner 4 2 Engine Air System 1 9 Engine Crankcase Breather 4 3 Engine Data 1 8 Engine Safety D evices 1 23 Engine Screw Threads
82. LIQUID SOLENOID VALVE 2ND 3RD COMP 8 9 Hee 9 0 i er ENGINE TO 3RR30 pe REN To Mps1 AUN 2 3 05 MANUAL DEFROST SWITCH C2ND 3RD COMP Pip x QD HECEZ 698 86 1 ORD 5PK11 5 15 HIO MGC _ MANUAL GLOW CRANK MGC 03 13 MP MICROPROCESSOR BOARD cuz gus 9 RI3 14 OCJ OPTION CONNECTOR JUMPER 10 WAY T SA 5 2 OP 01 PRESSURE SAFETY SWITCH N 0 SP T0 28885 BER F12 J7 OR OUT OF RANGE RELAY Ko TO 5 L7 ORL OUT OF RANGE LIGHT LIGHT FL fn JI3 NI3 2 3PL POWER LIGHT 2ND 3RD COMPARTMENT g oco p 9 SPK12 SPIS 2 2 PS POWER STUD s g 5 AB RAS RETURN AIR SENSOR 3er 2 85 8 696899 DFT c A12 2 3RAS RETURN AIR SENSOR 2ND 3RD COMPARTMENT 2RAS 2 e 2005 Cl 2 RCR REMOTE CONTROL RELAY nom EQ b n pi E RS RUN STO SWITCH UN RELAY 5 269 48 TOMPR2 J12 N12 09 011 2 3RR RUN RELAY 2ND 3RD COMPARTMENT 3C3HfB 83 G3 HC2J 5 8 SAS SUPPLY AIR SENSOR OPTIONAL Cs Do sp24 on oh STARTER MOTOR M EHHE 63 63 3 n Gets SP SPLICE POINT K SPK SPLICE PACK POLE i ali o GR pest AS SPT SUCTION PRESSURE TRANSDUCER 5515 41 STARTER SOLENOID e 51 304 H 87 69 8969 9 515 51 504 H 87 69 Q9 69 se15 RoR 2 NI SSC STARTER SOLENOID
83. LT LIGHT ON Low Oil Pressure Alarm The low oil pressure alarm is displayed with the description ENG OIL or ALO Thisalarm is generated if the control senses low oil pressure under the proper conditions The fault light FL isturned on Engine will shut down High Coolant Temperature Alarm Thehigh coolanttemperature alarm is displayed with the description ENG HOT orAL1 Thisalarmisgeneratedif the control senses a high coolant temperature 230 to 240 F 110 to 116 C for 5 minutes or immediately if over 240 116 C Thefaultlight FL isturned on and engine will shut down ALO AL1 AL2 AL3 AL5 AL6 AL7 AL8 AL9 AL10 AL11 AL12 AL13 AL14 AL15 AL17 AL18 AL19 AL20 AL21 AL22 62 10022 01 1 20 High Pressure Alarm The high pressure alarm is displayed with the description HI PRESS or AL2 This alarm is generated if the high pressure switch opens The fault light FL is turned on and engine will shut down Start Failure Alarm The start failure alarm is displayed with the description STARTFAIL or AL3 This alarm is generated if the engine fails to start The fault light FL is turned on If function MAN OP manual start mode is selected the start failure alarm will be generated if the engine fails to start in 5 minutes Low Battery Voltage Alarm The low battery voltage alarm is displayed with the description LOW BATT orAL4 Thisalarm is generated if the battery voltage falls below 10 v
84. NDS F6 J3 RR RELAY TO BTY 22 3 ADDRESS SYSTEM EXAMPLE HCD2 MPW2 E P10 SRR RUN RELAY CRD COMPAR THEN Pi INDICATES A WIRE BETWEEN PLUG HC 5 SPKS AB SAS SUPPLY AIR SENSOR OPTIONAL PIN D2 amp MICROPROCESSOR MP amp PIN M2 te 8 TERN 229 221 4 x VOLTAGE BELOW 12V REFER TO OWNERS 53 BUB _ SERIAL PORT MANUAL FOR TROUBLE SHOOTING PROCEDURE 85 STARTER MOTOR MPM2 F19 2 2 Xx DATA RECORDER SPEED PICKUP SP SPLICE POINT Saat 894 Her sao 6 1 THIS WIRE NOT PRESENT ON COMPARTMENT apk LICE 229 2722 20 AS apT SUCTION PRESSURE TRANSDUCER 2 INDICATES SOLDERED SPLICE POINT AG CR PIU SP32 F20 3 22 Kao N m s INDICATES A SPLICE PACK CONNECTION ma 55 STARTER SOLENOID Coe LIGHT LINES INDICATE SYSTEM WIRES NI 55c STARTER SOLENOID CONTACTOR 2EFR2 DIODE 15 WIRES FOR DIESEL ELECTRIC ONLY 7 856 STARTER SOLENOID RELAY 22297 23 WR IN DIODE TO MPH3 NORMALLY CLOSED CONTACTS ATT OIG 2SH e SELECTOR SWITCH ONLY 28 221 AN 20A NB12 XMY 5 gLocki SPK11 NORMALLY OPEN CONTACTS PB av1 COND PRESSURE CONTROL VALVE N 0 n Furl aa e org ts 35 rase tte ce lt er ye 9 ya Te 2 INDICATES CONNECTION Sv HOT GAS SOLENOID VALVE 20 EFRI CATHODE 11 MULTIPLE PLUG CONNECTION NUMBER NS bea UN OARDER FRONT BELAY
85. O WIRED SERA SPKI2 ENE SPK DECAL EN pr THE CATHODE ON PIN 5 AND THE INDICATES STANDARD OPTIONS 9 5 5 5 5 10 MPJ3 155 ANODE ON cr NSS OF TAE BLOCKS ROR INDICATES A CONNECTION WIRE LUG ETC so 62704003799 ALL DIODES NDA REVERSIBLE MULTI TEMP Figure 5 3 Electrical Schematic Wiring Diagram Dwg No 62 04003 NDA Starting with S N FAC90391017 Sheet 1 of 2 S S TO ZZOOT Z9 B c D F 6 H 1 K L M N 0 Q E T u x Y ZONE SYMBOL DESCRIPTION B 2EFR 62 66 F10 FUSE 20 AMP pie 38 0 KH 2017 63 6 F1l FUSE 20 AMP HIGH VOLTAGE CIRCUITS F12 3 2 5 6 32 CHVR 61 65 F12 FUSE 2 FAN 3 20 FAN SA 4 FAN 6 39 2HT SEE NOTE 5 63 68 F13 FUS
86. OMPARTMENT n gt E n m Ed HC2QJ DK H12 AK V Zo 52 2EM EVAPORATOR MOTORS 2ND COMPARTMENT x d sty Mos Wy n an ost 22 15A I A 8 F2 FUSE GO ANBERE OPTIONAL 5 2 HR2 SPA ui sexe FCG o oes 15 F4 FUSE 15 AMPERE M ENG gt Hex UF 92 Ae a 18 01 ES FO FUSE 775 AMBERED x es Eu RE FS 5 7 SPk8 ju 1 14 1 18 24 FUSE 20 AM H B x Wi 9 G8 1602 Aq S 69 L9 FUEL HEATER OPTIONAL cm QUEE cr HR2 SPKI3 Fie FUEL HEATER RELAY OPTIONAL SPK3 SPKS 7 5 87A 2 src fs 9 4 ig FHT FUEL_HEATER THERMOSTAT OPTIONAL Ce G ce Grr Ge eH nce LS FL FAULT LIGHT LIGHT BAR AND DOOR Pean sis SM Fle FLAS ata 718401 Qm 39 is 30 HC2F 90 e 02 FUEL PUMP OPTIONAL gt ar B oma AMET M P OOO H39 p34 FEHER A 9 675 ACNE FB J4 GPR GLOW PLUG RELAY As gt iai I E HCD4 Ger k s RS Bu Momo xe FC20 8 FLTAH LAHE FE te Ruta en srl E GH KE ip dr o HIGH PRESSURE CUT OUT SWITCH N CO a wo UN E UNSWITCHED R 8H 03 2 48co2 65 12V DATA FL TA HS A 5 gt 10 208086 F8 R6 N7 HR2 HEAT RELAY 2 HI TO SP35 5 15 ATS m RECORDER 7 DLKA of
87. ONTROL CIRCUITS 2212 BLACK GROUNDS 3212 RED AC CIRCUITS GREEN W YELLOW STRIPE AC GROUNDS sp A B 3 ADDRESS SYSTEM EXAMPLE HCD2 MPW2 INDICATES A WIRE AT GEN S 2 201 BETWEEN PLUG HC PIN D2 amp MICROPROCESSOR MP PIN W2 F13 BA 4 4 COILS FOR HVR CONTACTS ARE SHOWN ON THE CONTROL SCHEMATIC 3EFR LOCATED ON THE HIGH CURRENT BOX Ao 8 KH 3678 S THE NUMBER OF FANS DEPENDS ON YOUR COMPARTMENT F1S BA 4A CONFIGURATION i e 2 3 4 FANS EVAPORATOR CONNECTOR LABELS EXAMPLE 2C12 INDICATES 42 COMPARTMENT CONNECTOR PIN 12 R3 240 VAC 60 HZ HEATER CIRCUITS 7 THE NUMBER OF HEATERS DEPENDS ON YOUR EVAPORATOR TYPE SINGLE DISCHARGE 3 HEATERS DUAL DISCHARGE 6 HEATERS CONNECTOR MP FIG gt Lj p HH CONNECTOR HC CONNECTOR HC2 d EA e FL 2 3 EVAPORATOR CONNECTOR a _ HE JLA A3 E 81 83 LI C2 C3 C4 INDICATES A SOLDERED SPLICE POINT D1 D2 103 04 105 INDICATES A SPLICE PACK CONNECTION LIGHT LINES INDICATE SYSTEM WIRES P CONNECTOR M E1 PD NORMALLY CLOSED CONTACTS 1 G2 NORMALLY OPEN CONTACTS lx G1 x INDICATES CONNECTION HE 2 HS HC2F MULTIPLE PLUG CONNECTION NUMBER Ho Ji J2 T33T 44 COMPONENT CONNECTION NUMBER OR LETTER ju INDICATES MOMENTARY CONTACTS ES 1100 4 INDICATES A WIRE GROUND d ul th INDICATES A CHASSIS GROUND NO WIRE a INDICATES STANDARD OPTIONS EN o INDICATES A CONNECTION WIRE LUG
88. OW STRIPE AC GROUNDS Y u R2 240 VAC 60 HZ HEATER CIRCUITS 3 ADDRESS SYSTEM EXAMPLE HCD2 MPW2 INDICATES A WIRE BETWEEN PLUG HC PIN D2 amp MICROPROCESSOR MP amp PIN W2 4 COILS FOR HVR CONTACTS ARE SHOWN ON THE CONTROL SCHEMATI LOCATED ON THE HIGH CURRENT BOX EA 5 THE NUMBER OF FANS DEPENDS ON YOUR COMPARTMENT CONFIGURATION i e 2 3 4 FANS mA 3617 6 EVAPORATOR CONNECTOR LABELS EXAMPLE 2012 INDICATES 2 F14 4A COMPARTMENT CONNECTOR PIN 12 2EFR 7 THE NUMBER OF HEATERS DEPENDS ON YOUR EVAPORATOR TYPE AQ f 5017 SINGLE DISCHARGE 3 HEATERS DUAL DISCHARGE 6 HEATERS F12 8A 4A BHVR NDICATES SOLDERED SPLICE POINT GH 368 zl NDICATES A SPLICE PACK CONNECTION 2HVR au LIGHT LINES INDICATE SYSTEM WIRES GH 78 NORMALLY CLOSED CONTACTS RED ARR E m 8 d 1HT NORMALLY OPEN CONTACTS 210 204 SP6 NDICATES CONNECTION WHITE 02 US BROWN in 2HE MULTIPLE PLUG CONNECTION NUMBER 5 2 COMPONENT CONNECTION NUMBER OR LETTER U amp S ae 215 20A 2612 NDICATES MOMENTARY CONTACTS 3612 BEER NDICATES A WIRE GROUND Ca SEN 84 2619 NDICATES A CHASSIS GROUND NO WIRE F1377 BA 4 3EFR INDICATES STANDARD OPTIONS Ae J 5075 NDICATES A CONNECTION WIRE LUG ETC F15 4 DECAL NO REV R3 240 60 HZ HEATER CIRCUITS 62 03998 00 V NDAS4 HIGH VOLTAGE Figure 5 2 Electrical Schematic Wiring Diagram Dwg N
89. PR SSR RR URR FR ARR 2 DER js HR2 OR HR4 uoi 7 SR DR HR3 HR1 15 25 T x UFA S DB2 MODEL NDM ONLY 1 Ammeter 6 Relays Run RR Diesel Electric DER 2 Manual Glow Crank Switch Unloader Front UFR Unloader Rear URR 3 Buzzer Heat HR1 HR2 HR3 amp HR4 Defrost DR 4 Starter Solenoid Relay SSR and Fault FR Outof Range OR Auto Restart ARR Glow Plug Relay GPR Fuel Heater FHR 5 Fuses F1 80 25A F4 15A F5 7 5A 7 Diode Block DB1 DB2 amp DB3 F6 F7 F8 15A F9 5A Figure 1 9 Relay Module 1 7 62 10022 01 1 2 ENGINE DATA Engine Models CT4 134TV CT4 134DI V2203TV V2203DI Displacement 2 2 liters 134 in3 2 2 liters 134 in3 e Horsepower Weight Coolant Capacity 34 hp 1900 rpm 25 hp 1350 rpm 33 hp 1900 rpm 189 5 kg 417 8 165 7 6 liters 2 gallons Thermostat Starts to Open 157 to 162 F 69 to 72 C Fully Open 185 F 85 C Oil Capacity with Filter 14 liters 15 quarts Injection Setting
90. R Bu a Al B A2 LA3 B1 B2 B3 21 C1 C2 C3 C4 D1 102 03 104 105 INDICATES SOLDERED SPLICE POINT INDICATES A SPLICE PACK CONNECTION LIGHT LINES INDICATE SYSTEM WIRES CONNECTOR MP NORMALLY CLOSED CONTACTS wes NORMALLY OPEN CONTACTS q 6 INDICATES CONNECTION LE fs H1 n2 H3 H4 HS HC2F MULTIPLE PLUG CONNECTION NUMBER J J2 COMPONENT CONNECTION NUMBER OR LETTER T3 5 INDICATES MOMENTARY CONTACTS alls H oJen H INDICATES A WIRE GROUND w XS Y th INDICATES A CHASSIS GROUND NO WIRE L3 INDICATES STANDARD OPTIONS d o INDICATES A CONNECTION WIRE LUG ETC m lt DECAL NO REV 52 10135 00 NDA REVERSIBLE MULTI TEMP 10 22001 29 Figure 5 5 Electrical Schematic Wiring Diagram Dwg 62 10135 NDA with R404A Sheet 2 of 2 SECTION 6 MODEL NDM UNITS WITH STANDBY MOTOR 6 1 MODEL NDM UNITS WITH STANDBY MOTOR Table 6 1 Model Chart Refrigerant R22 404 Compressor LB KG LB NDM93 28 1127 sr sem EVAPORATORS Engine Speed rpm Low CT4 134 TV or 05G 37 cfm CT4 134 DI 1700 1350 Evaporator Models Number of Fans MMS 1000 3 a Model NDM Themodel NDM issimilartothe model NDA exceptthat it does not use the 5 kilowat single phase generator Instead the unit is equipped with an electric motor that functions as an induction generator in diesel
91. REAR REL SPR D D INDICATES MOMENTARY CONTACTS BS WTS WATER TEMPERATURE AT SOR DIODE 15 IN DIODE BLOCK DBD T INDICATES A HT RES GROUND DECANO TET D1 CATHODE ON PIN 5 AND THE z mE INDICATES A CHASSIS GROUND NO WIRE 15 ANODE ON PIN 9 OF THE BLOCK FOR INDICATES STANDARD OPTIONS 62 0401 4 00 ALL DIODES INDICATES A CONNECTION WIRE LUG ETC NDM94 REVERSIBLE MULTI TEMP Figure 6 8 Electrical Schematic Wiring Diagram Dwg No 62 04014 NDM with Buzzer 10 22001 29 B C D E P 5 H 1 K L M P Q R T U W X id ZONE SYMBOL DE
92. RO COMPARTMENT 12 11 UN LAY 2ND Beara 6362 6 63 62 60 63 3 aks ee ER 330 0 0 00 A SAS SUPPLY AIR SENSOR OPTIONAL To o 3 S0 H 87 68KcR969 9 ses ICR 0651 02 SM _ STARTER MOTOR SPK14 5 Go Hen Qo 5 15 TO SP1 2 TK SP SPK SPLICE POINT SPLICE PACK NOTES 20R NS SPK15 TO RCR2 AUCTION ERESSURE TRANSDUCER NOTES uec INDICATES A SOLDERED SPLICE POINT DDO AORA 3DR 10 3814 H LEN WIRE IDENTIFICATION SYSTEM 5 _ INDICATES A SPLICE PACK CONNECTION o T0 3571 F7 SSR STARTER SOLENOID RELAY COLOR WHITE DC CONTROL CIRCUITS LIGHT LINES INDICATE SYSTEM WIRES 2DWR Bm TO 3ER86 E 09 010 2 351 START STOP SWITCH BLACK GROUNDS NORMALLY CLOSED CONTACTS 87 2011 1 3DR 3DWR 10 2ER86 D PB SV COND PRESSURE CONTROL VALVE N O RED AC CIRCUITS 201 87 3011 1 5 C P4 572 LIQUID SOLENOID VALVE N C GREEN W YELLOW STRIPE AC GROUNDS NORMALLY OPEN CONTACTS 20R0 51565 L6 HOT GAS SOLENOID VALVE N C 3 ADDRESS SYSTEM EXAMPLE HCD2 MPW2 G 30 87 3DRO soos Bo PS ava HOT GAS SOLENOID VALVE N C INDICATES A WIRE BETWEEN PLUG HC INDICATES CONNECTION ea L u UNLOAI N PIN D2 amp MICROPROCESSOR MP amp PIN M2 sie MPH3 e SPK8 5 19 FB J6 UFR UNL ADER FRONT RELAY 4 VOL TAGE BELONE 1205 REFER IO OWNERS HC2F MULTIPLE PLUG CONNECTION NUMBER
93. SCRIPTION __ CONNECTOR MP F3 CAPACITOR 25uF a C2 CAPACITOR 25uF s TO 2 12 14 VAI LAY 1 BET 1 L n lt MOL oi gt F11 12 2EM EVAPORATOR MOTORS 2ND COMPARTMENT 2 gt F13 14 3EM EVAPORATOR MOTORS 3RD COMPARTMENT 6 2 12 L2 T2 2 9 FROM DER as 96 Al J3 FUSE B AMP 2 COMPT 4 AMP COMPT 87 FH FUSE B AMP 2 COMPT 4 AMP 3 COMPT 3 R L3 T3 O 3 d 34 F12 FUSE B AMP 2 COMPT 4 AMP 3 COMPT pour ua Jh FUSE B AMP 2 4 AMP 3 COMPT PSR OL 58 77 326 F14 FUSE 8 AMP 2 COMPT 4 AMP 3 COMPT _ 56 FI5 FUSE B 2 COMPT 4 AMP 3 COMPT SPX n B J 16 FUSE 4 3 COMPT ONLY COPTIONAL s 38 FI FUSE 4 AMP COMPT ONLY COPTIONAL F10 4 L4 38 F18 FUSE 4 AMP COMPT ONLY COPTIONAL G n n B Ios 1 0 U 20 AMI 8 CHO Ao f 39 1HE z 015 F21 FUSE Q0 AMPERE NE F1T BA q 013 F22 FUSE 20 AMPERE F g 5 D UY 014 4 USE 20 AMPERD i 2 8 I9 E6 F25 FUSE 4 AMPERE S F12 4 06 7 FLR FLASH RELAY M4 1HE HEATER ELEMENT M6 2HE HEATER ELEMENT 2ND COMPARTMENT A B 2 CONNECTOR MP MB 3HE HEATER ELEMENT 3RD COMPARTMENT o gt JAS CE 14 5 7 HVR HIGH VOLTAGE RELAY a4 nsun NS s C2 L2 MCI MOTOR CONTACTOR TO M6C2 HCC2 2HVR pas MOL MOTOR OVERLOADER CIO Ao GRY a d 8872 PSR PONER SUPPLY REC
94. SYSTEM EXAMPLE HCD2 MPW2 20R SPK8 Sv4 HOT GAS SOLENOID VALVE N C INDICATES CONNECTION INDICATES A WIRE BETWEEN PLUG HC a CORO eR L6 UF UNLOADER FRONT PIN D2 amp MICROPROCESSOR MP amp PIN N2 Ef Je UER UNLOADER FRONT RELAY CZF MULTIPLE PLUG CONNECTION NUMBER 4 x VOLTAGE BELOW 12V up 20uR FB N4 S URR _ UNLOADER REAR RELAY D CONNECTION NUMBER OR LETTER 5 THIS WIRE NOT PRESENI 3RD COMPAR IMENT 2 11 B4 WTS WATER TEMPERATURE SENSOR T S INDICATES MOMENTARY CONTACTS 2080 205 0 INDICATES A WIRE GROUND STO J7 INDICATES A CHASSIS GROUND NO WIRE SPK 5 1 INDICATES STANDARD OPTIONS 6 20L 9 INDICATES CONNECTION WIRE LUG ETC 2 osi DIODE IS IN DIODE BLOCK DBD REN THE CATHODE ON PIN 5 AND THE BHAA aspke ti ANODE ON PIN 9 OF THE BLOCK FOR Ku 82 03997 00 A ALL DIODES NDA REVERSIBLE Figure 5 1 Electrical Schematic Wiring Diagram Dwg No 62 03997 NDA Prior to S N FAC90391017 E S TO ZZOOT Z9 A B C D E F 6 H 1 J K L M N 0 P Q R
95. TRANSICOLD Trailer Refrigeration Unit Genesis TM900 Genesis TM1000 Multi Temp Prior to Serial Number HAY 90594029 OPERATION AND SERVICE 62 10022 01 Change 03 04 TRANSICOLD Tu i Cl iS OPERATION AND SERVICE MANUAL TRAILER REFRIGERATION UNIT Genesis TM900 Genesis TM1000 Multi Temp Prior to Serial Number HAY90594029 cold Boite Postale Nr mie anqueville int Pierre 76520 Boos FRANCE cold Division Carrier Corporation P O Bo paa s e N Y 13221 U S A Carrier Corporation 1998 D Printed in U S A 0298 Carrier Tra Carrier Tra gt Z Carrier A United Technologies Company Section 1 DESCRIPTION adams x RA OX WERE TCR Og x Oct 1 2 _ E AGUNG Data BER ete em ep eodd T3 Compressor Data y ll etr hy arr adda aa uie Rc st ra awa 14 Refrigeration System Data Hm 15 gt Electrical Data s 16 Engine Screw I hreads sisse take ered Rt eee Ro e REA LZ EngineAirSystem ay Veo mee ien eme edm e E HL x een L8 Safety D evices sc ee pe eoe Ub rete tete as 19 LubeOilandFuel Flow Diagrams 110 CompressorUnloaders sssssseeessrr e n nnn 110 1 Unloadingin Temperature Mode 1 10 2 Suction Pressure Operation 1 10 3 Unloading During 4 kw Hea
96. Table 1 1 Model Chart R32 R4 Compressor LB KG LB KG w Genesis TM900 NDASS N ___ 28 17 Npas4 N 28 127 Genesis TM1000 Engine Speed CT4 134 TV or 05G 37 cfm CT4 134 D 1700 a craasaiver ip 33 iz7 CTA134 D EVAPORATORS Evaporator Models MMD 1100 2 1 2 MMD 1100 3 1 2 MMD 2200 4 MMS 1100 2 1 2 MMS 2200 4 a System The Genesis TM 900 and TM 1000 M ulti Temp multiple compartment refrigeration systems offer the versatility of two or three compartment temperature control The M ulti Temp allows the shipper to ship frozen and perishable commodities in the same load under separate refrigeration control The Genesis M ulti Temp allows any compartment to be any temperature Theunit also is equipped with a 5 kilowatt single phase 240 v ac generator in the nosemount to power the electric heaters and fans in the evaporators Also mounted to the left of the generator isa high voltage In the high voltage boxare two 20 amp fuses and high voltage relay s This manual contains Operating Data Electrical Data and Service Instructions for the refrigeration units listed in Table 1 1 Table 1 1 also charts some significant differences between these models WARNING Beware of V belts and belt driven components as the unit may start automatically The unit operates on high voltage Before servicing unit make sure the Run Stop
97. Temperature Control Within 0 9 F 0 5 C of Set Point Cool light CL or heat light HL illuminated depending on mode of operation Ifin cooling unloaderrelays U FR orUFR amp URR may energize to unload compressor banks Refer to Table 1 3 1 2 Table 1 3 Unloading in Temperature Mode cc SETPOINT ABOVE 10 12 C SETPOINT BELOW 10 12 C b Perishable Cooling Back up Unloader Control D uring perishable cooling the unloaders are energized when the temperature approaches setpoint If a supply probe is present the unloaders are energized when the supply temperature decreases 5 4 F 3 C below setpoint It will stay unloaded until the supply temperature rises above setpoint If a supply probe is not present the unloaders are energized when the return temperature decreases more than 9 F 5 C above setpoint It will stay unloaded until the return temperature rises more than 14 4 F 8 C above setpoint With software revision 2 10 or higher the return probe logic is disabled for ambient temperature higher than 90 F 32 2 C c Perishable Heating Unloader Control During perishable heating the unloaders are energized when the control temperature increasesto 2 3 F 1 3 C below setpoint The unloaders will stay energized until the control temperature decreases to 2 7 F 1 5 C below setpoint Note These switch points may vary slightly depending on the amount of overshoot around setpoint 62 10022 01 1
98. URE THERMOSTAT 21 ES LAML Go Lar ENS 2ER 116 2HT H GH TEMP THERMOSTAT 2 2ND COMPARTMENT BHED ab 20 CT 2005 87 0 ME GRUT BOW OPT 108 ae ee Y CDT TO FHR8S 1HT 3 ESO 2i J16 L10 M16 HVR HIGH VOLTAGE RELA E 313 Z amp y IBUDO SOLENOID VALVE END COMPARTMENT AH CE p AH 5 Cao Fa 127 PRIS OOO 13 SC8v LIQUID SOLENOID VALVE SRD COMPARTMENT 19 E 111 2MDS MANUAL DEFROST SWITCH 2ND COMPARTMENT vo sena C ESE 882 la OUO Loe M c o 2 TO FLR1 G6 3 GS EBD To ves D2 12 MP MICROPROCESSOR BOARD 349183 O 650969 TA SPKI1 814 OCJ1 OPTION CONNECTION JUMPER 10 WAY CES 8 CAS OA Ga 2 OB OIL PRESSURE SAFETY SWITCH N O 2 ni E E ODOR 12 19 F2 7 OR OUT OF RANGE RELA amp D Gay ys Che SSRIS OEE ORL OUT OF RANGE LIH BAD 5 GEO CHO S1 Zi MER IER OP OY See TB 63 FETERE NOTES zm 95 POWER STUD 3RAS SPKS LBS cc 8 Seri ED 1 UNIT SHOWN IN OFF POSITION A RAS RETURN AIR SENSOR DO OEN Ao I S Ln BY EN AM DRAS RETURN AIR SENSOR C2ND COMPARTMENT 382 cse SPK12 COLOR WHITE DC CONTROL CIRCUITS pie E ROTE CONTROL RELAY COMPARTMENT BLACK GROUNDS N2 RES 5 65 63 0 spk11 GREEN
99. ain compartment is in defrost then no cool or heat will be allowed in the remote compartments Start Stop mode is also available for M ulti compartment units A remote compartment can override shutdown after the minimum run time if the temperature is not within L8 F 1C of setpoint A remote compartment will cause the unit to restart after the minimum off time if temperature is more than 3 6 F 2 C from setpoint The minimum off time can be overridden if the remote temperature is more than 6 C from setpoint 2 6 CONTROL CIRCUIT OPERATION 2 6 1 Introduction NOTE The schematic in this manual has map coordinates added to the margins For example to locate the ammeter A on the schematic it would follow the component designation by the designation 12 This would indicate that it is closest to lines and 2 on the schematic These locations have been added to the legend The controller boards shown on the electrical schematic Figure 5 1 that interface with unit components are the analog interface or processor board on the left and the relay module on the right Connections to these boards are made through 3 multiple pin plug connectors HC HC2 amp MP The address system example H C D 2 M PW 2 indicatesa wire between plug pin D2 and microprocessor M P amp pin W2 The processor board connections are mainly inputs and outputsfor control switches temperature sensors safety and auto start functions that control
100. al Voltage Regulator Operation 12 volts 115 3 Alternator Service Lu eaa kina Kuna ua kapa ees 116 Refrigerant Circuit During Cooling e nn 117 Refrigerant Circuit During Heating Defrosting 1171 HeatingandDefrost es 1 17 2 Defrost with Greater Than 100 F 37 8 C Ambient with Software Less Than 3 14 or 80 26 7 C with Software 3 14 or Higher 2 OPERATION xai ene eR n c Xa E Aa ea AE 2012 Preetrip IriSpection nee CR e CHR edd CH RR Gok aad eR NU EROR 22 Startingand Stopping Instructions 2 2 2 1 A tomiatlC Start e REIR UEM EE Ses 2 2 2 Manak Starting dues Eee ur 23 Remote Compartment Operation With Remote Control Box Figure 2 1 24 Compartment Operation With Optional Compartment Control Box Figure 2 2 TABLE OF CONTENTS 1 29 2 1 2 1 2 1 2 1 2 1 2 2 2 2 62 10022 01 Section 2 OPERATION CONT D nnns 25 Microprocessor Controller 26 Control Circuit Operation n 2 6 1 tpod u tI vou eet ea ws eet tnn peu Be Jie 26 2 c fet Re trees evo rent UC e P Re aw Ea 2 6 3 Heating Oddo ORI OHIO ROS OUI dO e dS 2 6 4 Defro depre ike ER iue MERERI eei 3 TROUBLESHOOTING n nnn 3 1 DieselEngin
101. apacitor 6 Evaporator Fan amp Motor Defrost Terminal Sensor 7 Expansion Valve High Temperature Klixon 8 Liquid Solenoid Valve LSV Heaters 9 Check Valve Thermostat Sensor Figure 1 2 Remote Evaporator 1 3 62 10022 01 1 Condenser Pressure Control Solenoid Valve SV 1 2 Defrost Air Switch 3 Receiver 4 Receiver Sight Glass 5 Filter Drier 6 Liquid Line Solenoid Valve SV 2 7 Quench Valve R 22 Only 8 High Voltage Control Box See Figure 1 8 9 Model Serial No Location 10 Battery Location Figure 1 3 Curbside 62 10022 01 1 4 Engine Air Cleaner Radiator Overflow Reservoir Radiator Fill Neck Radiator Control Box Door See Figure 1 7 Figure 1 4 Roadside 11 12 13 14 15 King Valve Hot Gas Solenoid Valve SV 3 Hot Gas Solenoid Valve SV 4 Generator 5kw Discharge Service Valve Compressor Discharge Temperature Sensor CDT Unloader Solenoid Valve High Pressure Cutout Switch HP 1 and Head Pressure Control Switch HP 2 Compressor 05G 10 11 12 13 Compressor Sight Glass Suction Service Valve Suction Pressure Transducer SPT Fuel Filter 16 17 18 19 20 Starter Motor Oil Drain Lube Oil Fill Mechanical Fuel Pump Lube Oil Filter Oil Pressure Switch Relay Module See Figure 1 9 Injection Pump Fuel Bleed Valve Alternator and Regulator Clutch Gearbox Air Cleaner Service
102. arallel TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in Figure 4 21 4 N i Ww s 1 Suction Line end view 2 TXV Bulb Clamp 3 Nut and Bolt clamp 4 Thermocouple 5 TXV Bulb Figure 4 21 Thermostatic Expansion Valve Bulb and Thermocouple NOTE When conducting this test the suction pressure must be 6 psig 0 4 kg cm below expansion valve maximum operating pressure M OP For example R 22 units use an expansion valve with a 35 MOP The recommended test pressure should be below 49 psig 3 44 kg cm Connect an accurate gauge to the 1 4 port on the suction service valve Run unituntil stabilized Set controller 10 F 5 5 C below box temperature Fromthe temperature pressure chart determinethe saturation temperature corresponding to the evaporator outlet pressure Note the temperature of the suction gas at the expansion valve bulb Subtract the saturation temperature determined in Step 6from the average temperature measured in Step 7 The difference is the superheat of the suction gas 62 10022 01 d Adjusting Superheat on Remote Evaporators One thirds Dual flow three thirds Dual flow evaporators have two expansion valves per evaporator CAUTION Make sure only one evaporator is operating No obstruction to the airflow should be present The unit should be in cooling The unloaders should be disconnected if fitted to make
103. are placed on the enclosing tube in proper sequence to avoid premature coil burnout Replacing the Coil NOTE The coil may be replaced without removing the refrigerant or pumping the unit down Disconnect leads remove coil retainer and coil assembly Verify coil type voltage and frequency This information appears on the coil housing Place new coil over enclosing tube retainer and connect wiring Replacing Solenoid Valve Internal Parts See Figure 4 16 The liquid line solenoid valve SV 2 may be serviced by pumping the unit down Refer to section 4 5 a Remove and storethe refrigerant charge in an evacuated container to service hot gas solenoid valve Refer to section 4 5 b 1 Remove coil retainer and coil assembly from valve Remove enclosing tube assembly and related items Check for foreign material in valve body Install new parts Tighten enclosing tube assembly to a torque value of 200 inch pounds 2 3 mkg and leak check the valve Refer to section 4 6 Install coil assembly and retainer Start unit and check refrigerant charge per section 4 8 f 7 Check refrigeration cycles R efer to section 2 o _ gt 5 Gasket 6 Piston Assembly 7 Body 8 Bracket Adapter 1 Retainer 2 Coil Assembly 3 Enclosing Tube Assembly 4 Plunger Assembly Figure 4 16 Solenoid Valves Alco 4 17 2 Solenoid Valve Sporlan SV1 a Replacing the Coil NOTE The coil may be replace
104. arm may result Start unit and check refrigeration cycle 62 10022 01 Condenser Fan Adapter Condenser Fan Sheave V Belt 5 Split Tapered Bushing 6 Key 7 Bearing Housing Shaft 9 Bushing 10 Blower Wheel 11 Venturi Ring Figure 4 19 Evaporator Condenser Fan Shaft Assembly 4 22 EVAPORATOR COIL CLEANING Theuseof recycled cardboard cartonsisincreasing across the country T herecycled cardboard cartons create much more fiber dust duringtransport than new cartons T he fiber dust and particles are drawn into the evaporator where they lodge between the evaporator fins If the coil is not cleaned on a regular basis sometimes as often as after each trip the accumulation can be great enough to restrict air flow cause coil icing repetitive defrosts and loss of unit capacity Due to the washing action of normal defrost the fiber dust and particles may not be visible on the face of the coil but may accumulate deep within It is recommended to clean the evaporator coil on a regular basis not only to remove cardboard dust but to remove any grease or oil film which sometimes coatsthe fins and prevents water from draining into the drain pan Cardboard fiber particles after being wetted and dried several times can be very hard to remove Therefore several washings may be necessary a Remove rubber check valves Kazoo from drain lines front of trailer Spray coil with a mi
105. art will also be initiated if box temperature is more than 11 F 6 C from set point a Start Stop Continuous NOTES 1 With software revisions 3 08 or 3 12 when configuration CNF11 is ON and setpoint is 32 to 42_F Oto 5 5 C the unitis locked into continuous run Start Stop Continuous key is disabled in this setpoint range 2 With software revision 3 15 or higher when configurations CNF3 amp CNF11 are ON and setpoint is 32 to 42 F 0to 5 5 C the unit is locked into continuous run Start Stop Continuous key is disabled in this setpoint range A key is provided to select between continuous run and auto start stop operating mode In the continuous run mode the diesel engine will not shut down except for safeties or if the engine stalls T his function also apply to the operation of the electric motor b Auto Mode Indicator The Auto Start Stop indicator islit and ARL light will be on to indicate the start stop mode has been selected c Auto Start Failure If the unit fails to start shuts down on a safety fails to run for the minimum run time three consecutive times the Auto Start Failure is activated d Continuous Run Mode continuous run mode the engine is started but not allowed to shut off except for safeties or if the engine stalls e Auto Start Sequence When the starting conditions are met the start sequence will begin by energizingthe run relay and after 5 seconds energize the glo
106. artment fans for 2 3 or 4 fans 15 Excessive current draw by Fuses F14 F15 Opens at 3 2 amps 3 compartment fans 62 10022 01 1 10 1 9 LUBE OIL AND FUEL FLOW DIAGRAMS 5 6 l Fuel Tank 7 Fuel Bleed Valve 2 Fuel Supply Line 8 Injection Pump 3 Fuel Pump 9 Injector Nozzles 4 Mechanical 10 Fuel Leak off Line Lift Pump 11 FuelReturn Line 5 FuelFilter 6 Fuel Warmer Optional Figure 1 10 Fuel System Dia gram 6 Engine Block Oil Pan Full Flow Oil Filter Bypass Oil Filter Optional Engine Oil Connection Oil Pressure Switch Oy Ord US IS Figure 1 11 Lube Oil Flow Diagram 1 10 COMPRESSOR UNLOADERS There are two modes of unloader operation temperature control and suction pressure control 1 10 1 Unloading in Temperature Mode The compressor is equipped with unloaders electronically controlled by the microprocessor for capacity control The capacity controlled cylinders are easily identified by the solenoid which extends from the side of the cylinder head When the solenoid is energized the cylinders unload The unloaded cylinders operate with little or no pressure differential consuming very little power A de energized solenoid reloads the cylinders NOTES The unloader relay is locked in for a 1 minimum of 2 minutes once it is energized due to suction pressure 2 There is a delay of 10 seconds between de energizing one unloader to de energizing the other unloader a
107. ates when the defrost termination thermostat DTT opens indicating the defrost cycle is complete The defrost timer runs only when the DTT is closed The defrost interval timer resets to zero when defrost is initiated by any means The timer does not accumulate time during defrost mode or auto start off cycles A defrost output is energized during defrost mode to de energize the clutch to prevent hot air circulation to the load In addition the heating outputs HR1 amp HR2 are enabled to apply heat for hot gas heating The compressor operates at maximum capacity on diesel and diesel electric units during defrost The suction pressure signal can force the unloaders to be unloaded e Fail safe Defrost Termination Should the defrost cycle not complete within 45 minutes or if the external defrost signal does not clear at defrost termination the defrost cycle isterminated T he internal timer isresetfor 1 5 hoursand the external defrost signal is ignored for defrost initiation The manual defrost switch will override this mode and start a new 45 minute cycle When defrost override is active the appropriate alarm will be indicated If the run relay is de energized during defrost defrost will be terminated f Defrost Termination The defrost terminates with HR1 de energizing HR2 will turn off 2 seconds later The defrost output will de energize 5 seconds after HR 1 to engage the clutch g Remote Evaporator Defrost D efrostfo
108. available for 5 minute Scroll through the configuration list using the FUNCTION key and compare the settings with those shown onthetablein the next column If any of the configurations need to be changed continue with step b below To change the configuration selection Bring the configuration to be changed onto the display Pressthe ENTER key to allow change access to the displayed configuration Press either the UP or DOWN keys to display available selections for that configuration L eave the correct selection on the screen T he selection display will flash warning the operator that the displayed value has not been entered Pressthe ENTER keyto enter the new selection into memory The display will revert to the original selection if no further action is taken for the next 5 seconds Continue to scroll through the configuration list by pressing the FUNCTION key Change any other configurations as required When finished turn the Run Stop switch to the Stop position then back to the Run position to start the unit 62 10022 01 4 20 Configuration CNF1 CNF2 CNF 90 Setpoint Heat lockout on 10 Heat lockout off Truck units MOP Disabled R 502 4 SONT EM Out of range alarm CNF CNF CNF1 CNF11 a Des oni CNF16 ON Akeuxslamshutuntdown With software revision 3 15 or higher when configurations CNF3 amp CNF11 are ON and setpoint is 32 to 4
109. be disabled if the REM PROBE is selected in the controlling probe functional parameter Coolant Temperature Sensor Alarm The coolant temperature sensor alarm is displayed with the description WT SENSOR or AL 11 This alarm is generated if the coolant temperature sensor is open or shorted Compressor Discharge Temperature Alarm The compressor discharge temperature alarm is displayed with the description HIGH CDT or AL12 This alarm is generated and unit shuts down if the temperature is sensed above 310 F for 3 minutes If the discharge temperature exceeds 350 F the 3 minute timer will be overridden and the unit shut down immediately If ambient temperature sensor ATS is at 120 F 49 C or higher the CDT limits are increased to 340 F 171 C for 3 minutes The fault light FL is turned on Compressor Discharge Temperature Sensor Alarm The compressor discharge temperature sensor alarm is displayed with the description CD SENSOR or AL 13 This alarm is generated if the sensor is open or shorted Standby Motor Overload Alarm The standby motor overload alarm is displayed with the description SBY MOTOR or AL14 This alarm is generated when the M OL input is sensed open with the Run Relay energized in electric mode Diesel E lectric Relay energized Fuse Alarm The fuse alarm is displayed with the description FUSE BAD 15 This alarm is generated when the FU SE input is sensed low The fault light FL isturned on Display
110. beyond 3 6 F 1 2 0 C of setpoint for the Perishable range or above 3 6 2 0 C of setpoint for the Frozen range for all compartments The minimum off time isoverridden if the temperature is than 11 F 6 C from setpoint i Battery Voltage Provisions are made to sense when the battery is good A good battery is defined as having 13 4v at 75 F This condition is used to allow shut off of the diesel engine If the battery voltage falls below 10v during glow cycle the starter will not engage and the start sequence will continue this is considered a failed start The start sequence will be repeated until the unit starts or three consecutive start attempts have failed 62 10022 01 Table 1 7 Battery Table 1 7 Battery Voltages Message Wesce en erases __ LOW BATT Unit will shut down except AL4 or E during cranking llto If the unit has cycled off in 13 4 auto start stop mode and battery voltage drops below 11 0 volts the unit is automatically started to charge battery U nit will operate until a battery voltage of 13 4 volts is obtained at which level unit will stop if temperatures are satisfied HI BATT 17 Unit will shut down AL5 or more Oil Pressure Signal fish the oil pressure switch is closed it shows that the engine is running and prevents engagement of the starter motor when operating in the auto mode k Maximum Off Time Provision for a keypad selectable feature is pr
111. cause of its inherent inaccuracy Keep the ambient temperature above 60 F 15 6 C to speed evaporation of moisture If ambient temperature is lower than 60 F 15 6 C ice might form before moisture removal is complete H eat lamps or alternate sources of heat may be used to raise system temperature 4 7 3 Procedure for Evacuation and Dehydrating System Remove refrigerant using a refrigerant recovery system The recommended method to evacuate and dehydrate the system is to connect three evacuation hoses D o not use standard service hoses asthey are not suited for evacuation purposes as shown in Figure 4 8 to the vacuum pump and refrigeration unit Also asshown connect a evacuation manifold with evacuation hoses only to the vacuum pump electronic vacuum gauge and refrigerant recovery system With the unit service valves closed back seated and the vacuum pump and electronic vacuum gauge valvesopen start the pump and draw a deep vacuum Shut off the pump and check to see if the vacuum holds This operation isto test the evacuation setup for leaks repair if necessary M idseat the refrigerant system service valves Then open the vacuum pump and electronic vacuum gauge valves if they are not already open Start the vacuum pump E vacuate unit until the electronic vac uum gauge indicates 2000 microns Close the elec tronic vacuum gauge and vacuum pump valves Shut off the vacuum pump Wait a few minutesto be sure th
112. ce valve frontseat and pump unit down to 2 to 4 psig 0 1 to 0 3 kg cm Frontseat discharge service valve and slowly bleed remaining refrigerant Remove the oil drain plug from the compressor and drain the proper amount of oil Replace the plug securely back into the compressor O pen service valves and run unit to check oil level repeat as required to ensure proper oil level F3 O Q HS c 62 10022 01 4 10 4 12 COMPRESSOR UNLOADER VALVE The compressor unloaders located on the compressor cylinder heads are controlled by relays UFR URR and the temperature controller Refer to section 1 10 a Checkout Procedure 1 Connect manifold gauges to the compressor suction and discharge service valves and start unit in cooling with the trailer temperature at least 5 F 2 8 C above set point and the compressor will be fully loaded both unloader coils are de energized Note suction pressure Remove wiring from the front unloader coil Place electrical tape over wire terminals Set controller upscale cooler to warmer This mechanically simulates falling temperature Approximately 2_F 1 1_C below box temperature the unloader coils will energize but only the rear unloader valve will unload Note suction pressure a rise of approximately 3 psig 0 2 kg cm will be noted on the suction pressure gauge Reconnect wiring on the front unloader The front unloader will retract and an additional 3 psig
113. ch OFF Connect an A C voltmeter to the generator output wires at the high voltage fuse block Connect two 2 jumper wires one to each of the generator capacitor terminals Start the unit and run in high speed leave the remote compartment power OFF Touch one jumper wire to a 12vdc ground connection Touch the other jumper wire to a 12vdc positive connection WARNING The jumpers should only be connected to 12vdc for no longer than one l second in order to flash the generator and restore the residual magnetism required for generator output O bserve the voltmeter the voltage should increase to approximately 220vac Shut the unit OFF and disconnect the jumper wires Restart the unit run in high speed and check the generator voltage output and rear compartment heater amperage 62 10022 01 ROTOR MAIN STATOR PER SECTION AUXILIARY WINDING 10 7 Ohms 0 89 Ohms 1 18 Ohms The rotating diodes can be tested Disconnect each lead and test during this same operation The Remove the wires from capacitor to resistance between U1 amp U2 and test diode s must be removed from the 05 amp U6 Note unit wiring must be circuit to test either diode or rotor winding resistance disconnected from generator for
114. changed the displayed data will then flash to indicate that the value has not been entered If the new value is not entered in 5 seconds the display will revert back to the last entered value If the ENTER key is pressed the display will stop flashingto indicate that the value has been entered The new value will continue to be displayed for 5 seconds before reverting back to the default display E ach time a key is pressed the 5 second delay will be reset To selecta 62 10022 01 different functional parameter the FUNCTION CHANGE key must be pressed first Code Vs English Messages The description messages of the functional parameters unit status and alarms can be displayed in English or Codes through this function selection The two choices will be displayed as ENGLISH or CODES With this parameter set to CODES all display descriptions will be set to their code display This parameter will not change due to this selection Refer to each section for the alternate display description 62 10022 01 1 16 Manual Glow Override The auto start glow time can be manually overridden through this function The messages is displayed as NORM GLOW or ADD GLOW If the ADD GLOW selection is entered the control will add 30 seconds of glow to the glow times listed in section 1 11 11 This feature must be selected before the 3 start attempts have been completed At higher ambients this override will only affect the second or third start attem
115. characteristics The engineisequipped with spin on lube oil and fuel oil filters for easier filter changes NOTE Throughout this manual whenever the left or right hand side of the engine is referred to it is the side as viewed from the flywheel end of the engine The diesel engine drives the compressor directly through anylon drive gear and adapter T he adapter also includes a V belt sheave which drives the clutch gearbox The condenser evaporator fan shaft is driven with a V belt from the clutch gearbox A separate V belt from the clutch gearbox drives the alternator Electrical power for the control system and for charging the batteries is provided by the 12 vdc alternator Also the auto start stop feature is standard equipment The auto start stop operation provides automatic cycling of the diesel engine which in turn offers an energy efficient alternative to continuous operation of the engine with control of temperature by alternate cooling and heating of the supply air evaporator outlet air c Remote Evaporators The compartments of the Multi Temp system are equipped with separate evaporators For Multi Temp applications single air discharge and double air discharge evaporators are available The evaporators are different in size capacity and number of fans but all work on the same principle and use the same single phase 50H z 60H z fan assembly The 230v 1 kw electrical heaters vary in length according
116. control switch HP 2 defective 4 15 Low refrigerant charge 4 9 Defrost air switch DA out of adjustment 4 19 amp 4 20 3 3 6 Abnormal Pressure 3 3 6 1 Cooling High discharge pressure Quench valve malfunction Replace Condenser coil dirty 4 23 Condenser fan defective 4 21 V belt broken or loose 4 4 Discharge check valve restricted 4 13 Noncondensibles or refrigerant overcharge Replace Solenoid valve SV 1 malfunction 4 18 Low discharge pressure Compressor valves s worn or broken High suction pressure Compressor valves s worn or broken Compressor gasket s defective Low suction pressure Suction service valve partially closed King valve partially closed Filter drier partially plugged Low refrigerant charge Expansion valve malfunction No evaporator air flow or restricted air flow Excessive frost on coil Solenoid valve SV 2 defective Suction and discharge Compressor valves defective pressures tend to equalize when unit is operating 62 10022 01 3 4 INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 3 3 6 2 Heating High discharge pressure Solenoid valves SV 1 SV 3 and SV 4 malfunction Condenser fan defective V belts broken or loose Noncondensibles in system Head pressure control switch HP 2 defective closed Low discharge pressure Compressor valve s worn or broken Head pressure control switch HP 2 defective open Solenoid valve SV 1 malfunction Low refrigerant charge Low suction pressure Refrigerant s
117. ct switch to a cylinder of dry nitrogen See Figure 4 15 Set nitrogen pressure regulator higher than cutout point on switch being tested Pressure switch cutout and cut in points are shown in sections 1 3 Close valve on cylinder and open bleed off valve O pen 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 Open pressure on gauge Slowly open bleed off valve to decrease pressure until switch closes light will light or ohmmeter will move 4 16 REPLACING RECEIVER SIGHT GLASS ASSEMBLY NOTE There are two types of receiver sight glasses Oneisthe floating ball type P N 14 00111 and the second is the prism type P N 14 50023 00 both are interchangeable 62 10022 01 4 12 e f Store the refrigerant in an evacuated container Refer to section 4 5 b U nscrew the sight glass assembly Spread some sealingcompound on pipe threads of new sight glass assembly and install Leak check receiver sight glass per section 4 6 After leak checking unit evacuate and dehydrate as outlined in section 4 7 A dd refrigerant charge Refer to section 4 8 Check for noncondensibles 4 17 SERVICING SOLENOID VALVES 4 17 1 Solenoid Valves Alco SV2 SV3 SV4 b CAUTION Do notdamage orovertighten the enclosing tube assembly Torque to 200 inch pounds 2 3 mkg Also make sure all parts
118. d of producing a reduced capacity state between heat and cool modes This is done by combining a null pulse with either heat or cool The capacity in this band can vary by adjusting the duty cycle of the null portion of operation During this null operation heat and cool valves are opened simultaneously to reduce heating or cooling capacity U ItraFresh 2 temperature control uses both supply and return air sensors to achieve control 11 both probes present and neither is defective or out of range the selected probe isthe active probe The controlling probe will switch depending on if the unit has pulled down to setpoint yet During pulldown the controlling temperature is from the active probe When not in pulldown mode the controlling temperature is supply air plus an integrator error which is based on the selected controlling active probe Again the 60 F exception occurs When not in pulldown mode and the setpoint is gt 60 F the active probe is used for control and integration There three possible modesfor U ItraFresh 2 control These are heat cool and null To enter COOL the control temperature must be greater than or equal to 1 C above setpoint To exit cool and enter NULL the control temperature must be less than 0 8 C above setpoint To exit NULL and enter HEAT the control temperature must be more than or equal to 1 C below setpoint and to exit heat and enter NULL the control temperature must belessthan 0 8 below setpo
119. d the list will change at a rate of one item every 0 5 seconds This list will be circular meaning once the end of the list is reached the list will go to the first entry Each time the UNIT DATA key the UP DOWN Arrow key is pressed the display time will be reset to 5 seconds If the ENTER 15 pressed the display time will be set to 30 seconds The position in the unit data list will remain at the last selected value except if power is removed If the display wereto time out and revert to the default display the operator would only have to press the UNIT DATA key to display the same data again 62 10022 01 Di CD2 CD3 WT Engine Temperature cba CDS CDe CD7 Ambient Temperature WT AS AS TS VP T EV RA RA CD cba CD10 CDI CD12 CD13 CDis Compartment 2 Air Temperature 3 Compartment 3 Air Temperature CD18 MHRI Maintenance Hour Meter 1 9 CD1 MHR2 Maintenance Hour Meter 2 CD20 Switch On Hour Meter Codes 5 amp 6 are variable SAS is displayed when the SUP Probe Function is selected REM is dis played when the REM Probe Function is selected O J Suction Pressure The suction pressure is displayed with the description SU CT or CD 1 Thedataisdisplayed with the proper unit designator P psig or B Bars i e SUCT 25P The display is inches of mercury for readings below 0 psig The display range is 20 HG to 420 psig 0 7 Bars to 29 4 Bars
120. d Unloaded Hot Gas Bypass 1 13 Compressor Cylinder Head Loaded Hot Gas Bypass 1 13 Microprocessor Control Panel 1 14 Auto Start Sequernce i ees ire cet o Rane Pa ek wa DR aa 1 22 U ItraFresh 2 Temperature Control Operating Sequence 1 24 Alternator and Regulator P N 30 00409 1 25 R 404A Refrigerant Circuit eect tenet teens 1 27 R 22 Refrigerant Circuit Cooling 1 28 R 22 Refrigerant Circuit Heating and Defrosting 1 30 R 404A Refrigerant Circuit H eating Defrosting 1 30 Remote Control BOX v on a A E ene en 2 2 Compartment Control Box Optional 2 3 Ws 4 3 Engine Crankcase Breather 4 3 Mechanical Fuel Pump r Geena rm pnr 4 4 Electric Fuel Pump Optional 4 4 Belt Tension Gauge Part No 07 00253 4 4 V Belt Arrangement di CR DR UR KC c 4 5 Removing V Belt from Engine Adapter DriveSheave 4 6 Vacuum Pump
121. d electrical connections at starter Starter motor malfunctions Starter motor solenoid defective Open starting circuit Incorrect grade of lubricating oil Starter motor cranks No fuel in tank but engine fails to start Air in fuel system Water in fuel system Plugged fuel filters Plugged fuel lines to injector s Fuel control operation erratic Glow plug s defective Fuel solenoid defective Fuel pump FP malfunction Starter cranks engages Engine lube oil too heavy but dies after a few seconds Voltage drop in starter cable s 3 1 2 Engine Starts Then Stops Engine stops after Fuel supply restricted several rotations No fuel in tank Leak in fuel system Faulty fuel control operation Fuel filter restricted Injector nozzle s defective Injection pump defective Air cleaner or hose restricted Safety device open Fuel solenoid defective Fuel pump FP malfunction 3 1 3 Starter Motor Malfunction Starter motor will not crank or turns slowly Battery insufficiently charged Battery cable connections loose or oxidized Battery cables defective Starter brushes shorted out Starter brushes hang up or have no contact Starter solenoid damaged Run Stop switch defective Engine lube oil too heavy 3 1 Check Check Check 3 1 3 Engine Manual Drain Sump Replace Check Engine Manual 4 3 6 Engine Manual 4 2 Check Check Check Engine Replace Engine Manual Engine Manual 4 3 3 1 8 Engine Manual 4 2 Check Check Replace En
122. d without removing the refrigerant or pumping the unit down 1 Remove top locknut spacer cup and nameplate SV 1 2 Disconnect wiring and remove coil 3 Replace coil by reversing steps 1 and 2 b Replacing Internal Components See Figure 4 17 1 Remove and store the refrigerant charge in an evacuated container Refer to section 4 5 b 2 Removethe top locknut spacer cup nameplate coil assembly and spacer 3 Usinga 12 point 1 3 8 inch box wrench loosen the enclosing tube locknut and bleed off remaining refrigerant 4 Remove enclosing tube and locknut assembly The gasket is inside the enclosing tube 5 Remove seat disc from inside of body and check for obstructions and foreign material 6 Place the seat disc into the valve body with the smaller diameter end facing up 7 Placethe enclosing tube locknut over the enclosing tube Install spacer over enclosing tube making sure it is seated properly in the enclosing tube locknut Tighten enclosing tube locknut to a torque value of 20 ft Ib 2 78 mkg Do not overtighten 1 SV 1 1 Locknut Screw 6 Enclosing Tube 2 Spacer Cup Locknut 3 Nameplate 7 Enclosing Tube 4 Coil 8 Gasket 5 Spacer 9 Seat Disc 10 Body Figure 4 17 Solenoid Valves Sporlan 8 Install coil assembly nameplate and top locknut or SCrew Dehydrate and evacuate the system Refer to section 4 7 Charge unit with refrigerant per sections 4 8 and 4 9 10 Start unit and check
123. dc The fault light FL 15 turned on and engine will shut down High Battery Voltage Alarm The high battery voltage alarm is displayed with the description HI BATT or AL5 This alarm is generated if the battery voltage is above 17 vdc The fault light FL is turned on and engine will shut down Defrost Override Alarm The defrost override alarm is displayed with the description DEFR FAIL or AL6 Thisalarm is generated if the unit is in a defrost override mode See Section 1 11 10 Alternator Auxiliary Alarm The alternator auxiliary alarm is displayed with the description ALT AU X orAL 7 This alarm is generated if the alternator auxiliary signal is not present with the enginerunning See Section 1 11 11 The fault light FL is turned on Starter Motor Alarm The starter motor alarm is displayed with the description STARTER orAL8 This alarm is generated if the starter motor input signal is not present with starter solenoid energized The fault light FL is turned on Return Air Sensor Alarm The return air sensor alarm is displayed with the description RA SENSOR or 9 This alarm is generated if the return air sensor is open or shorted The fault light FL isturned on ifthe unit shuts down because there is no controlling probe Supply Air Sensor Alarm The supply air sensor alarm is displayed with the description SA SENSOR or AL10 This alarm is generated if the supply air sensor is open or shorted T his alarm will
124. e Pa De EA n fe 311 Engine Will Not Start eee 9 9 3 1 2 Engine Starts Then Stops 3 1 3 Starter Motor Malfunction 3 14 Malfunction In the Engine Starting Circuit 32 Alternator Automotive Type 3 3 Refrigerallon xe died e CR teh ua tele vad RE Ad 3 317 JU miEWIILNOECOOl uo nak had EH alin eee PROC Sets 3 32 Unit Runs But Has Insufficient Cooling 3 3 3 Unit Operates Long or Continuously in Cooling 3 34 Unit Will Not Heat or H as Insufficient 3 35 Defrost CycleMalfunction 3 8 6 Abnormal Pressure eee ie i rer EIR E RRE 3 3 611 5 COO ITI te nace hb apn are ilar yaa dac ap quat Ba Aira 3 3 6 2 Heating hei 3 9 Abnormal NoiSe za otc y kite PWN dice tae nd de NER ete 3 3 8 Control System Malfunction 3 39 Evaporator Air Flow or Restricted Air Flow 3 3 10 Expansion Valve Malfunction 3 3 11 Solenoid Valve Malfunction 344 SKW Generator taucus hias a ERR 4 puasa VEDINA DU VAS 41 Maintenance 5
125. e Never exceed more than a 50 concentration of anti freeze Use a low silicate anti freeze meeting GM specifications GM 6038M or equal a Removeall foreign material from the radiator 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 It may be necessary to use warm water mixed 62 10022 01 4 2 with any good commercial dishwasher detergent R inse coil with fresh water if a detergent is used b Draincoolantcompletely by removing lower radiator hose and radiator cap c Install hose and fill system with clean untreated water to which three to five percent of an akalined based radiator cleaner should be added six ounces dry 151 grams to one gallon 3 78 liters of water d Run engine 6 to 12 hours and drain system while warm R inse system three times after it has cooled down Refill system with water e Run engine to operating temperature Drain system again and fill with treated water anti freeze see Caution Note and refer to section 1 2 NEVER POUR COLD WATER INTO A HOT ENGINE however hot water can always be added to a cold engine 4 3 2 Lube Oil Filters After warming up the engine stop engine remove drain plug from oil reservoir and drain engine lube oil Lightly oil gasket on filter before installing CAUTION When changing oil filters the new filters should be primed with clean oil if the
126. e Main Compartment Remotes Control When the main compartment is either heating or cooling The remote compartments can override the unloaders If a remote goes to cooling the unloaders will be de energized If a remote goes to heat mode the unloaders will be controlled by the main compartment unless another remote is cooling 1 15 BATTERY CHARGING ALTERNATOR 1 15 1 Alternator Operation CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes alternator As precautionary measure disconnect positive battery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator Thealternator converts mechanical and magnetic energy to alternating current A and voltage by the rotation of an electromagnetic field rotor inside a three phase stator assembly The alternating current and voltage is changed to direct current and voltage by passing A C energy through a three phase full wave rectifier system Six silicon rectifier diodes are used D O POS OUTPUT STATOR L6RN RED Pi FIELD Q NEGATIVE YEL GRN O OUTPUT YEL o BLK O O T D EMULATION REGULATOR 1 D Emulation Orange 2 10
127. e leaks C If system is without refrigerant charge system with refrigerantto build up pressure between 30to 50 psig 2 1 to 3 5 kg cm Remove refrigerant drum and leak check all connections NOTE It must be emphasized that only the correct refrigerant drum be connected to pressurize the system A ny other gas or vapor will contaminate the system which will require additional purging and evacuation of the high side discharge of the system d Remove refrigerant using a refrigerant recovery system and repair any leaks E vacuate and dehydrate the unit Refer to section 4 7 Charge unit with refrigerant Refer to section 4 8 4 7 EVACUATION AND DEHYDRATION 4 7 1 General M oisture isthe deadly enemy of refrigerant systems T he presence of moisture in a refrigeration system can have many undesirable effects The most common are copper plating acid sludge formation freezing up of metering devices by free water and formation of acids resultingin metal corrosion 4 7 2 Preparation a Evacuate and dehydrate only after pressure leak test Refer to section 4 6 Essential tools to properly evacuate and dehydrate any system include a good vacuum pump 5 cfm 8m H volume displacement P N 07 00176 01 anda good vacuum indicator such as a thermocouple vacuum gauge vacuum indicator Available through Robinair M anufacturing M ontpelier O hio Part Number 14010 NOTE It isnot recommended using a compound gauge be
128. e lower portion of the fixed element should be inspected each timethe oil cup isinspected or serviced If there is any sign of contaminant buildup or plugging the body assembly should be removed and back flushed At 4 3 least one a year or at regular engine service periods remove the entire air cleaner and perform the following a Remove oil cup Check and clean center tube DO NOT USE GASOLINE b Pump solvent through the air outlet with suffi cient force and volume to produce a hard even stream out the bottom of the body assembly R everse flush until all foreign material is removed 4 3 4 Engine Crankcase Breather The engine uses a closed type breather with the breather line attached to the cylinder head cover See Figure 4 2 The breather assembly should be cleaned once a year or at every 3000 hours maintenance interval whichever comes first 5 Breather Oil Shield 1 Cylinder Head Cover 2 Breather Cover 6 Bolt 3 Breather Element 7 Breather Assembly 4 Plate 8 O Ring Figure 4 2 Engine Crankcase Breather 4 3 5 Servicing Fuel Pump a Mechanical Pump See Figure 4 3 Due to foreign particles in the fuel and wax asa result of using the wrong grade of fuel or untreated fuel in cold weather The fuel filter may become plugged or restricted and the engine will loose capacity The filter must be cleaned on a regular schedule such as unit pre trip or when the oil and fuel filters are changed Refer to sect
129. e vacuum holds 4 7 10 Ed d bo ose vell 8 TRANSIT 11 12 DLE erat Refrigerant Recovery Unit Refrigerant Cylinder Evacuation Manifold Valve Vacuum Pump Vacuum Gauge King Valve Receiver Condenser Evaporator Discharge Valve Suction Valve 13 Compressor Figure 4 8 Vacuum Pump Connection mee Ut ND Break the vacuum with clean dry refrigerant U se refrigerant that the unit calls for Raise system pressure to approximately 2 psig Remove refrigerant using a refrigerant recovery system Repeat steps e through g one time Evacuate unit to 500 microns Close off vacuum pump valve and stop pump Wait five minutes to see if vacuum holds This checks for residual moisture and or leaks With a vacuum still in the unit the refrigerant charge may be drawn into the system from a refrigerant container on weight scales The correct amount of refrigerant may be added by observing the scales Refer to section 4 8 62 10022 01 4 8 ADDING REFRIGERANT TO SYSTEM FULL CHARGE a Dehydrate unit and leave in deep vacuum Refer to section 4 7 b Place drum of refrigerant on scale and connect charging line from drum to king valve Note weight of drum and refrigerant d Openliquid valve on drum O pen king valve half way and allow
130. efore performing step 3 Check the level of the oil in the sight glass with the compressor operating See Figure 4 11 1 4 Maximum Sight Glass Minimum Old Sight Glass Location and Proper Level Figure 4 11 Oil Level in Sight Glass New Sight Glass Location and Proper Level b Adding Oil with Compressor in System Two methods for adding oil are oil pump method and closed system method 1 Oil Pump M ethod 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 item4 Figure 4 12 150 thereis 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 servicemen to develop sufficient pressure to overcome the operating suction pressure to add oil as necessary Backseat suction service valve and connect oil charging hose to oil fill item4 Figure 4 12 Purge the oil hose at oil pump A dd oil as necessary Refer to section 1 3 2 Closed System M ethod In an emergency where an oil pump is not available oil may be drawn into the compressor through the suction service valve CAUTION Extreme care must be taken to ensure the manifold common connection remains immersed in oil at all times Otherwise air and moist
131. er and requires 55 60 ft lbs torque DO NOT over tighten this type 62 10022 01 TEMPERATURE _F 40 40 36 38 32 36 28 33 26 32 24 31 22 30 20 29 18 28 16 27 14 26 12 24 10 23 8 22 6 21 4 20 2 19 0 18 2 17 4 16 6 14 8 13 10 12 12 11 14 10 16 9 18 8 20 7 22 6 24 4 26 3 28 2 30 1 32 0 62 10022 01 Psig Table 4 8 R 22 Pressure Temperature Chart PRESSURE Kg cm Bar 4 26 TEMPERATURE F Psig 60 5 63 3 66 1 69 75 0 81 4 88 1 91 5 102 5 110 2 118 3 126 8 135 7 145 154 7 164 9 175 4 186 5 197 9 209 9 222 3 235 2 248 7 262 6 277 0 291 8 307 1 323 6 341 3 359 4 377 9 396 6 415 6 434 6 PRESSURE Kg cm 4 25 4 45 4 65 4 85 5 27 5 72 6 19 6 43 7 21 7 75 8 32 8 91 9 54 10 19 10 88 11 59 12 33 13 11 13 91 14 76 15 63 16 54 17 49 18 46 19 48 20 52 21 59 22 75 24 0 25 27 26 57 27 88 29 22 30 56 Bar 4 17 4 36 4 56 4 76 5 17 5 61 6 07 6 31 7 07 7 6 8 16 8 74 9 36 10 0 10 67 11 37 12 09 12 86 13 64 14 47 15 33 16 22 17 15 18 11 19 10 20 12 21 17 22 31 23 53 24 78 26 06 27 34 28 65 29 96 Table 4 9 R 404A Temperature Pressure Chart mr af 3 115 J 124 2 135 7146 sr 9 1 68 165 180177 spi spp 8
132. ergize SV 1 with the unit in high speed cooling and observe the discharge and receiver pressures If the valve is closing properly compressor discharge pressure will begin to rise and the receiver pressure will remain the same or begin to drop slowly If the valve is not seat ing properly both discharge and receiver pressure will rise slowly or remain the same Operate the unit until discharge pressure reaches 200 psig 14 kg cm 9 and disconnect jumper wire to SV 1 valve Discharge and receiver pressure should be within 5 to 15 psig 0 4 to 1 0 kg cm of each other 4 19 CHECKING DEFROST OR HEATING CYCLE NOTE The evaporator temperature must be 35 F 17 C approximately 40 44 C box temperature or lower before any checks can be made a HotGas Solenoid Valve SV 1 SV 3 amp SV 4 Heating and Defrosting 1 Connectadischarge pressure gaugeto the K ingvalve and another gauge to the compressor discharge service valve Connect a gauge to the compressor suction service valve 2 Start unit with controller set at least 10 F 2 5 5 C below indicated box temperature to obtain high speed cooling Pressthe MANUAL DEFROST key to initiate defrost Box temperature must be below 40 F 44 C Thehotgassolenoid valve SV 4 will energize and the hot gas line will be hot to touch on either side of the valve The condenser pressure control solenoid SV 1 closes and suction pressure will rise approximately 10 to 15 psig 0 70 to 1 05 kg c
133. g to solenoid Disconnect linkage arm item 6 Figure 6 3 from solenoid Remove mounting hardware from solenoid and then remove solenoid b Install replacement solenoid and mounting hardware Do not tighten at this time c Attach linkage to solenoid and install the clip to the linkage rod d Hold the speed lever against the low speed stop and check the R PM s Referto Table 6 1 Adjust the low speed stop screw if necessary 6 3 e Check engine speed With the engine stopped place a mark on the crankshaft sheave white paint for example Speed may be verified by a Strobette model 964 strobe tachometer Carrier Transicold P N 07 00206 f Hold the speed lever against the high speed stop and check the RPM s Refer to Table 1 1 Adjust the high speed stop screw if necessary g Energize the speed solenoid Push the solenoid so that the speed arm rests against the high speed stop screw and tighten solenoid mounting bolts Connect wiring to solenoid 6 4 STANDBY MOTOR V BELTS NDM NOTE The standby motor V belts are a matched set Always replace both belt Remove V belt guard Remove 6 bolts on rear face of clutch flange See Figure 6 4 c Slide clutch flange forward inside clutch sheave d Remove and replace V belt through opening e Adjust belt tension to 70 to 80 Install V belt guard DO NOT START UNIT UNTIL V BELT GUARD ISINSTALLED f Start unit and run for 10 minutes to allow for belt stretch g
134. ghten enclosing tube assembly Torque to a value of 100 inch pounds 1 15 mkg Remove supplied installation removal tool Install coil voltage plate and retainer Evacuate and dehydrate the compressor Refer to section 4 10 p through 4 10 w Start unit and check unloader operation Refer to section 4 12 a 4 13 SERVICING THE CHECK VALVE SERVICEABLE TYPE The check valve allows the hot gas to travel in one direction only The function of the condenser coil bypass isto raise the receiver pressure when the ambient temperature islow so that refrigerant can flow from the receiver to the evaporator when the unit is in heating or defrost SEN 4 3 7 7 5 4 BOLT 1 Cap 4 Brass Teflon Seat 2 Copper Washer 5 Body 3 Spring 6 Cover Figure 4 14 Check Valve Serviceable Type a To replace check valve store the refrigerant into an evacuated container Refer to section 4 5 b Replace necessary parts Evacuate and dehydrate unit Refer to section 4 7 d Add refrigerant charge Refer to section 4 8 4 14 CHECKING AND REPLACING FILTER DRIER To Check Filter D rier Check for a restricted or plugged filter drier by feeling the liquid line inlet and outlet connections of the drier cartridge If the outlet side feels cooler than the inlet side then the filter drier should be changed To Replace Filter D rier a Pump down the unit per section 4 5
135. gine Manual Engine Manual Engine Manual Replace 1 2 62 10022 3 1 3 Starter Motor Malfunction CONTINUED INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION Starter motor turns but pinion does not engage Pinion or ring gear obstructed or worn Starter motor does not disen Run Stop switch defective gage after switch was depressed Starter motor solenoid defective Clean both remove burrs or replace apply grease Replace Engine Manual Pinion does not disengage Defective starter Engine Manual after engine is running 3 1 4 Malfunction In the Engine Starting Circuit No power to starter motor solenoid SS Fuel solenoid does not energize or does not remain energized Battery defective Loose electrical connections Oil pressure safety switch OP defective Run relay RR defective Water temperature sensor WTS defective Fuel solenoid defective Run Stop switch defective 3 2 ALTERNATOR Low Voltage Alternator fails to charge Limited charging system operating time Battery condition Alternator belt loose broken Loose dirty corroded terminals or broken leads Excessively worn open or defective brushes Open blocking diode Regulator faulty Open isolation diode Open rotor field coil Alternator belt loose Loose dirty corroded terminals or broken leads Excessively worn sticky or intermittent brushes Faulty regulator Grounded or shorted turns in rotor Open grounded or shorted turns i
136. h Installation Install field coil assembly 1 a Place field coil assembly 1 on pilot diameter of gearbox Align slot in field coil assembly with locator pin in gearbox housing b Install field coil retaining ring 2 IMPORTANT The retaining ring s beveled or tapered edge must face away from the gearbox to obtain proper retention force 2 Install rotor pulley assembly 3 a b Slide rotor pulley onto gearbox housing DO NOT POUND on rotor assembly rock back and forth gently with hand pressure until unit slides on Install bearing retainer nut 4 Tighten nut to 65 lb ft Rotor should spin free without noise Install armature pulley assembly 6 a Slide armature assembly 6 onto gearbox shaft Measure air gap between armature face and rotor face using a wire type feeler gauge Three access holes are provided in the pulley face If the air gap is less than 0 025 in remove armature assembly and add shim s 5 to shaft as shown in Figure 4 25 Use only new shims Repeat steps a and b until an average air gap of 0 025 to 0 035 in is obtained Install a new key 7 in shaft Apply Loctite 609 to shaft and pulley hub bore Slide armature pulley onto gearbox shaft Install washer 8 and lock nut 9 NOTE two types of locking nuts may be used Standard nylon locknut uses flat washer and requires 65 70 ft Ibs torque U pset thread type with integral washer DOES NOT use a separate wash
137. he operating parameters E ach time this key is pressed the display will advance to the next parameter This key in conjunction with the UP DOWN Arrow and ENTER keys will allow the user to change the parameters See Section 1 11 5 Unit Data Key TheUNIT DATA keyisusedto display the unit operating data Thiskey in conjunction with the UP DOWN Arrow keys will allow the user to display the unit s operating data values i e coolant temperature battery voltage etc See Section 1 11 6 1 11 3 SETPOINT Setpoints of 22_F to 86 F 30 Cto 30_C maybe entered via keypad T controller always retains last entered setpoint in memory If no setpoint isin memory i e on initial startup the controller will lock out the run relay and flash SP on the left hand display until a valid setpoint is entered The setpoint may be changed up or down in whole numbers until the desired setpoint is displayed The display will flash to indicate that the setpoint reading being displayed is a non entered value Each time the UP DOWN Arrow key is pressed the 5 second display timer will be reset Depressing the ENTER key will cause the new displayed setpoint value to become active If the display is flashing and the new value is not entered after 5 seconds of no keyboard activity the display will revert back to the active setpoint 1 11 4 DIGITAL DISPLAY The digital display has 9 digits The default display is setpoint on
138. he refrigerant gasto the air T his removal of heat causes the refrigerant to liquefy thus liquid refrigerant leaves the condenser and flows through the solenoid valve SV 1 normally open and to the receiver The receiver stores the additional charge necessary for low ambient operation and for the heating and defrost modes T hereceiver isequipped with afusible plug which melts if the refrigerant temperature is abnormally high and releases the refrigerant charge Therefrigerant leavesthe receiver and flowsthrough the manual receiver shutoff valve King valve The refrigerant then flows through the subcooler The subcooler occupies a portion of the main condensing coil surface and gives off further heat to the passing air Therefrigerantthen flows through a filter drier where an absorbent keeps the refrigerant clean and dry and the electrically controlled liquid line solenoid valve SV 2 which starts or stops the flow of liquid refrigerant In R 404A units the refrigerant flows to the Liquid suction heat exchanger Here the liquid is 62 10022 01 1 28 further reduced in temperature by giving off some of its heat to the suction gas The liquid then flows to an externally equalized thermostatic expansion valve which reduces the pressure of the liquid and meters the flow of liquid refrigerant to the evaporator to obtain maximum use of the evaporator heat transfer surface The refrigerant pressure drop caused by the expansi
139. hortage Solenoid SV 1 open Defective HP 2 3 3 7 Abnormal Noise Compressor Loose mounting bolts Tighten Worn bearings 4 10 Worn or broken valves 4 10 Liquid slugging 3 3 10 Insufficient oil 4 11 Condenser or Loose or striking shroud Check evaporator fan Bearings defective 4 21 Bent shaft 4 21 Cluich Gearbox 3 3 8 Control System Malfunction Will not control Sensor defective Relay s defective Microprocessor controller malfunction 3 3 9 No Evaporator Air Flow or Restricted Air Flow Evaporator coil blocked Frost on coil 4 19 Dirty coil 4 22 4 4 No or partial evaporator V belt broken or loose air flow Clutch G earbox defective Replace Evaporator fan loose or defective Evaporator fan rotating backwards Evaporator air flow blocked in trailer 3 5 62 10022 INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 3 3 10 Expansion Valve Malfunction Low suction pressure with high superheat Low superheat and liquid slugging in compressor Low refrigerant charge External equalizer line plugged Ice formation at valve seat Wax oil or dirt plugging valve or orifice Broken capillary Power assembly failure or partial Replace Loss of element bulb charge Replace Superheat setting too high 4 24 SV2 stuck closed 3 3 11 Superheat setting too low External equalizer line plugged Ice holding valve open Foreign material in valve Pin and seat of expansion valve eroded or held open by foreign material
140. i pankasa Nee d et 4 7 4 7 3 Procedure for Evacuation and D ehydrating System 4 7 48 Adding Refrigerant To System Full Charge 4 8 49 Adding Refrigerant To System Partial Charge R 22 Only 4 8 410 Replacing The 4 8 411 Checking Compressor Oil Level 0 4 9 4 12 Compressor Unloader Valve 4 10 413 Servicing The Check Valve ServiceableType 4 11 4 14 Checking and ReplacingFilter drier 4 11 4 15 Checking and Replacing High Pressure Cutout Switch 4 11 4 15 1 Replacing High Pressure Switch 4 11 4 15 2 Checking High Pressure Switch 1 2 4 12 4 16 Replacing Receiver Sight Glass Assembly 4 12 417 Servicing Solenoid Valves mn 4 12 4 17 1 Solenoid Valves Alco SV2 SV4 4 12 4 17 2 Solenoid Valve Sporlan SV 5 3 cece eens 4 13 4 18 Solenoid Valve SV 1 Checkout Procedure 4 13 4 19 Checking Defrost or Heating Cycle 4 14 4 20 Checking Calibration of The Defrost Air S
141. int See Figure 1 16 Null mode operates with a pulse which combines cooling or heating with a null valve combination over a 10 second period Thenull valve portion of the period is defined as HR1 and HR 4 de energized and HR 2 energized The calculated pulse percentage determines the type of pulse needed and the percentage of the 10 second period to pulse At the end of each period the type of pulse and percentage is updated When in the null mode The HEAT and COOL LCD s on the microprocessor display will blank out The heat and cool lights on light bar will flash back and forth every 10 seconds or less UltraFresh 2 only operates when Setpoint is in the perishable range 10 12 C and the unit isset for continuous run operation Thereisa delay of 10 seconds between de energizingone unloader to de energizing the other unloader under all operating conditions excluding engine starting 62 10022 01 FALLING TEMPERATURE RISING TEMPERATURE 2 0 C 43 6 LOADED COOL 15 C 2 7_F LOADED COOL UNLOADED COOL UNLOADED COOL 1 0 1 8 F 0 5 C 40 9 PULSED PULSED NULL BAND SET POINT NULL BAND 0 5 0 9 1 0 C 1 8 F UNLOADED HEAT UNLOADED HEAT 1 5 C 2 LOADED HEAT LOADED HEAT 2 0 C 3 6 Figure 1 16 UltraFresh 2 Temperature Control Operating Sequence 62 10022 01 1 26 1 14 ULTRA FREEZE TEMPERATURE CONTROL WITH SOFTWARE 3 14 OR HIGHER For f
142. ion 4 1 1 Turn nut counter clockwise to loosen and remove item 1 Figure 4 3 2 Remove banjo fitting item 2 and let it hang loose making sure to keep copper rings item 4 for replacement 3 Turn filter item 3 counter clockwise and remove Check and clean 4 To install reverse steps 1 through 3 62 10022 01 1 Nut 2 Banjo 3 Filter 4 Copper Rings Figure 4 3 Mechanical Fuel Pump b Electrical Pump See Figure 4 4 To Check or Replace Filter 1 Remove3 screws from cover item 1 Figure 4 4 2 Remove cover gasket and filter 3 Wash filter in cleaning solvent and blow out with air pressure Clean cover 4 To Install reverse above steps 1 Cover 2 Gasket 3 Filter Figure 4 4 Electric Fuel Pump Optional 62 10022 01 4 4 4 3 6 Servicing Glow Plugs The glow plugs when energized draw a nominal 7 0 amps at 10 5 vdc When servicing the glow plug is to be fitted carefully into the cylinder head to prevent damage to glow plug Torque value for the glow plugis 14 to 18 ft lb 1 9 to 2 5 mko Checking for a D efective Glow Plug a One method is to place an ammeter or clip on ammeter in series with each glow plug and energize the plugs Each plug if good should show 7 to 10 amps draw b A second method is to disconnect the wire connection to the plug and test the resistance from the plugto aground the engine bloc
143. ion and maintenance of the equipment covered herein WARNING High voltage in electrical box disconnect power before servicing unit WARNING Beware of V belts and belt driven components as the unit may start automatically Before servicing nx make sure the Run Stop switch is in the STOP position Also disconnect the negative battery cable WARNING Beware of unannounced starting of the evaporator and condenser fan WARNING Make sure power to unit is OFF and negative battery cable is disconnected before servicing the compressor unloader CAUTION Under no circumstances should anyone attempt to repair the logic or display boards Should a m develop with these components contact your nearest Carrier Transicold dealer for replacement CAUTION Under no circumstances should a technician electrically probe the processor atany point other than the connector terminals where the harness attaches Microprocessor components operate at differentvoltage levels and atextremely low currentlevels Improper use of voltmeters jumper wires continuity testers etc could permanently damage the processor CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precautionary measure disconnect positive battery terminal when charging battery in unit Connecting chargerin reverse will destroy the rectifier diodes in alternator 5 1 62 10022
144. k T hereading should be 0 7 to 1 2 ohms if the plug is good 4 4 SERVICING AND ADJ USTING V BELTS WARNING Beware of V belts and belt driven components as the unit may start automatically 4 4 1 Belt Tension Gauge Itisrecommended using a belt tension gauge tester P N 07 00253 shown in Figure 4 5 whenever V belts are adjusted or replaced A belt tension gauge provides an accurate and easy method of adjusting belts to their proper tension Properly adjusted belts give long lasting and efficient service Too much tension SHORTENS belt and bearing life and too little tension causes slippage and excessive belt wear It is also important to keep belts and sheaves free of any foreign material which may cause the belts to slip The belt tension gauge can be used to adjust all belts The readings which we specify for Carrier Transicold unitsare applicable only for our belts and application as the tension is dependent on the size of the belt and distance between sheaves When using this gauge it should be placed as close as possible to the midpoint between two sheaves See Figure 4 6 The V belts must be kept in good condition with the proper tension to provide adequate air movement across the coils 5kw Generator to Drivershaft 70 to 80 Figure 4 5 Belt Tension Gauge Part No 07 00253 4 4 2 Water Pump V Belt The water pump V belt is driven by a sheave on the engine crankshaft Frayed cracked or worn belts must be re
145. ked out with set points below 10 F 12 2 C When vapor refrigerant is compressed to a high pressure and temperature in a reciprocating compressor the mechanical energy necessary to operate the compressor is transferred to the gas as it is being compressed T his energy isreferred to asthe heat of compression and isused asthe source of heat during the heating cycle The quench valve R 22 Only opens as required to maintain a 265 to 285 F 129 to 141 C maximum discharge temperature 1 17 1 Heating and Defrost NOTES l Solenoid valve SV 2 remains open during heating or defrosting to allow additional refrigerantto be metered into the hot gas cycle through the expansion valve providing additional heating capacity until de energized by head pressure control switch HP 2 2 SV 3 will open after a 60 second delay if the difference between ambient and discharge temperatures exceeds 100 F 55 5 C If the difference between ambient and discharge temperatures goes below 50 F 27 8 C SV 3 will close When the controller calls for heating hot gas solenoid valve SV 4 opens and the condenser pressure control solenoid valve SV 1 closes T he condenser coil then fills with refrigerant and hot gas from the compressor enters the evaporator A so the liquid line solenoid valve SV 2 will remain energized valve open as the head pressure control switch HP 2 will remain closed until the compressor discharge pressure increases to
146. ld SOLENOIBY _ 513 NC LN Y CONDENSER PRESSURE p NC CONTROL SOLENOID COMPRESSOR pisCHARGE lt Sv NO CHECK VALVE Daz CONDENSER VIBRASORBER gt Figure 1 21 R 404A Refrigerant Circuit Heating and Defrosting 62 10022 01 1 32 SECTION 2 OPERATION 2 1 PRE TRIP INSPECTION a Before Starting Engine WARNING 1 Drain water and sediment from fuel tank sump T hen Under no circumstances should ether or fill tank with diesel fuel Refer to section 1 2 any other starting aids be used to start 2 Check radiator coolant level Add pre mixed 50 50 engine permanent antifreeze water as required USE ETHYLENE GLYCOL ONLY Refer to section NOTES 12 1 Whenever starting the engine in order to reduce Check evaporator and condenser coil for cleanliness starter cranking and engine loads the Check engine lubrication and fuel filter oil lines and always operates In connections for leaks Tighten connections and or unloaded cool for the first 15 seconds A fter first replace gaskets 21449 15 secondsthe microprocessor will allow the unit 9 to operate normally providing the coolant 5 Check engine oil level Refer to section 1 2 temperature is above 79 F 26 C 6 Check V belts for proper tension fraying or cracks 2 With software revisions 3 08 or 3 12 when A djust belt or replace configuration CNF1lis ON and setpoint is 32 to 42 O
147. ld detergent solution such as Oakite 164 or any good commercial grade automatic 62 10022 01 4 16 dish washer detergent such as E lectrosol or Cascade and let the solution stand for a few minutes and reverse flush opposite normal air flow with clean water at mild pressure garden hose with spray nozzle is usually sufficient M ake sure drain linesare clean Run unit until defrost mode can be initiated to check for proper draining from drain pan Refer to section 2 4 23 CONDENSER COIL CLEANING Remove all foreign material from the condenser coil by reversingthe normal air flow Airis pulled in through the front and discharges over the engine Compressed air or water may be used as a cleaning agent It may be necessary to use warm water mixed with any good commercial dishwasher detergent Rinse coil with fresh water if a detergent is used 4 24 THERMOSTATIC EXPANSION VALVE The thermal expansion valve is an automatic device which maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure The valve functions are a automatic response of refrigerant flow to match the evaporator load and b prevention of liquid refrigerant entering the compressor U nless the valve is defective it seldom requires any maintenance a Replacing Expansion Valve 1 PumpdowntheunitbyclosingtheK ing valve R efer to section 4 5 a Remove insulation Presstite from expansion valve bulb and
148. lection or modify the displayed data Enter Key The ENTER key is used to accept a change in unit parameters or a change in setpoint Manual Defrost Key The MANUAL DEFROST key is used to initiate a defrost cycle given that the proper conditions are met Refer section 1 11 10 Pretrip Check Key The PRETRIP CHECK key is used to initiate a pretrip cycle given that the proper conditions are met Refer to section 1 11 8 Auto Start Stop Continuous Key NOTES With software revisions 3 08 or 3 12 when configuration CNF11 is ON and setpoint is 32 to 42_F 0to 5 5 C the unitis locked into continuous run Start Stop Continuous key is disabled in this setpoint range With software revision 3 15 or higher when configurations CNF3 amp CNF11 are ON and setpoint is 32 to 42 F 0to 5 5 C the unit is 1 locked into continuous Start Stop Continuous key is disabled in this setpoint range The START STOP CONTINUOUS key is used to change the operating mode from auto start continuous run to auto start stop Each push of the key will alternate the operating modes T he operating status will be stored in memory and will be retained through power outages T he digital display will indicate when stop start is enabled Also See Section 1 11 11 To start the unit in manual start mode the START STOP CONTINUOUS selection must be in continuous run mode Function Change Key The FUNCTION CHANGE key is used to display t
149. lowest up to five 7 Pressthe Carrier logo for ten seconds and this will remove the lock light and store the pre set setpoints in memory c To Remove a Pre set Setpoint Start unit and press system on off button to ON position see Figure 2 2 2 PressCarrier logo and the lock light will be displayed 3 Presshost compartment up arrow for 10 seconds P1 will be displayed in all compartments 4 Set temperature to lowest possible and OF will be displayed 5 Press the up arrow on remote compartments will display the presets take the temperature to the lowest possible and OF will be displayed 6 Pressthe Carrier logo for ten seconds and the new information will be stored in memory 2 5 MICROPROCESSOR CONTROLLER NOTE The Genesis nosemount unit microprocessor controller controls all compartments Refer to section 1 11 The Genesis microprocessor controller controls up to two remote compartments The compartments are enabled by the compartment O N OFF switch located on the remote control box When a compartment is enabled the controller will maintain temperature based on setpoints entered via the keypad function parameter 2 3 selections Two temperature thermistor sensors are used to monitor the return air of each evaporator Temperature control is achieved by switching between modes cool null and heat There are overriding factors which would prevent the remote compartments from cooling or heating If the m
150. m after 5 minutes on unit operation Refer to section 4 18 if unit does not heat properly 3 SV 3will open after a 60 second delay if the engineis in high speed and the difference between ambient and discharge temperatures exceeds 100 F 55 6 C If the difference between ambient and 62 10022 01 4 14 discharge temperatures goes below 50 F 27 8 C SV 3 will close The unit will remain in defrost until coil temperature increasesto 50 F 10 C wherethe defrost thermostats open and the unit resumes automatic operation Defrost Air Switch DA To check air switch run unit in high speed cooling and jump across the air switch terminals This will start the defrost cycle asit simulatesthe action ofthe defrost air switch Bypassing the switch in this manner operates all components involved in defrost U nit should remain in defrost until evaporator coil temperature reaches 50 F 10 C Atthis point the two defrost thermostats should open to terminate the defrost cycle Replace the defrost thermostats if unit fails to terminate defrost If the above test indicates satisfactory operation test defrost air switch DA settings using a Dwyer Magnehelic gauge P N 07 00177 or similar instrument Refer to section 4 20 Solid State Defrost Timer Refer to section 1 11 10 for description 4 20 CHECKING CALIBRATION OF THE DEFROST AIR SWITCH 1 Ohmmeter or Continuity Device 2 Adjustment Screw 0 050 socket head size 3 L
151. n in dusty conditions in order to protect against over heating of the capacitor and generator windings When trouble shooting the 5KW generator it is important to check the internal capacitor the forward reverse rotating diodes and the internal windings The forward reverse rotating diodes are located at the filter end of the generator T he reverse diode is marked with a red dot on the solder terminal The forward diode is unmarked A faulty diode will give a short circuit or open circuit reading in both directions Generally premature capacitor failure can be attributed to over speeding or over heating of the generator The maximum speed for the generator is 3600 rpm Setting engine speed on multi temp units is critical to proper operation of the generator The engine speed should be set to 1700 rpm with unit operating in fully loaded cool mode with all compartments turned on Refer to Table 4 7 for corresponding generator voltage output Table 4 7 Generator Voltage Output UNIT Generator an A generator fault finding guide is shown in Figure 4 24 Thisshould be used whenever troubleshooting a problem with a 5K W generator Engine RPM 1700 1700 4 34 1 Generator Flashing In the event of voltage output failure the generator may have lost its residual magnetism T 1151055 be restored by flashing the generator by following these steps 1 Shuttheunit OFF and turn the remote compartment power swit
152. n stator Low or unsteady charging rate Excessive charging rate as evidenced by battery Regulator leads loose dirty corroded terminals or wires broken requiring too frequent refilling or Defective regulator charge indicator shows constant charge with engine idling Noisy alternator Defective or badly worn V belt Worn bearing s Misaligned belt or pulley Loose pulley 62 10022 01 3 2 Battery defective Check Loose electrical connections Tighten Check Tighten Replace Replace Replace Engine Manual Replace Check Check 4 4 Check Repair Check Check Check Check Replace 4 4 Check Repair Check Check Check Replace Clean Repair Check 4 4 Replace 4 4 Tighten INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 3 3 REFRIGERATION 3 3 1 Unit Will Not Cool Compressor malfunction Compressor drive defective 4 10 Compressor defective 4 10 Refrigeration system Defrost cycle did not terminate Abnormal pressure Solenoid valve malfunction 3 3 2 Unit Runs But Has Insufficient Cooling Compressor Compressor valves defective 4 10 Unloader malfunction 4 12 Refrigeration system Abnormal pressure Unloader malfunction Expansion valve malfunction No or restricted evaporator airflow Engine does not Engine malfunction 3 1 develop full rom 3 3 3 Unit Operates Long or Continuously in Cooling Trailer Hot Load Allow time to pull down Defective box insulation or air leak Correct Poor air dis
153. nds continuously NOTE Once the unit is programmed for M an OP the AUTO S S CONTINUOUS key can be used to toggle between Auto Start Stop and Continuous Run Table 2 1 Manual Glow Time Ambient Temperature Seconds For TV 33 F to 50 F 1 C to 10 C 5LFto77 F llCto25C 5 Greater than 78 F 26 C O 5 0 5 40 b Stopping Instructions Place RU N STOP switch in the STOP position to stop unit 2 3 REMOTE COMPARTMENT OPERATION a With Remote Control Box Figure 2 1 To start remote evaporator place the remote compartment switch in the ON position See Figure 2 1 Set desired temperature using nosemount unit microprocessor controller Refer to section 1 11 The manual defrost switch and function lights for each compartment are on the remote control box Turn remote compartment switch O FF when remote evaporator is not required NOTE For starting instructions on the nosemount unit refer to section 2 2 62 10022 01 3 1691 sP n COMPARTMENT 1 ETT 2 2 3 MANUAL lt DEFROST OFF 471 2 0 l 1 Cool Heat Defrost Power Lights 2 Manual Defrost Switch 3 Compartment ON OFF Switch 2ST
154. ng the housing to the drive hub Remove snap ring and housing After replacing necessary parts reassembly by reversing above steps Install snap ring painted side must face away from bearing Start unit and check operation 13 77 ERIS RS SRN N 10 J 9 S Rotor Plate 9 Housing Friction Shoe 10 Screw Delta Bridge 11 Washer Spring Leaf 12 Ball Bearing Assembly Screw 13 Snap Ring Washer 14 Retaining Plate Coupling Adapter 15 Snap Ring External Housing Assembly Figure 6 5 Standby Clutch Assembly NDM o 10 22001 29
155. o 62 03998 NDA Prior to S N FAC90391017 10 22001 29 YS
156. ompressor if removed with defective compressor m Figure 4 10 Pressure Switches 1 and HP 2 Install compressor in unit by reversing step 4 12 c through n It is recommended using new locknuts when replacing compressor Torque bolts to a value of 46 ft Ib 6 4 mkg Install new gaskets on service valves and tighten bolts uniformly Attach two lines with hand valves near vacuum pump to the suction and discharge service valves D ehydrate and evacuate compressor to 500 microns 29 90 H g vacuum 75 9 cm g vacuum Turn off valves on both linesto pump Fully backseat open both suction and discharge service valves Remove vacuum pump lines and install manifold gauges Start unit and check for noncondensibles Check refrigerant level section 4 9 b Check compressor oil level Refer to section 4 11 A dd oil if necessary 4 9 v Check compressor unloader operation Refer to section 4 12 w Check refrigerant cycles Refer to section 2 4 11 CHECKING COMPRESSOR OIL LEVEL To Check the Oil Level in the Compressor Operate the unit in high speed cooling for at least 20 minutes Check the oil sight glass on the compressor to ensure that no foaming of the oil is present after 20 minutes of operation If the oil isfoaming excessively after 20 minutes of operation check the refrigerant system for flood back of liquid refrigerant Correct this situation b
157. on valve is accompanied by a drop in temperature thus the low pressure low temperature fluid that flows into the evaporator tubes is colder than the air that is circulated over the evaporator 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 T his cold air is circulated throughout the trailer 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 In R 22 units this low temperature low pressure vapor returnsto the compressor In R 404A unitsthislow temperature low pressure vapor passes through the suction line liquid line heat exchanger where it absorbs more heat from the high pressure high temperature liquid and then returns to the compressor The quench valve R 22 Only opens as required to maintain a 265 to 285 F 129 to 141 C maximum discharge temperature The remote evaporator s refrigerant flows through the electrically controlled liquid line solenoid valve L SV which starts or stops the flow of liquid refrigerant E
158. onds If 330 seconds 15 reached stage two Defrost Begins will automatically be entered regardless of suction pressure Stage 2isdefrost Stage 3 Defrost Termination is the termination of defrost W hen defrost is terminated SV 4 will remain energized for 15 seconds SV 3 is locked out e Electric Standby Motor Operation Refer to Section 6 On electric standby motor operation HR 4 relay is used to initiate a pump down cycle in heat or defrost Table 1 8 Stages for Defrost with Greater Than 100_F 37 8_C or 80_F 26 7_C Ambient with Software 3 14 or higher SV1 SV2 SV3 SV4 CLH STGE ui oma om omn W ou OPEN oan CLOSED eee De energ rd Contro 9 Energ OPEN OPEN CLOSED OPEN Energ ER De energ De energ De energ Energ De energ De energ De energized OPEN Energ Energ Energized 62 10022 01
159. operation and allows for electric standby operation Also there isa standby motor contactor and a receptacle for a power plug The diesel engine drivesthe compressor directly through a centrifugal clutch except during standby operation During standby operation the centrifugal clutch is disengaged from the compressor sheave T he compressor is then belt driven by the standby motor b Remote Evaporator There is only one remote evaporator used per compartment with model This evaporator has a single discharge with 3 DC fan motors and electric heaters See Figure 6 1 6 2 ELECTRICAL DATA 3000 watis 6 1 Host Evaporator Heaters Two Compartment Voltage Wattage Number Remote Evaporator Heaters Two Compart Number Voltage Wattage Remote Evaporator Heaters Three Compart ment Number Voliage 62 10022 01 62 10022 01 TS r Defrost Terminal Sensor High Temperature Klixon Heaters Thermostat Sensor 5 Evaporator Fan Motor 6 Expansion Valve 7 Liquid Solenoid Valve LSV Figure 6 1 Remote Evaporator 6 2 1 Capacitor 2 Fuse4 amp F10 FH 12 FR F13 Fl4 Fl5 FI6 FI F18 1HVR 2HVR 3HVR 3 Contactor 4 Relays 30 amp Figure 6 2 High Voltage Control Box 6 3 SERVICING SPEED CONTROL SOLENOID AND LINKAGE 3 1 Solenoid 4 Linkage Speed 2 Bolt 5 Clip 3 Solenoid Bracket Figure 6 3 Speed Control Solenoid a Disconnect wirin
160. oprocessor inputs operate at voltage levels other than the conventional 12 vdc Connector points and the associated approximate voltage levels are listed below for reference only U nder no circumstances should 12 vdc be applied at these connection points Grounded wrist cuffs are available at most radio computer and electronic supply stores It is recommended that these be worn whenever handling a microprocessor Table 4 3 Connection Point Voltage Connection Point Approximate Voltage CDT RAS SAS WTS 2 5 vdc Variable CAUTION Most electronic components are susceptible to damage caused by electrical static discharge ESD In certain cases the human body can have enough static electricity to cause resultant damage to the components by touch This is especially true of the integrated circuits found on the truck trailer microprocessor Although there isless danger of electrical static discharge ESD damage in the outdoor environment where the processor is likely to be handled proper board handling techniques should always be stressed Boards should always be handled by their edges in much the same way one would handle a photograph T his not only precludes the possibility of ESD damage but also lowers the possibility of physical damage to the electronic components Although the microprocessor boards are fairly rugged when assembled they are more fragile when separated and should always be handled carefully D uring
161. or 3ST 4 Defrost Timer 5 Relays 6 Diode Block Figure 2 1 Remote Control Box 2 4 COMPARTMENT OPERATION With Optional Compartment Control Box Figure 2 2 a Starting Compartment 1 Switch unit E ngine Start run switch ON For starting instructions on the nosemount unit refer to section 2 2 2 Press system on off button to ON position see Figure 2 2 3 Press required compartment on off button to ON position see Figure 2 2 4 The unit will start and display DEF for 20 seconds The last temperature setpoint and current compartment temperature will then be displayed 5 Set required temperature by pressing up or down arrow keys as required 6 Turn compartment button OFF when evaporator is not required b To SetPre set Setpoint 1 Switch main on off switch on the unit to ON Press system on off button to ON position see Figure 2 2 2 PressCarrier logo and the lock light will be displayed 3 Press host compartment up arrow for 10 seconds P1 will be displayed in all compartments Figure 2 2 Compartment Control Box Optional 4 Setlowest setpoint temperature required 5 PressCarrier logo and P2 will be displayed Set next lowest temperature required up to five pre set setpoints are available 6 Pressingthe second compartment up or down arrow will allow the lowest temperature required to be preset in the second compartment pressing the Carrier logo will then move on to the next
162. or 90 minutes T he data for the off time will be displayed with two digits and then the capital letter M minutes i e OFF T 20M On Time Theon time selection for the auto start mode isdisplayed with the description ON T or FN3 With software revision less than 3 11 the on times are 4 or 7 minutes With software revision 3 11 higherthe on time is 4 minutes The data for the on time will be displayed with two digits and then the capital letter M for minutes i e ON T 4M Controlling Probe The number of controlling probes is displayed with the following abbreviations REM PROBE fora single probe return air control SUP PROBE for a dual probe control return and supply air The code display is FN 4 The 1 probe setting is A and the 2 probe setting is Standard Units Select The standard unit select will control how all parameters are displayed The two choices are DEGREES F and DEGREESC Thisparameter also will control units that dataisdisplayed in psigor bars i e D egreesF or D egrees C The code display is FN5 The selections are F or Maximum Off Time The description for the maximum off time is TEMP STRT OR TIME STRT The code display is F N 6 and the selections are or OFF ON corresponds to TIME STRT With the unit in time start the control will force the engine to restart 30 minutes after shutoff MOP STD Future Expansion Thisfunction is not used at this time The displa
163. ore starting 2 Pre Trip Inspection after starting 3 Check engine hours l Pre Trip Inspection before starting 2 Change lube oil and filter 3 Pre Trip Inspection after starting 4 Check engine hours gt Complete 400 Hour Maintenance Refer to paragraph 1 2 for oil change intervals Tighten engine compressor and unit mounting bolts Tighten all electrical connection in control box Calibrate defrost air switch Replace air cleaner check hose and connections Check water pump bearing end play Check alternator brushes Clean evaporator and condenser coils Check fuel pump FP filter Replace fuel filters X X X X X X X X X d Every 3000 Hour Maintenance Complete a 1500 Hour Maintenance 4 1 Clean crankcase breather 4 3 Replace all V belts 4 Check starter condition E Check and adjust injector nozzles Engine Manual e Every 6000 Hour or 2 Years Maintenance 1 Check and adjust injector nozzles Engine Manual 2 Check engine compression Engine Manual 3 Adjustengine valves Engine Manual 4 Drain and flush cooling system 4 3 1 4 1 62 10022 01 4 2 PRIMING THE FUEL SYSTEM a Mechanical Fuel Pump Theunitisequipped with a mechanical fuel lift pump itis mounted on the engine next to the injection pump also see section 4 3 5 This pump has a manual plunger for bleeding fuel when the fuel tank has been run dry Since the unit employs a closed fuel circuit it is recommended to use the following ste
164. ovided which will cause the engine to be started 30 minutes after the engine has stopped regardless of the box temperature 1 11 12 Remote Monitoring DataTrak Optional The microprocessor controller is equipped with a R S232 communication port This port can be used to communicate unit operating data to a mobile satellite transmitter T hisinformation will then be relayed back to the office via a modem to a computer There are presently two 2 protocols supported The protocol for the QualComm transmitter and Carrier Communication Protocol The microprocessor will transmit in the Carrier QualComm protocol if a data packet is requested 1 12 SWITCHES AND CONTROLS 1 12 1 Introduction Componentsrequired for monitoringand controllingthe diesel engine refrigeration system are located in the control box door and relay module The water temperature sensor is located on top of the engine 1 12 2 Control Box Door and Relay Module See Figure 1 7 and Figure 1 9 a Gauges 1 Ammeter Gauge A Thed cammeter indicatesthe rate of charge or discharge of the battery charging system including batteries battery charging alternator and the voltage regulator b Switches 1 Run Stop Switch R S When placed in the RUN position this switch provides power to the microprocessor The microprocessor performs a self test all segments of display are illuminated Then Set Point and Box Temperature are displayed To stop the unit
165. ow Side Connection 4 Pressure Line or Aspirator Bulb P N 07 00177 01 5 Magnehelic Gauge P N 07 00177 6 High Side Connection Figure 4 18 Defrost Air Switch Test Setup M ake sure magnehelic gauge isin 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 CALIBRATED With air switch in vertical position connect high pressure side of magnehelic gauge to high side connection of air switch See Figure 4 18 Install tee in pressure line to high side connection Tee should be approximately half way between gauge and air switch or an improper reading may result d Attach an ohmmeter to the air switch electrical contacts to check switch action NOTE Use a hand aspirator P N 07 00177 01 since blowing into tube by mouth may cause an incorrect reading e With the gauge reading at zero apply air pressure very slowly to the air switch An ohmmeter will indicate continuity when switch actuates f Referto section 1 3for switch settings If switch fails to actuate at correct gauge reading adjust switch by turning adjusting screw clockwise to increase setting or counterclockwise to decrease setting g Repeat checkout procedure until switch actuates at correct gauge reading h After switch is adjusted place a small amount of paint or glycerol on the adjusting screw
166. placed A djustment is achieved by alteringthe position of the front side idler When replacing V belt avoid excessive force when applying tension to the V belt to prevent damage to the water pump bearings Refer to Table 4 1 4 4 3 Alternator V Belt a Make sure negative battery terminal is disconnected and remove old belt b Place V belt on alternator sheave and then install alternator with two bolts loosely in position C Check the center alignment of the Clutch G earbox driving pulley and alternator pulley to ensure proper drive Pulley misalignment will create excess belt wear and limit alternator bearing life T he center line of the alternator sheave and the driving sheave must be in line d Pivot alternator to place tension on belt using hand force only Do not use pry bar or excessive force as it may cause bearing failure For correct belt tension see table 4 1 Tighten pivot and adjustment bolts e iG Q 4 y 1 Evaporator Condenser Fan V Belt 2 Idler Pulley 3 Alternator V Belt 4 Drive V Belt Figure 4 6 V Belt Arrangement 4 5 4 4 4 Driveshaft to Clutch Gearbox and Clutch Gearbox To Evaporator C ondenser Fans a Clutch Gearbox to Fan Shaft V Belt To Replace V belt 1 Disconnect negative battery cable and remove V belt guard Loosen idler pulley Remo
167. ps or remove fuel filter and fill with fuel and replace 1 Turn bleed valve Red counter clockwise until fully opened See Figure 1 5 2 Turn the top of the manual plunger counter clockwise to unlock it See Figure 1 5 Then slowly hand pump the manual plunger until a positive pressure resistance is felt which will indicate fuel flow 3 Depress and turn the top of the manual plunger clockwise to lock in place 4 Start engine 5 When engine is running properly turn bleed valve clockwise until fully closed b Electrical Fuel Pump If the unit is equipped with electrical fuel pumps they are mounted on the fuel tank mounting bracket also see section 4 3 5 It is recommended to use the following steps 1 Open bleed valve located on top of the injection pump See Figure 1 5 2 Start engine 3 When engine is running properly turn bleed valve clockwise until fully closed 4 3 ENGINE SERVICE AND COMPONENTS 4 3 1 Cooling System Air flows through the radiator by using the engine fan The radiator externally and internally must be clean for adequate cooling The water pump V belt must be adjusted periodically to provide maximum air flow Refer to section 4 4 2 Do the following to service the cooling system 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 engin
168. pt The add glow time is deselected when the engine starts or fails to start This parameter will not change due to the Code vs E nglish selection Alarm Reset Alarms can be reset through this function messages are displayed aa ALARM RST or ALARM CLR If the ALARM RST isdisplayed then thereis atleast one alarm present Pressingthe ENTER keywill clear all the alarms present If the ALARM CLR 15 displayed then there are no alarms present See section 1 11 7 This parameter will not change due to the code vs English selection REM Controlling Probe PROBE Return Air SUP Controlling Probe PROBE Supply Air Degrees Temperature Unit Forc F STRT Maximum Off time 30 Min F FN1 ON FNI OF F F N N FNAA n Z e FN4B 2 3 5 7 9 FN FN6 ON FN6 OFF N STRT Restarting FNIO OF FN11 Out of Range Tolerance Alarm Reset Alarm Reset or No Alarms a FN10 ON F Defrost Interval Main Unit The defrost interval is displayed with the description DEFR or FNO The data for the interval will be displayed with one decimal place and then the capital letter H for hours i e DEFR 12 0H The defrost intervals are 1 5 3 12 hours Airflow Not Applicable The data is not applicable for this application Off Time The off time selection for the auto start mode is displayed with the description OFF T or FN2 The off timesare 10 20 30 45
169. r RCS 51 39 KS 05 R2 DK DATALINK OPTIONAL TERM pi gj PKT AS DL DEFROST LIGHT LIGHT BAR asar Kis PIS 2 3DL DEFROST LIGHT REMOTE LIGHT spis O Heca 39731 SR SPK1 URR DR DEFROST RELAY mo s GH Hera 7125 J14 15 N14 15 2 3DR DEFROST RELAY 2ND 3RD COMPARTMENT L gt m 315 K11 N15 011 2 30 DEFROST RELAY C2ND 3RD COMPARTMENT 10 so 63 F4 DTI _ DEFROST _ 5 SIUS Spk1 HR4 K15 P15 973 DEFROST THERMUSTAT QND 3RD COMPARTMENT VECES 62 x CL COS K14 2098 DRAIN WATER HEATER COMPARTMENT wy 24 B14 SOWR DRAIN WATER HEATER CORD COMPARTMENT K14 2 FR EVAPORATOR FAN RELAY 2ND COMPARTMENT 9 x VV V3 15 014 3EFR EVAPORATOR FAN RELAY COMPARTMENT NI oj 4829 DKC L2 FI FUSE CHAK FUSE B0 AMPERED 19 F2 USE 20 AMPERE BC HED x q gt V JP URR 13 FUSE 25 AMPERE 15 3 87 HC21 C 0 15 4 FUSE 15 5 x UFR SPK V VV 16 F5 FUSE 7 5 AMPERE Dig ee aes 7 15 E FUSE CIS AMPERE 12 USE 15 AMPERE ED x mre An F Ke 218 n t8 FUSE 15 AMPERE F5 Hi SP15 01 USE 5 SP20 SPK3 SPKS ho f ME L9 FH FUEL HEATER OPTIONAL r 35 CGT 85 6 4 25 uesa ol Heer J9 R3 FHR FUEL HEATER RELAY OPTIONAL 7 7 5 HR2 L3 FHT FUEL HEATER THERMOSTAT OPTIONAL OR L9 FL FAULT LIGHT LIGHT BAR ANI B BH gcn OF c
170. r securing nuts or bolts is 15 inch Ibs b Hour Meters The hour meter can be setto any value viathe serial port if the meter has less then 5 hours on it This allows a replacement microprocessor to be set to the same hours as the microprocessor it is replacing The microprocessor has 2 programmable registers which are set viathe serial port T hese registersare compared to one of the hour meters diesel standby or switch on If the hour meter is greater than the register then the proper alarm is set 62 10022 01 4 28 CONFIGURATION of MICROPROCESSOR When replacing a microprocessor it isimportant to check that the configurations are compatible for the unit into which it will be installed This same board fits both trailer and truck model units All configuration fields should be viewed before starting the unit a To reach the configuration fields 1 Turn the Run Stop switch to the Stop position 2 With the unit off locate the serial port plug located below the control panel Remove the protective plug to gain access to the wire terminals Place an insulated jumper wire between wires SPA and SPB at the serial port plug CAUTION Do not allow jumper wire to touch any ground Turn the Run Stop switch to the Run position The FAULT light will come on and the micro display will read CNF1TV or CNFIDI Removethejumper wire from the serial port and reinstall the protective plug The configuration screen will now remain
171. r Discharge 2 Valve Stem Valve 3 Gas Bypass Port 12 Valve Plate 4 Spring Guide 13 Cylinder Suction 5 Spring Valve 6 Piston 14 Discharge Piston 7 Piston Bypass Valve Check Valve 8 Bleed Orifice Assembly 9 Strainer 15 Discharge Manifold 10 Suction Manifold Figure 1 12 Compressor Cylinder Head Unloaded Hot Gas Bypass c Loaded Operation Discharge pressure bleeds from the discharge manifold Figure 1 13 item 15 through the strainer 9 and 8 bleed orifice to the solenoid valve stem 2 chamber and the back of the piston bypass valve 7 With the solenoid valve 1 de energized the solenoid valve stem will closethe gas bypass port 3 Refrigerant pressure will overcome the bypass valve spring 5 tension and force the piston 6 forward closing the gas bypassfrom the discharge manifold to the suction manifold 10 Cylinder discharge pressure will force open the discharge piston check valve assembly 14 Refrigerant gas will pass into the compressor discharge manifold The loaded cylinder bank will continue to operate fully loaded until the solenoid valve control device is energized and the gas bypass port is opened 1 Solenoid Valve 11 Cylinder Discharge 2 Valve Stem Valve 3 Gas Bypass Port 12 Valve Plate 4 Spring Guide 13 Cylinder Suction 5 Spring Valve 6 Piston 14 Discharge Piston 7 Piston Bypass Valve Check Valve 8 Bleed Orifice Assembly 9 Strainer 15 Discharge Manifold
172. r remote evaporatorscan beinitiated two ways the manual defrost switch located on the remote control box or a solid state defrost timer that automatically initiates defrost at preset interval of 1 1 2 3 or 6 hours The defrost interval is selectable by placing jumper in the appropriate location which is shown on the side of the timer Defrost is terminated by one of two methods selected by a second jumper T he jumper should bein the 1 location which is termination by opening of defrost thermostats The alternate jumper position 20 is defrost termination after 20 minutes NOTE The evaporator coil temperature must be below 35 F 1 7 C before defrost can be initiated 1 11 11 AUTO START STOP OPERATION Automatic start stop is provided to permit starting restarting of the diesel driven compressor as required This feature fully enables automatic control of the diesel engine starting and stopping The main function of automatic engine cycling is to turn off the refrigeration system near setpoint to provide a fuel efficient temperature control system and to initiate a restart sequence after conditions are met System shut off is allowed only if the battery condition signal is good The engine coolant temperature shall override the minimum off time and out of range condition to force engine restarting when the engine coolant temperature drops below 34 F 1 C A restart will also be initiated if the battery voltage falls below 11 0V dc A rest
173. ription M HR 10r CD 18 The maintenance hour meter is compared to one of the hour meters diesel standby or switch on determined by its mode If the hour meter is greater than the maintenance hour meter an alarm will be generated Maintenance Hour Meter 2 The maintenance hour meter 2 setting is displayed with the description M HR2 on the left side or CD 19 The maintenance hour meter is compared to one of the hour meters diesel standby or switch on determined by its mode If the hour meter is greater than the maintenance hour meter an alarm will be generated Switch On Hour Meter The number of switch on hours is displayed with the description SON or CD20 i e SON 2347H or CD20 2347H The display range is 0 to 99999 62 10022 01 1 11 7 ALARM DISPLAY The fault light FL is turned on only for alarms that specify it T he default display will be overridden if a alarm is generated W hen an alarm is generated the display will alternate the default display setpoint air temperature and the active alarm s E ach item will be displayed for 3 to 10 seconds and will continue to scroll through the list See section 1 11 5 for the procedure on resetting alarms R Coolant Temperature WT SENSO Sensor wHigh Discharge HIGH CDT Temperature Discharge Temperature CD SENSOR Sensor OUT Y Main Compartment Out of range RANGE 2RA OUT WRemote Compartment 2 Out of range OUT WRemote Compartment 3 Out of range v FAU
174. rolling probe functional parameter Ambient Temperature The ambient temperature is displayed with the description ATS or CD 7 The data is displayed with one decimal place and the proper unit designator D egree C or DegreeF i e ATS 85 0F Thedisplayrangeis 36 to 158 F 38 Cto70 C Ifthere 15 sensor then display will read for the data Evp Future Expansion Thisunit data isnot used at thistime The Code displayis CD8 Compressor Discharge Temperature The compressor discharge temperature is displayed with the description CDT or CD9 The data is displayed with the proper unit designator Degree or Degree F i e CDT 85 40 to 392 F 40 C to 200 C Ifthere sensor then the display will read for the data Battery Voltage The battery voltage is displayed with the description BATT or CD 10 The data is displayed with one decimal place and then the capital letter V for volts i e BATT 12 2V or CD 10 12 2V The voltage reading is displayed with a plussign if the battery status is high enough to allow unit shut down in Auto Start Stop Standby Hours The number of electric motor hours are displayed with the description SBY or CD11 The data is displayed in hours and units designator H i e SBY 5040H or CD11 5040H The display range is 0 to 99999 Mod V Future Expansion Thisunit data isnot used at thistime
175. rozen setpoints a modified Ultra Fresh 2 temperature control is used to keep the unit from over cooling Ultra Freeze operates the same as Ultra Fresh 2 except as noted in this section Ultra Freeze control will be used anytime a frozen setpoint is selected in both diesel and standby units in both continuous and start stop operation When in standard multi temp temperature control Ultra Freeze is used to control the main compartment if it has a frozen setpoint selected Ultra Freeze operates independently of the setting of CNF 15 If Ultra Freeze is active the Ultra Fresh 2 unloader cooling logic is not invoked a Ultra Freeze Offset In continuousruna 3 F offset is added which will force the unit to control to 3 F below setpoint b Ultra Freeze Start Stop In start stop operation the unit s control will not have the 3 F offset and will control to setpoint by cycling the unit on and off according to the standard frozen mode start stop startup and shutdown logic The exception to this is when a low battery voltage or low engine coolant temperature defeats the normal shutdown logic then the Ultra Freeze logic will control to the 3 F below setpoint offset c Ultra Freeze Main Compartment Heat Mode The main compartment is limited to 2 cylinder heat If either or both of the remote compartments are enabled and the main compartment goes to heat mode the remotes are immediately forced to null mode no heat or cool d Ultra Freez
176. safe Conditions Safety Device Device Setting 1 Low engine lubricating oil Oil pressure safety switch OP Opens below 15 3 psig pressure microprocessor reset 2 11 1 2 kg cm 2 High engine cooling water Water temperature sensor Engine off if 230 to 240 F for 5 temperature microprocessor reset minutes or immediately over 240 F 116 C 3 Excessive current draw by glow Fuse F1 Opens at 80 amps plug circuit control circuit or starter solenoid SS 4 Excessive current draw by Fuse F3 Opens at 25 amps control circuit 5 Excessive current draw by front Fuse F4 Opens at 15 amps or rear unloader 6 F5 7 Excessive current draw by Fuse F9 Opens at 5 amps microprocessor 8 Excessive compressor High pressure cutout switch Refer to section 1 4 9 discharge pressure HP 1 automatic reset 9 Excessive compressor Compressor discharge Refer to section 1 8 discharge temperature temperature sensor CDT microprocessor reset 10 Defrostheater over temperature High Temperature Klixon 120 5F 11 Excessive current draw by Fuse F7 Opens at 15 amps 2 compartment controls 12 Excessive current draw by Fuse F8 Opens at 15 amps 3 compartment controls Excessive current draw by SV3 Fuse Opens at 7 1 2 amps auto restart or out of range lights 2 13 Excessive current draw by Fuses F10 F11 Opens at 20 amps electric heaters 14 Excessive current draw by Fuses F12 F13 Opens at 3 2 5 or 6 3 amps 2 comp
177. sconnect ground strap from frame Disconnect suction pressure transducer from compressor Attach sling or other device to the compressor Slide compressor enough to clear nylon drive gear or clutch housing on model ND M Figure 4 9 and remove compressor from unit Drain oil from defective compressor before shipping The original unloader valves must be transferred to the replacement compressor The plug arrangement removed from the replacement is installed in the original compressor asa seal If piston isstuck it may be extracted by threading socket head cap screw into top of piston A small teflon seat ring at bottom of piston must be removed NOTES The service replacement compressor is sold without shutoff valves but with valve pads Customer should retain the original capacity control valves for use on replacement compressor Check oil level in service replacement compressor Refer to sections 1 3 and 4 11 1 2 3 4 5 Compressor 6 Locking Tab Bolts 7 Nylon Drive Gear Spacer 8 Drive Sheave Bolts Key 9 V Belt Compressor Drive 10 Engine Adapter Gear Drive Sheave Figure 4 9 Compressor Drive Assembly Remove the complete high pressure switch assembly 1 and H P 2 See Figure 4 10 and install on new compressor after checking switch settings Remove compressor discharge temperature sensor CDT and suction pressure transducer and install on new compressor Install compressor frame to new c
178. so that vibration will not change switch setting 4 21 REPLACING THE CONDENSER EVAPORATOR FAN SHAFT OR BEARING WARNING Beware of unannounced starting of the evaporator and condenser fan To Remove the Fan Shaft 1 Disconnect negative battery cable 2 Remove 4 screws securing condenser fan item 1 Figure 4 19 to adapter Qo c Ov Ur Es CO 10 11 12 13 14 15 15 Remove V Belt Refer to section 4 4 4 Remove 3 screws securing adapter item 2 Remove 3 screws securing sheave item 3 Remove tapered bushing item 5 Remove evaporator panels Remove two screws securing split tapered bushing to blower wheel items 10 and 11 Figure 4 19 Place the two screws in the threaded holes of the fan hub and use screws as jacking bolts to remove bushing from blower wheel Remove venturi ring item 11 Figure 4 19 by removing 4 screws Remove 4 screws from the bearing housing item 7 Figure 4 19 Remove the shaft and bearing housing Install bearing housing assembly into unit by reversing steps 1 through 9 using caulk Locate the fan and key so that 1 3 of the condenser fan extends beyond the leaving edge of the fan shroud Secure fan and hub to shaft Install evaporator fan venturi ring Then install tapered hub and blower wheel loosely A djust blower wheel and tighten Install evaporator panels WARNING Do not start unit without installing the evaporator panels as unit damage or body h
179. sure compressor is working at maximum efficiency The Superheat check should be carried out inside a workshop or with a minimum air ambient of 41 F 5 C The coil should be clean and free of ice Remove the Presstolite from the bulb and loosen the clamps Put a thermocouple above parallel TXV bulb next to the bulb Retighten clamp and re insulate with Presstolite Make the standard adjustment to the expansion valve which is to unscrew completely the superheat setting screw in the counter clockwise direction Then tighten three turns 3 3607 in the clockwise direction Allow the unit to stabilize at 32 F 0 C making sure that the unit is in cooling Notethe temperature of the suction gasatthe expansion valve bulb Subtract the saturation temperature taken from the suction gauge to determine superheat Adjust each valve a turn at a time allowing the unit to stabilize between adjustments 4 25 REPLACING EVAPORATOR FAN MOTOR Remove two retaining screws which hold the door assembly in position The complete hinged assembly drops down allowing access to the fan Disconnect wires in terminal box relative to fan being removed Remove four bolts and fan assembly Fit new fan to mounting plate Install fan assembly into evaporator 62 10022 01 4 18 4 26 EVAPORATOR ELECTRICAL CONNECTIONS All wiring harnesses to the evaporator section are identical The only difference is the length WARNING For safety
180. t in each compartment for a 3 compartment system or 4 kw of heat in each compartment for a 2 compartment system On the host unit automatic evaporator coil defrosting is initiated by either sensingtheair pressure drop acrossthe coil with a differential air switch or with the defrosttimer in the microprocessor Remote evaporators have a defrost timer 62 10022 01 The control door and relay module include manual switches microprocessor ammeter fuses and associated wiring Also the unit is equipped with a remote light bar as standard equipment It is mounted separately on the front roadside corner of the trailer The temperature controller is a microprocessor solid state controller Refer to section 1 11 Once the controller is set at the desired temperature the unit will operate automatically to maintain the desired temperature within very close limits The control system automatically selects cooling or heating as necessary to maintain the desired temperature within the trailer The refrigeration compressor used R efer to Table 1 1 is equipped with Varipowr as standard equipment Varipowr is used as a compressor capacity control to unload the compressor during periods of reduced loads This provides closer temperature control reduces potential for top freezing and reduces power required to operate the compressor thus reducingfuel consumption The engine Refer to Table 1 1 gives excellent fuel economy and has easy starting
181. t limits by providing refrigeration control heat and defrostto ensure conditioned air deliveryto theload b Dualindependent readouts of set point and supply or return air temperatures 62 10022 01 C Digital readout and ability to select data Refer to Table 1 4 for Function Code and Table1 5 for Unit Data d For alarm digital display identification refer to Table 1 6 e A pre trip checkout of refrigeration unit operation Refer to section 1 11 8 f A self test check on program memory and data memory The self test is executed each time the system is switched from Stop to Start Errors if any shall be indicated on the display as a ERR X where X isa number corresponding to the number of the test The unit shall display this error for 5 seconds and then reset the micro ERROR CAUSE ERR 1 Processor failure ERR 2 Check chip installation or Replace ERR 3 microprocessor Display board to logic board communication failure This can be caused by a defective ribbon cable or ribbon cable not plugged in properly ERR 4 or Display g A communication link to transmit unit operational data to a remote computer Refer to section 1 11 12 1 11 2 KEYPAD The keypad has 8 keys which will allow the operator to initiate various functions display operating data and change operating parameters Arrow Keys The keypad has and DOWN Arrow keys which are used to modify increment or decrement the setpoint se
182. t K2 indicates that at least one defrost termination thermostat is closed The unit will shift to the defrost mode if voltage is present at K 2 If both defrost thermostats klixons are open no voltage at K 2 defrost cannot be initiated by any means In defrost the microprocessor pullsterminals N 1and X1 low to shift the unit into heat The processor also pulls terminal W2 low to energize the defrost relay coil This closes the N O defrost relay contacts to energize the defrost light on the remote light bar T he defrost and heat display will also be illuminated Also N C defrost relay contacts open to de energize the clutch CLH to stop the evaporator and condenser fans The unit will remain in defrost until both defrost termination thermostats open to remove voltage from the defrost relay If the thermostats fail to open in 45 minutes the microprocessor will terminate defrost and shift between normal control and defrost at 1 1 2 hour intervals This will also occur if the defrost air switch is stuck closed If the problem corrects itself thermostats opens for example the unit will automatically resume its normal functions The defrost termination starts with H R 1 HR2 will turn off 2 seconds later The defrost output will de energize 5 seconds after 1 Table 2 2 Two Compartment Multi Temp Logic Control X Compartment Need Host 1HVR 2CR UNLOADERS UR M Electric Lor Lo rp cA
183. tage Psig Voltage 0 0466 40 0860 80 1253 Pao 0564 50 0958 90 1352 20 0663 60 1056 100 1450 4 31 UNIDRIVE TORQUE REQUIREMENTS See Figure 4 22 Extensive damage may occur if the proper hardware and procedures are not followed Periodic inspection of hardware and bolt torque is recommended to insure the integrity of the unidrive NOTE Thread lockingsealant 5 16 flat washer and 5 16 lock washer must be used on bolts between the compressor mounting flange and the adapter spacers The recommended sealant is Loctite screw lock no 262 The figure below shows the torque value size and grade of the hardware to be used when reassembling the unidrive assembly 4 21 62 10022 01 62 10022 01 M8 x 1 25 x 20 mm lg 4 Req d 28 ft lbs 3 87 mkg 5 16 18 x 3 4 lg Grade 8 4 Req d 25 ft lbs 3 46 mkg 3 8 24 x 1 00 lg Grade 8 28 ft lbs 3 87 mkg o 4 4 TE TA Figure 4 22 Unidrive Torque Requiremen
184. tes and then partially block off air flow to condenser coil so discharge pressure will rise 10 psig 0 7 kg cm Refrigerant should appear at center line of the lower receiver sight glass If charge is inadequate add refrigerant charge with condenser coil still blocked e Open suction service valve three turns Add charge until level appearsat center line of the lower receiver sight glass f Backseat close suction service valve Close vapor valve on refrigerant drum noting weight Vent charging line and replace all caps g Start unit and check for noncondensibles 62 10022 01 4 8 4 10 REPLACING THE COMPRESSOR If compressor isinoperative and unit still has refrigerant pressure frontseat suction and discharge service valves to trap most of the refrigerant in the unit If compressor runs pump down the unit Refer to section 4 5 a a Remove the two rear compressor bracket mounting bolts compressor shockmount end Block up engine Slowly release compressor pressure to a recovery system Remove bolts from suction and discharge service valve flanges Remove oil filter and bracket from 05G compressor Disconnect wiring to unloader valve assemblies compressor discharge temperature sensor CDT suction pressure transducer and the wiring to the high pressure cutout switches HP 1 and HP 2 Identify wiring and switches if necessary See Figure 4 10 Remove 10 bolts from the engine compressor spacer Di
185. the left and controlled air temperature on the right The readout is keypad selectable for D egrees C or Degrees F Also digital displays are provided to indicate the following modes COOL HEAT DEFROST IN RANGE HI AIR START STOP On each power up the unit will display a Display Testfor 5 seconds then display the default reading 1 11 5 FUNCTIONAL PARAMETERS NOTE If configuration CNF11 is ON functional parameters are lockout The ability to change functional parameters from keypad are disabled The functional parameters will control selected operating features of the unit These parameters can be displayed by pressing the FUNCTION CHANGE key All functional parameters are retained in memory The following sections describe the list of functions which can be modified via the keypad A description of the function will be displayed on the left side with the corresponding data on the right side The function parameter list can be scrolled through by pressingthe FUNCTION CHANGE key or by using the UP DOWN Arrow keys With each FUNCTION CHANGE key push the list will be advanced one If the function key is pressed and held for one second the list will be advanced one item at a time Thislist will be circular meaningoncethe end of the listis reached the list will go to the first entry While the functional parameter is displayed the data can be changed by pressing ENTER then pressingeither the U P or DOWN Arrow keys If the value is
186. the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added asindicated by scales Correct charge will befound in section 1 3 NOTE Itis possible that all liquid may not be pulled into the receiver as outlined in step d In this case frontseat the receiver outlet valve king valve and the liquid will be pulled into the system U nit must be operating in the cooling mode e When drum weight scale indicates that the correct charge has been added close liquid line valve on drum and backseat the king valve f Start unit in cooling mode Run approximately ten minutes Partially block off air flow to condenser coil so discharge pressure rises to 230 psig 16 kg cm Refrigerant should appear at center line of lower receiver sight glass If chargeis inadequate add refrigerant charge per section 4 9 4 9 ADDING REFRIGERANT TO SYSTEM PARTIAL CHARGE R 22 ONLY CAUTION Do not vapor charge R 404A Only liquid charging through the liquid line king valve is acceptable a Place drum of refrigerant on scale and note weight Backseat suction service valve and connect charging line between suction valve port and drum Open VAPOR valve on drum b Run the host unit and the remote compartments in cooling for two minutes This will fill the remote liquid line with refrigerant c Turn OFF the remote compartments Continue running the host in cooling d Runthehostunitin coolingfor ten minu
187. then remove bulb from suction line Loosen flare nut and disconnect equalizer line from expansion valve Remove flange screws and lift off power assembly Then remove the cage assembly Check for foreign material in valve body The thermal bulb is located below the center of the suction line See Figure 4 21 This area must be clean to ensure positive bulb contact Strap thermal bulb to suction line and insulate both with Presstite Power Assembly 5 Cage Assembly Body Flange Gaskets 6 Body Flange Seat Gasket 7 Body Flange Screws Bulb Figure 4 20 Thermostatic Expansion Valve Install new gaskets and insert cage assembly and install power assembly Fasten equalizer tube to expansion valve E vacuate by placing vacuum pump on suction service valve Open King valve and then check refrigerant level Refer to section 4 9 b 10 Check superheat Refer to section 1 3 h b Checking Superheat f It is not recommended adjusting expansion valves unless absolutely necessary Due to the time involved in adjusting the superheat replace the valve rather than adjusting it c To Measure Superheat NOTE Theexpansion valveand bulblocation areshown in Figure 1 6 Remove evaporator panel from rear of unit andthen remove Presstite from expansion valve bulb and suction line Loosen one TXV bulb clamp and make sure area under clamp above T X V bulb is clean Place thermocouple above p
188. ting R404A Only 110 4 Hot Gas Bypass 111 Microprocessor Controller LILl Introduction sce esas She bebe ete chisha LIL2 Keypad et e ce E LR Reid 3 SetpolnE obiret eie t e ode pe am ed od 111 4 Digital Display ethos e eas ee nes C C a 1115 Functional Parameters ees TILO UnitData ee u DEM Sae NE ip D ues T3 AlarmiDISplayia n i etie recs edet edes ree eee Mn US ice Masi ade Rrethi p be ete oa nen M Rd wacker bani ims 1 11 9 Modes eor ance rtr reed ete toe Ra ett deg 1 1110 D efrosb Gyclee 322 52 leh tue de tte 4 aaa rte heh ka klikay ua a 1 11 11 Auto Start Stop Operation 1 11 12 Remote M onitoring DataTrak Optional 1112 Switches and Controls ec eR ee o et de dea eed 112 1 Introduction x imet rem bel USUS eter ead aed 112 2 Control Box Door and RelayModule 1 12 3 Location of Engine Safety Devices 133 Ultrafresh 2 Temperature Control n 114 Ultra Freeze Temperature Control With Software 3 11 or Higher 1 15 Battery Charging Alternator m 1 15 1 Alternator Operation dad dane EE ots 1 15 2 Integr
189. ting The controller will shift the unit into unloaded heat when the trailer temperature falls below set point The microprocessor pulls terminals N1 X1 and S2 low to complete the ground paths for the heat relays H R 1 and HR2 When these relays energize several things happen Thisopensthe N C contacts to the cool light and solenoid valve SV2 SV2 now operates in conjunction with the head pressure control switch H P2 Refer to section 1 17 Also HR1 closes a set of normally open contacts to energize solenoid valve SV 1to closethe condenser outlet line Energizing HR2 closes two sets of N O contacts Solenoid SV4 energizes and opens to allow hot refrigerant vapor to enter the evaporator section 1 17 The other set of HR 2 contacts supply power to the heat light on light bar 30 SECONDS 15 seconds No Refrigerant Flow 5 Seconds 10 seconds No Refrigerant Flow Figure 2 3 Pulsed Cooling Timing Diagram 62 10022 01 FALLING TEMPERATURE RISING TEMPERATURE 2 0 3 6 F 1 5 2 7 F 13 PULSED COOL T or COOL 1 0 C 41 8 F 0 8 C 0 5_C 1 4_F NULL NULL FAN ONLY FAN ONLY SET POIN 0 5 1 4 F 0 3 C 1 0 1 8 F 1 5 C 2 7 2 0 C 3 6 F There is no Pulsed Cool in the main compartment Only 279 amp 3rd compartment have Pulsed Cool Figure 2 4 Perishable Range Temperature Controller Operating Sequence Controller Set Point Above 12 C 10
190. to 5 5 C the unitis locked into 7 Check battery terminals for cleanliness and tightness Clean and coat with a mineral type grease edam start Stop Continuous key is such as Vaseline isabled in this setpoint range 3 With software revision 3 15 or higher when 8 MA fan shaft bearing for configurations CNF3 amp are ON and y setpoint is 32 to 42 F 0 to 5 5 C the unit is 9 Check engine air cleaner for cleanliness and locked into continuous run Start Stop condition of air cleaner hose Continuous key is disabled in this setpoint 10 Check oil level in compressor sight glass range 11 Check defrost drain pan hoses Should be clear of 2 2 1 AUTOMATIC START debris MN a Starting Instructions 12 Check defrost air switch tubes and connections for 1 Place the RUN STOP switch in the RUN position breaks or air leaks The microprocessor will perform a self test all b After Starting Refrigeration Unit display messages will appear in display window l Check water temperature Should be 150 to 180 Then setpointand boxtemperature will be displayed 65 to 82 i 2 The microprocessor will energize glow cycle length 2 Check ammeter Should indicate 2 to 10 amps of time depends on engine temperature and start after start up the engine 3 Tochangethesetpoint pressthe U P or DOWN arrow 3 Listen for abnormal Hels Refer to SCHON 3 3 7 key and ENTER key 4 Check compressor oil level
191. tribution Product Loading Correct Refrigeration system Abnormal pressure 3 3 6 Temperature controller malfunction 3 3 8 Compressor Defective 4 10 Unloader malfunction 4 12 3 3 4 Unit Will Not Heat or Has Insufficient Heating Refrigeration Head pressure control switch HP 2 defective Abnormal pressure Temperature controller malfunction Solenoid valve malfunction 1 4 check valve bypass defective Compressor Compressor drive defective 10 Compressor defective 4 10 Engine does not develop Engine malfunction full rpm 3 3 62 10022 INDICATION REFERENCE 3 3 5 Defrost Cycle Malfunction Will not initiate defrost Defrost air switch DA out of calibration 4 20 automatically Defrost thermostats DTT open or defective 4 19 Defrost air switch DA defective 4 19 amp 4 20 Loose terminal connections Tighten Air sensing tubes defective or disconnected Check Remote Defrost timer defective Check Will not initiate defrost manually Microprocessor defective Replace Loose terminal connections Tighten Defrost thermostats DTT open or defective Replace Glow Crank switch defective Replace Initiates but does not defrost Solenoid valve malfunction 3 3 11 Defrost relay DR defective Replace Clutch G earbox defective Replace Frequent defrost Defrost air switch DA out of adjustment 4 19 amp 4 20 Wet load Normal Air leakage Check Does not terminate or Defrost thermostats DTT shorted closed 4 19 cycles on defrost Head pressure
192. ts 4 22 90 ft lbs 12 45 mkg 4 32 SERVICING LIQUID SOLENOID VALVE LSV NOTE The liquid solenoid valve LSV is the same valve as SV2 Refer to section 4 17 for servicing H OR ADJUSTING GENERATOR a Loosen locknut on adjusting screw Item 3 Figure 4 23 enough to clear generator V belt from the sheave b To remove generator V belt from drive shaft follow instructions in section 4 4 See Figure 4 7 c After replacing belt take up on jam nut and locknut on adjusting screw until a belt tension of 70 to 80 ft lbs is maintained 1 Generator 5kw 2 Nut 3 Locknut 4 Adjusting Screw 5 V Belt Figure 4 23 Generator 4 345KW GENERATOR MAINTENANCE The 5KW generator require very little preventative maintenance to insure good performance l Belttension should be maintained at 70 to 80 ft Ibs Refer to section Figure 4 23 2 The generator is equipped with an air filter located under the black plastic housing at the back of the generator Air is drawn through this filter as the generator operates and keeps all internal components cool Any restriction caused by a dirty filter can result in generator overheating problems The air filter should be removed and cleaned with warm water and soap then rinsed well at every regularly scheduled service interval at least once a year or more frequently depending on environmental conditions more ofte
193. ure will be drawn into the compressor 62 10022 01 Connect suction connection of the gauge manifold to the compressor suction service valve port and immerse the common connection of the gauge manifold in an open container of refrigeration oil Crack the suction service valve and gauge valve to vent a small amount of refrigerant through the common connection and the oil to purge the lines of air Close the gauge manifold valve With the unit running frontseat the suction service valve and pull a vacuum in the compressor crankcase SLOWLY crack the suction gauge manifold valve and oil will flow through the suction service valve into the compressor dd oil as necessary Refer to section 1 3 UD UD UU UL UD 05G High Pressure Switch Connection Suction Pressure Transducer Connection Suction Service Valve Oil Fill Plug Bottom Plate Oil Drain Plug Oil Level Sight Glass Oil Pump Unloader Solenoid Discharge Thermistor Connection Discharge Service Valve Figure 4 12 Compressor Adding Oil to Service Replacement Compressor Service replacement compressors may or may not be shipped with oil If compressor is without oil A dd correct oil charge Refer to section 1 3 through the suction service valve flange cavity or by removing the oil fill plug See Figure 4 12 d To remove oil from the compressor 1 Closesuction servi
194. ve old belt and replace with new belt See Figure 4 6 U sing a belt tension gauge Figure 4 5 on the belt rotate idler pulley so that the gauge readsthe correct tension Refer to Table 4 1 Tighten idler carriage bolt and bolts NOTE Both belts must be checked and retensioned if necessary after a brief run in period see step 6 Operate unit in high speed for 5 to 10 minutes Repeat steps 4 and 5 Replace belt guard Driveshaft to Clutch Gearbox Disconnect negative battery cable and remove V belt guard and then loosen idler bolt Match mark adapter to engine flywheel See Figure 4 7A for ease of assembly Remove six bolts 5 16 18 x 1 19 securing adapter drive sheave to engine flywheel Figure 4 7A Insert 2 of the six bolts 5 16 18 x 1 19 into the threaded holes jacking holes provided on engine adapter J ack adapter from engine flywheel Remove the 2 screws from adapter Insert a pry bar between engine flywheel and adapter Figure 4 7A and slide the adapter sheave toward the compressor enough to change the V belt as shown in Figure 4 7B Replace V belt Pry the adapter back toward the engine flywheel or use 5 16 18 x 2 1 2 10 bolts 3 in every other hole of adapter and take up evenly on the bolts until the 5 16 18 x 1 19 bolts will start in the engine flywheel Apply thread sealer L octite 262 to the bolts used to secure adapter to flywheel Take up on all bolts evenly and then torque to a value of 2
195. w plugrelay G PR to supply power to the glow plugs and 5 seconds later the starter is energized On initial power up the control will delay 5 seconds before the starting sequence begins If the required glow timeiszero the control will energize the starter after a 10 second delay The engine will crank for 10 seconds or until engine operation is sensed by the alternator signal The glow relay will be de energized after the auxiliary input is sensed on A 15 second null cycle will elapse before subsequent start attempts The run relay will remain energized until the next starting sequence Before the next starting sequence the oil pressure is checked to determine if the engine is running and the alternator auxiliary has failed For the second and third start attempts the glow time is increased by 5 seconds over the glow time of the first attempt listed below The control allows three consecutive start attempts before the starting is locked out and the start failure alarm is activated REPEAT A 5 Seconds GLOW THIRD ATTEMPT 15 Seconds STOP REPEAT A 5 Seconds GLOW SECOND ATTEMPT 15 Seconds STOP MAXIMUM 10 Seconds Checked at CRAN 2 Seconds VARIABLE 0 to 30 SE CONDS Figure 1 15 Auto Start Sequence f Variable Glow Time The glow time for the first start attempt will vary in duration based on engine coolant temperature and the engine as follows FIRST ATTEMPT A 62 1
196. witch 4 14 4 21 Replacing The Condenser E vaporator Fan Shaft or Bearing 4 15 4 22 Evaporator Coil mmn 4 16 423 Condenser Coil ec err iy bete ERR MER peed ed 4 16 4 24 Thermostatic Expansion Valve nee 4 17 4 25 Replacing Evaporator Fan Motor nn 4 18 4 26 Evaporator Electrical lt 4 18 4 27 Microprocessor Controller HH 4 19 4 28 Configuration of Microprocessor ne 4 20 4 29 Controller Sensor Checkout ee 4 21 4 30 Suction Pressure Transducer 4 21 4 31 Unidrive Torque Requirements See Figure 4 22 4 21 4 32 Servicing Liquid Solenoid Valve LSV 4 23 4 33 Replacing or Adjusting Generator Belt 4 23 4 34 5KW Generator Maintenance 4 23 4341 Generator seas sasa on ORT Yu da 4 23 4 35 0 tht tu Rn tme Dien bean ke nea Deh oa ai 4 25 5 ELECTRICAL SCHEMATIC WIRING DIAGRAM 5 1 SE gt Introductio s pre aie Sani as OR ena nate eat ara nct 5 1 6 MODEL UNITS WITH STANDBY MOTOR 6 1
197. y isF N7 Compartment 2 Setpoint Setpoints of 22 30 to 86 F 30 C maybe entered through this function for the second compartment The setpoint function will be displayed with the abbreviated description 2SET The code display isFN8 Thesetpoint may be changed up or down in whole numbers until the desired setpoint is displayed The display will flash to indicate that the setpoint reading being displayed isa non entered value E ach time the U P key or the DOWN key is pressed the 5 second display timer will be reset Depressingthe ENTER key will cause the new displayed setpoint value to become active If the display isflashing and the new value isnot entered after 5 seconds of no keyboard activity the display will revert back to the active setpoint T he update rate is once every 0 5 seconds if the UP or DOWN keys are held down 62 10022 01 Compartment 3 Setpoint Setpoints of 22 30 C to 86 F 30 C maybe entered through thisfunction for the third compartment The setpoint function will be displayed with the abbreviated description 3SET The code display is FN9 The setpoint may be changed the same as the 279 compartment Auto Manual Start Operation The selection for starting the unit are displayed AUTO OP code FN10 ON for auto start operation or MAN OP code FN10 OFF for manual start operation To start the unit in manual start mode the START STOP CONTINUOUS selection must be in continuous run mode
198. z ss SPKI3 67 2 2 dg FL EAULT LIGHT ms NONE An c DR 02 FP FUEL PUMP OPTIONAL AH D 3 506 H REX 56 Fe P2 FS FUEL S aee H GPR GLOW PLUG RELAY 8 02 x 3 D OORE 39 ny 34 894 z 18 Gye era DR C1 E1 F4 12 62 7 19 10 HC HIGH CURRENT BOX PLUG i Son FEN LSet bonamen 1 end ais J16 N16 3HL HEAT LIGHT 2ND MP ARTMENT x SHE F6 API HIGH PRESSURE CUT OUT SWITCH 7 C2DHBY FL JA SPK1 HRI AIR 5 em K R4 HP2 HIGH PRESSURE CUT OUT CONTROL N C 8H 03 x Fn SA Her HC33 F9 NB HRT HEAT RELAY 1 ws mm SP20 as FB N6 7 ee HEAT RELAY 2 Hi H F11 J6 Hf HEA L UNE 3 x 83 HCD1 DOC CUNSWITCHED cet Heca Ses n F10 N4 HR4 HEAT RELAY 4 eke 12V DATA DKA TO SP35 J16 N15 010 012 2 3HR HEAT RELAY 2ND 3RD COMPARTMENT BHI 3 FCHSH SSbERI amp S 6 LINK 257 F2 1HVR HIGH VOLTAGE RELAY o WR e Gi ts S DRUSI Go GOAT B 016 HIGH VOLTAI LAY MPARTMEN H m Fn 0 5 2 XTHHRCF2 B1 0 1 JUMPER SHUT DOWN OPTIONS 2 Bose in CHE EON NE ps J11 N11 3MI MANUAL W H 2ND SP20 SPK4 3 93 sPKi3 PKA TO sP35 lt HIO MGC MANUAL GLOW CRANK 9 eeoa seis ENGINE Lad D2 12 MP MICROPROCESSOR BOARD FEATHAS RANGE i ORD SP36 23 212 19 E2 OIL PRESSURE SAFETY SWITCH N 0 2 0 w a

Genesis TM900 and TM1000 Service Manual

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