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Integra 30s service manual - Grease Monkey Road Service

1. 45217 y 10 5 1438305 cli o 13 DOC T 62 10848 6 9 A Abnormal Noise 5 4 Abnormal Pressure 5 3 Accessing Alarm Messages 2 4 Alarm Display 2 4 Alarm Indications 5 1 B Belt Adjustment 4 2 Belt Tension 4 2 C Cab Command 2 1 Cab Command Malfunction 5 4 Checking The Eeprom Version 2 5 Checking the Refrigerant Charge 4 5 Clearing Alarm Messages 2 5 Compressor 1 3 Compressor Pressure Regulating Valve 4 8 Compressor Pressure Regulating Valve 1 4 Condenser Coil Cleaning 4 9 Condenser Fan Motor 1 10 Condenser Fan Motor Brushes 4 7 Condenser Pressure Control Solenoid 4 7 Condenser Pressure Control Valve 1 10 Condenser Pressure Control Valve 1 3 Condenser Pressure Switch 4 6 Condenser Pressure Switch 1 4 Condenser Pressure Switch HP2 1 9 Condenser Subcooler 1 1 Connect Power 2 3 Control System 2 1 Cooling 1 12 D Defrost Cycle 2 3 3 2 Defrost Malfunction 5 3 Defrost Termination Thermostat 1 9 Defrost Timer 1 9 INDEX Description 1 1 Diagnostic Tool 4 9 E Electrical Data 1 10 Evacuatio
2. FILTER DRIER SIGHTGLASS DEFROST ELEMENT SUCTION CHARG Y ING PORT d OIL SEPARATOR DISCHARGE CHARGING PORT QUENCH THERMOSTAT BPT ROAD COMPRESSOR CONDENSER KING VALVE RECEIVER HOT GAS SOLENOID VALVE HGS1 A COND DISCHARGE ERS J CHECK VALVE ann MANIFOLD ASSEMBLY HGS2 115V HP1 ONLY J A gt HP2 66 STAND BY COMPRESSOR X DISCHARGE LIQUID LIQUID INJECTION LINE HOT GAS LINE SUCTION LINE Figure 1 9 Refrigeration Circuit Cooling Cycle 1 13 62 10848 TXV EQUALIZER LINE QUENCH VALVE BPV SUBCOOLER un FILTER DRIER SIGHTGLASS DEFROST ELEMENT SUCTION CHARG ING PORT d OIL SEPARATOR DISCHARGE CHARGING PORT
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4. Temperature Selector Road fuse 25 Positive Battery Connection Negative Battery Connection Microprocessor PC Figure 1 7 Road Microprocessor Module 1 7 62 10848 1 5 SYSTEM OPERATING CONTROLS AND COMPONENTS The unit is furnished with a microprocessor control sys tem Once the set point is entered at the Cab Command the unit will operate automatically to maintain the de sired temperature within very close limits AX WARNING Beware of unannounced starting of the standby motor evaporator fan or conden ser fan The unit may cycle the standby mo tor or fans unexpectedly as control require ments dictate The control system consists of the Cab Command lo cated in the driver s section See Figure 1 8 and the microprocessor module See Figure 1 6 located in the control box The Carrier Transicold Control System incorporates the following features a Control return air temperature to tight limits by provid ing refrigeration control heat and defrost to ensure conditioned air delivery to the load b Permanently displays the return air temperature and on request the set point temperature c Digital display and selection of data 62 10848 1 8 CAUTION Under no circumstances should anyone at tempt to repair the microprocessor module or Cab Command Should a problem devel op with these components contact your nearest Carrier Transicold dealer for re placement
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8. ee EINER ERU ORE 5 4 5 2 11 Malfunction Hot Gas Solenoid or Condenser Pressure Regulating Valve 5 4 5 2 12 Standby Compressor Malfunction 5 4 SCHEMATIC DIAGRAMS 2 2 1 en aan re I 6 1 INTRODUCTION uu net Bia eed ea ae de dered vis dese 6 1 Hi 62 10848 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figurest ds cINtegraSOS rect petro PRE Sad dup eR es 1 2 Figure 1 2 Top VieW ac Fa epe Bae E eg RR ERU EHE CORRIERE Bae Ec e 1 2 Figure 1 3 Rear View Evaporator 1 3 Figure 1 4 Oil Separator 1 3 Figure 1 5 Typical Standby Control Box 1 5 Figure 1 6 Standby Microprocessor Module 1 6 Figure 1 7 Road Microprocessor Module 1 7 Figure 1 8 Cab Command 1 8 Figure 1 9 Refrigeration Circuit Cooling Cycle 1 13 Figure 1 10 Refrigeration Circuit Heating Cycle 1 14 251 22 xdi E Iud REIR IER I ERI ee 2 1 Figure 2 2 Gre
9. 4 5 4 9 REPLACING THE COMPRESSOR 4 6 4 9 4 Removing 550 4 6 4 9 2 Installing Compressor 4 6 4 10 CHECKING AND REPLACING FILTER DRIER 4 6 4 10 1 Checking 4 6 4 10 2 Replacing The Filter Drier ux ore rr eds bee RUDI eee gue IRE gue 4 6 4 11 HIGH PRESSURE HP1 AND CONDENSER PRESSURE HP2 SWITCHES 4 6 4 11 1 Removing 4 6 4 11 2 Checking Pressure Switch 4 6 4 12 CHECKING AND REPLACING CONDENSER FAN MOTOR BRUSHES 4 7 4 13 HOT GAS HGS1 AND CONDENSER PRESSURE CONTROL SOLENOID VALVES 4 7 4 13 1 Replacing Solenoid Coil 4 7 4 13 2 Replacing Valve Internal Parts 4 7 4 14 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE CPR 115V ONLY 4 8 4 15 THERMOSTATIC EXPANSION VALVE 4 8 4 15 1 Replacing expansion valve 4
10. 4 2 4 3 INSTALLING R 134A MANIFOLD GUAGE SET 4 2 4 3 1 Preparing Manifold Gauge Hose Set For Use 4 2 4 3 2 Connecting Manifold Gauge Hose 4 2 4 3 8 Removing the Manifold Gauge Set 4 3 44 REMOVING THE REFRIGERANT CHARGE 4 3 4 4 1 Refrigerant Removal From A Non Working Compressor 4 3 45 REFRIGERANT LEAK CHECKING 4 3 4 6 EVACUATION AND DEHYDRATION 4 4 4 63 General ee ae 4 4 4 6 2 Preparation Ee e e erit Beers a Dead Mech bu Sha cea nee AER 4 4 4 6 3 Procedure For Evacuation And Dehydrating System 4 4 62 10848 ii TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page SERVICE Continued raroa u ern 2 1 47 CHARGING THE REFRIGERATION SYSTEM 4 5 4 7 1 Checking The Refrigerant Charge 4 5 4 7 2 Installing A Complete Charge 4 5 4 7 3 Adding A Partial Charge mrien ee pe 4 5 4 8 CHECKING FOR NON CONDENSABLES
11. Table 1 1 Model Chart Road Model No Description Kg Compressor Sandby Condenser Weight Condenser Weight Road and Evap Wt Compressor Standby me se Table 1 2 Additional Support Manuals Manual Number Equipment Covered Type of Manual 62 10835 Supra 30S 62 10847 Supra 30S Easy To Run 62 10849 Supra 30S Operator s Manual 1 1 62 10848 Figure 1 1 Integra 30S 1 Nameplate 10 Sight Glass 2 Condenser Coil 11 Receiver 3 Transformer TR 12 Discharge Manifold 4 Oil Separator 13 Hot Gas Solenoid Valve HGS1 5 Standby Motor 14 Condenser Pressure Control Switch HP2 6 Standby Compressor See Table 1 1 15 Frame 7 Control Box 16 High Pressure Switch HP1 8 Filter Drier 17 Condenser Pressure Control Valve HGS2 9 Liquid Line Check Valve Figure 1 2 Top View 62 10848 1 2 2 4 1 Low Pressure Switch LP 5 Evaporator coil 2 Expansion Valve TXV 6 Compressor Pressure Regulating Valve 3 Quench Valve BPV CPR 115V only 4 Defrost Termination Thermostat DTT Figure 1 3 Rear View Evaporator 1 3 3 Oil Separator The oil separator is installed in the discharge line from the road compressor The hot gas coming from the com pressor is forced through a filter which separates the gas from the oil The oil collects at the bottom after passing through a second filter and then returns to the compressor via a ca
12. When refrigerant vapor is compressed to a high pressure and temperature in a compressor the mechanical energy necessary to operate the compressor is transferred to the gas as it is being compressed This energy is referred to as the heat of compression and is used as the source of heat during the heating or defrost cycle When the microprocessor activates heating or defrost the hot gas solenoid valve energizes and the condenser pressure control valve energizes closing the port to the condenser and opening a port which allows heated refrigerant vapor to flow directly to the evaporator coil The main difference between heating and defrosting is that when in heating mode the evaporator fans continue to run thus circulating the air throughout the truck to heat the product When in defrost the evaporator fans stop thus allowing the heated vapor to defrost any ice build up on the coil When the pressure is above the setting of the condenser pressure control switch the condenser pressure control valve HGS2 is closed to prevent additional pressure rise in the system When pressure is below the setting of the condenser pressure control switch the valve is opened to pressurize the receiver and force additional refrigerant into the system and increase heating capacity TXV EQUALIZER LINE QUENCH VALVE BPV SUBCOOLER
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14. j Check oil level in standby compressor sight glass 2 2 2 Connect Power Ifthe unitis to be operated inthe standby mode connect power as follows WARNING Do not attempt to connect or remove power plug before ensuring the unit is OFF press OFF key on Cab Command and external power circuit breaker is open WARNING Make sure the power plug is clean and dry before connecting to any power source a Check that the external power source corresponds to the characteristics of the unit see paragraph 1 6 3 step c Make sure external power source circuit breaker is open b Make sure unit is OFF by pressing the OFF button on the Cab Command c Plug the power cord into unit receptacle 2 2 3 Starting CAUTION If starting unit for the first time afterinstalla tion the compressor pressure regulating valve will need to be reset refer to para graph 4 14 CAUTION If starting unit for the first time afterinstalla tion or starting after adding removing an optional feature or if Owners operating pa rameters have changed the Configuration will need to be reset refer to paragraph 2 9 Depending on desired mode of operation either start the vehicle engine or close the power source circuit breaker Press the ON key to start the unit For Standby units start up is time delayed for 10 seconds For Road units start up is time delayed for 40 seconds The digital display of the Cab Command displays the
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16. Truck Refrigeration OPERATION amp SERVICE for INTEGRA 30S Truck Refrigeration Units Beginning With S N PB 225225 62 10848 Rev B TRANSICOLD OPERATION AND SERVICE MANUAL INTEGRA 305 TRUCK REFRIGERATION UNIT BEGINNING WITH S N PB 225225 TABLE OF CONTENTS PARAGRAPH NUMBER Page GENERAL SAFETY NOTICES deb OE Safety 1 FIRST AID Susa Rue abet ex uh S Safety 1 OPERATING PRECAUTIONS Safety 1 MAINTENANCE PRECAUTIONS Safety 1 SPECIFIC WARNING AND CAUTION STATEMENTS Safety 2 DESCRIPTION e 1 1 1 INTRODUCTION shine Cue oe ES 1 1 1 2 GENERAL DESCRIPTION ober opc rpm km xp an e Rn 1 1 1 3 SGONDENSING SECTION sa b NE ded 1 1 1 31 a ea ME Es 1 1 1 3 2 Filter Drier 1 1 1 8 3 Ol Separator l Se e De CORPER en 1 3 1 3 4 Hot Gas Solenoid Valve HGS1 1 3 1 3 5 Condenser Pressure Control Valve HGS2 1 3 1 9 6
17. If ambient temper ature is lower than 60 F 15 6 C ice might form be fore moisture removal is complete Heat lamps or al ternate sources of heat may be used to raise system temperature d Additional time may be saved during a complete sys tem pump down by replacing the filter drier with a section of copper tubing and the appropriate fittings Installation of a new filter drier may be performed during the charging procedure 1 Refrigerant Recovery Unit 2 Refrigerant Cylinder 3 Evacuation Manifold 4 Valve 5 Vacuum Pump 6 Electronic Vacuum Gauge Figure 4 4 Vacuum Pump Connection 4 6 3 Procedure For Evacuation And Dehydrating System a Remove refrigerant using a refrigerant recovery sys tem b The recommended method to evacuate and dehy drate the system is to connect three evacuation hoses Do not use standard service hoses as they are not suited for evacuation purposes as shown in Figure 4 4to the vacuum pump and refrigeration unit 62 10848 Also as shown connect a evacuation manifold with evacuation hoses only to the vacuum pump elec tronic vacuum gauge and refrigerant recovery sys tem c Connect lines to unit and manifold and make sure vac uum gauge valve i
18. TRANSICOLD Figure 1 8 Cab Command 1 6 UNIT SPECIFICATIONS 1 6 4 Compressor Data TM 16 ind Displacement 22 aa 15 5 lbs Weight 7 kg Oil Charge 5 07in 180 cm Approved Oil Mobil Arctic EAL68 1 6 2 Refrigeration System Data a Defrost Timer Automatic triggering or at preset intervals 0 Disabled auto 1h 2h 3h 4h 5h 6h b Defrost Termination Thermostat DTT Standby Only Opens at 48 5 F 9 3 C Closes at 37 5 F 8 3 C c High Pressure Switch HP1 Opens at 355 psig 10 PSI 24 5 bars Closes at 290 psig 10 PSI 20 bars d Condenser Pressure Control Switch HP2 Opens 130 psig 10 PSI 9 bars Closes at 175 psig 10 PSI 12 bars e Refrigerant charge Refer to Table 1 1 f Compressor Pressure Regulating Valve CPR 115V only 19 1 psig 1 3 Bar g Thermostatic Expansion Valve TXV Superheat setting 4 C 7 2 F at refrigerated compartment temperature of 20 C 0 F h Low Pressure switch LP Opens at 13 23 in HG 6 in HG 0 45 0 2 bar Closes at 6 5 psig 3 psig 0 44 0 2 bar i Quench Thermostat BPT Opens at 248 F 120 C Closes at 220 F 104 C 1 9 62 10848 1 6 3 Electrical Data a Fan Motors Evaporator Fan Motor EFM Condenser Fan Motor CFM Bearing Lubrication Factory Lubricated Bearing Lubrication Factory Lubricated Operating Amps 108amps Operating Amps Speed 2800
19. leat EM tee RO ME puit be E rM ere 1 3 1 9 7 Standby Motor Mee Y ee dete a 1 3 1 3 8 anni rue te eked te t oboe eub ee 1 3 1 3 9 High Pressure Switch HP1 1 4 1 3 10 Condenser Pressure Control Switch 1 4 1 4 EVAPORATOR SECTION Ha 2 284 thes masm beeen whet ik Qepa 1 4 1 4 1 Thermostatic Expansion Valve 1 4 1 4 2 Compressor Pressure Regulating Valve CPR 115V Only 1 4 1 4 3 Defrost Termination Thermostat DTT 1 4 1 4 4 Quench Valve 1 4 1 4 5 1 4 1 4 6 Low Pressure Switch LP 1 4 1 5 SYSTEM OPERATING CONTROLS AND COMPONENTS 1 8 1 6 UNIT SPECIFICATIONS I A eee 1 9 1 6 1 Compressor Data irpo 1 9 1 6 2 Refrigeration System 1 9 1 6 3 Electrical rub y Ae be ME 1 10 1 6 4 ValUes Alas tik OPE Rec
20. 2 7 Abnormal Noise Loose mounting bolts Tighten Worn bearings 4 9 Compressor Worn or broken valves 4 9 Liquid slugging 5 2 10 Insufficient oil Check Loose shroud Bearings defective Fan loose on shaft Bent shaft 5 2 8 Cab Command Malfunction Fuse open Replace Cab Command non operational Micros malfunction Replace Microprocessor Cab command cable Check 5 2 9 No Evaporator Air Flow or Restricted Air Flow Heavy frost on coil Check Evaporator coil blocked Coil dirty Evaporator fan loose or defective Check Evaporator fan rotating backwards Check Evaporator air flow blocked in refrigerated compartment Check Fan motor s malfunction Replace Condenser or evaporator fan No or partial evaporator air flow 5 2 10 Expansion Valve Low refrigerant charge External equalizer line plugged Broken capillary Superheat setting too high Low suction pressure with high superheat Superheat setting too low Low superheat and liquids lug External equalizer line plugged ging in compressor Pin and seat of expansion valve eroded or held open by foreign material Improper bulb location or installation 4 15 Fluctuating suction pressure Insulation missing from sensing bulb Replace Low superheat setting 4 15 2 High superheat Expansion valve setting 4 15 2 5 2 11 Malfunction Hot Gas Solenoid or Condenser Pressure Regulating Valve No power to valve Improper wiring or loose connections Valve improperly assembled Coil or co
21. 4 1 Maintenance Schedules 5 60 so 120 150 180 210 000 000 ooo ooo ooo ooo ooo ooo 18 36 54 72 so 108 126 ooo 000 ooo ooo ooo ooo ooo ooo qc oper sq qe s Refrigerant Type R134a Road compressor oil type The road compressors are supplied with CARRIER POLYESTER POE oil Oils of PAG type are strictly incompatible with the operation ofthis unit never use an oil other than that approved by CARRIER Table 4 2 Service Category Descriptions Service A i the tension of the compressor elt s 2 Check that the vehicle engine idles correctly with unit operating Check compressor mounting hardware and belt tension Paragraph 4 2 3 Check the tightness of bolts and screws and that the unit is correctly fastened onto the box Service B 1 Clean evaporator amp condenser Paragraphs 4 18 amp 4 19 2 Replace the road and standby com pressor belt s 3 Check and if required replace the filter drier Paragraph 4 10 4 Check the operation of cab com mand 5 Check the defrost eCut in eFan shut down eCut out eDefrost water drain Service C 1 Check the operation of the evapora tor and condenser fans Change the condenser evaporator motor brushes 2 Change the compressor oil Use polyester oil POE approved by CAR RIER Refer to paragraph 1 6 1 Service D 1 Change the removable relays fuses and capacitor if any in the control bo
22. ANY 924 9014 4055390440991H 33M138 V S31VOIONI r 5489 E 89d J ldWVX3 W31SAS SS3800V SSVHd 51119319 OV 11092412 AYALLVE dJAI1V93N NOV 18 51109813 OV ANTE 1102412 311 8 SATLISOd 034 MOTI3A N33J9 SLINOYIO 50 0049 20 3349 1109819 51109412 1081 03 20 3lIHM q00 102 N31SAS NOILIVOIJIIN3GI 2 09 0 111504 440 NMOHS LINN SJLON 62 10848 6 8 29219 29 peseg BuurM 25 12917991F 9 9 e1n614 ZH09 0E7 ul NI 11 Hp SL HI 3j aj aj v _ vaooe 502 SOE AZL au S 1 S 335 ul i LYWHO 335 VS 1 198 T 2 vs 54 L LYVHO 336 E 1 LYVHO luVHO 335 54 1AdNI Ag ONVLS 19 335 9140315373 e L 335 O3 S NOILINSI OL LYVHO 335 WS JOO
23. DISPLAY In the event of a malfunction the unit will shut down and the Cab Command will display an error message or alarm message The message will remain displayed until the malfunction is corrected If standby power is connected and the malfunction is such that standby operation can be allowed the unit will start in the standby mode A listing of the error messages and alarm codes is provided in Table 2 1 2 6 1 Accessing Alarm Messages To access the alarm messages Press SET for 5 seconds ena bles access to alarm messages In the event of more than one alarm press the or keys to list them Table 2 1 Alarms For Road Only Units Malfunction ALARM ALARM SHUT Red LED flashes No malfunction Unit in operation 0 eo A04 foad clutch matunton A08 Condenser fan motor at Evaporator fan motorat 208 pe gas snenia vaise orn _ Ser adjusted out of the range i 2 15 86 F 29 C 30 C below the low threshold Low battery voltage Probe malfunction or evaporator temperature out of limits 49 to 174 F 45 to 79 C E Programming error on part of operator 62 10848 Table 2 2 Alarms For Standby Units Malfunction ALARM ALARM AND UNIT SHUT Red LED flashes A00 No malfunction Unit in operation AFTER 3 SUCCESSIVE 3 Electric motor overload X AFTER 3 SUCCESSIVE protection on start up FAULTS 4 Road clutch ma
24. Expansion Valve 1 9 Torque Values 1 10 Troubleshooting 5 1 U Unit Operates Long or Continuously in Cooling 5 3 Unit Will Not Cool 5 2 Unit Will Not Heat or Heating Insufficient 5 3 W Wiring Diagram 6 2 6 3 6 5 6 6 6 7 6 9 Index 2 TRANSICOLD North America Central America Carrier Transicold and Mexico 700 Olympic Drive Ejercito Nacional No 418 Athens GA 30601 USA Piso 9 Torre Yumal Tel 1 706 357 7223 Col Chapultepec Morales Fax 1 706 355 5435 11570 Mexico D F Tel 5255 9126 0300 Fax 5255 9126 0373 A member of the United Technologies Corporation family Stock symbol UTX 2009 Carrier Corporation e Printed in U S A 0909 Carrier A United Technologies Company Carrier Transicold Division Carrier Corporation Truck Trailer Products Group P O Box 4805 Syracuse N Y 13221 U S A www carrier transicold com
25. HGS1 HGS2 valve operation E A range 20 2 to 86 F EN Table 5 2 Mechanical Indications REFERENCE INDICATION TROUBLE POSSIBLE CAUSES SECTION 5 2 REFRIGERATION 5 2 1 Unit Will Not Cool Compressor drive clutch defective Replace Compressor malfunction Compressor defective 49 Defrost cycle has not terminated 2 Refrigeration system Abnormal pressure 2 Hot gas solenoid malfunction HGS1 1 5 2 2 Unit Runs But Has Insufficient Cooling Compressor Compressor defective Abnormal pressure Refrigeration system Expansion valve malfunction Non existent or restricted evaporator airflow 62 10848 5 2 Table 5 2 Mechanical Indications Continued INDICATION TROUBLE POSSIBLE CAUSES Ale 5 2 3 Unit Operates Long or Continuously in Cooling Hot Load Insufficient pull Refrigerated compartment down time Defective refrigerated compartment insulation or air leak Correct Refrigeration system Abnormal pressure 5 2 6 Temperature microprocessor malfunction 5 2 8 5 2 4 Unit Will Not Heat or Heating Insufficient Abnormal pressure 5 2 6 Refrigeration Temperature microprocessor malfunction 5 2 8 Hot gas solenoid malfunction HGS1 4 13 Compressor Compressor drive clutch defective Compressor defective 5 2 5 Defrost Malfunction Defrost thermostat DTT open or defective Automatic defrost will not initiate Hot gas solenoid valve malfunction Defrost disabled through cab command Microprocessor defective De
26. Screw Figure 4 8 Compressor Pressure Regulating Valve 4 14 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE CPR 115V ONLY When adjusting the compressor pressure regulating valve CPR see Figure 4 8 the unit must be running in heating or defrost mode This will ensure a suction pressure above the proper CPR setting To adjust the CPR valve proceed as follows a Install a gauge on the suction line b Remove cap from CPR valve c With an 8 mm Allen wrench loosen the jam nut d Using the 8 mm Allen wrench adjust the set screw To raise the suction pressure turn the set screw clock wise to lower the suction pressure turn counter clockwise Refer to paragraph 1 6 2 for CPR valve setting When the setting has been adjusted tighten the jam nut securely against the set screw This will prevent any movement of the set screw due to vibrations in the unit Replace the cap 4 15 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 Unless the valve is defective it seldom requires any maintenance NOTE Due to the time involved in adjusting the super heat replace the valve rather than adjusting it 4 15 1 Rep
27. controlled by the opening of the defrost termination thermostat See Section 1 8 2 for a description of the refrigeration circuit during heat and defrost 3 3 MINIMUM OFF TIME Once the unit has cycled off it will remain off for the minimum off time of 5 minutes This prevents the unit from rapid cycling due to changes in air temperature Air temperature in the refrigerated compartment changes rapidly but it takes time for the product temperature to change SECTION 4 SERVICE WARNING Beware of unannounced starting of the unit The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate Press OFF key on the cab command and disconnect CAUTION Compressor failure will occur if inert gas brazing procedures are not used on units with R134A and POE oil For more information see Technical Procedure 98 50553 00 Inert Gas power plug Brazing NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing refrigerant When working with refrigerants you must comply with alllocal government environmental laws U S A EPA section 608 4 1 MAINTENANCE SCHEDULE Regular servicing is required in order to optimize the life and reliability of your unit The recommended scheduled maintenance intervals and categories are provided in Table 4 1 while descriptions of the service procedures to be carried out under each category are provided in Table 4 2 Table
28. moves freely ___________ plunger moves freely Replace contactor Replace contactor a nmm Verify motor rotates freely ondenser Fan Motor high amp draw Verify condition of brushes Replacemotor Evaporator Fan Motor EFM Verify motor rotates freely high amp draw Four aaa 5 1 62 10848 Table 5 1 Alarm Indications Continued ee Standby the hot water control relay or the electric heat contactor coil amp Hot Gas Solenoid Valve urrent draw of coil high or low approx 1 6 amp mern Ao9 HGS1 Kee Ll exe in T31 Quench Valve BPV Current draw oF high or low approx TZ amp high amp draw Condenser Pressure Control Valve HGS2 high amp draw 4151 oporaton arm Hot gas solenoid open 4 13 1 Unit out of range for more than 15 minutes Verify Setting Verity heating operation of unit Heating option not active Set configuration 4 2 9 Defrost Cycle 45 minutes 13 Set point adjusted out of the 2 3 Out of Range Low Tempera ture 29 C 30 C or below the Check set point programmed low threshold Return air sensor defective Replace Vehicle battery voltage low pow Berea voltage heck alternator system eee s Using Road amp Standby opera wee on road disconnect standby power sup tion at the same time If operating on standby shut down vehicle engine Programming error Reset Verify
29. necessary to use warm water mixed with any good commercial dishwasher detergent Rinse coil with fresh water if a detergent is used 62 10848 Table 4 4 R 134a Temperature Pressure Chart BOLD FIGURES Inches Mercury Vacuum cm Hg VAC LIGHT FIGURES psig kg cm and Bar TEMPERATURE PRESSURE p je 7 x 2 0 7 08 6 gt N N x 10 8 12 0 13 2 14 5 15 8 17 1 18 5 19 9 21 4 22 9 24 5 1 02 1 11 1 20 1 30 1 40 1 50 1 61 1 72 5 NCC Ege EE RE REC 8 13 10 42 NE 46 z 2 2 24 26 3 28 2 al o o NIO N 4 2 2 4 10 12 14 16 18 20 22 24 26 28 62 10848 TEMPERATURE ET i 16 18 21 24 27 29 32 35 38 41 43 46 26 1 27 8 29 6 31 3 33 2 35 1 40 1 45 5 51 2 57 4 64 1 71 1 78 7 86 7 95 3 104 3 114 0 24 2 35 0 46 4 58 4 71 2 84 6 98 7 213 6 29 2 45 6 62 9 81 1 Bar 949 9 31 SECTION 5 TROUBLESHOOTING WARNING Beware of unannounced starting of the unit The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate Press OFF key on the cab command turn vehicle en gine off or disconnect power plug and open circuit breaker CAUTION Under no c
30. nitrogen to raise system pressure to 150 to 200 psig 10 21 to 13 61 bar Check for leaks The recommended procedure for finding leaks in a system is with an electronic leak de tector Carrier P N 07 00295 00 Testing joints with soap suds is satisfactory for locating large leaks but be necessary when an electronic leak detector will not function correctly Remove refrigerant using a refrigerant recovery sys tem and repair any leaks Evacuate and dehydrate theunit Refer to section 4 6 Charge unit with refrig erant Refer to section 4 7 62 10848 4 6 EVACUATION AND DEHYDRATION 4 6 1 General Moisture can seriously damage refrigerant systems The presence of moisture in a refrigeration system can have many undesirable effects The most common are copper plating acid sludge formation freezing up of metering devices by free water and formation of acids resulting in metal corrosion 4 6 2 Preparation a Evacuate and dehydrate only after pressure leak test Refer to section 4 5 b Essential tools to properly evacuate and dehydrate any system include a good vacuum pump 5 cfm 8m3H volume displacement P N 07 00176 01 anda good vacuum indicator such as a thermocouple vacu um gauge vacuum 0700414 00 indicator Carrier P N NOTE Use of a compound gauge is not recommended because of its inherent inaccuracy Keep the ambient temperature above 60 F 15 6 C to speed evaporation of moisture
31. 19 29 poseg ureabeiq oneuieuos 2 9 14 qqvos 01901 uN 34 2 YSTIOULNODOYNDIN 912 09 CA33 S NOILIN9I OL LI 148 I 27 62 10848 6 3 aanva ems 64 HOLOW e uossaooudouo _____ oa 28 ___ ewa N aviayavos ora ABGNVIS smo r ___ sa T3NVa HOLSISAY u JAVA 1OH1NOO 3tinSS3tid s 080 usa wo HolOWASONvis lVISOWH3H L TWNHALNI HOLOW oa anne DAAN abo xoa1ou noo so en ASGNVIS HOLOVINOO HOLOW ow vw
32. 5000 Speed 9900 pm b Standby Compressor Speed 1740 rpm 60 hz c Standby Motor Ratings Voltage Type of Connection 115 1 60 Speed wma LRAT E 1 5 2 399mm o Las 230 1 60 230 3 60 9 2 1715 rpm 8 5 1700 rpm meum A MRA Maximum Rotor Amps LRA Locked Rotor Amps Resistance 9 2Q d Road Compressor Clutch Amp Draw 3 75A Resistance 3 2Q e Hot Gas Solenoid Valve HGS1 Coil Amp Draw 1 33 Amp Resistance 9 2Q f Condenser Pressure Control Valve HGS2 Coil Amp Draw 1 65 Amp Resistance 7 3Q g Quench Valve BPV Coil Amp Draw 1 16 Amp Resistance 10 3Q h Standby Motor Contactor Coil Amp Draw 0 19 Amp Resistance 60Q 1 6 4 Torque Values Assembly fib 9m 62 10848 1 10 1 7 SAFETY DEVICES System components are protected from damage caused by unsafe operating conditions by automatically shutting down the unit when such conditions occur This is accomplished by the following fuses and safety devices Automatic 821 restart A 1 Unsafe Conditions Safety Device with fault Device setting cleared 1 Excessive drop in pressure Automatic reset of low Cutout 13 23 in HG pressure switch LP YES 0 45 bar Timer 5 min 2 Excessive current draw on all mi Electronic relay Self protected opening croprocessor outputs evaporator and condenser fan 3 Excessive current draw control Fuse on electronic board Self p
33. 8 4 15 2 Measuring Superheat 4 8 4 16 DIAGNOSTIC i us er im rss EE 4 9 4 17 MICROPROCESSOR ie pani ate eg en X bac a ie Le 4 9 4 18 EVAPORATOR COIL CLEANING 4 9 4 19 CONDENSER COIL CLEANING 4 9 TROUBLESHOOTING 5 stent CONG eee es ees ee ee 5 1 5 1 INTRODUCTION Zura apupa rn Pee eae GUY EN 5 1 5 2 REFRIGERATION Ee xA ee aig ane lg eh EN ues 5 2 5 2 1 Unit Willi NOUCOON ele pace as Satukaq da 5 2 5 2 2 Unit Runs But Has Insufficient Cooling 5 2 5 2 3 Unit Operates Long or Continuously in Cooling 5 3 5 2 4 Unit Will Not Heat or Heating Insufficient 5 3 5 2 5 Defrost Malf nctlon ete a aee era oce ee Es 5 3 5 2 6 Abnormal Pressure cce retri aS tent Ment tee tent there eine 5 3 5 2 7 Abnormal ss e n s De ence es Mc SU ee 5 4 5 2 8 Cab Command Malfunction 5 4 5 2 9 No Evaporator Air Flow or Restricted Air Flow 5 4 5 2 10 Expansion
34. 848 Table 4 3 Belt Tension See Figure 4 2 BELTS New Install Running Tension Tension 80 to 90 ft Ibs 98 a 122 Standby Motor a ft In 4 2 1 Standby Motor Compressor V Belt a Loosen the retaining bolts of the standby motor sup port plate b Replace the V belt Position the motor to correct belt tension Tighten the motor retaining bolts 4 3 INSTALLING R 134A MANIFOLD GUAGE SET A R 134a manifold gauge hose set with self sealing hoses is required for service of models covered within this manual The manifold gauge hose set is available from Carrier Transicold Carrier Transicold P N 07 00294 00 which includes items 1 through 6 Figure 4 3 To perform service using the manifold gauge hose set do the following 4 3 1 Preparing Manifold Gauge Hose Set For Use a If the manifold gauge hose set is new or was exposed to the atmosphere it will need to be eva cuated to remove contaminants and air as follows Back seat turn counterclockwise both field service couplers see Figure 4 3 and midseat both hand valves Connect the yellow hose to a vacuum pump and an R 134a cylinder Evacuate to 10 inHg 254mmHg and then charge with R 134a to a slightly positive pressure of 1 0 psig 0 07 Bar Front seat both manifold gauge set hand valves and disconnect from cylinder The gauge set is now ready for use 4 3 2 Connecting Manifold Gauge Hose Set To connect the manifold gauge hose set for reading press
35. ES ES ES NO xz 62 10848 1 8 REFRIGERANT Circuit 1 8 1 Cooling See Figure 1 9 When cooling the unit operates as a vapor compression refrigeration system The main components of the system are the reciprocating compressor air cooled condenser thermostatic expansion valve and the direct expansion evaporator The compressor raises the pressure and temperature of therefrigerant and forces it through the discharge check valve and condenser pressure control valve into the condenser tubes The discharge check valves prevent reverse flow through the non operating compressor When operating on the road compressor the flow also passes through the oil separator where oil is removed and returned to the road compressor The condenser fan circulates surrounding air over the outside of the condenser tubes Heat transfer is thus established from the refrigerant gas inside the tubes to the condenser air flowing over the tubes The condenser tubes have fins designed to improve the transfer of heat This removal of heat causes the refrigerant to liquefy Liquid refrigerant flows from the condenser to the receiver The receiver stores the additional charge necessary for low ambient operation and for heating and defrost modes The refrigerant leaves the receiver and flows through a manual receiver shut off valve king valve The refrigerant then flows through a check valve The check valve serves to prevent reverse flow of refri
36. OIGNI 108WNAS HOLIMS 2 9 1 06 WSLSAS SHL NI S3HIM S31VOIQNI S3NIT IH9I1 INANVNUS en si sv za va ors ea nox uawooovou 1v190 83H1 198 ow HOLIMS oa ma vro We TW r toawas TOMAS 6 6 30018 H38W N NOTLOANNOD INId Ald LAW SLIVLNOI 390 ATIVWHON SLIVLNOI 035019 ATIVWHON NOTLOANNOD dS INIOd 391145 04434105 V SSLVOIGNI k 540 9014 CENTd 304 9014 YOSSAIONdOYO IW N33M138 v SHO E SO0d AIdWVXS W31SAS SS380GV 3SVHd 51102412 OV 1112412 AYSLLVE SATLVSAN 39V 18 valnan 51102412 OV 3018 11092412 11 8 3AILISOd 034 MOTI3A N3399 51119412 5 9 00 3339 94192 SONVYO SLINOYIO 1081 03 00 ALIHM eNO 102 WSLSAS NOILVOIJIIN3GI NOILISO4 430 NMOHS LINN 9 9 peseg Buu AN 9143999 9 9
37. QUENCH THERMOSTAT BPT ROAD COMPRESSOR CONDENSER KING VALVE RECEIVER HOT GAS SOLENOID VALVE HGS1 lt COND PRESS DISCHARGE CONTROL CHECK VALVE A VALVE MANIFOLD HGS2 CPR ASSEMBLY HP1 d 115V ee ed ONLY gt A HP2 6 STAND BY COMPRESSOR DISCHARGE LIQUID c __ LIQUID INJECTION LINE HOT GAS LINE SUCTION LINE 62 10848 Figure 1 10 Refrigeration Circuit Heating Cycle SECTION 2 OPERATION 2 1 CONTROL SYSTEM 211 Introduction CAUTION Under no circumstances should anyone at tempt to service the microprocessor mod ule and Cab Command Should a problem develop with the control system contact your nearest Carrier Transicold dealer for replacement components The Control System consists of the microprocessor module Figure 1 6 Cab Command Figure 2 1 and interconnecting wiring a The Microprocessor Module includes the tempera ture control software and necessary input output cir cuitry to interface with the unit controls The Cab Command is remotely mounted in the truck The Cab Command includes the LCD display and keypad The keypad and display serve to provide user access and readouts of microprocessor infor mation The information is accessed by keypad selections and viewed on the display 1 8 3 Microprocessor Module The microprocessor controls the following fu
38. SWITCHES 4 11 1 Removing Switch a ASCHRAEDER valveis located under each switch to allow removal and installation without removing the refrigerant charge Remove switch and test in accordance with para graph 4 11 2 c Replace or reinstall switch 4 11 2 Checking Pressure Switch WARNING Do not use a nitrogen cylinder without a pressure regulator See Figure 4 5 Cylin der pressure is approximately 2350 psig 160 bars Do not use oxygen in or near refrigerant system as an explosion may oc cur Remove switch as outlined paragraph 4 11 1 Connect ohmmeter across switch terminals Ohm meter will indicate resistance if switch is closed HP1 or open HP2 after relieving pressure Connect switch to a cylinder of dry nitrogen see Figure 4 5 Set nitrogen pressure regulator higher than cut out point on switch being tested Pressure switch settings points are provided in paragraph 1 6 2 o Close valve on cylinder and open bleed off valve Open cylinder valve While observing meter slowly close bleed off valve and increase pressure until the switch opens HP1 or closes HP2 Slowly open bleed off valve to decrease pressure until switch re verts to normal position f The meter will indicate open Open pressure on gauge Slowly open bleed off valve to decrease pressure until switch closes ohmmeter will move If switch does not activate within toleranc
39. The difference is the superheat of the suction gas Refer to paragraph 1 6 2 for superheat setting If required adjust superheat by turning the adjusting screw located under the cap on the side of the valve 1 Suction Line 3 TXV Bulb end view 4 Thermocouple 2 TXV Bulb Clamp 5 Nut and Bolt Clamp Figure 4 9 Thermostatic Expansion Valve Bulb And Thermocouple 4 16 DIAGNOSTIC TOOL NOTE The Cab Command diagnostic tool comes with two jumpers These are not applicable to the 30S system and should not be used in this ap plication REMOTE TOOL PRIMARY TOOL Figure 4 10 Cab Command Diagnostic Tool CTD P N 07 00440 00 a Testing a cab command cable that is already installed on the unit and routed into the truck cab re quires the use of both pieces of the diagnostic tool b Unplug the cab command cable from the micropro cessor and also from the back of the cab command module c Plug one end of the cable into the primary tool and the other end into the remote tool d Begin the test by turning onthe power switch and ob serving the sequence of green lights As each circuit is tested the corresponding light is illuminated fault is found in the cable the light that corresponds to that particular circuit is not illuminated e To test a cable that is not installed on a unit simply plug each end of the cable into the primary tool and perform the test as above 4 17 MICROPROCESSOR AX WARNING Unde
40. able 5 2 Mechanical 5 5 2 62 10848 iv SAFETY SUMMARY SAFETY PRECAUTIONS Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind During normal operation all moving parts are fully enclosed to help prevent injury During all pre trip inspections daily inspections and problem troubleshooting you may be exposed to moving parts Stay clear of all moving parts when the unit is in operation and when the ON OFF switch is in the ON position FIRST AID No injury no matter how slight should go unattended Always obtain first aid or medical attention immediately OPERATING PRECAUTIONS Always wear safety glasses Wear hearing protection as required Keep hands clothing and tools clear of the evaporator and condenser fans No work should be performed on the unit until all circuit breakers are turned off and battery power supply is disconnected Always work in pairs Never work on the equipment alone In case of severe vibration or unusual noise stop the unit and investigate MAINTENANCE PRECAUTIONS Beware of unannounced starting of the unit This unit is equipped with Auto Start in both the road and standby modes The unit may start at any time When performing any check of the system make certain all circuit breakers are turned off and battery power supply is disconnected Be sure power is turned off before wor
41. arge valves of the new compressor to vent the nitrogen holding charge WARNING Do not use a nitrogen cylinder without a pressure regulator See Figure 4 5 Cylinder pressure is approximately 2350 psig 160 bars Do not use oxygen in or near a refrigerant system as an explo sion may occur 62 10848 Safety 2 CAUTION Under no circumstances should anyone attempt to repair the microprocessor module or Cab Com mand Should a problem develop with these components contact your nearest Carrier Transicold dealer for replacement CAUTION If starting unit for the first time after installation or starting after adding removing an optional feature or if Owners operating parameters have changed the Configuration will need to be reset CAUTION Compressor failure will occur if inert gas brazing procedures are not used on units with R134A and POE oil For more information see Technical Procedure 98 50553 00 Inert Gas Brazing CAUTION To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before disconnecting CAUTION Do not damage or over tighten the enclosing tube assembly Place all parts in the enclosing tube in proper sequence in order to avoid premature coil burn out CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded CAUTION Under no circumstances should atechnician electrically probe th
42. arm Messages 2 4 2 6 2 Low Battery Voltage Alarm for Road Only Units 2 5 2 6 3 Clearing Alarm Messages 2 5 27 CHECKING THE EEPROM 5 2 5 2 8 STOPPING TEE UNIT I ea a Ga ER eel hs 2 5 2 9 MICROPROCESSOR CONFIGURATION 2 6 2 9 1 ROAD ONLY FUNCTIONAL SETTINGS 2 6 2 9 2 ROAD STANDBY FUNCTIONAL SETTINGS 2 7 TEMPERATURE CONTROL a 3 1 31 SEQUENCE OF 3 1 Perishable Mode Y Ree T xe Y Rer E 3 1 31 2 Frozen Mode S py AMETE OVE ER EM E FM TRE 3 1 3 22 DEFROST CYCLE sce sut esectrstelsber ute entr ee aa in eae dae ed seen tte denies 3 2 3 3 MINIMUM OFF TIME 3 2 SERVICE vin tie ee a ne ee 4 1 4 1 MAINTENANCE 2 4 1 4 2 BELT MAINTENANCE AND ADJUSTMENT 4 2 4 2 1 Standby Motor Compressor V Belt
43. ction 1 6 2 1 4 5 Evaporator The evaporator is of the tube and fin type The operation of the compressor maintains a reduced pressure within the coil At this reduced pressure the liquid refrigerant evaporates at a temperature sufficiently low enough to absorb heat from the air Air movement over the evapo rator is provided by an electric fan 1 4 6 Low Pressure Switch LP The low pressure switch is a normally closed switch which signals the microprocessor to shut down the unit when the system is outside the low pressure limit For LP settings refer to section 1 6 2 13 5 1 60 12 115 1 60 13 230 1 60 230 1 60 1 Standby clutch fuse F2 30 Amp 8 Diode 2 Standby Fuse F3 5 Amp 9 Rectifier Bridge Assembly BR 3 Transformer Fuse F4 5 Amp 10 Filter Capacitor C1 4 Clutch Time Delay Relay CT Single Phase 11 Start Relay STBR Only 12 Run Capacitor CR 5 Clutch Relay CR 18 Start Capacitor CS 6 Motor Contactor MC 14 Heat sink rectifier bridge 7 Overload Relay OL 230V Only Figure 1 5 Typical Standby Control Box 1 5 62 10848 7 6 5 1 Connector 6 C or F Temperature Selector 2 Road Relay RR 7 Microprocessor PC 3 12 Volt dc Road Connection 8 Road Fuse F1 30A 4 12 Volt dc Standby Connection 9 Overload Relay OL 25A 115V Only 5 Standby Relay SH Figure 1 6 Standby Microprocessor Module 62 10848 1 6
44. d Service Coupler Figure 4 3 Manifold Gauge Set R 134a 4 3 4 4 REMOVING THE REFRIGERANT CHARGE NOTE To avoid damage to the earth s ozone layer use arefrigerant recovery system whenever remov ing refrigerant Connect a refrigerant recovery system Carrier P N MVS 115 F L CT 115V or MVS 240 F L CT 240V to the unit to remove refrigerant charge Refer to instructions provided by the manufacturer of the re frigerant recovery system 4 4 1 Refrigerant Removal From A Non Working Compressor To remove the refrigerant from a compressor that is not operational do the following a Attach a manifold gauge set as shown in Figure 4 3 b Recover refrigerant with a refrigerant recovery sys tem c Service or replace components as required and leak check the entire system See Section 4 5 4 5 REFRIGERANT LEAK CHECKING A refrigerant leak check should always be performed after the system has been opened to replace or repair a component To check for leaks in the refrigeration system perform the following procedure NOTE Use only R134a to pressurize the system Any other gas or vapor will contaminate the system which will require additional purging and evacu ation of the high side discharge of the system a If system is without refrigerant charge system with refrigerant to build up pressure between 30 to 50 psig 2 to 3 4 Bars Remove refrigerant cylinder and leak check all connections Add sufficient
45. d with a remote mounted power recep tacle 1 3 8 Receiver Liquid refrigerant from the condenser is deliver to the receiver The receiver serves as a liquid reservoir when there are surges due to load changes in the system as a storage space when pumping down the system and as liquid seal against the entrance of refrigerant gas into the liquid line 62 10848 1 3 9 High Pressure Switch HP1 HP1 is a normally closed switch which monitors the system for high pressure and shuts down the unit when pressure rises above predetermined setting For HP1 settings see Section 1 6 2 1 3 10 Condenser Pressure Control Switch HP2 HP2 is a normally open switch which closes to signal the microprocessor to activate the condenser fan HP2 also cycles the condenser pressure control valve HGS2 andthe quench valve BPV in addition to the condenser fan in order to maintain head pressure for heating ca pacity For HP2 settings see Section 1 6 2 1 4 EVAPORATOR SECTION The evaporator assembly consists of an evaporator fan evaporator coil thermostatic expansion valve defrost termination thermostat compressor pressure regulating valve 115V only and a quench valve 1 4 4 Thermostatic Expansion Valve The thermostatic expansion valve is an automatic de vice which controls the flow of liquid to the evaporator according to changes in superheat to the refrigerant leaving the evaporator The thermal expansion valve maintains a relative
46. e processor atany point otherthan the connector terminals where the harness attaches Microprocessor components operate at differ ent voltage levels and at extremely low current levels Improper use of voltmeters jumper wires con tinuity testers etc could permanently damage the processor CAUTION Most electronic components are susceptible to damage caused by electrical static discharge ESD In certain cases the human body can have enough static electricity to cause resultant damage to the components by touch This is especially true of the integrated circuits found on the microprocessor Use proper board handling techniques See Section 4 17 Safety 3 62 10848 SECTION 1 DESCRIPTION 1 1 INTRODUCTION WARNING Beware of unannounced starting of the unit The unit may cycle the fans and operat ing compressor unexpectedly as control re quirements dictate Press OFF key on the Cab Command and disconnect power plug This manual contains Operating Data Electrical Data and Service Instructions for the Carrier Transicold Model 305 truck refrigeration units listed in Table 1 1 Additional support manuals are listed in Table 1 2 The model serial nameplate is located on the cover 1 2 GENERAL DESCRIPTION The unit Figure 1 1 is of the split system type with the condenser mounted outside the truck body evaporator mounted in the body and a Cab Command control center mounted in the driver s compartment Two types of c
47. en Light Status Standby 2 2 Figure 2 3 Green Light Status Road Only 2 2 Figure 2 4 Temperature Selection 2 7 Figure 3 1 Operating Sequence Perishable Mode 3 1 Figure 3 2 Operating Sequence Frozen Mode 3 1 Figure 4 1 Belt Tension Gauge 4 2 Figure 4 2 Layout 4 2 Figure 4 3 Manifold Gauge Set R 134a 4 3 Figure 4 4 Vacuum Pump Connection 4 4 Figure 4 5 Typical Setup For Testing Pressure Switches HP1 And HP2 4 7 Figure 4 6 Fan Motor Brushes 4 7 Figure 4 7 Hot Gas or Condenser Pressure Control Solenoid 4 7 Figure 4 8 Compressor Pressure Regulating Valve 4 8 Figure 4 9 Thermostatic Expansion Valve Bulb And Thermocouple 4 8 Figure 4 10 Cab Command Diagnostic Tool 4 9 Figure 6 1 E
48. es provided replace switch Test new switch before installation Cylinder valve and gauge Pressure regulator Nitrogen cylinder Pressure gauge 0 to 400 psig 0 to 28 bars Bleed off valve 1 4 inch connection Figure 4 5 Typical Setup For Testing Pressure Switches HP1 And HP2 4 12 CHECKING AND REPLACING CONDENSER FAN MOTOR BRUSHES To maintain proper operation of the fan motors the fan motor commutator and brushes should be checked periodically for cleanliness and wear 1 Brush Cap 2 Brush Figure 4 6 Fan Motor Brushes To check brushes proceed as follows a With unit off and battery disconnected remove brush cap Item 1 2 per motor See Figure 4 6 Remove brushes Item 2 2 per motor and check the length of the brush If the length is less than 1 4 inch 6 mm the brushes should be replaced Blow out the brush holder with low pressure air to re move any carbon dust in the holder This dust could prevent a good contact between the brushes and commutator Remove the back cover of the motor and inspect the commutator If the commutator is heavily grooved polish it using fine sandpaper Do not use abrasive b 4 7 paper Wipe out any accumulation of greasy material using a clean rag dampened with solvent Reassem ble the motor Install new brushes and replace cap 4 13 HOT GAS HGS1 AND CONDENSER PRESSURE CONTROL SOLENOID VALVES 4 13 1 Replacing S
49. eta Ree EA Re OR CN ER 1 10 1 4 SABEEDYGDEVIGES de Den 1 11 1 8 REFRIGERANT nue b eR SP vat beber 1 12 GOONG ee wie he te UEM 1 12 1 8 2 Heat And Detrost tree lisa a ber gate athe dees Eg Ue 1 12 i 62 10848 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page OPERATION er 2 1 2 1 CONTROL SYSTEM eng REIR Lee ee REX 2 1 2 11 Introduction Pa Gets 2 1 1 8 3 Microprocessor Module 2 1 2 1 2 Cab EP qp OG PP TINTA Sie RT 2 1 2 27 STARTSUR sts ca cn un o od nea 2 2 2 2 1 INSPECHON eek odie ns Sateen ie Mawes dee Pero us 2 2 2 2 2 2 2GOnnect PoOWer Ree reet 2 3 2 2 3 Starting re ar ADR Recta 2 3 2 9 SETPOINT ADJUSTMENT 5 2 222 oie et aid wine ee Rees 2 3 2 4 MANUAL DEFROST ic ae tees ney eed eed ones dre id 2 3 2 5 DEFROST CYCLE ADJUSTMENT 2 3 2 6 ALARM DISPLAY c gue eh pusana ig en epe 2 4 2 6 1 Accessing Al
50. frost thermostat DTT open or defective Defrost cycle initiates but does Hot gas solenoid malfunction HGS1 4 13 not defrost Condenser Pressure Control valve malfunction HGS2 4 13 Wet load Frequent defrost Defrost settings set to low Does not terminate or cycles Defrost thermostats DTT shorted closed defrost 5 2 6 Abnormal Pressure 5 2 6 1 Cooling Manual defrost will not initiate Condenser coil dirty Noncondensibles in system Refrigerant overcharge Condenser fan motor defective Compressor defective Hot gas solenoid malfunction Low refrigerant charge Compressor defective Hot gas solenoid malfunction Compressor pressure regulator misadjusted CPR Filter drier partially plugged Low refrigerant charge Low suction pressure Expansion valve malfunction No evaporator air flow or restricted air flow Excessive frost on coil Chec Suction and discharge pressures Compressor defective 4 9 tend to equalize when unit is Hot gas solenoid malfunction 4 13 operating 5 2 6 2 Heating High discharge pressure Overcharged system Condenser fan or HP2 pressure switch defective Noncondensibles in system Condenser motor fan defective Low refrigerant charge Low suction pressure Compressor pressure regulating valve misadjusted CPR Condenser Pressure Regulating valve fault HGS2 5 3 High discharge pressure 62 10848 Table 5 2 Mechanical Indications Continued INDICATION TROUBLE POSSIBLE CAUSES ENS 5
51. gerant during the heating defrost cycle The refrigerant then flows through the filter drier where an absorbent keeps it dry and clean The refrigerant then flows though a sight glass The sight glass is fitted with an indicator that changes color to indicate moisture content of the refrigerant The refrigerant then flows through the subcooler which removes additional heat from the liquid to improve system efficiency The liquid than enters the thermostatic expansion valve with external pressure equalizer which regulates the flow rate of refrigerant towards the evaporator in orderto obtain maximum use of the evaporator heat transfer surface 62 10848 1 12 The evaporator tubes have aluminium fins to increase heat transfer therefore heat is removed from the air circulated through the evaporator This cold air is circulated throughout the truck 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 The vapor at low temperature and is then drawn out by the compressor From this point the cycle starts over On 115v units the refrigerant then enters the compressor regulating valve CPR which regulates refrigerant pressure entering the compressor The cycle then starts over The quench valve opens as required to maintain a maximum discharge temperature Refer to section 1 6 2 for settings 1 8 2 Heat And Defrost See Figure 1 10
52. hese components contact your nearest Carrier Transicold dealer for replacement CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded CAUTION Under no circumstances should atechnician electrically probe the processor at any point other than the connector terminals where the harness attaches Microprocessor components operate at different voltage levels and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could permanently damage the processor CAUTION Most electronic components are susceptible to damage caused by electrical static discharge ESD In certain cases the human body can have enough static electricity to cause resultant damage to the components by touch This is especially true of the integrated circuits found on the microprocessor Use proper board handling techniques See Section 4 17 6 1 62 10848 09219 29 peseg Bun 1291179917 1 9 HOLIVHOdV d YASNACNOD 5 5 5 21901 LNFSNLYVANOD HOLIVHOdV d IN3IA LHVdINOO 5 avo HOLIVHOdV d HOSSIH4NOD qvod HOLIVHOdV d LINN NI NOILVDO71 7831131 YO YAEGWAN NOIIO3NNOO LNANOd SNTLV 105 913 901 38IM NOILO3NNOO 5 SNOILdO GYVONVLS 5317210 3gIM ON
53. iber 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 zu on the face of the coil but may accumulate deep within It is recommended to clean the evaporator coil regular basis not only to remove cardboard dust but to remove any grease oil film which sometimes coats the fins and prevents water from draining into the drain pan Cardboard fiber particles after being wetted and dried several times can be very hard to remove Therefore several washings may be necessary a Spray coil with a mild detergent solution such as any good commercial grade automatic dish washer de tergent and let the solution stand for a few minutes Reverse flush opposite normal air flow with clean water at mild pressure A garden hose with spray nozzle is usually sufficient Make sure drain lines are clean b Run unit until defrost mode be initiated to check for proper draining from drain pan 4 19 CONDENSER COIL CLEANING Remove all foreign material from the condenser coil by reversing the normal air flow Air is pulled in through the front Compressed air or water may be used as a cleaning agent It may be
54. il sleeve improperly assembled Movement of plunger restricted due to a Corroded or worn parts b Foreign material lodged in valve c Bent or dented enclosing tube Valve shifts but refrigerant Foreign material lodged under seat 4 13 continues to flow Defective seat 5 2 12 Standby Compressor Malfunction Motor contactor defective Replace Motor Overload open Check Improper power supply Correct 5 minute timer active Check Standby motor starts then stops Motor Overload open Valve does not function properly Standby compressor fails to start 62 10848 5 4 SECTION 6 ELECTRICAL SCHEMATIC WIRING DIAGRAM 6 1 INTRODUCTION This section contains Electrical Schematic Wiring Diagram covering the Models listed in Table 1 1 The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein WARNING Beware of unannounced starting of the unit The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate Press OFF key on the cab command and disconnect power plug WARNING Under no circumstances should ether or any other starting aids be used to start engine WARNING Under no circumstances should anyone attempt to repair the microprocessor module or Cab Command Should a problem develop with t
55. ircumstances should anyone attempt to service the microprocessor module and cab com mand Should a problem develop with the control system contact your nearest Carrier Transicold dealer for replacement components 5 1 INTRODUCTION Under normal circumstances unit problems will be indicated by an active alarm in the alarm list Suggested troubleshooting actions for each alarm indication are provided in Table 5 1 Suggested corrective actions for mechanical type problems are listed under subject headings in Table 5 2 Table 5 1 Alarm Indications xa Fa No Malfunction All components functioning normally Unit undercharged 4 7 1 Liquid line filter drier restricted Low Pressure Switch LP or strai 1 d with forei terial ice 1 TE High Pressure Switch HP1 5 plugged with foreign materia ice Open Road Verify operation of evaporator fans Failed switch 4 11 2 Unit overcharged 4 7 1 Low Pressure Switch LP or Verify operation of condenser fan High Pressure Switch HP1 Noncondensibles in system Open Discharge check valve failed closed standby only Fioplace Failed switch A03 Thermal overload open in motor windings Electric motor overload Current overload tripped Only Verify line voltage 04 Current draw of road clutch coil either high or low Contactor coil either high or low 0 2A for 3 phase Standby Standby Contactor MC high 0 5 for 1 u i Verify plunger
56. king on motors controllers solenoid valves and electrical control switches Tag circuit breaker and vehicle ignition to prevent accidental energizing of circuit Do not bypass any electrical safety devices e g bridging an overload or using any sort of jumper wires Problems with the system should be diagnosed and any necessary repairs performed by qualified service personnel When performing any arc welding on the unit or container disconnect all wire harness connectors from the microprocessor Do not remove wire harness from the modules unless you are grounded to the unit frame with a static safe wrist strap In case of electrical fire open circuit switch and extinguish with never use water REFRIGERANTS The refrigerant contained in your unit can cause frostbite severe burns or blindness when in direct contact with the skin or eyes For this reason and because of legislation regarding the handling of refrigerants during system service we recommend that you contact your nearest Carrier Transicold authorized repair facility whenever your unit requires refrigeration system service Safety 1 62 10848 SPECIFIC WARNING AND CAUTION STATEMENTS To help identify the label hazards on the unit and explain the level of awareness each one carries an explanation is given with the appropriate consequences DANGER means an immediate hazard which WILL result in severe personal injury or death WARNING means to warn against haza
57. lacing expansion valve a Remove refrigerant charge See section 4 4 b Remove insulation from expansion valve bulb and then remove bulb from suction line c Loosen flare nut and disconnect equalizer line from expansion valve d The txv bulb is located below the center of the suction line This area must be clean to ensure positive bulb contact Strap bulb to suction line and insulate both 62 10848 Braze the equalizer tubes to expansion valve f Evacuate dehydrate and recharge unit See Sec tions 4 6 and 4 7 Check superheat See Section 1 6 2 g 4 15 2 Measuring Superheat a Remove insulation from expansion valve bulb and suction line See Figure 4 9 Loosen TXV bulb clamp and make sure area un der clamp above TXV bulb is clean Place thermocouple above parallel to the TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in Figure 4 9 Connect an accurate gauge to the 1 2 port on the suc tion service valve Run unit until stabilized at 4 F 20 C refrigerated compartmenttemperature f From the temperature pressure chart Table 4 4 de termine the saturation temperature corresponding to the evaporator outlet pressure Note the temperature of the suction gas at the expan sion valve bulb Subtract the saturation temperature determined in Step f from the average temperature measured in Step g
58. lectrical Schematic Wiring Diagram Based On Dwg No 62 61350 Rev D 6 2 Figure 6 2 Electrical Schematic Wiring Diagram Based On Dwg No 62 61350 Rev D 6 3 Figure 6 3 Electrical Schematic Wiring Diagram Based On Dwg No 62 61353 Rev 6 5 Figure 6 4 Electrical Schematic Wiring Diagram Based On Dwg No 62 61354 Rev 6 6 Figure 6 5 Electrical Schematic Wiring Diagram Based On Dwg No 62 61354 Rev 6 7 Figure 6 6 Electrical Schematic Wiring Diagram Based On Dwg 62 61352 Rev 6 9 LIST OF TABLES TABLE NUMBER Page Table 1 1 Model Chart ss Ka eae ee 1 1 Table 1 2 Additional Support Manuals 1 1 Table2 1 Alarms For Road Only Units 2 4 Table 2 2 Alarms For Standby Units 2 5 Table 41 Maintenance Schedules 4 1 Table 4 2 Service Category Descriptions 4 1 Table 4 3 Belt Tension See Figure 4 2 4 2 Table 4 4 134 Temperature Pressure Chart 4 10 Table 5 1 Alarm Indications 5 1 T
59. lfunction 5 Standby clutch and contactor 0 0 06 Condenser fan motorat 07 Evaporator an motorat U 08 Heaing opion command 09 Hotgas vave malfunction HGS A A A A A A A A10 Quench valve malfunction BPV A11 Condenser pressure control valve HGS2 A12 High temperature alarm 14 Defrost alarm gt 45 minutes Setpoint adjusted out of the range 20 2 to A15 86 F 29 C 30 C or below the x programmed minimum set point x Probe malfunction or evaporator temperature X out of limits 49 to 174 F 45 to 79 C BAT SEE SECTION 2 6 2 2 6 2 Low Battery Voltage Alarm for Road Only has been noted and service is complete the alarm list Units may be cleared To clear the alarm messages There is 40 second time delay during start up After this delay if the battery voltage dips below 10V 0 2V Press the ON the and for Standby units or 10 5V 0 5V for Road only units the the keys at the same microprocessor will react 20 seconds later and the unit time will go out of temperature control mode The microprocessor will check the voltage after another 20 seconds If battery voltage still has not risen the unit will remain out of temperature control mode for another 10 minutes and the battery alarm will be activated and the Cab Command will display the message Unit will return to temperature control mode if battery voltage Start up unit has 10 mi
60. lsius or Fahrenheit The display also includes settings for defrost operation dF The display also includes three LEDs 888 Digital Display Standby operation LED Road operation LED Unit operating LED e Green cycling left hand side Red malfunction right hand side 62 10848 Unit operating LEDs a Green Light Status for Standby Units Under normal operation the green LED will indicate the temperature control status as follows Setpoint 9 F Green LED flashing 3 Hz Setpoint differential of 1 8 F 1 3 6 F Green LED flashing 0 5 Hz green LED SETPOINT Steady green LED Setpoint differential of 1 8 F 1 C 3 6 F 2 C or 5 4 F 3 C Green LED flashing 0 5 Hz Green LED Setpoint 9 F P flashing 3 Hz 5 Figure 2 2 Green Light Status Standby a Green Light Status for Road Only Units Under normal operation the green LED will indicate the temperature control status as follows Steady green COOLING Green LED is SETPOINT Green LED flashing 1 Hz HEATING Figure 2 3 Green Light Status Road Only 62 10848 2 2 b Red Light Status After an alarm has been present for 15 minutes the red unit indicating light flashes at 3 Hz The light will continue to flash at 0 5 Hz until the temperature returns to set point differential At that point the steady green indicator light will light and the alarm become inactive c Keypad The keypad co
61. ly constant degree of superheat in the gas leaving the evaporator regardless of suction pressure Thus the valve has a dual function automatic expansion control and preventing liquid from returning to the compressor For TXV superheat settings see Section 1 6 2 To adjust the refer to Section 4 15 2 1 4 2 Compressor Pressure Regulating Valve CPR 115V Only See Figure 1 3 The CPR valve is installed on the suction line of the standby compressor to regulate the suction pressure entering the compressor The CPR valve is set to limit the maximum suction pressure For CPR settings refer to section 1 6 2 The suction pressure is controlled to avoid overloading the electric motor during high refrigerated compartment temperature operation To adjust the CPR valve refer to section 4 17 62 10848 1 4 1 4 3 Defrost Termination Thermostat DTT Normally closed thermal switch on Standby units only As evaporator cools to set point the switch closes and signals microprocessor that defrost may be initiated Switch terminates defrost by opening at predetermined set point For DTT settings refer to section 1 6 2 1 4 4 Quench Valve The quench valve is a normally closed solenoid valve controlled by the quench thermostat BPT mounted on the road compressor discharge line The valve allows metered liquid refrigerant to enter the suction line in the evaporator in order to provide compressor cooling For BPT settings refer to se
62. n and Dehydrating System 4 4 Evacuation And Dehydration 4 4 Evaporator 1 4 Evaporator Coil Cleaning 4 9 Evaporator Fan Motor 1 10 Expansion Valve 5 4 F Filter Drier 1 1 FILTER DRIER 4 6 Frozen Mode 3 1 H Heat And Defrost 1 12 High Pressure Safety Switch 1 4 High Pressure Switch 4 6 Hot Gas Solenoid 4 7 Hot Gas Valve 1 10 Hot Gas Valve 1 1 3 Inspection 2 2 Installing a Complete Charge 4 5 Insufficient Cooling 5 2 L Low Battery Alarm 2 5 Low Pressure Switch 1 4 Maintenance Schedule 4 1 Manual Defrost 2 3 Microprocessor 4 9 Minimum Off Time 3 2 Index 1 62 10848 N No Evaporator Air Flow or Restricted Air Flow 5 4 O Oil Separator 1 3 OPERATION 2 1 P Partial Charge 4 5 Perishable Mode 3 1 Q Quench Valve 1 4 1 10 Quench Valve BPV 1 9 R Receiver 1 3 Refrigerant Leak Checking 4 3 Refrigerant Removal From Compressor 4 3 Refrigeration System 1 9 Replacing The Compressor 4 6 Road Compressor Clutch 1 10 S Safety Devices 1 11 Sequence Of Operation 3 1 62 10848 INDEX Service 4 1 Set point 2 3 Standby Compressor Malfunction 5 4 Standby Compressor Speed 1 10 Standby Motor 1 3 Standby Motor Contactor 1 10 Standby Motor Ratings 1 10 Standby Motor Compressor V Belt 4 2 Start up 2 2 Starting 2 3 Stopping 2 5 T Temperature Control 3 1 Thermal Expansion Valve 1 4 Thermostatic Expansion Valve 4 8 Thermostatic
63. nctions a Maintains the refrigerated compartment tempera ture at set point by regulating the cooling heat off mode and automatic defrost cycles b Permanently displays the return air temperature and on request the set point temperature c Digital display and selection of data For further details on digital message display see section 2 6 2 1 2 Cab Command The Cab Command is mounted in the cab and allows the driver to carry out the control operations start up and shut down the unit automatic start up in road or standby mode adjust the set point defrost The driver can display the refrigerated compartment temperature and see whether the set point is being maintained by checking the green indicator The indicator lights up red in the event of a malfunction When the battery voltage is too low a fail safe system shuts down the unit Unit restart is automatic and time delayed if the voltage rises to the normal level The command consists of the display and the keypad The keypad and display serve to provide user access and readouts of microprocessor information The information is accessed by keypad selections and viewed on the display g ff ser TRANSICOLD Figure 2 1 Cab Command a Display The digital display consists of 3 alphanumeric characters The default value displayed is the refrigerated compartment temperature The microprocessor enables selection of the display in degrees Ce
64. ndenser pressure switch HP2 Ifthe engine coolant or electric heat op tionis installed the optional heaters will also be ener gized See Section 1 8 2 for a description of the re frigeration circuit during heat and defrost 1 8 F 190 3 6 F 2 C or 5 4 F 3 UNIT STOPPED SETPOINT 1 8 F 1 C or 3 6 F 2 C or 5 4 F 3 C setting Figure 3 1 Operating Sequence Perishable Mode 3 1 2 Frozen Mode The unit operates in the frozen mode with set points at or below 10 F 12 C Operation in the frozen mode is the same as in the perishable mode except no heating takes place 1 8 F 190 or 3 6 F 2 C or 5 4 F 3 SETPOINT 1 8 F 1 C or 3 6 F 2 C or 5 4 F 3 C setting UNIT STOPPED Figure 3 2 Operating Sequence Frozen Mode 62 10848 3 2 DEFROST CYCLE Defrost is an independent cycle overriding cooling and heating functions in order to melt frost and ice from the evaporator when necessary Defrost may be initiated by the microprocessor or manually by the operator once the defrost termination thermostat has closed See Section 1 6 2 for settings In defrost mode the microprocessor displays dF on the cab command and set point is no longer displayed 62 10848 During defrost the evaporator fans shut down and operation of the condenser fan is controlled by the microprocessor The end of the cycle is
65. nsists of six keys that enable the operator to activate various functions display operating data and modify operating parameters Manual defrost control key Unit start up key Unit shut down key in standby or road mode On road operation the unit can also be shut down with the ignition key Unit data and function modification keys The SET key together with the and keys enables display and modification of unit operating data The display scrolls through parameters each time the SET key is pressed Decrease key selected data 152 Increase key for selected data 2 2 START UP 2 2 4 Inspection Before starting the truck engine or connecting standby power check the following a Check condenser coil for cleanliness b Check condition of refrigerant hoses c Check condition and tension of compressor belt s d Check condition of condenser fan blade motor and brushes e Check truck battery fluid level f Check truck battery and terminal connections clean and tighten as necessary WARNING Inspect battery cables for signs of wear abrasion or damage at every Pre Trip inspection and replace if necessary Also check battery cable routing to en sure that clamps are secure and that cables are not pinched or chafing against any components Check defrost water drains from evaporator Check evaporator coil for cleanliness i Check condition of evaporator fan blades motor and brushes
66. nutes If the battery voltage has not risen after this 10 minute period the unit will remain out of temperature control mode another 2 minutes and the microprocessor will check the battery voltage every 2 minutes Unit will return to temperature control mode in its current configuration when battery voltage rises to Press SET key to return to refrigerated 10V 0 2V for Standby units or 10 5V 0 5V for Road compartment temperature only units 28 STOPPING THE UNIT 27 CHECKING THE EEPROM VERSION 2 6 3 Clearing Alarm Messages The alarm list provides information on current alarms Press the OFF key or turn the ignition and past alarms which may be helpful in trouble key to off position shooting unit problems Once all the alarm information 2 5 62 10848 2 9 MICROPROCESSOR CONFIGURATION CAUTION If starting unit for the first time afterinstalla tion or starting after adding removing an optional feature or if Owners operating pa rameters have changed the Configuration will need to be reset 2 9 4 ROAD ONLY FUNCTIONAL SETTINGS The procedure for adjusting the functional parameters is as follows 1 The temperature display is selectable between Fahr enheit and Celsius Units are configured for Celsius from the factory To set the display to Fahrenheit the selection jumper must be removed and discarded See Figure 1 6 NOTE The board contains another set of pins simila
67. olenoid Coil It is not necessary to remove the refrigerant charge to replace the coil see Figure 4 7 a Remove coil snap cap voltage plate and coil assem bly Disconnect leads and remove coil junction box if necessary Verify coil type voltage and frequency This informa tion appears on the coil voltage plate and the coil housing Place new coil over enclosing tube and then install voltage plate and snap cap Snap cap Voltage plate Coil assembly Enclosing tube 5 Plunger assembly 6 Valve body assembly 7 Direction of flow PON gt Figure 4 7 Hot Gas or Condenser Pressure Control Solenoid 4 13 2 Replacing Valve Internal Parts Remove the refrigerant charge See Section 4 4 Remove coil snap cap voltage cover and coil assem bly Remove the enclosing tube Check for foreign material in valve body Check for damaged plunger and o ring If o ring is to be replaced always put refrigerant oil on o rings be fore installing CAUTION Do not damage or over tighten the enclos ing tube assembly Place all parts in the en closing tube in proper sequence in orderto avoid premature coil burn out e Tighten enclosing tube f Install coil assembly voltage cover and snap cap 62 10848 g Evacuate dehydrate and recharge unit See Sec tions 4 6 and 4 7 h Start unit and check operation 7 S fr 41 9 ZA CZ lZ 1 Cap 2 Jam Nut 3 Set
68. ompressor drive are available e Road operation the road compressor is located in the engine compartment and is driven by the engine of the vehicle when in operation over the road e Road Standby version a second compressor is mounted in the condensing section and is driven by an electric motor when in standby mode 1 3 CONDENSING SECTION The condensing section see Figure 1 2 contains the condenser fan amp coil filter drier oil separator hot gas solenoid valve receiver and a condenser pressure control valve On road standby units the condensing section also houses the standby compressor control box and rectifier and houses the transformer assembly see Figure 1 2 and Figure 1 5 1 3 1 Condenser Subcooler The condenser is of the tube and fin type and acts as a heat exchanger in which the compressed refrigerant gas is condensed into a liquid and lowered in tempera ture Air movement over the condenser is provided by a fan mounted in the condensing section A portion of the condenser is occupied by the subcooler Refrigerant leaving the receiver is passed through the subcooler where additional heat is removed Removal of this additional heat helps to ensure that only liquid refrigerant enters the thermal expansion valve 1 3 2 Filter Drier The drier is a cylindrical shell containing a drying agent and screen It is installed in the liquid line and functions to keep the system clean and remove moisture from the refrigerant
69. pillary tube OIL AND GAS REFRIGERANT FROM COMP COMP SUCTION LINE Figure 1 4 Oil Separator 1 3 4 Hot Gas Solenoid Valve HGS1 HGS1 is normally closed and prevents discharge gas from entering the evaporator The valve opens to allow hot gas refrigerant to be delivered from the compressor to the evaporator during heat or defrost modes 1 3 1 3 5 Condenser Pressure Control Valve HGS2 The condenser pressure control valve or condenser closing valve is a normally open valve that is powered when the condenser pressure control switch HP2 is closed With the solenoid coil de energized the valve is in the cool mode and the compressor discharge gas is delivered to the condenser In the cool mode heat is removed from the air inside the truck body and rejected to the surrounding air With the solenoid coil energized the valve is in the heat mode and the compressor dis charge gas is diverted to the evaporator and rejected to the air inside the truck body 1 3 6 Compressor The compressor withdraws refrigerant gas from the evaporator and delivers it to the condenser at an in creased pressure The pressure is such that refrigerant heat can be absorbed by the surrounding air at ordinary temperatures 1 3 7 Standby Motor The standby motor operates nominal 115v 1ph 60hz or 208 230v 1ph 60hz or 230v 3ph 60hz power An overload and short cycle protection is provided along with automatic reset Units are also equippe
70. r no circumstances should anyone at tempt to repair the microprocessor module or Cab Command Should a problem devel op with these components contact your nearest Carrier Transicold dealer for re placement Although there is less danger of electrical static discharge ESD damage in the outdoor environment where the processor is likely to be handled proper board handling techniques should be stressed Boards should always be handled by their edges in much the same way one would handle a photograph This not only precludes the possibility of ESD damage 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 When welding is required on the unit frame or on the front area of the truck ALL wiring to the microprocessor MUST be disconnected When welding is performed on other areas of the truck and van the welder ground connection MUST 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 truck to prevent possible damage to other components such as the alternator and voltage regulator 4 18 EVAPORATOR COIL CLEANING The use of recycled cardboard cartons is increasing The recycled cardboard cartons create much more fiber dust during transport than new cartons The f
71. raph 4 7 3 Dehydrate unit and leave in deep vacuum Refer to section 4 6 Place refrigerant cylinder on scale and connect charging line from cylinder to receiver outlet king valve Purge charging line at outlet valve Note weight of refrigerant cylinder Open liquid valve on refrigerant cylinder Open king valve half way and allow the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added as indicated by scale Correct charge will be found in Table 1 1 NOTE It is possible that all liquid may not be pulled into the receiver as outlined in step d above In this case vapor charge remaining refrigerant through the suction service port See Section 4 7 3 When refrigerant cylinder scale indicates that the cor rect charge has been added close liquid line valve on cylinder and backseat the king valve Replace all valve caps g Start unit and check for non condensables 4 7 3 Adding A Partial Charge NOTE When partially charging the refrigeration sys tem with R134a install a vapor charge Place refrigerant cylinder on scale and connect charging line between suction port and refrigerant cylinder Note weight of refrigerant cylinder Run unit on high speed cool and open cylinder vapor valve If necessary partially block off air flow to condenser coil so discharge pressure rises to 174 psig 12 Bars The unit is correctly charged when the
72. rds or unsafe conditions which COULD result in severe personal injury or death CAUTION means to warn against potential hazard or unsafe practice which could result in minor personal injury product or property damage The statements listed below are applicable to the refrigeration unit and appear elsewhere in this manual These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein WARNING Beware of unannounced starting of the unit The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate Press OFF key on the cab command and disconnect power plug WARNING Inspect battery cables for signs of wear abrasion or damage at every Pre Trip inspection and replace if necessary Also check battery cable routing to ensure that clamps are secure and that cables are not pinched or chafing against any components WARNING Do not attempt to connect or remove power plug before ensuring the unit is OFF press OFF key on Cab Command and external power circuit breaker is open WARNING Beware of V belt and belt driven components as the unit may start automatically 4A WARNING Ensure power to the unit is OFF power plug is disconnected and circuit breaker is open or vehicle engine is OFF and negative battery cable is connected before replacing compressor WARNING Slowly open the plug on the suction and disch
73. re are no bubbles in the sight glass f Start unit and check for non condensables 4 8 CHECKING FOR NON CONDENSABLES To check for non condensables proceed as follows a Stabilize system to equalize pressure between the suction and discharge side of the system Check temperature at the condenser and receiver Check pressure at the receiver outlet King valve Check saturation pressure as it corresponds to the condenser receiver temperature using the Tempera ture Pressure Chart Table 4 4 If gauge reading is 3 psig 0 2 Bar or more than the calculated P T pressure in step d non condens ables are present f Remove refrigerant using a refrigerant recovery sys tem Refer to section 4 4 Evacuate and dehydrate the system Refer to sec tion 4 6 Charge the unit Refer to section 4 7 62 10848 4 9 REPLACING THE COMPRESSOR 4 9 4 Removing Compressor WARNING Ensure power to the unit is OFF power plug is disconnected and circuit breaker is open or vehicle engine is OFF and negative bat tery cable is connected before replacing compressor a Remove the refrigerant See Section 4 4 1 WARNING Slowly open the plug on the suction and discharge valves of the new compressor to vent the nitrogen holding charge b Remove bolts from flanges c Release and remove belt d Remove the bolts mounting the compressor Re move the compressor from chassis e Remove the pulley from
74. refriger ated compartment temperature Check that temperature set point is correct by pressing the SET key The set point temperature is highlighted on the digital display 2 3 SET POINT ADJUSTMENT It is possible to increase or decrease the set point by whole numbers until the required set point is displayed If display stays highlighted the set point displayed has not been validated The new setting for the set point is validated by pressing the SET key Displays the set point temperature Decrease the set point Increase the set point Validate set point temperature Return to display of refrigerated compartment temperature SE 2 4 MANUAL DEFROST Check that refrigerated compartment temperature is 40 F 4 4 C or lower Press manual defrost key to initiate manual defrost 62 10848 2 5 DEFROST CYCLE ADJUSTMENT Defrost parameters may be set to eliminate defrost decrease the time between defrosts allow full automatic defrost increase the time between defrosts or set a forced interval between defrosts To adjust the defrost cycle do the following OOO Display parameters Modify parameters Validate modified settings Return to display of refrigerated compartment temperature NOTE If no key is pressed within 5 seconds of adjusting settings the system reverts to dis playing the refrigerated compartment tempera ture Only validated changes are recorded 2 6 ALARM
75. ressor and evaporator fans operating See Section 1 8 1 for a description of the refrigeration circuit during cool ing The condenser fan will operate for the first three minutes after start up then operate under the control of the condenser pressure control switch HP2 The green unit operating LED will operate in accordance with Figure 2 2 or Figure 2 3 If discharge temperature increases to the set point of the quench thermostat BPT the thermostat will close energizing the quench valve BPV This will al low liquid into the suction line in order to cool com pressor Once the discharge temperature decreases to the certainty of the PPT the thermostat will open DE energizing the PP c Once temperature decreases to the certainty the unit will enter the null mode If the continuous air flow pa rameter is set to ON the evaporator fans will continue to operate with all other components OFF If the con tinuous air flow parameter is OFF the evaporator fans and all other components will be OFF A 5 ute delay is required before restart is allowed d If temperature increases during the null mode the unit will restart in cooling e If temperature continues to decrease the unit will en ter the heating mode with the compressor and evapo rator fans operating and the hot gas solenoid valve HGS1 energized open The condenser fan and condenser pressure control valve HGS2 will oper ate under the control of the co
76. rotected opening circuit 4 Excessive current draw motor 230 Overload relay YES NO Depending on Selection compressor 115 1 60 Circuit Breaker See electrical wiring diagram 5 Excessive current draw evapora Electronic relay Self protected opening tor and condenser fan motors 6 Excessive compressor discharge Automatic reset of High i a 7 an current draw standby Opens at 5 A 12 V 8 Excessive current draw unit in Standby fuse F2 2 Opens at 30 A 12 V standby operation 9 Excessive current draw unit in Fuse Opens at 30 A 12 V road operation 1 Excessive temperature on stand Internal Motor Thermostat Self protected opening by motor bearing PTO 12 Clutch malfunction road exces Electronic relay sive current draw 13 Clutch malfunction road insuffi Electronic relay cient current draw 14 Double power supply road Microprocessor standby Self protected opening Opens 311 F 155 C Detection of min threshold at 750 mA Display on Cab Command until one of the 2 power sup plies have been discon nected 15 _ Low battery voltage Cutout cut in at 10 V 16 Excessive current draw on igni Fuse Fl Opens at 1 A tion circuit Neiman a On road standby unit only b This fuse is located close to the vehicle battery 12 v Y Y Y Y Y Y Y Y 10 Connection error on primary Fuse F4 and or F5 8 Opens at 4 A transformer ee ES NO NO ES ES NO NO NO NO ES ES
77. rto the Degrees C Degrees F selection jumper marked as J1 This jumper is not used for unit operation but it is used during the microproces sor controller manufacturing process DO NOT CONNECT THE J1 PINS TOGETHER 2 The following steps must be performed with the unit OFF Hold both keys momentarily in order to display parameters Modify parameters See a and b below Validate modified settings NOTE If no buttons are depressed within 5 seconds of pressing the Defrost and On Keys Step 2 ofthe above procedure or modifying parameters the Cab Command reverts to refrigerated compart ment temperature display and the configuration procedure is aborted a The defrost duration parameter is displayed This set ting determines the length of time in minutes the unit will remain in defrost once defrost is initiated The de frost duration can be selected by scrolling through available options 10 20 25 30 or 45 minutes using the or keys Selection MUST be validated by pressing the SET key b The defrost interval parameter is displayed next This setting determines the time between defrosts in hours The defrost interval can be selected by scroll ing through available options 0 1 1 5 2 2 5 3 4 5 62 10848 6 hours using the or keys Selection MUST be validated by pressing the SET key 3 The next steps must be performed with the unit ON Press the then then DEFROST keys All ke
78. s closed and vacuum pump valve is open Start vacuum pump Slowly open valves halfway and then open vacuum gauge valve Evacuate unit until the electronic vacuum gauge indi cates 2000 microns Close the electronic vacuum gauge and vacuum pump valves Shut off the vacuum pump Wait a few minutes to be sure the vacuum holds Break the vacuum with clean dry nitrogen Raise sys tem pressure to approximately 2 psig 0 14 Bar Purge nitrogen from 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 con tainer on a scale The correct amount of refrigerant may be added by observing the scale Refer to sec tion 4 7 4 7 CHARGING THE REFRIGERATION SYSTEM 4 7 1 Checking The Refrigerant Charge C Start unit in cooling mode and run approximately ten minutes Partially block off air flow to condenser coil so dis charge pressure rises to 174 psig 12 Bars The unit is correctly charged when there are no bubbles in the sight glass 4 7 2 Installing A Complete Charge It may be necessary to finish charging the unit using the partial charge method due to pres sure rise in the high side of the system Refer to parag
79. ter the above sequence 2 9 2 ROAD STANDBY FUNCTIONAL SETTINGS The procedure for adjusting the functional parameters is as follows 1 The temperature display is selectable between Fahr enheit and Celsius Units are configured for Celsius from the factory To set the display to Fahrenheit move the Celsius end of the jumper to the Fahrenheit pin as shown in Figure 2 4 Figure 2 4 Temperature Selection Jumper NOTE The board contains another set of pins similar to the Degrees C Degrees F selection jumper marked as J1 This jumper is not used for unit operation but it is used during the microproces sor controller manufacturing process DO NOT CONNECT THE J1 PINS TOGETHER 2 The following steps must be performed with the unit OFF Hold both keys momentarily in order to display parameters Modify parameters See a and b below Validate modified settings NOTE If no buttons are depressed within 5 seconds of pressing the Defrost and On Keys Step 2 of the above procedure or modifying parameters the Cab Command reverts to refrigerated compart ment temperature display and the configuration procedure is aborted a The defrost interval parameter is displayed This set ting determines the time between defrosts in hours The defrost interval can be selected by scrolling through available options Settings are for either au tomatic defrost AUT or fixed time intervals between 1 to 6 hours The set
80. the compressor 4 9 2 Installing Compressor a Toinstall the compressor reverse the procedure out lined when removing the compressor Refer to sec tion 1 6 4 for torque values NOTE The service replacement compressor is sold without flanges b Pump down the compressor See Section 4 4 c Charge compressor See Section 4 7 2 NOTE It is important to check the compressor oil level ofthe new compressor and fill if necessary Re fer to section 1 6 1 d Check refrigerant cycles Compressor oil type The road compressors are supplied with CARRIER POLYESTER POE oil Ensure compressor is marked with a factory sticker indicating the correct oil has been installed Oils of PAG typeare strictly incompatible with the operation ofthis unit never use an oil other than that approved by CARRIER 62 10848 4 10 CHECKING AND REPLACING FILTER DRIER 4 10 1 Checking Filter Drier Check for any obstruction ofthe filter drier by feeling the inlet and outlet connections of the liquid line on the filter cartridge If the temperature of the outlet connection seems lower than the temperature of the inlet connection replace the filter drier 4 10 2 Replacing The Filter Drier Remove refrigerant charge See section 4 4 Remove the drier mounting clip then replace the filter drier Following drier replacement evacuate and recharge unit refer to sections 4 6 amp 4 7 4 11 HIGH PRESSURE HP1 AND CONDENSER PRESSURE HP2
81. ting be selected by pressing the or keys Selection MUST be validated by pressing the SET key The next steps must be performed with the unit ON 2 7 Press the then then DEFROST keys All THEN keys should be held 8 W momentarily after pressing in the correct sequence OR Modify parameters D See a b c and d below NOTE Keys must be pressed before the unit starts NOTE If no buttons are depressed within 5 seconds of pressing the ON key or modifying parameters the Cab Command reverts to refrigerated com partment temperature display and the configu ration procedure is aborted a The minimum set point parameter is displayed The minimum set point can be selected by scrolling through available options 20 F 28 9 C 4 F 20 C 32 F 0 C using the or keys Facto ry setting is 20 F Selection MUST be validated by pressing the SET key b The null mode differential temperature is displayed next This setting determines the temperature differ ence between refrigerated compartment tempera ture and set point that controls compressor cycling The differential can be selected by scrolling through available options 1 8 F 1 C 3 6 F 2 C or 5 4 F 3 C using the or keys Factory setting is 3 6 F 2 C Selection MUST be validated by press ing the SET key c The ON OFF Continuous airflow parameter for the evaporator fan is displa
82. ures do the following a b Remove access valve cap Connect the field service coupler see Figure 4 3 to the access valve Turn the field service coupling knob clockwise which will open the system to the gauge set Read system pressures Repeat the procedure to connect the other side of the gauge set 4 3 8 Removing the Manifold Gauge Set 1 While the compressor is still ON backseat the high side service valve Midseat both hand valves on the manifold gauge set and allow the pressure in the manifold gauge set to be drawn down to low side pressure This returns any liquid that may be in the high side hose to the system CAUTION To preventtrapping liquid refrigerant in the manifold gauge set be sure set is broughtto suction pressure before disconnecting 2 Backseat the low side service valve Backseat both field service couplers and frontseat both manifold set hand valves Remove the couplers from the access valves Install both service valve stem caps and access valve caps finger tight only Low Pressure High Pressure Gauge Gauge Backseated Hand Valve Frontseated Hand Valve To Low Side Access Valve To High Side 5 Red Knob 6 Blue Knob 1 2 3 4 5 6 Manifold Gauge Set Hose Fitting 0 5 16 Acme Refrigeration and or Evacuation Hose SAE J2196 R 134a Hose Fitting w O ring M14 x 1 5 High Side Field Service Coupler Low Side Fiel
83. x 62 10848 4 2 BELT MAINTENANCE AND ADJUSTMENT WARNING Beware of V belt and belt driven compo nents as the unit may start automatically 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 units are 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 Figure 4 1 Belt Tension Gauge Carrier Part Number 07 00203 00 Belt tension depends on each kit Refer to Installation Instructions provided with the kit for belt tension requirements In each kit installation instruction we indicate the belt tension given with belt tension gauge P N 07 00203 00 When installing a new V belt the tension should be somewhat higher than specified and readjusted after allowing the unit to run for some time Standby motor Compressor 1 Standby Motor Compressor V belt Figure 4 2 Layout of V belt 62 10
84. yed next This feature deter mines whether the evaporator fan is on or off when the unit cycles off upon reaching set point The factory setting is OFF Change setting by using the or keys Selection MUST be validated by pressing the SET key d The 2ET or 3ET parameter is now displayed This feature determines heating mode operation based on the presence of a condenser pressure control valve Since all 30S units covered by this manual have a condenser pressure control valve installed 3ET must be selected This enables cooling null and heating modes of operation Selection MUST be validated by pressing the SET key Change setting by using the or keys Selection MUST be validated by pressing the SET key AX WARNING Beware of unannounced starting of the unit The unit may cycle the fans and operat ing compressor unexpectedly as control re quirements dictate Press OFF key on the Cab Command and disconnect power plug 62 10848 SECTION 3 TEMPERATURE CONTROL 31 SEQUENCE OF OPERATION General operation sequences for cooling null and heating are provided in the following paragraphs The microprocessor automatically selects the mode necessary to maintain refrigerated compartment temperature at set point 3 1 1 Perishable Mode The unit operates in the perishable mode with set points above 10 F 12 C a With return air temperature above set point and de creasing the unit will be cooling with the comp
85. ys should be held momentarily after pressing in the correct sequence Modify parameters See a b and c below qiu NOTE If no buttons are depressed within 5 seconds of pressing the ON key or modifying parameters the Cab Command reverts to refrigerated com partment temperature display and the configu ration procedure is aborted a The minimum set point parameter is displayed The minimum set point can be selected by scrolling through available options 20 F 28 9 C 4 F 20 C 32 F 0 C using the or keys Facto ry setting is 20 F Selection MUST be validated by pressing the SET key b The null mode differential temperature is displayed next This setting determines the temperature differ ence between refrigerated compartment tempera ture and set point that controls compressor cycling The differential can be selected by scrolling through available options 1 8 F 1 C 3 6 F 2 C or 5 4 F 3 C using the or keys Factory setting is 3 6 F 2 C Selection MUST be validated by press ing the SET key The ON OFF Continuous airflow parameter for the evaporator fan is displayed next This feature deter mines whether the evaporator fan is on or off when the unit cycles off upon reaching set point The factory setting is OFF Change setting by using the or keys Selection MUST be validated by pressing the SET key The return air temperature will be displayed af

Integra 30s service manual - Grease Monkey Road Service

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