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OPERATIONS AND SERVICE MANUAL 69NT40

1. D E F L M N P R T f 230 3 60 450 3 460 3760 10 4 0 OR OR OR wis POWER PLUG 50 CABLE 1 CABLE cg TRU R1 LIJA 1 TW 11 m B ul E TI ss 2 52 lt wr 12 2 52 lt z ym 12 22 L2 r2 L2 T2 2 RIKZ LS 3 rs 1 RED T3 RED BRN 13 23 cc L3 ts LS 3 61 Lil E ferl 4 B 34 cs
2. A B c D E F J K L M N P R T N 230 360 460 360 460 3 60 190 5 50 sp 3805 50 1 E 8 4 DW 737 ES i ler POWER PLUG 50 aes e ep A PA CH CABLE cpp BLK 7 A WHT 1 R1 lt A 7 11 21 Lj Li T1 Ar B 1 74186 BLK oy T lt T n W B 2 s2 4 12 2 52 lt 12 22 121 T2 L2 5 AA wr z L3 e 3 T3 RED Lod 13 3 T5 lt RED eran E BRN 13 23 L3 L3 T3 1 3 8 Iori G L lt GRN Y zi 4 cs ler c lt eR CORE GRN YEL pB 12 4 SOW R UN CABLE COMMUNICATIONS wal LS BLK I INTERFACE 1 L3 5 22 MODULE lt IST RED
3. CONFIGURATION TITLE DEFAULT OPTION NUMBER CnF02 Evaporator Fan Speed dS Dual SS Single CnF03 Control Temperature Sensors FOUr duAL CnF04 Enable Dehumidification On OFF CnF08 Evaporator Motor Type 1Ph 3Ph 09 Refrigerant Type r134a r744 CnF 11 Defrost Off Selection noOFF OFF CnF15 Enable Discharge Temperature Sensor Out In CnF16 Enable DataCORDER On Yes Not Allowed CnF17 Enable Discharge Pressure Transducer Out No In Yes CnF18 Heater Type Old Low Watt nEW High Watt CnF20 Enable Suction Pressure Transducer Out No In Yes CnF22 Economy Mode OFF Std Full CnF23 Enable Defrost Interval Save noSAv SAv CnF24 Enable Long Pre trip Test Series Auto Auto2 Auto 3 CnF25 Enable Pre trip Data Recording rSLtS dAtA CnF26 Heat Lockout Temperature Set to 10C Set to 5C CnF27 Enable Suction Temperature Sensor Out In CnF28 Enable Bulb Mode NOr bULb CnF31 Probe Check SPEC Std CnF32 Enable Single Evaporator Fan Option 2EFO Not Allowed CnF33 Enable Snap Freeze OFF SnAP CnF34 Temperature Unit Display nOth F CnF37 Electronic Chart Probe rEtUR SUPPL bOth CnF41 Enable Low DTT Setting Out In CnF44 Autoslide Enable Out LO UP CnF45 Low Humidity Enabled Out In CnF46 Quench liquid Injection Valve Type nO 0 no nC 1 nc CnF47 Vent Position OFF UP LOW CUStOM CnF49 OEM Reset Option OFF 0 off 1 std 2 spec 3 cust CnF50 Enhanced Bulb Mode Interface 0 out 1 in CnF51 Timed Defrost Disable 0
4. 7 15 Figure 7 14 View of Digital Unloader Valve DUV Assembly 7 16 Figure 7 15 Autotransformer eei e vv RETIA GERENTE aed 7 18 vii T 362 Rev B Figure 7 16 Controller Section of the Control 7 19 Figure 7 17 5 Types 22 22 2212 4 440 dee eot Se edere des erbe dU eee ea 7 25 Figure 7 18 Sensor and Cable Splice 1 2 7 25 Figure 7 19 Supply Sensor Positioning 7 26 Figure 7 20 Return Sensor Positioning 1 1 7 26 Figure 7 21 Evaporator Temperature Sensor Positioning 7 26 Figure 7 22 Compressor Discharge Temperature Sensor 7 27 Figure 7 23 Stepper Components 7 28 Figure 7 24 Jumper Assembly Glee e a PIA 4 vw EP 7 28 Figure 7 25 Motor Cup Replacement ccc ete eee 7 30 Figure 7 26 Communications Interface Installation 7 31 Figure 8 1 LEGEND Standard Unit Configuration 8 1 Figure 8 2 SCHEMATIC DIAGRAM
5. 2 1 4 1 Figure 4 2 Keypad sam etat ded ates edet ao ens 4 2 Figure 4 3 Display Module 1 4 3 Figure 4 4 Control Mod le 2 he 4 3 Figure 4 5 Controller Operation Perishable Mode 4 5 Figure 4 6 Perishable Mode Cooling 4 7 Figure 4 7 Perishable Mode Heating 4 7 Figure 4 8 Controller Operation Frozen Mode 4 8 Fig re 4 9 Frozen Mode ies eee acetone cand due bot Sa aida dene des 4 9 Foue AIO Defrost bales de de oe 4 11 Figure 4 11 Standard Configuration Download Report 4 16 Figure 4 12 DataCorder Configuration Screen 4 19 Figure 4 13 DataCorder Probe Calibration Screen 4 19 Figure 4 14 DataCorder Probe Calibration Screen 4 19 Figure 4 15 DataCorder Systems Tool Screen 4 19 Figure 4 16 Alarm Troubleshooting Sequence
6. 4 31 Figure 5 1 Autotransformer cise oad te ts ee deba eerie etes 5 2 Figure 5 2 Upper Fresh Air Up Flow Chart 5 2 Figure 5 3 Diagram of Emergency Bypass Connections 5 8 Figure 7 1 Manifold Gauge Set ele e le e ERR IEEE eee eens 7 1 Figure 7 2 R 134a Manifold Gauge Hose Set 7 1 Figure 7 3 Service ValVe 7 2 Figure 7 4 Refrigeration System Service Connections 7 4 Figure 7 5 Compressor Kit ets 7 6 Figure 7 6 High Pressure Switch Testing 7 7 Figure 7 7 Condenser Fan Position 7 9 Figure 7 8 Heater Arrangement 7 11 Figure 7 9 Evaporator Fan Assembly 0 4 7 12 Figure 7 10 Electronic Expansion Valve 7 14 Figure 7 11 Coil View of Economizer Solenoid Valve ESV 7 14 Figure 7 12 Economizer Expansion Valve 2 7 15 Figure 7 13 Adapter and O Ring
7. 2 5 5 5 7 2 Check Controller Function Codes 5 5 5 7 3 Start Temperature Recorder 5 5 5 7 4 Complete Inspection 2 5 5 5 8 PRE TRIP DIAGNOSIS 1 0 4 5 5 5 9 PROBE DIAGNOSTICS Ee ee race eed e bx dha 5 7 5 10 EMERGENCY BYPASS OPERATION OPTION 5 7 TROUBLESHOOTING 25 ene e ERI e WERE Patt p IRE 6 1 6 1 UNIT WILL NOT START OR STARTS THEN STOPS 6 1 6 2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING 6 1 6 3 UNIT RUNS BUT HAS INSUFFICIENT COOLING 6 2 6 4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING 6 2 6 5 UNIT WILL NOT TERMINATE HEATING 6 2 6 6 UNIT WILL NOT DEFROST PROPERLY 1 1 6 2 6 7 ABNORMAL PRESSURES iiziseseeswesugeg uper e nexu mg s BG Re EE WE Res 6 3 68 ABNORMAL NOISE OR VIBRATIONS 2 6 3 6 9 MICROPROCESSOR MALFUNCTION 6 4 6 10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW
8. h g i J ECP1 Kod 5526 ILL 5252 _ 4 DOQ 2 emm X P deg cm CIG nari ECG2 7 7 5 M ux 8 ECG1 V pro O mc 55598 EVI 19 e 532 4 ES em Ot M pogo 22 4 ote 222 5 gii 8 8 8 8 P Ans s v9yYY TAN 1 M 10 ane 4 e s 8 f ORN p EM M37 E Te 1 yyy us MCA Em LE b T 362 Rev B Based on Drawing 62 11737 8 3 DISPLAY MODULE Ce RM Gy T LOCATING TAB ON BOTTOM OOOO Q lt COMMUNICATIONS CONTROLLER INTERFACE E MOPPLE 3 sts MAINS POWER 83 RED FUSE cpps ms 2 AT 63 A 2 om 12 r ESV lt Ver t TS per Mato 9 amp OOO o T gt IF EQUIPPED PHASE 2 IF EQUIPPED KEYWAY SIDE PHASE 5 FUSE 1 AT IF EQUIPPED 9191616191916
9. Parameter Selection Pressing CODE SELECT key in a selection menu cancels the current selection activity and ascends back up to the next higher selection menu or to Cd53 display mode if that is the next higher If the operator does not press any key for five seconds the interface reverts to normal sys tem display and the current selection menu is cancelled but any previously committed changes are retained Available parameters and parameter ranges are a function of configuration options and previously selected parameters as indicated above Parameter with the exception of ASC may not be altered if Cd53 is re entered if ASC is When ASC has completed including reaching the last setpoint done on the left display and the MONTH DAY of completion on the right display will be displayed as the second entry in the menu Turning ASC off clears this entry This action also resets Cd53 to initial time remaining ASC must then be turned on to view or modify the additional pa rameters Whenever any auto pretrip test or Trip Start is initiated ASC mode goes to OFF Display Only Functions Cd54 through Cd58 are display only functions Suction Port Superheat Reading for evaporator superheat suction temperature minus suction saturation tem Cd54 Electronic Expansion perature as calculated from suction pressure is shown on the right display Valve Status Press ENTER at Cd54 to show reading for
10. AL07 FRESH AIR VENT OPEN WITH FROZEN SET POINT Corrective Action If unable to obtain zero reading replace defective VPS AL08 HIGH COMPRESSOR PRESSURE RATIO Cause Controller detects discharge pressure to suction pressure ratio is too high The controller will attempt to correct the situation by restarting the compressor Component Discharge Pressure Transducer DPT Troubleshooting Confirm accurate DPT pressure readings refer to MANIFOLD GAUGE SET Section 7 2 Corrective Action Replace DPT if defective AL10 CO2 SENSOR FAILURE Cause Alarm 10 is triggered when the sensor voltage is operating outside of the 0 9 v to 4 7 range or if the sensor is out of range Component This is a display alarm and has no associated failure action Troubleshooting Refer to eAutoFresh manual Corrective Action The alarm is triggered off when voltage is within operating range AL14 PHASE SEQUENCE DETECT FAULT Cause Controller is unable to determine the correct phase relationship Component N A Troubleshooting Power cycle the unit Corrective Action Resetting the unit may correct problem monitor the unit Component Wiring Troubleshooting Check unit wiring Confirm pressure readings during start up suction pressure should de crease and discharge pressure should increase Corrective Action Correct wiring Component Current Sensor Troubleshooting Check Cd41 right most digit If display is 3 or 4 c
11. 6 1 Table 7 1 Valve Override Control Displays 1 2 7 18 Table 7 2 Sensor Resistance 7 23 Table 7 3 Sensor Resistance CPDS 7 24 Table 7 4 R 134a Temperature Pressure Chart 7 31 Table 7 5 Recommended Bolt Torque Values 7 33 ix T 362 Rev B SECTION 1 1 4 GENERAL SAFETY NOTICES Installation and servicing of refrigeration equipment can be hazardous due to system pressures and electri cal components Only trained and qualified service per sonnel should install repair or service refrigeration equipment When working on refrigeration equipment observe all potential Danger Warning and Caution hazards including those shown below and on hazard labels attached to the unit The following general safety notices supplement spe cific warnings and cautions appearing elsewhere in this manual They are recommended precautions that must be understood and applied during operation and main tenance of the equipment covered herein The general safety notices are presented in the following three sec tions labeled First Aid Operating Precautions and Maintenance Precautions A listing of the specific warnings and cautions appearing else
12. Unit does self test Check Power Supply Did Evaporator fans start No Check Power Supply Correct software version Install Latest Software Revision Unit configured correctly Load correct unit configuration Acti See alarm Al details amp arms repair Pass Pre trip Correct inspection all faults Operatin Correct Refrigerant normal issue 4 31 Refer to CONNECT POWER Section 5 2 Refer to CONNECT POWER Section 5 2 Refer to CONTROLLER SOFTWARE Section 4 2 Refer to Configuration Software Variables Section 4 2 1 Refer to Controller Alarm Indications Table 4 6 Refer to Pre trip Diagnostics Section 4 7 Refer to REFRIGERATION SYSTEM SERVICE Section 7 3 T 362 Rev B 4 11 CONTROLLER ALARM INDICATIONS AL03 LOSS OF SUPERHEAT CONTROL Cause Superheat has remained below 1 66 C 3 F degrees for five minutes continuously while compressor running Compressor drawing more than 2 0 amps compressor pressure ratio is greater than 1 8 and Electronic Expansion Valve EEV is at 096 open Component Electronic Expansion Valve EEV Troubleshooting Check the operation of the EEV using Cd41 Corrective Action Replace EEV if def
13. Quest ze dy eee m e de Communications Interface Module Au totransformer tee ramosa Gutters oo p retos ERN tete Handles siu s seb st cect E Thermometer Port 22252 08 ln Eee RI RA EE A Water Gooling 13545 i sp EP eae eds eei ben dp dites 460 Volt Cable 230 Volt Cable x Lex ASA Gable Restraint eta btn ea eee pale bee ee Upper Air Fresh Air Up Lower Air Fresh Air Ra bed Reet tam teen Controler tuo tin en ee Sas hie Condenser Grille Emergency Bypass eAutoEresh a cates oe aeta T 362 Rev B DESCRIPTION d adiectae Oa dol 3 1 3 1 GENERAL DESCRIPTION n eee eng pedes 3 1 3 1 4 Refrigeration Unit Front Section 3 1 3 1 2 Fresh Air Makeup Vent 3 1 3 1 3 EvaporatorSection
14. Unit operating in frozen mode Section 5 4 3 Check CO sensor Section 5 4 3 Gas Limit mode unavailable Wiring disconnected Check wiring Unit operating in frozen mode Section 5 4 3 Enter Key not held for sufficient length of time Section 5 4 3 25 odo set CO outside of acceptable levels Check Check sensor Section 5 4 3 Unit not Configured for eAutoFresh Operation No action Code 44 displays Check sensor Section 5 4 3 6 12 ELECTRONIC EXPANSION VALVE MALFUNCTION Incorrect software and or controller configuration Check Failed suction pressure transducer SPT or evapo Replace rator pressure transducer EPT Suction service valve partially closed Open Filter drier partially plugged Section 7 12 Low refrigerant charge Section 7 3 No evaporator air flow or restricted air flow Section 7 13 Excessive frost on evaporator coil Section 6 6 Evaporator fan s rotating backwards Section 7 14 3 EEV control malfunction Section 7 16 Failed digital unloader valve DUV Replace Loose or insufficiently clamped sensor Replace T 362 Rev B 6 4 Table 6 1 TROUBLESHOOTING CONDITION POSSIBLE CAUSE REMEDY REFERENCE SECTION Foreign material in valve Section 7 16 Failed suction pressure transducer SPT or evapo Replace High suction pressure with rator pressure transducer EPT low superheat EEV control malfunction Replace Improperly seated powerhead Ensure is
15. 4 8 6 Sampling Type 05 amp dCF06 4 8 7 Alarm Configuration QCF07 10 48 8 DataCORDER Power Up 4 8 9 Pre trip Data Recording 4 8 10 DataCORDER Communications 4 8 11 USDA Cold Treatment 4 8 12 USDA Cold Treatment Procedure 4 8 13 DataCORDER Alarms 4 8 14 ISO Trip Header 4 9 CONTROLLER CONFIGURATION VARIABLES 4 10 CONTROLLER FUNCTION CODES 4 11 CONTROLLER ALARM INDICATIONS 4 12 CONTROLLER PRE TRIP TEST CODES 5 1 INSPECTION 5 2 CONNECT POWER 5 2 1 Connection To 380 460 VAC Power 5 2 2 Connection To 190 230 VAC Power 5 3 ADJUST FRESH AIR MAKEUP VENT 5 3 1 Upper Fresh Air Makeup Vent 5 3 2 Lower Fresh Air Makeup Vent 5 3 3 Vent Position Sensor 5 4 EAUTOFRESH OPERATION 5 4 1 eAutoFresh Pre Trip Inspection 5 4 2 AutoFresh Start Up Procedure 5 4 3 eAutoFresh Modes of Operation 5 5 CONNECT REMOTE MONITORING RECEPTACLE 5 6 STARTING AND STOPPING INSTRUCTIONS 5 6 1 Starting the Unit 5 6 2 Stopping the Unit T 362 Rev B 5 7 START UP INSPECTION san mer sott rie gu e Ia Den 5 5 5 7 1 Physical Inspection
16. 5090 Lv pus 7 de KB7 Based on Drawing 62 11737 T 362 Rev B 8 8 INDEX Numerics 230 Volt Cable 2 2 460 Volt Cable 2 2 A Adding Refrigerant to System 7 5 ADJUST FRESH AIR MAKEUP VENT 5 2 Air Cooled Condenser Section 3 4 AutoFresh Start Up Procedure 5 3 Autotransformer 2 2 B Back Panels 2 2 Battery 2 1 7 21 C Cable Restraint 2 2 CCPC 2 2 Check Controller Function Codes 5 5 Checking the Refrigerant Charge 7 5 Communications Interface Module 2 2 3 5 COMMUNICATIONS INTERFACE MODULE INSTAL LATION 7 31 Complete Inspection 5 5 Compressor 2 1 Compressor Section 3 3 CONDENSER COIL 7 8 Condenser Coil 2 1 Condenser Coil Cleaning 7 8 Condenser Coil Installation 7 9 Condenser Coil Preparation 7 8 Condenser Coil Removal 7 8 CONDENSER FAN AND FAN MOTOR 7 9 Condenser Fan Motor Remove Replace 7 10 Condenser Grille 2 2 Configuration Identification 2 1 Configuration Software CnF Variables 4 3 CONNECT POWER 5 1 CONNECT REMOTE MONITORING RECEPTACLE 5 5 Connection To 190 230 VAC Power 5 1 Connection To 380 460 VAC Power 5 1 Control Box 2 1 Control Box Section 3 5 CONTROLLER 7 19 Controller 2 2 4 3 CONTROLLER ALARM INDICATIONS 4 45 Index 1 CONTROLLER PRE TRIP TEST CODES 4 45 Controller Software 4 3 Controller Troubleshooting 7 19 CPDS 7 26 D DataCORDER 5 5 Def
17. 6 4 6 11 EAUTOFRESH NOT OPERATING 6 4 6 12 ELECTRONIC EXPANSION VALVE MALFUNCTION 6 4 6 13 AUTOTRANSFORMER MALFUNCTION 43 4 6 5 6 14 COMPRESSOR OPERATING IN REVERSE 6 5 6 15 ABNORMAL TEMPERATURES 6 5 6 16 ABNORMAL CURRENTS ice eG 6 5 SERVIGE eT ree nr fa caren se T ADEM LES 7 1 7 1 SEGTION EAY OLEI eden iecur b beu o teta cox te PRU EA Apt 7 1 7 2 SET OLNE E RDR tha deat aa aes og pen 7 1 7 3 SERVICE CONNECTIONS 7 2 7 4 PUMP DOWN THE UNIT PE S PECIRSPENWEpUPS4 7 2 7 5 REFRIGERANT LEAK CHECKING 1 7 3 7 6 EVACUATION AND DEHYDRATION hr 7 3 General i euet bete y eade Retz dte p geo 7 3 7 0 2 Preparation enel ve Spells pere en ela eect queue 7 3 7 6 3 Complete System cov o ae tate ee wee eee ed 7 4 1 0 4 Partial System sees ee Les ee Y Meee ee ede RUNS 7 4 7 7 REFRIGERANT CHARGE antic eases a ale ba 7 5 7 7 1 Chec
18. a 990 99 VN g893 eva 2 1034 NOS whina 2 m N33 1493 ID 2493 gt ENI Gy GE gt gt 9 Based on Drawing 62 11737 T 362 Rev B 8 4 Figure 8 4 LEGEND Unit With Autotransformer LEGEND SYMBOL DESCRIPTION AMBS CB1 CB2 CE CH CM CP CPDS GS DHBL DHBR DHML DHMR DHTL DHTR DL DPT DTS DUV DVM DVR EEV EF EM EPT ES ETS ESV FLA HPS HR AMBIENT SENSOR C 23 CONTROLLER L 21 CIRCUIT BREAKER 460 VOLT 2 1 OPTIONAL CIRCUIT BREAKER DVM OPTION D 1 TERMINAL BLOCK WHEN CB2 NOT PRESENT CONDENSER FAN CONTACTOR N 8 L 11 COMPRESSOR CONTACTOR L 10 P 1 COMMUNICATIONS INTERFACE MODULE OPTION 4 COOL LIGHT OPTION L 12 CONDENSER FAN MOTOR E 11 G 11 R 9 COMPRESSOR MOTOR T 4 DISCHARGE TEMPERATURE SENSOR A 23 CURRENT SENSOR M 2 DEFROST HEATER BOTTOM LEFT R 8 DEFROST HEATER BOTTOM RIGHT T 7 DEFROST HEATER MIDDLE LEFT R 7 DEFROST HEATER MIDDLE RIGHT T 7 DEFROST HEATER TOP LEFT R 7 DEFROST HEATER TOP RIGHT T 8 DEFROST LIGHT OPTION L 7 DISCHARGE PRESSURE TRANSDUCER K 23 DEFROST TEMPERATURE SENSOR C 23 DIGITAL UNLOADER VALVE F 24 DUAL VOLTAGE MODULE OPTIONAL D
19. 8 2 Figure 8 3 UNIT WIRING DIAGRAM Sheet 1 2 8 3 Figure 8 4 LEGEND Unit With Autotransformer 1 8 5 Figure 8 5 SCHEMATIC DIAGRAM Unit With Autotransformer 8 6 Figure 8 6 UNIT WIRING DIAGRAM Unit With Autotransformer Sheet 1 of 2 8 7 T 362 Rev B viii LIST OF TABLES TABLE NUMBER Page Table 3 1 Safety and Protective Devices 3 8 Table 4 1 Keypad Function erint eee eR EU Ene iet AR De 4 2 Table 4 2 DataCORDER Configuration Variables 4 15 Table 4 3 DataCORDER Standard Configurations 4 17 Table 4 4 Controller Configuration Variables 2 4 4 21 Table 4 5 Controller Function Codes 4 22 Table 4 6 Controller Pre trip Test Codes 4 45 Table 4 7 DataCORDER Function Code Assignments 4 51 Table 4 8 DataCORDER Pre trip Result Records 4 52 Table 4 9 DataCORDER Alarm Indications 4 53 Table 6 1 TROUBLESHOOTING
20. ECOn Economizer Open Figure 7 15 Autotransformer Dual Voltage Modular Autotransformer Circuit Breaker CB 2 230 Volt 460 VAC Power Receptacle 7 23 CONTROLLER 7 23 4 Handling Modules Do not remove wire harnesses from mod ule unless you are grounded to the unit frame with a static safe wrist strap Unplug all module connectors before per forming arc welding on any part of the container The guidelines and cautions provided herein should be followed when handling the modules These precau tions and procedures should be implemented when replacing a module when doing any arc welding on the unit or when service to the refrigeration unit requires handling and removal of a module a Obtain a grounding wrist strap Carrier Transi cold P N 07 00304 00 and a static dissipation mat Carrier Transicold P N 07 00277 00 The wrist strap when properly grounded will dissi pate any potential static buildup on the body The dissipation mat will provide a static free work surface on which to place and or service the modules b Disconnect and secure power to the unit c c Place strap on wrist and attach the ground end to any exposed unpainted metal area on the refrigeration unit frame bolts screws etc d Carefully remove the module Do not touch any of the electrical connections if possible Place the module on the static mat e The strap should be worn during any service work on a modu
21. c lt AN GRN YEL u DVR PE 3 L1 T1 12 4 SOW 3 GABLE COMMUNICATIONS _ TRANS AUTO L2 T2 BLK INTERFACE 1 m TR H4 zs is wert 2 MODULE 3 4 5 lt 7 lt D e d 1 1 3 eis LI oTo s 70 POs os lt 59 on AN NN LEI 5 AN NN val T2 QW gt DHBL DHIR TCP PB PA Yo cal 55 KD1 21 22 1 2 Kigu TEP PA PB Lal mri T T lt iz lt 2 lt 2 21 22 1 2 515 ual F3 lt 8 HPS 5 boys 5 KA2 kB9 2 1 7 A2 ES TS L1 Ti g tal Fe ECYS z c3 hs ERV L1 Ti Tie TN hz 5 gt ECG1 4 IP IP cWe ECH2 1 2 Tie s 0919 ANN ECG2 ECH1 2 TL RM c gt a 1 gt 21 22 AT AZ 2 5 gt lt gt lt gt lt gt ECJ1 14 Pru P geme 26 Pru 24 A2 1 Tie TH HR 7 9 79 lt 7 15 ECD3 A2 n RM 2 RM gt gt lt KBB KB1 Ex 16 E EEV VPS 8LK ORG KEYPAD 3 17 9 TP9 5 gh zi NK RED DISPLAY RECHARGEABLE 18 MODULE BATTERY PACK NB Z 2VDC 4 16 1 1 19 d 20 918 6 1 6 5 4 3 2 1 4 5 20110 9 1 1 6 5 4 3 2 1 4
22. F Ohms F Ohms F Ohms 40 40 2 889 600 38 100 4 49 656 116 240 8 3 759 38 364 2 532 872 40 1040 45 812 118 2444 3 550 36 32 8 2 225 078 42 1076 42294 120 248 0 3 354 34 29 2 1 957 446 44 1112 39 078 122 251 6 3 173 32 25 6 1 724386 46 1148 36 145 124 2552 3004 30 22 0 1 522 200 48 1184 33 445 126 258 8 2 850 28 18 4 1 345 074 50 1220 30 985 128 2624 2 711 26 14 8 1 190 945 52 1256 28 724 130 266 0 2 580 24 11 2 1 056 140 54 1292 26651 132 2696 2 454 22 76 938 045 56 1328 27 750 134 2732 2 335 20 40 834 716 58 1364 23 005 136 276 8 2 223 18 04 743 581 60 140 0 21 396 138 2804 2 119 16 32 663 593 62 143 6 19909 140 2840 2021 14 68 593 030 64 1472 18 550 142 287 6 1 928 12 104 530714 66 1508 17 94 144 291 2 1 839 10 140 475 743 68 1544 16 133 146 294 8 1 753 8 176 426904 70 1580 15 067 148 2984 1 670 6 21 2 383 706 72 161 6 14 078 150 302 0 1 591 4 248 345315 74 1652 13 158 152 305 6 1 508 2 284 311 165 76 168 8 12 306 154 309 2 1 430 0 32 0 280 824 78 1724 11 524 156 312 8 1 362 2 35 6 253 682 80 1760 10 793 158 316 4 1 302 4 39 2 229 499 82 179 6 10 122 160 320 0 1 247 6 428 207 870 84 183 2 9 494 162 3
23. locked and in place Failed suction pressure transducer SPT or evapo Replace Liquid slugging in compressor rator pressure transducer Failed EEV Replace 6 13 AUTOTRANSFORMER MALFUNCTION Circuit breaker CB 1 or CB 2 tripped Check Autotransformer defective Section 7 22 Unit will not start Power source not turned ON Check 460 VAC power plug is not inserted into the recepta Section 5 2 2 cle 6 14 COMPRESSOR OPERATING IN REVERSE The compressor may start in reverse for up to 10 seconds to determine correct phase rota NOTE tion if required for phase detection Allowing the scroll compressor to operate in reverse formore than two minutes will result in internal compressor damage Turn the start stop switch OFF immediately Electrical Incorrect wiring of compressor Incorrect wiring of compressor contactor s Incorrect wiring of current sensor 6 15 ABNORMAL TEMPERATURES Check High discharge temperature Condenser coil dirty Section 7 10 2 Condenser fan rotating backwards Section 7 11 Condenser fan inoperative Section 7 11 1 Refrigerant overcharge or noncondensibles Section 7 3 Discharge service valve partially closed Open Electronic expansion valve EEV control malfunction Replace Failed suction pressure transducer SPT or evapo Replace rator pressure transducer EPT Discharge temperature sensor drifting high Replace Failed
24. Open control box door Check for loose electrical connections or hardware Check color of moisture liquid indicator 5 2 CONNECT POWER Do not attempt to remove power plug s before turning OFF start stop switch ST unit circuit breaker s and external power source Make sure the power plugs are clean and dry before connecting to power receptacle 5 2 1 Connection To 380 460 VAC Power 1 Make sure start stop switch ST on control panel and circuit breaker CB 1 in the control box are in position 0 OFF 2 Plug the 460 VAC yellow cable into a de ener gized 380 460 VAC 3 phase power source Energize the power source Place circuit breaker CB 1 in position I ON Close secure control box door 5 2 2 Connection To 190 230 VAC Power An autotransformer Figure 5 1 is required to allow operation on nominal 230 volt power It is fitted with a 230 VAC cable and a receptacle to accept the standard 460 VAC power plug The 230 volt cable is black in color while the 460 volt cable is yellow The transformer may also be equipped with a circuit breaker CB 2 The transformer is a step up transformer that will pro vide 380 460 VAC 3 phase 50 60 Hz power to the unit when the 230 VAC power cable is connected to a 190 230 VAC 3 phase power source 1 Make sure that the start stop switch ST on con trol panel and circuit breakers CB 1 in the control box and CB 2 on the transformer are i
25. low main voltage when a voltage drop of over 25 occurs an indication is given on the display but the unit will con tinue to run When an Alarm Occurs a The red alarm light will illuminate for alarm code numbers 15 17 20 21 22 23 24 25 26 and 27 b Ifa detectable problem exists its alarm code will be alternately displayed with the set point on the left display c The user should scroll through the alarm list to determine what alarms exist or have existed Alarms must be diagnosed and corrected before the Alarm List can be cleared To Display Alarm Codes a While in the Default Display mode press the ALARM LIST key This accesses the Alarm List Display Mode which displays any alarms archived in the alarm queue b The alarm queue stores up to 16 alarms in the sequence in which they occurred The user may scroll through the list by depressing an ARROW key The left display will show AL where is the alarm number sequentially in the queue d The right display will show the actual alarm code AA will display for an active alarm where is the alarm code Or will dis play for an inactive alarm see Section 4 11 e is displayed to indicate the end of the alarm list if any alarms are active f CLEAr is displayed if all alarms are inactive The alarm queue may then be cleared by press ing ENTER The alarm list will clear and will be d
26. 3 2 3 1 4 Compressor Section 3 3 3 1 5 Air Cooled Condenser Section 3 4 3 1 6 Control Box Section 3 5 3 1 7 Communications Interface 3 5 3 2 REFRIGERATION SYSTEM DATA 3 6 3 3 ELECTRICAL DATA cp ed ep eu oe aet eda dte ne eins 3 7 3 4 SAFETY AND PROTECTIVE DEVICES 1 3 8 3 5 REFRIGERATION CIRCUIT 3 9 3 5 1 Standard Operation IRR A RICE le A E 3 9 3 5 2 Economized Operation 3 9 3 5 3 Electronic Expansion Valve 3 9 MICROPROCESSOR cdo stare eden ce we eee Gap gs eme pou eR eR x 4 1 4 1 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM 4 1 Keypad duxere uec LESE Soe vr tween ewe i 4 2 4 1 2 Display Module x udis meta tenes beoe at dpa vd oed dvd Oiled is 4 2 433 Controller MOST dle nd 4 3 4 2 CONTROLLER SOFTWARE 4 3 4 2 1 Configu
27. 3 6 F Factory Default If the control temperature is the green IN RANGE light will be illuminated In range tolerance shall be set to 2 0 C upon activation of dehumidification or bulb mode Cd33 Cd35 Cd48 When is actively controlling in range tolerance is not considered will be displayed whenever Dehumidification or Bulb mode is enabled or when CCPC with six hour re activation is actively controlling will be displayed whenever Frozen Economy Mode is operating Stagger Start Offset Time Cast Seconds The stagger start offset time is the amount of time that the unit will delay at start up thus allowing multiple units to stagger their control initiation when all units are powered up to gether The eight possible offset values are 0 Factory Default 3 6 9 12 15 18 or 21 seconds Cd32 Current Limit Amperes The current limit is the maximum current draw allowed on any phase at any time Limiting the unit s current reduces the load on the main power supply When desirable the limit can be lowered Note however that capacity is also reduced The five values for 460 VAC operation are 15 17 19 21 or 23 amperes The factory default setting is 21 am peres Cd33 Humidity Setpoint This is the value in percent to which the system will dehumidify or humidify There are con figuration variables that determine whether dehumidification humidification capabilities a
28. Display Only Function Cd44 is a display only function eAutoFresh Values Sensor Status Code Cd44 displays the eAutoFresh and values CO and O5 and CO and O5 limits CO LIM and Os LIM respectively This function code will be dashed out if not configured for eAutofresh This function code will be dashed if sensor is not detected and a sensor is not ex pected didn t have one previously This function code will display ChECK if a sensor has not been auto detected at the most recent power up and was detected at a previous power up If ChECK is dis played and the ENTER key is pressed SEnSr is displayed with the choices of YES and YES sensor should be remembered as detected present sensor should not be remembered as being detected not present Configurable Functions Cd45 through Cd48 are user selectable functions The operator can change the value of these func tions to meet the operational needs of the container 4 25 T 362 Rev B Table 4 5 Controller Function Codes Code TITLE No DESCRIPTION Vent Position Sensor caso VPS Position Values 0 to 240 for UPPER 0 to 225 for LOWER This function code will be dashed out if not configured for VPS When configured for VPS Cd45 displays the current vent position in units of 5 CMH units displayed as or units displayed as CF dependi
29. 4 cl 5 T3 7 GRN c 5 st ea 6 5 1 1 3 i9 Tog 25 n 4 H AO S HR DHTL RMR Lim F3B F3A L d U 4 v T Me 121 SOU gt KB7 DHBL DHIR TCP is 5 gt U PA 21 22 A1 A2 mii TCP PA PB Cal fri lt iz lt 2 lt 21 22 A1 A2 PES tal ER 5 HPS i eg T 5 KB9 2 99 1 7 1 A2 7 ES TS L1 T1 7 lt Lal ge o s L1 T1 IP CM T TN lt gt lt 1 4 cue 2 T3 dinis 9 5 lt gt ANN ECG2 ECH1 E 2 TL RM ZA RM KA1 gt KA4 21 22 A1 2 IP EM1 IP EM2 5 lt gt lt lt gt ECJ1 14 Po P Eme 26 24 A1 A2 EN HTT TP10 TH HR one gt LI 15 ECD3 A2 a RM RM gt lt lt R Dy KB8 KB3 KB1 16 vps BLk ong KEYPAD e 3 17 YY Y 9 yyy CRY PYEL NK RED DISPLAY RECHARGEABLE 18 MODULE BATTERY_ us 7 2VDC X VV 4g 4 1 T 19 123456113 5 20 1 86 6 5 4 3 2 1 h4hsheh iholefel 1 bol 1 5 4 3 2 1 4 3 2 1 5 4 3 2 1 79101112121 28 TP KH KA KB KD KE MX Ren 20
30. 4 38 AL50 AIR VENT POSITION SENSOR VPS Corrective Action Manually tighten panel Troubleshooting If the alarm persists replace the sensor or the assembly Corrective Action Replace VPS AL51 EEPROM FAILURE Cause Controller Memory Failure Component Controller Troubleshooting Pressing the ENTER key when CLEAr is displayed will result in an at tempt to clear the alarm Corrective Action If action is successful all alarms are inactive alarm 51 will be reset Troubleshooting Power cycle the unit If the alarm persists it indicates defective control ler memory Corrective Action Replace defective controller refer to Controller Service Section 7 23 AL52 EEPROM ALARM LIST FULL Cause Alarm list queue is full Component Active Alarms Troubleshooting Repair any alarms in the queue that are active Indicated by AA Corrective Action Clear alarms refer to CONTROLLER ALARMS Section 4 6 AL53 BATTERY PACK FAILURE Cause Battery voltage low Component Battery Troubleshooting If this alarm occurs on start up allow a unit fitted with rechargeable bat teries to operate for up to 24 hours to charge rechargeable batteries suf ficiently Once fully charged the alarm will deactivate Corrective Action To clear the alarm press ENTER and ALT simultaneously at the startup of Cd19
31. Refrigerant R 134a Conforming to AHRI standard 700 specifications optimal unit performance Charge water cooled condenser or receiver according to nameplate specifications to ensure Refrigerant Charge Receiver 4 54 kg 10 Ibs Fusible Plug Melting point 99 210 F Torque 6 2 to 6 9 mkg 45 to 50 ft lbs Rupture Disc Bursts at 35 5 kg cm 500 596 psig Torque 6 2 to 6 9 mkg 45 to 50 ft lbs Unit Weight Refer to unit model number plate Water Pressure Switch Cut In 0 5 0 2 kg cm 7 3 psig Cut Out 1 6 0 4 kg cm 22 5 psig T 362 Rev B 3 3 ELECTRICAL DATA a Circuit Breaker CB 1 25 amp Trips at 29 amps CB 2 50 amp Trips at 62 5 amps CB 2 70 amp Trips at 87 5 amps b Compressor Motor Full Load Amps FLA 13 amps 460 Nominal Supply 380 VAC Three Phase 50 460 VAC Three Phase 60 Hz Hz Full Load Amps 1 amps 2 amps 2 Cond nser Horsepower 0 21 hp 0 36 hp Motor Rotations Per Minute 1450 rpm 1750 rpm Voltage and Frequency 360 460 2 5 Hz 400 500 VAC 2 5 Hz Bearing Lubrication Factory lubricated additional grease not required Rotation Counter clockwise when viewed from shaft end Number of Heaters 6 d Evaporator Rating 750 watts 5 10 each 230 VAC Heat
32. F1 r2 F34 F38 T CONTROLLER 21 PROGRAMMING SLOT Z EC A B c D L M EC N P R 5 x Y EC 1 1 1 2 d d 2 2 22 3 h h h 3 can CH o gt m Y MN NM MN 23 a 1 4 3 2423 39 8 52 3 4 L 474 T0 TN PRA 0 HS SPT DPT m BEAD DUV 5 S u Pa FN o 24 B E 362 Rev Based on Drawina 62 11737 RED XB amp I ECL2 arn c L ECUS ORN TKA amp T ECL1 Figure 8 3 UNIT WIRING DIAGRAM Sheet 1 of 2 A c LT N 5 5 Y GRD lt lt lt lt lt p gt RED yVilyyvilyyvilyyv lyyyyy T2 wr i Ll dm RX 2 SEEKERS fu ud COU luii d k 8 ooo o gs f Doo m 075 lt ri RIS qun DOO 8 RRS RED WHT BE we II al SRS Ir ffffitf t n Lw amp k h AMBS OOo 5 ECL3 T 1q
33. M MANIFOLD GAUGE SET 7 1 Manual Pump Down 7 3 MICROPROCESSOR 4 1 modes OF operation 4 4 MOTOR ASSEMBLY 7 11 Operating Precautions 1 1 OPERATION 5 1 Operational Software Cd Function Codes 4 4 P PAINTED SURFACES 7 30 Partial System 7 4 Perishable Dehumidification 4 5 Perishable Dehumidification Bulb Mode 4 6 Perishable Economy 4 6 Perishable Heating 4 5 T 362 Rev B Perishable Idle Air Circulation 4 5 Perishable Mode Cooling Sequence of Operation 4 6 Perishable Mode Heating Sequence of Operation 4 7 Perishable Mode Temperature Control 4 4 Perishable Pulldown 4 4 Perishable Steady State 4 4 Physical Inspection 5 5 Plate Set 2 1 PRE TRIP DIAGNOSIS 5 5 Pressure Readout 2 1 PROBE DIAGNOSTICS 5 7 PROTECTION MODES OF OPERATION 4 11 PUMP DOWN 7 2 Q Quest 2 2 R REFRIGERANT LEAK CHECKING 7 3 Refrigeration Circuit 3 9 Refrigeration System Data 3 6 Refrigeration Unit 3 1 Remote Monitoring 2 2 Replacing High Pressure Switch 7 8 Replacing the Evaporator Fan Assembly 7 12 return temperature sensor 4 11 RRS 7 26 RTS 7 26 S SAFETY AND PROTECTIVE DEVICES 3 8 SAFETY NOTICES 1 1 SAFETY SUMMARY 1 1 Sensor 7 25 Sensor Checkout 7 22 Sensor DTS 7 26 SERVICE 7 1 SERVICE CONNECTIONS 7 2 Specific Hazard Statements 1 1 SRS 7 26 Standard Battery 7 21 Standard Operation 3 9 Start Temperature Recorder 5 5 Start up Compressor P
34. Out Evaporator speed select goes to Hi for units with PWM Compres sor Control Cnf57 In DTT setting goes to 25 6 C or 18 0 C depending on Cnf41 Whenever dehumidification mode is set to bUlb DTT setting goes to 18 0 C if it had been set higher Whenever dehumidification mode is set to dEhUM DTT setting goes to 25 6 C or 18 0 C depending on Cnf41 For units without PWM Compressor Control Cnf57 Out Whenever dehumidification control setpoint is set below 65 RH evaporator speed select goes to LO if it had been set to Hi Whenever dehumidification control setpoint is set above 64 RH evaporator speed select goes to Alt if it had been set to LO For units with PWM Compressor Control Cnf57 In Whenever dehumidification control set point is set below 6096 RH the evaporator fan speed is set to LO the user has the ability to set the evaporator fan speed to Hi via the keypad Whenever dehumidification control set point is set equal to or above 6096 RH the evaporator fan speed is set to Hi the user has the ability to set the evaporator fan speed to LO via the keypad Display Only Function Cd49 is a display only function Cd49 Days Since Last Successful Pre trip Displays the number of days since last successful pretrip sequence Press ENTER to view the number of days since the last successful pretrip for Auto1 Au to2 and Auto2 in sequence Press CODE SELECT to step back through the list and ultimat
35. VALVE REMOVAL The preferred method of removing the valve is to cut the connection between the brazed section and the valve using a small tube cutter Remove valve Alternately use a wet rag to keep valve cool Heat inlet and outlet connections to valve body and remove valve 5 Clean the valve stem with mild cleaner if neces sary b Installing an EEV Reverse steps 1 through4 above to install a new valve 1 Install the valve and a new strainer with the cone of strainer screen pointing into liquid line at the inlet to the valve T 362 Rev B During installation make sure the EEV coil is snapped down fully and the coil retention tab is properly seated in one of the valve body dim ples Also ensure that coil boot is properly fitted Brass Spacer a Removing a Solenoid Valve Coil over valve body See Figure 7 10 Figure 7 10 Electronic Expansion Valve 00000 Coil Boot Coil Electronic Expansion Valve Flow Direction Strainer 3 Replace filter drier 4 Evacuate to 500 microns by placing vacuum pump on liquid line and suction service valve 5 Open liquid line service valve and check refrig erant level 6 Check superheat Refer to Section 3 2 7 Check unit operation by running Pre trip Refer to Section 4 8 7 17 ECONOMIZER SOLENOID VALVE Figure 7 11 Coil View of Economizer Solenoid Valv
36. average snapshot andUSDA When configured to average the average of readings taken every minute over the recording period is recorded When configured to snap shot the sensor reading at the log interval time is recorded When USDA is configured supply and return temperature readings are averaged and the three USDA probe readings are snapshot 4 8 7 Alarm Configuration dCF07 dCF10 USDA and cargo probe alarms may be configured to OFF ON or AUTO If a probe alarm is configured to OFF the alarm for this probe is always disabled If a probe alarm is configured to ON the associated alarm is always enabled If the probes are configured to AUTO they act as a group This function is designed to assist users who keep the DataCORDER configured for USDA record ing but do not install the probes for every trip If all the probes are disconnected no alarms are activated As soon as one of the probes is installed all of the alarms are enabled and the remaining probes that are not installed will give active alarm indications 4 8 8 DataCORDER Power Up The DataCORDER may be powered up in any one of four ways 4 17 1 Normal AC power The DataCORDER is pow ered up when the unit is turned on via the Stop Start switch 2 Controller DC battery pack power If a battery pack is installed the DataCORDER will power up for communication when an interrogation cable is plugged into an interrogation recepta cle 3 External
37. the defrost interval is determined using the Auto matic Defrost Interval Determination logic In either case PuLS remains displayed in this function select code If any Auto Pretrip sequence is initiated the Defrost Interval setting will be set to AUTO unless CnF49 OEM Reset is set to Custom AND CnF64 Evapora tor Fan Pulsing Logic configuration variable is set to IN in which case the Defrost Interval setting on the Trip Settings screen will be set to Pulse If defrost does not terminate correctly and temperature reaches the set point of the Heat Termination Thermo stat HTT 54 C 130 F the HTT will open to de ener gize the heaters ALO59 amp ALO60 If the HTT does open and termination does not occur within two hours the controller will terminate defrost ALO60 will be acti vated to inform of a possible DTS failure 4 4 PROTECTION MODES OF OPERATION 4 4 1 Evaporator Fan Operation Opening of an evaporator fan internal protector will shut down the unit 4 4 2 Failure Action Function code Cd29 may be operator set to select the action the controller will take upon a system failure The factory default is full system shutdown Refer to Table 4 5 4 4 3 Function codes Cd31 Stagger Start Offset Time and Cd32 Current Limit may be operator set to control the start up sequence of multiple units and operating cur rent draw The factory default allows on demand start ing no delay of units and
38. 1 DUAL VOLTAGE RECEPTACLE OPTIONAL F 3 ELECTRONIC EXPANSION VALVE R 16 EVAPORATOR FAN CONTACTOR HIGH SPEED N 11 K 13 EVAPORATOR FAN MOTOR T 11 T 13 E 14 F 14 G 14 EVAPORATOR PRESSURE TRANSDUCER H 23 EVAPORATOR FAN CONTACTOR LOW SPEED P 10 L 13 EVAPORATOR TEMPERATURE SENSOR SUCTION D 23 ECONOMIZER SOLENOID VALVE J 11 FUSE C 7 D 7 F 21 G 21 FULL LOAD AMPS HIGH PRESSURE SWITCH G 9 HEATER CONTACTOR N 7 L 15 SYMBOL _ DESCRIPTION HS HIT ICF ICR IRL PA PB PR PTC RM RRS RTS SPT SRS ST STS TBU TC TCC TCP TE TH TF TI TL TN TP TR TRANS TRC TS VPS WCR WP HUMIDITY SENSOR OPTIONAL F 23 HEAT TERMINATION THERMOSTAT E 15 INTERROGATOR CONNECTOR FRONT T 23 INTERROGATOR CONNECTOR REAR T 24 INTERNAL PROTECTOR E 14 F 11 G 14 IN RANGE LIGHT OPTION K 15 UNIT PHASE CONTACTOR K 9 L 8 N 1 UNIT PHASE CONTACTOR K 8 L 9 N 3 USDA PROBE RECEPTACLE M 24 N 24 P 24 PTC FOR VENT POSITIONING SENSOR N 17 REMOTE MONITORING RECEPTACLE OPTION K 7 L 7 K 12 L 12 K 15 L 15 RETURN RECORDER SENSOR C 23 RETURN TEMPERATURE SENSOR B 23 SUCTION PRESSURE TRANSDUCER H 23 SUPPLY RECORDER SENSOR L 23 START STOP SWITCH K 5 SUPPLY TEMPERATURE SENSOR A 23 TRANSFORMER BRIDGING UNIT D 1 D 2 CONTROLLER RELAY COOLING J 9 TRANSFRESH COMMUNICATIONS CONNECTOR OPTION
39. 4 6 If no selection is made the Pre trip menu selection process will terminate automatically However dehumidification and bulb mode must be reactivated manually if required Scrolling down to the rSLts code and pressing ENTER will allow the user to scroll through the results of the last Pre trip testing run If no Pre testing has been run or an individual test has not been run since the unit was powered up will be displayed To start a Pre trip test do the following NOTE 1 Prior to starting a Pre trip test verify that unit voltage Cd07 is within tolerance and unit amperage draw Cd04 Cd05 Cd06 are within expected limits Otherwise tests may fail incorrectly 2 All alarms must be rectified and cleared before starting tests 3 Pre trip may also be initiated via commu nications The operation is the same as for the keypad initiation described below except that should a test fail the Pre trip mode will automatically terminate When initiated via communications a Pre trip test may not be interrupted with an arrow key but the Pre trip test can be terminated with the PRE TRIP key a Press the PRE TRIP key to accesses the Pre trip test selection menu b TO RUN AN AUTOMATIC TEST Scroll through the selections by pressing the UP ARROW or DOWN ARROW keys to display AUTO AUTO 1 AUTO 2 or AUTO 3 as desired then press ENTER 1 The unit will execute the series of tests without any nee
40. 7 27 7 26 2 Checking eAutoFresh Drive System 7 27 7 26 3 Checking the Controller 22 7 28 7 26 4 Servicing the eAutoFresh Drive System 7 29 7 27 MAINTENANCE OF PAINTED SURFACES 7 30 7 28 COMMUNICATIONS INTERFACE MODULE INSTALLATION 7 31 V T 362 Rev B ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS 8 1 INDEX INTRODUCTION TP LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 3 1 Refrigeration Unit Front Section 3 1 Figure 3 2 Evaporator Section P uera NR CIR ashe rip Efe deg 3 2 Figure 3 3 Compressor Section oss nh edt URP PO Pb IO Dia eps 3 3 Figure 3 4 Air Cooled Condenser Section 3 4 Figure 3 5 Control Box Section 2 2222 2224 lt 5 Pk RR eae ars 3 5 Figure 3 6 Refrigeration Circuit Schematic Standard Operation 3 10 Figure 3 7 Refrigeration Circuit Schematic Economized Operation 3 11 Figure 3 8 Refrigeration Circuit Schematic Water Cooled Condenser Operation 3 12 Figure 4 1 Temperature Control System
41. Auto C Intemal Enter Ice Bath Temperature Auto po USDA Probe 1 USDA Probe 3 Extemal USDA Probe 2 Cargo Probe Successfully connected with the refrigeration unit 5307 3 Pre cool the container to the treatment tempera ture or below 4 Install the DataCORDER module battery pack if not already installed 5 Place the three probes Refer to USDA Treat ment Manual for directions on placement of probes in fruit and probe locations in container Sensor 1 Place the first sensor labeled USDA in a box at the top of the stack of the fruit near est to the air return intake Sensor 2 Place the second sensor labeled USDA2 slightly aft of the middle of the container halfway between the top and bottom of the stack Sensor 3 Place the third sensor labeled USDA3 one pallet stack in from the doors of the con tainer halfway between the top and bottom of the stack 6 To initiate USDA recording connect the per sonal computer and Enter ISO header informa tion using the DataLINE software Refer to figure below and DataCorder Alarms Section a Enter ISO header information b Enter a trip comment if desired c Using the System Tools screen in the DataLine software perform a trip start Refer to figure below Figure 4 15 DataCorder Systems Tool Screen Exe System Tools Tx Current Configurations Controller
42. Closed and Open Test During P9 0 the defrost temperature sensor DTS reading will be dis played on the left display The right display will show the supply air tem perature The unit will run FULL COOL for 30 minutes maximum until the DTT is considered closed This step may not have to be executed Once the DTT is considered closed the unit simulates defrost by running the heaters for up to two hours or until the DTT is considered open Test fails if The DTT is not considered closed after the 30 minutes of full cooling HTT opens when DTT is considered closed or if return air tem perature rises above 48 120 F Test passes if the DTT is considered open within the 2 hour heat cycle time limit P10 Tests Frozen Mode Tests P10 0 Frozen Mode Hea t Test If the container temperature is below 7 2 C the setpoint is changed to 7 2 C and 180 Minute timer is started The control will then be placed in the equivalent of normal heating If the container temperature is above 7 2 at the start of the test then the test proceeds immediately to test 10 1 During this test the control temperature will be shown on the right display The test fails if the 180 Minute timer expires before the control tempera ture reaches setpoint 0 3 C If the test fails it will not auto repeat There is no pass display for this test Once the control temperature reaches setpoint the test proceeds to test 10 1 P10 1 Froz
43. Discharge Pres sure if the sensor is configured and valid else Discharge Temperature The unit needs to disable Discharge Pressure limit and enable Current Limit checks High Pressure Switch The test fails immediately if P7 0 Ambient Temperature Sensor invalid HES Opening Test Composite Return Temperature Sensor invalid HPS is open The test fails if HPS fails to open before 900 seconds total test time Evaporator or Compressor IP Alarm Calculated Dome Temperature exceeds 137 78 C 280 Discharge pressure exceeds 370 psig Compressor Current exceeds limits The test passes if HPS opens within the 15 minute time limit If return temperature greater than 2 4 C set setpoint to 5 0 C else set setpoint to 30 C Restart unit according to normal startup logic Run 7 1 High Pressure Switch normally for 120 seconds HPS Closing Test The test passes if the high pressure switch closes within 75 seconds af ter end of Test 7 0 else the test fails Test P7 0 must pass for this test to execute P8 Tests Perishable Mode Tests Pretrip tests P7 0 and P7 1 must have passed or have been skipped for these tests to execute T 362 Rev B 4 48 Table 4 6 Controller Pre trip Test Codes P8 0 Perishable Mode Test If the control temperature is below 15 6 the setpoint is changed to 15 6 and a 180 Minute timer is started The control will then be placed in the equivalent of normal heating If
44. NO ALARM STORED Cause This message will be alternately displayed with the set point whenever the supply voltage is less than 75 of its proper value T 362 Rev B 4 4 4 12 CONTROLLER PRE TRIP TEST CODES Table 4 6 Controller Pre trip Test Codes NOTE Auto or Auto1 menu includes the PO P1 P2 P4 P5 P6 and rSLts Auto2 menu includes PO P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 and rSLts Auto3 menu includes PO P1 P2 P3 P4 P5 P6 P7 and P8 Pre Trip Initiated Configuration Display Indi cator Lamps LEDs and Displays P0 0 Container identifier code Cd18 Software Revision Number Cd20 Con tainer Unit Model Number amp configuration database identifier CFM MYYDD are displayed in sequence Next the unit will indicate the presence or non presence of an RMU ac cording to whether any RMU inquiry messages have been received since the unit was booted Units equipped with Autoslide Enabled Cnf44 will cause the vent to seek to its closed position followed by two sequences of opening to 10096 and returning to the closed position No other autoslide mode of operation will be available until the two cycles of opening and closing have completed Since the system cannot recognize lights and display failures there are no test codes or results associated with this phase of Pretrip To know if the test passes the operator must observe that the LCD display ele ments and the indica
45. Probe Temperatures in the Container USDA Cold treatment and Cargo probe record ing Return Air Temperature Set Point Change Supply Air Temperature Real Time Clock Battery Internal Replacement T 362 Rev B Real Time Clock Modification Trip Start SO Trip Header When entered via Interroga tion program Economy Mode Start and End Auto 1 Auto 2 Auto 3 Pre trip Start and End Bulb Mode Start Bulb Mode Changes Bulb Mode End USDA Trip Comment Humidification Start and End USDA Probe Calibration Fresh Air Vent Position 4 8 2 DataCORDER Software The DataCORDER Software is subdivided into Opera tional Software Configuration Software and the Data Memory a Operational Software The Operational Software reads and interprets inputs for use by the Configuration Software The inputs are labeled Function Codes Controller functions see Table 4 7 which the operator may access to examine the current input data or stored data To access these codes do the following 1 Press the ALT MODE and CODE SELECT keys 2 Press an arrow key until the left window displays the desired code number The right window will display the value of this item for five seconds before returning to the normal display mode 3 If a longer display time is desired press the ENTER key to extend the display time to 30 sec onds b Configuration Software The configuration software controls the recor
46. Protective Devices winding temperature Reset UNSAFE CONDITION DEVICE DEVICE SETTING Excessive compressor motor Internal Protector IP CP Automatic Re N A winding temperature set Excessive evaporator fan motor s Internal Protector s IP EM Automatic N A Abnormal pressures tempera tures in the high refrigerant side Condenser Fusible Plug Used on the Receiver Rupture Disc Used on the Water Cooled 99 C 210 F 35 kg cm 500 psig Abnormally high discharge pres sure High Pressure Switch HPS Opens at 25 kg cm 350 psig 3 5 REFRIGERATION CIRCUIT 3 5 1 Starting at the compressor see Figure 3 6 upper schematic the suction gas is compressed to a higher pressure and temperature Standard Operation The refrigerant gas flows through the discharge line and continues into the air cooled condenser When operating with the air cooled condenser active air flowing across the coil fins and tubes cools the gas to saturation temperature By removing latent heat the gas condenses to a high pressure high temperature liq uid and flows to the receiver which stores the addi tional charge necessary for low temperature operation The liquid refrigerant continues through the liquid line the filter drier which keeps refrigerant clean and dry and the economizer not active during standard opera tion to the electronic expansion valve EEV As the liquid refrigerant p
47. The remaining keys function the same as described above except the read ings or changes are made to the DataCORDER programming ALT MODE NOTE The controlling probe in perishable range is the SUPPLY air probe and the controlling probe in frozen range is the RETURN air probe 5 SUPPLY Yellow LED Energized when the supply air probe is used for control When this LED is illuminated the temperature displayed in the AIR TEMPERATURE display is the reading at the supply air probe This LED will flash if dehumidification or humidification is enabled RETURN Yellow LED Energized when the return air probe is used for control When this LED is illuminated the temperature displayed in the AIR TEMPERATURE display is the reading at the return air probe ALARM Red LED Energized when an active or an inactive shutdown alarm in the alarm queue T Figure 4 3 Display Module HEAT DEFROST INRANGE ALARM SUPPLY RETURN COOL SETPOINT Code AIR TEMPERATURE Data 4 1 3 Controller Do not remove wire harnesses from con troller modules unless you are grounded to the unit frame with a static safe wrist strap Unplug all controller module wire har ness connectors before performing arc welding on any part of the container Do not attempt to use anML2i PC card in an ML3 equipped unit The PC cards are physically different and will result in damage to the controller NOTE Do not attempt to service the controlle
48. Thermistor Test If Alarm 64 is active the test fails Otherwise the test passes P6 1 Suction Thermistor Test If the Suction Temperature Sensor CPSS both is configured ON and is invalid the test fails Otherwise the test passes Discharge Pressure Trans Alarm 65 is active any time during the first 45 second period the test P6 2 ducer Test fails Otherwise the test passes P6 3 Suction Pressure Alarm 66 is active the test fails Otherwise the test passes ducer Test GConptassor Curent Draw Compressor current is tested before and 10 seconds after start up If P6 4 P current does not increase the test fails P6 7 is run at the end of P6 4 Test If this test fails P6 6 is skipped 4 47 362 Table 4 6 Controller Pre trip Test Codes Pre trip P6 5 ensures that the compressor holds pressure After com pressor pump up and pump down the compressor is turned off for 62 seconds When suction side pressure holds less than 8 psi rise for 10 seconds P6 5 passes otherwise the Compressor Leak Test fails NOTE P6 6 through P6 10 are conducted by changing status of each valve and comparing suction pressure change and or compressor current change with predetermined values Tests will cause compressor and condenser fans to cycle on and off as needed to generate the pressure required for individual Pre trip sub tests The compressor will start in order to build discharge pressure followed by com
49. USDA Recording A special type of recording is used for USDA cold treatment purposes Cold treatment record ing requires three remote temperature probes be placed at prescribed locations in the cargo Pro vision is made to connect these probes to the DataCORDER via receptacles located at the rear left hand side of the unit Four or five recep tacles are provided The four 3 pin receptacles are for the probes The 5 pin receptacle is the rear connection for the Interrogator The probe receptacles are sized to accept plugs with tricam coupling locking devices A label on the back panel of the unit shows which receptacle is used for each probe The standard DataCORDER report displays the supply and return air temperatures The cold treatment report displays USDA 1 2 3 and the supply and return air temperatures Cold treatment recording is backed up by a battery so recording can continue if AC power is lost b USDA Message Trip Comment A special feature in DataLINE allows the user to enter a USDA or other message in the header of a data report The maximum message length is 78 characters Only one message will be recorded per day 4 8 12 USDA Cold Treatment Procedure The following is a summary of the steps required to initiate a USDA Cold Treatment If configured for USDA probes setup can be verified as follows Refer to the Data Retrieval manual 62 10629 for more details 1 Ensure the DataCorder is configured as Ref
50. and C Pass Fail Skip Result STS RTS SRS and RRS Secondary Supply Probe SRS Test Pass Fail Skip Secondary Return Probe RRS Test Pass Fail Skip Discharge Thermistor Test Pass Fail Skip Suction Thermistor Test Pass Fail Skip Discharge Pressure Transducer Test Suction Pressure Transducer Test Pass Fail Skip Pass Fail Skip Compressor Current Draw Test Pass Fail Skip Compressor Leak Test Pass Fail Skip Economizer Valve Test Pass Fail Skip Digital Unloader Valve Test Pass Fail Skip Liquid Injection Valve Test If equipped Electronic Expansion Valve Test Pass Fail Skip Pass Fail Skip High Pressure Switch Closed Pass Fail Skip Result AMBS DPT or CPT if equipped Input values that component opens High Pressure Switch Open Pass Fail Skip Result STS DPT or CPT if equipped Input values that component closes Perishable Mode Heat Test Pass Fail Skip Result STS time it takes to heat to 16 C 60 F Perishable Mode Pulldown Test Pass Fail Skip Result STS time it takes to pull down to 0 C 32 F Perishable Mode Maintain Test Defrost Test Pass Fail Skip Result Averaged DataCORDER supply temperature SRS over last recording interval Pass Fail Skip Result DTS reading at end of test line voltage line frequency time in defrost 10 0 Frozen Mode Heat Test Pass Fail Skip Result STS time unit i
51. and remove the fan from the shaft Remove the washers and key c Remove the four 1 4 20 x 3 4 long bolts that are located under the fan that support the motor and stator housing Remove the motor and plastic spacer 7 14 3 Assemble the Evaporator Fan Assembly a Assemble the motor and plastic spacer onto the stator NOTE When removing the black nylon evaporator fan blade care must be taken to assure that the blade is not damaged In the past it was a common practice to insert a screwdriver between the fan blades to keep it from turn ing This practice can no longer be used as the blade is made up of a material that will be damaged It is recommended that an impact wrench be used when removing the blade Do not use the impact wrench when reinstalling as galling of the stainless steel shaft can occur b Apply Loctite to the 1 4 20 x 3 4 long bolts and torque to 0 81 mkg 70 inch pounds T 362 Rev B c Place one 5 8 flat washer on the shoulder of the fan motor shaft Insert the key in the keyway and lubricate the fan motor shaft and threads with a graphite oil solution such as Never seez d Install the fan onto the motor shaft Place one 5 8 flat washer with a 5 8 18 locknut onto the motor shaft and torque to 40 foot pounds Figure 7 9 Evaporator Fan Assembly Washer Fan Stator crews Washers Motor e Install the evaporator fan assembly in reverse order of removal Torque the fou
52. connector from the Step per Drive to the Stepper Motor see Figure 7 23 T 362 Rev B Stepper Drive SD Figure 7 23 Stepper Components Stepper Motor AF Attach the SMA 12 portable stepper drive tester to the Stepper Motor Set the SMA 12 pulse per second PPS to one PPS and press button to open or close the valve Each LED should light sequentially until all four are lit If an LED fails to light it indicates an open on that leg caused by a poor connec tion or an open coil Repair or replace as required to achieve proper operation Set the SMA 12 step rate to 200 PPS Press open or close while watching the slide mecha nism for movement this is an indication that the motor is working If the slide moves using the SMA 12 but fails to move when connected in the unit refer to Checking the Drive Module in the section that follows Checking the Drive Module a Turn unit OFF b Disconnect the four pin connector to the Stepper Motor c With a voltmeter set to read 24 volts AC attach the positive lead to the drive module outlet pin A wire 1A of the four pin connector and the nega tive lead to the B pin wire 1B d Turn ON unit and watch the volt meter After a short delay the reading should rise to approxi mately 12 volts e Repeat for pins C and D wires 2A and 2B f If only one set of pins reads a voltage check connections and retest g If the retest reads out the same the drive mo
53. dAL89 non volatile FLASH memory dAL90 Future Expansion This alarm is for future expansion and is not in use at this time dAL91 Alarm List Full The DataCORDER alarm queue is determined to be full eight alarms 4 53 T 362 Rev B T 362 Rev B 4 54 5 1 SECTION 5 OPERATION INSPECTION Beware of unannounced starting of the evaporator and condenser fans The unit may cycle the fans and compress or unexpectedly as control requirements dictate Check inside for the following Check channels or T bar floor for cleanliness Channels must be free of debris for proper air circulation Check container panels insulation and door seals for damage Effect permanent or tempo rary repairs Visually check evaporator fan motor mounting bolts for proper securement refer to Section 7 14 Check for visible corrosion on the evaporator stator and fan deck refer to Section 7 15 Check for dirt or grease on evaporator fans or fan deck and clean if necessary Check evaporator coil for cleanliness or obstruc tions Wash with fresh water refer to Section 7 15 Check defrost drain pans and drain lines for obstructions and clear if necessary Wash with fresh water Check panels on refrigeration unit for loose bolts and condition of panels Make sure T I R devices are in place on access panels Check condenser coil for cleanliness Wash with fresh water refer to Section 7 10
54. economizer expansion valve economizer coil Replace or economizer solenoid valve Plugged economizer expansion valve economizer coil or economizer solenoid valve Replace Loose or insufficiently clamped sensor Replace 6 16 ABNORMAL CURRENTS Unit reads abnormal currents Current sensor wiring Check 6 5 T 362 Rev B SECTION 7 SERVICE NOTE Use a refrigerant recovery system whenever removing refrigerant When working with refrigerants you must comply with all local government environmental laws In the U S A refer to EPA section 608 EXPLOSION HAZARD Failure to follow this WARNING can result in death seri ous personal injury and or property damage Never use air or gas mixtures containing oxygen for leak testing or operating the product Charge only with R 134a Refrigerant must conform to AHRI Standard 700 specification 7 1 SECTION LAYOUT Service procedures are provided in this section begin ning with refrigeration system service then refrigeration system component service electrical system service temperature recorder service and general service Refer to the Table of Contents to locate specific topics 7 2 MANIFOLD GAUGE SET The manifold gauge set see Figure 7 1 is used to determine system operating pressure add refrigerant charge and to equalize or evacuate the system Figure 7 1 Manifold Gauge Set Suction Pressure Valve shown backseated Suction Pressu
55. for steady state control the unit must first complete a setpoint pulldown phase and a CCPC pull down phase T 362 Rev B During setpoint pulldown supply air tempera ture is controlled according to the unit s nomi nal supply air setpoint During CCPC pulldown the supply air tempera ture is lowered somewhat relative to the nomi nal setpoint Evaporator fans are forced to operate at high speed Steady state CCPC control maintains the same low ered supply air temperature that was used during CCPC pulldown The compressor cycles on and off according to return air high and low limits Depending on the fan mode of operation selected the evaporator fans may be programmed to run at low speed some or all of the time according to the control logic 4 6 CONTROLLER ALARMS Alarm display is an independent controller software function If an operating parameter is outside of expected range or a component does not return the correct signals back to the controller an alarm is gen erated A listing of the alarms is provided in Section 4 11 The alarm philosophy balances the protection of the refrigeration unit and that of the refrigerated cargo The action taken when an error is detected always consid ers the survival of the cargo Rechecks are made to confirm that an error actually exists Some alarms requiring compressor shutdown have time delays before and after to try to keep the compres sor on line An example is alarm code LO
56. gt CD EM BLU EM24 R VPS1 OGG N H 5 2 KH ETS2 A q gt RED WHT epe 71 d is ay F38 ey Ce RRS A RED WHT 60 1 T3 yy 52 KA11 LOCATING TAB ON BOTTOM OOOO ICFB Rp C o 4 m 3 E foe e G3 xy Te sns TRXZ CFD ed e ICFC s HG PHASE 1 Esv v v2 amp iIcRc RED FUSE WCR PR2B KA14 CIB PRIB STH 1 AT PR3B IF EQUIPPED PRAB f 8 E c co m KE KEYWAY SIDE IF EQUIPPED even EFAt EF 21 I EEVA Nce2t FUSE 1 K89 N IF EQUIPPED 0900600 i PAZ PB2H J BATTERY 803 VO3 Z03 13403 gt gt enon ZNO m N93 m o Ox gt 1 123s 2403 gt ENI 99099099 2999 199999 2 0
57. header through the ISO Trip Header screen ISO Trip Header The ISO Trip Header screen is displayed when the user clicks on the ISO Trip Header button in the Trip Functions Group Box on the System Tools screen F9 function Provides the user with a shortcut for man ually triggering the refresh operation Before sending modified parameter values the user must ensure that a successful connection is established with the controller If the connection is established with the DataCORDER the current contents of the ISO Trip Header from the DataCORDER will be displayed in each field If the connection is not established with the DataCORDER all fields on the screen will be displayed as Xs If at any time during the display of the ISO Trip Header screen the connection is not established or is lost the user is alerted to the status of the connection After modifying the values and ensuring a successful connection has been made with the DataCORDER click on the Send button to send the modified param eter values The maximum allowed length of the ISO Trip Header is 128 characters If the user tries to refresh the screen or close the utility without sending the changes made on the screen to the DataCORDER the user is alerted with a message 4 20 49 CONTROLLER CONFIGURATION VARIABLES Table 4 4 Controller Configuration Variables
58. high speed In Economy Fan Mode the fan speed is varied a When supply air temperature is above set point and decreasing the unit will cool with the con denser fan motor CF compressor motor CH and evaporator fan motors EF energized and the white COOL light illuminated See Figure 4 6 Also if current or pressure limiting is not active the controller will close contacts TS to open the economizer solenoid valve ESV and place the unit in economized operation Figure 4 6 Perishable Mode Cooling ENERGIZED DE ENERGIZED 24 VOLT POWER When supply air temperature decreases to a predetermined tolerance above set point Cd30 the green IN RANGE light is illuminated As air temperature continues to fall unloaded cooling starts DUV pulses opens as the supply air temperature approaches set point See Fig ure 4 5 When unloaded cooling starts EEV control will transition from a full cool superheat set point to a lower modulated cool superheat set point Once unloading starts the EEV controls evapo rator superheat based on the system duty cycle where instantaneous superheat will vary When the supply air temperature has fallen to within 1 9 C 3 4 F of set point temperature and the average capacity of the system has fallen below 7096 the unit will open contacts TS to close the ESV and take the unit out of econo mized operation The contro
59. mm 1 1 2 inches See Figure 7 17 Figure 7 17 Sensor Types Figure 7 18 Sensor and Cable Splice If required slide the cap and grommet assembly onto the replacement sensor Slip crimp fittings over dressed wires keeping wire colors together Make sure wires are pushed into crimp fittings as far as possible and crimp with crimping tool Solder spliced wires with a 6096 tin and 4096 lead Rosincore solder Slide heat shrink tubing over each splice so that ends of tubing cover both ends of crimp as shown in Figure 7 18 Heat tubing to shrink over splice Make sure all seams are sealed tightly against the wiring to prevent moisture seepage Do not allow moisture to enter wire splice area as this may affect sensor resistance Slide large heat shrink tubing over both splices and shrink Position sensor in unit as shown in Figure 7 18 and re check sensor resistance Figure 7 17 Return Sensor Positioning Figure 7 19 Supply Sensor Positioning Figure 7 21 ETS Sensor Positioning Reinstall sensor refer to Section 7 24 3 For STS and SRS Re Installa tion Section 7 24 4 For RRS and RTS Re Installa 2 40 mm 1 1 2 in 2 or 3 wires as required tion 3 6 3mm 1 4 in e Strip back insulation on all wiring 6 3 mm 1 4 inch Section 7 24 5 For DTS Re Installation Section 7 24 6 For ETS1 and ETS2 Re Instal lation f Slide a large piece of heat shrink tubing over the cable a
60. of the controlling probes can trig ger a defrost probe check which will occur when the difference between the sensors is greater than 2 0 C 3 6 F Normally the controlling probes are the return probes but if both return probes are invalidated the supply probes are used for control purposes Probe disagreement of the non controlling probe pair will not trigger a defrost probe check If after the defrost probe check the supply probes agree and return probes agree all supply and return sensors are considered valid and the unit returns to normal control In the Case of Probe Disagreement If the supply probes disagree and the return probes agree the controller will invalidate the worst supply probe If the probe check is run as part of Pre trip P 5 an alarm will be triggered for the invalidated probe If it is a run time defrost probe check the invalidated probe will be passed over and no alarm will be triggered However if the best supply probe is greater than 1 2 C 2 2 F dif ference with respect to its return probes the best supply probe is also invalidated If unit is in Perishable Mode a probe alarm will be triggered for both supply probes If the supply probes agree and the return probes dis agree invalidate the worst return probe If the probe check is being run as part of Pre trip P 5 an alarm will be triggered for the invalidated probe If it is a run time defrost probe check the invalidated probe will be pas
61. onds Start Temperature Recorder 4 The Trip Start event will be entered in the DataCORDER 5 7 4 Allow the unit to run for five minutes to stabilize condi tions and then perform a Pre trip diagnosis in accor dance with Section 5 8 Complete Inspection 5 8 PRE TRIP DIAGNOSIS Pre trip inspection should not be per formed with critical temperature cargoes in the container When Pre trip key is pressed economy dehumidification and bulb mode will be deactivated At the completion of Pre trip activity economy dehumidification and bulb mode must be reactivated T 362 Rev B Pre trip diagnosis provides automatic testing of the unit components using internal measurements and comparison logic The program will provide a PASS or FAIL display to indicate test results The testing begins with access to a Pre trip selection menu The user may have the option of selecting one of two automatic tests These tests will automatically perform a series of indi vidual Pre trip tests The user may also scroll down to select any of the individual tests When only the short sequence is configured it will appear as AUtO in the display Otherwise AUtO1 will indicate the short sequence and AUtO2 will indi cate the long sequence The test short sequence will run tests PO through P6 The long test sequence will run tests PO through P10 A detailed description of the Pre trip test codes is listed in Table
62. refer to Section 5 7 Snap Freeze allows the system to cool for a period of time after de icing with the evaporator fans turned off and is only carried out if configured by model number Snap Freeze allows for the removal of latent de icing heat from the evaporator coils and freezes any remaining moisture that might otherwise be blown into the container T 362 Rev B For more information on Probe Check refer to Section 5 9 4 3 21 Initiation of defrost is dependent on the state of the Defrost Temperature Sensor DTS When then DTS senses a temperature less than 10 C 50 F the defrost options become active and the timer is engaged for the initiation of the defrost cycle The defrost time accumu lates when the compressor is running In the perishable mode this is the same as real time as the compressor in general runs continuously In frozen mode the actual time necessary to count down to the next defrost will exceed the defrost interval depending on the compres sor duty cycle Defrost Operation When the defrost mode is in the active state defrost can be initiated when any one of the following addi tional conditions become true 1 Manually While in the Defrost screen when the Manual Defrost soft key is selected if condi tions will allow for a defrost a manual defrost is initiated The Defrost Indicator light is lit and the user is brought back to the Main Default screen While in the Defrost screen when Manu
63. set point 0 2 0 4 the unit will turn off the evaporator fans and restart another 60 minute off cycle 4 3 19 Frozen Mode Cooling Sequence of Oper ation a When the return air temperature is above set point and decreasing the unit will transition to economized cooling with the condenser fan motor CF compressor motor CH econo mizer solenoid valve ESV low speed evapora tor fan motors ES energized and the white COOL light illuminated See Figure 4 9 b When the return air temperature decreases to a predetermined tolerance above set point the green INRANGE light is illuminated c When the return air temperature decreases to 0 2 0 4 F below set point contacts TC TS and TN are opened to de energize the compres sor economizer solenoid valve and condenser fan motor The white COOL light is also de ener gized The EEV will close d The evaporator fan motors continue to run in low speed to circulate air throughout the container The green IN RANGE light remains illuminated as long as the return air is within tolerance of set point e If return air temperature drops to 10 C 18 F or more below set point the evaporator fans increase to high speed f When the return air temperature increases to 0 2 0 4 above set point and three minutes have elapsed the EEV opens and contacts TC TS and TN close to restart the compressor open the ESV and restart the condenser fan motor The wh
64. so that the majority of the compo nents are accessible from the front see Figure 3 1 The unit model number serial number and parts identi fication number can be found on the serial plate on the back wall of the condenser section provide ventilation for commodities that require fresh air circulation A manually operated venting system is located in the upper left access panel The optional eAutoFresh vent system is used to mod erate the atmospheric level in the container in response to cargo respiration When transporting fro zen cargo loads the vent will be closed The upper left access panel contains the vent slide and motor assem bly It may be removed to allow entry into the evapora tor section where the sensor and drive pack are located Figure 3 1 Refrigeration Unit Front Section Access Panel Evap Fan 1 Fork Lift Pockets Control Box Unit Display Control Panel Remote Monitoring Receptacle Start Stop Switch ST Compressor 3 1 9 Supply Temperature Supply Recorder Sensor Assembly STS SRS 10 Economizer 11 Ambient Temperature Sensor AMBS 12 Power Cables and Plug Location 13 Autotransformer 14 Condenser Grille 15 Upper Fresh Air Makeup Vent Panel Evap Fan 2 T 362 Rev B 3 1 3 The evaporator section is shown below The evapora tor fans circulate air through the container by pulling it in the top of the unit directing
65. source OFF Turn ON Circuit breaker or fuse defective Replace Control Transformer defective Replace No control power Evaporator fan internal motor protector open Section 7 14 Heat relay defective Check Heater termination thermostat open Section 7 13 Heater s defective Section 7 13 Heater contactor or coil defective Replace Evaporator fan motor s defective or rotating back wards Section 7 13 Section 7 14 Unit will not heat or has insuf ih Evaporator fan motor contactor defective Replace ficient heat Controller malfunction Section 6 9 Defective wiring Replace Loose terminal connections Tighten Low line voltage Section 3 3 6 5 UNIT WILL NOT TERMINATE HEATING Controller improperly set Reset Unit fails to stop heating Controller malfunction Section 6 9 Heater termination thermostat remains closed along Section 7 13 with the heat relay 6 6 UNIT WILL NOT DEFROST PROPERLY Defrost timer malfunction Cd27 Table 4 4 Loose terminal connections Tighten Will not initiate defrost auto Defective wiring Replace matically Defrost temperature sensor defective or heat termi Replace nation thermostat open Heater contactor or coil defective Replace T 362 Rev B Table 6 1 TROUBLESHOOTING CONDITION POSSIBLE CAUSE REMEDY REFERENCE SECTION Manual defrost switch de
66. the control temperature is above 15 6 at the start of the test then the test proceeds immediate ly to test 8 1 While in test 8 0 the right display will show the value of the control temperature The test fails if the 180 Minute timer expires before the control tempera ture reaches setpoint 0 3 C If the test fails it will not auto repeat There is no pass display for this test Once the control temperature reaches setpoint the test proceeds to test 8 1 Perishable Pull P8 1 Down Test eAutofresh Sensor Calibration Control temperature must be at least 15 6 C 60 F The set point is changed to 0 C 32 F and a 180 minute timer is start ed The left display will read P8 1 the right display will show the supply air temperature The unit will then start to pull down the temperature to the 0 set point The test passes if the container temperature reaches set point before the 180 minute timer expires On units where the Sensor Status indicates that a sensor is present calibration of the CO sensor will be attempted during P8 1 Once P8 1 begins calibration will be attempted when the supply tem perature goes below 5 If the sensor voltage reads within the 0 95 lt gt 1 15Vdc range before the end of P8 1 the sensor will be cali brated by holding the CO zero line low for 4 seconds Once calibration is performed the sensor voltage will be verified to make sure it is in
67. the fan motor mounting hardware and remove motor Loosely mount the new motor using new lock nuts Connect the fan motor wiring to the new fan motor Replace the shims in the same configuration as they were removed Tighten the fan motor mounting bolts to properly secure the motor To make sure that the motor is aligned properly slide the condenser fan onto the motor shaft reversed but do not secure Rotate the fan to make sure the fan blades do not contact the shroud 1 If the fan motor is misaligned vertically add or remove shims to align 2 If the fan motor is not properly centered loosen the mounting bolts and adjust the motor position on the bracket and then secure the motor Remove the condenser fan and connect the fan motor wiring to the fan motor 7 12 a 7 13 Place the condenser fan on the shaft facing the correct direction Adjust the fan to the correct position 37mm 1 5 from the fan shroud see Figure 7 7 Use Loctite H on the fan set screws and tighten Refit the left and right infill panels Refit the condenser fan grille ensuring the grille is properly centered around condenser fan FILTER DRIER To check filter drier 1 Test for a restricted or plugged filter drier by feeling the liquid line inlet and outlet connec tions If the outlet side feels cooler than the inlet side then the filter drier should be changed 2 Check the moisture liquid indicator if the
68. the menu Turning ACT off clears this entry This action also resets Cd51 to initial time remaining ACT must then be turned on to view or modify the additional param eters Whenever any auto Pre trip test or Trip Start is initiated ACT mode goes to OFF T 362 Rev B 4 28 Table 4 5 Controller Function Codes Code TITLE DESCRIPTION No ASC mode C453 increments of 1 day 1hr Display default 0 0 done mm dd this will be display is ASC has completed value OFF Display Select default OFF nSC value 1 6 This is the value for the subsequent entries SP n 1 value F on 0 1 degree increments Display Select default 10 0 DAY n 1 value 1 99 increments of 1 Display Select default 1 SP n value C F on 0 1 degree increments Display Select default 10 0 C Initially Cd53 will display current count down timer increments of 1 day 1hr default 0 0 Pressing ENTER key will take the interface down into a hierarchy of parameter selection menus mode act treat days probe and spnew setting Pressing ENTER key in any of the parameter selection menus selects the currently displayed parameter and causes the interface to descend into the next parameter selection menu All parameter selection Automatic Set point menus alternate between a blank display and the current selection in the right hand dis 53
69. 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 extin guish with CO2 never use water 1 5 SPECIFIC HAZARD 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 conse quences DANGER means an immediate hazard that WILL result in severe personal injury or death WARNING means to warn against hazards or unsafe conditions that COULD result in severe personal injury or death CAUTION means to warn against potential hazard or unsafe practice that could result in 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 EXPLOSION HAZARD Failure to follow this WARNING can result in death seri ous personal injury and or property damage Never use air or gas mixtures containing oxygen O2 for leak testing or operating the product Charge Only With R 134a Refrigerant must conform to AHRI Standard 700 specification Beware of unannounced starting of the evaporator and condenser fans The unit may cycle the fans and compressor unex pectedly as control requirements dictate T 362 Rev B Do not attempt to rem
70. the result is displayed for four seconds btest will again be displayed and the user may continue to scroll through the various codes T 362 Rev B 4 22 Table 4 5 Controller Function Codes Code No TITLE DESCRIPTION Cd20 Config Model This code indicates the dash number of the model for which the Controller is configured i e if the unit is a G9NT40 551 100 the display will show 51100 To display controller configuration database information press ENTER Values in CFYYMMDD format are displayed if the controller was configured with a configuration card or with a valid OEM serial port configuration update YYMMDD represents the publication date of the model configuration database 21 The mode of operation is displayed Unloaded Standard Economized Cd22 Compressor State The status of the compressor is displayed OFF On Cd23 Evaporator Fan Displays the current evaporator fan state OFF LOW HIGH Compressor Run This code displays the time remaining until the unit goes into defrost in tenths of an hour Cd25 Time Remaining This value is based on the actual accumulated compressor running time Until Defrost Cd26 Defrost Temperature Defrost temperature sensor reading is displayed Sensor Reading Configurable Functions Cd27 through Cd37 are user selectable functions The operator can change the value of these func tions to meet the oper
71. the speci fied tolerance of set point T 362 Rev B Table 4 1 Keypad Function KEY FUNCTION CODE SELECT function codes Displays Pre trip selection menu Discontinues Pre trip in progress Displays alarm list and clears the alarm queue PRE TRIP ALARM LIST Displays selected defrost mode Depress and hold the MANUAL DE FROST INTERVAL key for five 5 seconds to initiate defrost using the same logic as if the optional manual defrost switch was toggled on MANUAL DEFROST INTERVAL Confirms a selection or saves a se ENTER lection to the controller Change or scroll a selection up Pre trip advance or test interrupt Change or scroll selection down ward Pre trip repeat backward Arrow Up Arrow Down RETURN SUPPLY Display non controlling probe tem perature momentary display Display alternate English Metric scale momentary display When set to F pressure is displayed in psig and vacuum in hg appears af ter the value to indicate psig and i appears for inches of mercury When set to C pressure readings are in bars b appears after the val ue to indicate bars Celsius Fahrenheit Initiate battery backup mode to allow set point amp function code selection if AC power is not connected BATTERY POWER This key is pressed to switch the functions from temperature software to the DataCORDER software
72. to the frozen steady state mode Frozen Idle Mode Figure 4 8 Controller Operation Frozen Mode Frozen Mode Controller Set Point at or BELOW 10 C 14 or 5 C 23 F optionally Falling Temperature 4 3 17 If the temperature drops 10 C 18 F below set point the unit will transition to the frozen heating mode The evaporator fans are brought to high speed and the heat from the fans is circulated through the container The unit will transition back to frozen steady state when the temperature rises back to the transition point Frozen Heat Mode T 362 Rev B 4 8 Temperature 4 3 18 Frozen Economy Mode In order to activate Frozen Economy Mode a frozen set point temperature must be selected and Cd34 Economy Mode set to When economy mode is active the system will perform normal frozen mode operations except that the entire refrigeration system excluding the controller will be turned off when the control temperature is less than or equal to the set point 2 4 After an off cycle period of 60 minutes the unit will turn on high speed evaporator fans for three minutes and then check the control temperature If the control tem perature is greater than or equal to the frozen set point 0 2 0 4 F the unit will restart the refrigeration sys tem and continue to cool until the off cycle temperature criteria are met If the control temperature is less than the frozen
73. unit If the alarm persists it indicates a defective micro processor Replace defective microprocessor refer to Controller Service Section 7 23 AL28 LOW SUCTION PRESSURE Cause Suction pressure too low for normal operation Component N A Troubleshooting Power cycle the unit Corrective Action Resetting the unit may correct problem monitor the unit Component Suction Pressure Transducer SPT Troubleshooting Confirm accurate SPT pressure readings refer to MANIFOLD GAUGE SET Section 7 2 Corrective Action Replace SPT if defective Component Discharge Pressure Transducer DPT Troubleshooting Confirm accurate DPT pressure readings refer to MANIFOLD GAUGE SET Section 7 2 Corrective Action Replace DPT if defective AL29 AUTOFRESH FAILURE Cause Alarm 29 is triggered if CO or longer than 90 minutes Component level is outside of the limit range and the vent position is at 100 for Alarm LED will be activated and user intervention is required Troubleshooting Refer to eAutoFresh manual Corrective Action The alarm is triggered off when atmospheric conditions are within limit settings AL50 AIR VENT POSITION SENSOR VPS Cause VPS Sensor out of range Component Vent Position Sensor VPS Troubleshooting Make sure VPS is secure T 362 Rev B
74. yond edi ue ub 7 19 7 23 1 Handling Modules edie 7 19 7 23 2 Controller Troubleshooting 1 7 19 7 23 3 Controller Programming Procedure 7 19 7 23 4 Removing and Installing a Controller 7 21 7 23 5 Battery Replacement 2 2 ERR EAE 7 21 7 24 TEMPERATURE SENSOR SERVICE 7 22 7 24 1 Sensor Checkout Procedure 7 22 7 24 2 Sensor Replacement 1 7 25 7 24 3 Sensors STS and SRS Re Installation 7 26 7 24 4 Sensors RRS RTS Re Installation 7 26 7 24 5 Sensor DTS Re Installation 7 26 7 24 6 Sensors ETS1 and 52 Re Installation 7 26 7 24 7 Sensor CPDS Re Installation 7 26 7 25 VENT POSITION SENSOR 5 7 27 7 26 EAUTOFRESH SERVICE REO etes Pda Gin Re ee aa 7 27 7 26 1 Servicing the eAutoFresh Air Filter
75. 1 V 90 2 97V 3 4 SAFETY AND PROTECTIVE DEVICES Unit components are protected from damage by safety and protective devices listed in Table 3 1 These devices monitor the unit operating conditions and open a set of electrical contacts when an unsafe condition occurs Open safety switch contacts on either or both of devices IP CP or HPS will shut down the compressor Open safety switch contacts on device IP CM will shut down the condenser fan motor The entire refrigeration unit will shut down if one of the following safety devices open a circuit breaker s b fuse F3A F3B 7 5A or c evaporator fan motor inter nal protector s IP Table 3 1 Safety and Protective Devices UNSAFE CONDITION DEVICE DEVICE SETTING Reset Circuit Breaker CB 1 25 amp Manual Trips at 29 amps 460 VAC Excessive current draw Reset Circuit Breaker CB 2 50 amp Manual Trips at 62 5 amps 230 VAC Reset Circuit Breaker CB 2 70 amp Manual Trips at 87 5 amps 230 VAC Excessive current draw in the con Fuse F3A amp F3B trol circuit 7 5 amp rating Excessive current draw by the con Fuse F1 amp F2 troller 5 amp rating Excessive current draw by the Fuse FEB Emergency Bypass module 10 amp rating winding temperature set Excessive condenser fan motor Internal Protector IP CM Automatic Re N A T 362 Rev B 3 8 Table 3 1 Safety and
76. 15 Frozen SteadyState i e ess eee e p nae d oe eek ae a Eau ges 4 8 4 3 16 Frozen Idle Mode 4 8 ASAT Frozen Heat Mode Rede a A NER areal 4 8 4 3 18 Frozen Economy Mode 4 2 1 4 8 4 3 19 Frozen Mode Cooling Sequence of Operation 4 9 423 20 DefrOSU cb eeu eat iba i piat wasted fae heated 4 9 4 3 21 Defrost Operation 4 10 4 3 22 Defrost Related Settings 4 11 T 362 Rev B ii OPERATION 44 PROTECTION MODES OF OPERATION 4 4 1 Evaporator Fan Operation 442 Failure Action 4 4 3 Generator Protection 4 4 4 Compressor High Temperature Protection 4 4 5 Compressor Low Pressure Protection 4 4 6 Perishable Mode System Pressure Regulation 4 4 7 Condenser Fan Override 4 5 QUEST CCPG eR alo pha doe etwas 46 CONTROLLER ALARMS 4 7 PRE TRIP DIAGNOSTICS 4 8 DATACORDER beide e ees 4 8 1 Description 4 8 2 DataCORDER Software 4 8 3 Sensor Configuration dCFO2 4 8 4 Logging Interval 4 8 5 Thermistor Format ICF04
77. 2 by all of the high voltage com Compressor Motor ponents It also measures current draw in compressor motor leg T3 The compressor leg Current Line Current Phase A Line Current Phase B Line Current Phase C T3 current is displayed The current sensor measures current on two legs The third unmeasured leg is calculated based on a current algorithm The current measured is used for control and diagnostic purposes For control processing the highest of the Phase A and B current values is used for current limiting purposes For diagnostic processing the current draws are used to monitor component energization Whenever a heater or a motor is turned ON or OFF the current draw increase reduction for that activity is measured The current draw is then tested to determine if it falls within the expected range of values for the component Fail ure of this test will result in a Pre trip failure or a control alarm indication Main Power Voltage The main supply voltage is displayed Main Power Frequency Ambient Temperature The value of the main power frequency is displayed in Hertz The frequency displayed will be halved if either fuse F1 or F2 is bad alarm code AL21 The ambient sensor reading is displayed Evaporator Temperature Sensor Evaporator temperature sensor reading is shown on the right display Compressor Discharge Temperature Compressor discharge temperature sensor reading using
78. 2 zr CACO2 CTU n t RH EE I EE ITE I ELE I III II HINT A A VL tuin a animar ana vamus mra annua um ama rm a mnc un vam malnm m amma uma m am ma mcam an t tm n na n a na MM nan an nn nnm m nm 140 iii Te ee eee ee eee ee F1 Help 234567aadcx 21 ABC1234567 04163552 Astar gs viewD ata Graph Wy Microsoft Word Documenti 1 41PM T 362 Rev B 4 16 Table 4 3 DataCORDER Standard Configurations Standard Description Config 2 sensors 2 thermistor inputs supply amp return dCF02 2 5 sensors 2 thermistor inputs supply amp return 02 5 3 USDA thermistor inputs 2 thermistor inputs Supply amp return acces 3 USDA thermistor inputs 1 humidity input 9 sensors Not Applicable dCF02 9 2 thermistor inputs Supply amp return 3 USDA thermistor inputs 1 cargo probe thermistor input 2 thermistor inputs supply amp return 7 sensors 3 USDA thermistor inputs 02 64 1 humidity input 1 cargo probe thermistor input 2 thermistor inputs supply amp return 10 sensors 3 USDA thermistor inputs 02 94 1 humidity input 1 cargo probe thermistor input 4 8 6 Sampling Type dCF05 amp dCF06 Three types of data sampling are available
79. 23 6 1 193 8 464 188494 86 1868 8918 164 3272 1 142 10 50 0 171 165 88 1904 8 376 166 330 8 1 096 12 53 6 155 574 90 194 0 7 869 168 3344 1 054 14 572 141 590 92 197 6 7 404 170 338 0 1 014 16 60 8 129 000 94 201 2 6972 172 3416 975 18 644 117 656 96 2048 6 571 174 3452 938 20 680 107439 98 2084 6 197 176 3488 902 22 716 98 194 100 2120 5 848 178 3524 867 24 952 89916 102 2156 5 529 180 3560 834 26 78 8 82 310 104 2192 5 233 182 359 6 798 28 824 75 473 106 2228 4 953 184 3632 764 30 830 69 281 108 2264 4 692 186 366 8 733 32 89 6 63 648 110 230 0 4 446 188 3704 706 34 932 58 531 112 233 6 4 204 190 3740 697 36 96 8 53 887 114 2372 3 977 T 362 Rev B 7 24 7 24 2 Sensor Replacement Always turn OFF the unit circuit breaker CB 1 and disconnect main power sup ply before removing electrical parts a Turn unit power OFF and disconnect power sup ply NOTE Include white date code label when cutting out and removing defective sensors The label could be required for warranty returns Cut cable Slide the cap and grommet off a bulb type sensor and save for reuse Do not cut the grommet Cut one wire of existing cable 40 mm 1 1 2 inches shorter than the other wire Cut replacement sensor wires opposite colors back 40
80. 3 hr 5 cfm volume displacement and an elec tronic vacuum gauge The pump is available from Carrier Transicold P N 07 00176 11 The micron gauge is P N 07 00414 00 If possible keep the ambient temperature above 15 6 C 60 F to speed evaporation of moisture If the ambient temperature is lower than 15 6 C 60 F ice might form before moisture removal is complete Heat lamps or alternate sources of heat may be used to raise the system tempera ture T 362 Rev B d Additional time may be saved during a complete system pump down by replacing the filter drier with a section of copper tubing and the appropri evacuation it is necessary to open the ESV using a magnet tool Carrier Transicold part number 07 00512 00 ate fittings Installation of a new drier may be performed during the charging procedure c Remove the ESV coil from the valve body Place the magnet tool over the valve stem an audible click will be heard when the ESV opens Figure 7 4 Refrigeration System Service Connec tions NOTE Make sure to replace the valve coil before restating the unit Starting the unit with the coil removed from the valve will burn out the coil d Test the evacuation setup for leaks by backseat ing the unit service valves and drawing a deep vacuum with the vacuum pump and gauge valves open Shut off the pump and check to see if the vacuum holds Repair leaks if necessary e Midseat the refrigerant system servic
81. 3 21 51415 211 79101112121 28 Kc KD KE fee LL eet 20 r1 F2 F35 CONTROLLER 21 PROGRAMMING SLOT EC A B c D E e k M EC N P R 5 wW x Y 1 1 1 2 d d d 2 2 22 3 h H hiis 3 vy NAA LAA NAA CBA C B ANM T v TS TH MN NM 9 ASB 20 2 25 3 7 ee ge PRA 4 n IL 9 HS EPT SPT DPT a DE DUV oo 4 S n seo 5 Ai Ai 5 A PRI PR3 PR2 BERD OR S P T 362 Rev B Based on Drawing 62 66088 Figure 8 6 UNIT WIRING DIAGRAM Unit With Autotransformer Sheet 1 of 2 O e Ls 9 T 7 gt gt 7 GRN mo mo mo oo moaou D RED Y vlt vibe vibe i lyyyyy T2 bE war 1 11 is T T T fo Hu 5 ag 88 3 FF 880260 gaa Re Oc eco lt g Li A DOO 55 I EY Ea ii 5 558 Mes RED WHT 2 Pamo Iper Some die Es 2 2 2 Os st 52 3
82. 5 1 92 34 1 29 6 204 1 2 08 2 04 36 2 31 3 215 8 2 20 2 16 38 3 33 2 228 9 2 33 2 29 40 4 35 1 242 0 2 47 2 42 45 7 40 1 276 5 2 82 2 76 50 1 45 5 313 7 3 20 3 14 55 13 51 2 353 0 3 60 3 53 60 16 57 4 395 8 4 04 3 96 65 18 64 1 441 0 4 51 4 42 70 21 71 1 490 2 5 00 4 90 75 24 78 7 542 6 5 53 5 43 80 27 86 7 597 8 6 10 5 98 85 29 95 3 657 1 6 70 6 57 90 32 104 3 719 1 7 33 7 19 95 35 1114 0 786 0 8 01 7 86 100 38 124 2 856 4 8 73 8 56 105 41 135 0 930 8 9 49 9 31 110 43 146 4 1009 10 29 10 09 115 46 158 4 1092 11 14 10 92 7 32 Table 7 4 R 134a Temperature Pressure Chart Temperature Vacuum 120 49 171 2 1180 12 04 11 80 125 52 184 6 1273 12 98 12 73 130 54 198 7 1370 13 97 13 70 135 57 213 6 1473 15 02 14 73 140 60 229 2 1580 16 11 15 80 145 63 245 6 1693 17 27 16 93 150 66 262 9 1813 18 48 18 13 155 68 281 1 1938 19 76 19 37 Table 7 5 Recommended Bolt Torque Values BOLT DIA THREADS TORQUE Nm FREE SPINNING 4 40 5 2 in lbs 0 6 6 32 9 6 in Ibs 1 1 8 32 20 in Ibs 2 0 10 24 23 in lbs 2 5 1 4 20 75 in lbs 8 4 5 16 18 11 ft Ibs 15 3 8 16 20 ft lbs 28 7 16 14 31 ft lbs 42 1 2 13 43 ft lbs 59 9 16 12 57 ft lbs 78 5 8 11 92 ft lbs 127 3 4 10 124 ft lbs 171 NONFREE SPINNING LOCKNUTS ETC 1 4 20 82 5 in Ibs 9 3 5 16 18 145 2 in lbs 16 4 3 8 16 22 0 ft Ibs 23 7 16 14 34 1 ft lbs 47 1 2 13 47 3 ft lbs 65 9 16 12 62 7 ft lbs 86
83. 5 8 11 101 2 ft lbs 139 3 4 10 136 4 ft lbs 188 7 33 T 362 Rev B 8 1 SECTION 8 ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS INTRODUCTION This section contains the Electrical Schematics and Wiring Diagrams Figure 8 1 LEGEND Standard Unit Configuration SYMBOL DESCRIPTION AMBS C CB1 CB2 CF CH CM CP CPDS CS DHBL DHBR DHML DHMR DHTL DHTR DL DPT DTS DUV DVM DVR EEV EF EM EPT ES ETS ESV FLA HPS HR AMBIENT SENSOR C 23 CONTROLLER L 21 CIRCUIT BREAKER 460 VOLT 1 OPTIONAL CIRCUIT BREAKER DVM OPTION D 1 TERMINAL BLOCK WHEN CB2 NOT PRESENT CONDENSER FAN N 8 L 11 COMPRESSOR CONTACTOR L 10 P 1 COMMUNICATIONS INTERFACE MODULE OPTION A 4 COOL LIGHT OPTION L 12 CONDENSER FAN MOTOR E 11 G 11 R 9 COMPRESSOR MOTOR T 4 DISCHARGE TEMPERATURE SENSOR A 23 CURRENT SENSOR M 2 DEFROST HEATER BOTTOM LEFT R 8 DEFROST HEATER BOTTOM RIGHT T 7 DEFROST HEATER MIDDLE LEFT R 7 DEFROST HEATER MIDDLE RIGHT T 7 DEFROST HEATER TOP LEFT R 7 DEFROST HEATER TOP RIGHT T 8 DEFROST LIGHT OPTION L 7 DISCHARGE PRESSURE TRANSDUCER K 23 DEFROST TEMPERATURE SENSOR C 23 DIGITAL UNLOADER VALVE F 24 DUAL VOLTAGE MODULE OPTIONAL D 1 DUAL VOLTAGE RECEPTACLE OPTIONAL F 3 ELECTRONIC EXPANSION VALVE R 16 EVAPORATOR FAN CONTACTOR HIGH SPEED N 11 K 13 EVAPORATOR FAN MO
84. 5 8225 5224 LU LU SRS if SER P 1 ESO 5 12 oasa 8f 35 ECP lt D 9 m t5 99 E 554 211 Tet uw olde co sae 1 CIAt J ul 8 ECG1 A N IEEE Zu 256004 D4 25 pods Beste dx b 9525 GUN 29 HE is 222 X5 5 5 Iz Fleg 8 lt 85885 eels 0 7 YYvYYY 4 mel dE o ET CB22 PAL2 pL 2 Q s MP ee I ILL 362 Rev Based on Drawing 62 11737 8 7 DISPLAY MODULE lt KEYPAD lt D OHH 020 lt gt CIC6 ao cies amp OH eim 3 MB9 MB10 CONTROLLER 90 COMMUNICATIONS INTERFACE MODULE MB2 MB11 MB3 MB12 GRD MB13 MAINS POWER FUSE 2 AT IF EQUIPPED GT Reb MB RIS 7 BLK Gees TDTS 02 34 AMBS ERED cs RED ERAM OO HD O O Gra 3 2 94 ORN MB14 MB6 MB15 MB16 MBB elo Doro Fl a 509090 B
85. After the first 15 minutes of the vent opening the con troller will again evaluate the level of and or Os levels If after the first 15 minutes the gas limit values are satisfied the vent will close if either gas limit has not been satisfied within 15 minutes the air exchange vent will open in 10 CMH increments every 15 minutes until both gas concentrations are satisfied Once all lim its are satisfied the vent will return to the closed posi tion If conditions are not met with the slide open 10096 for 90 minutes AL29 will be activated To operate in GAS LIMIT mode scroll until gASLM appears in the left window and press ENTER to acti vate the submenu The first selection is the maximum level CO2LM Select the maximum CO level by using the UP and DOWN arrow keys The range is from 0 to 19 in 1 increments Press ENTER to set the value and move to the minimum level O2LM The range is from 296 to 2096 in 196 increments Press ENTER to set the value and move to the FLO rate Use the UP or DOWN arrow key to scroll to the desired FLO rate The range is from 0 to 220CM 0 to 129CF in increments of 5 and 3 respectively Press ENTER to set the value and begin operation Operational Parameters Sub Menu Options FLO indicates the opening to which the slide will move based on the stored value in CMH in increments of 5 or CFM depending on the selection of Cd46 Airflow display units Cd28 Metric Imperial or the p
86. Battery Check If alarm persists replace the battery pack refer to Section 7 23 5 Bat tery Replacement AL54 PRIMARY SUPPLY SENSOR STS Cause Invalid Supply Temperature Sensor STS reading Component Supply Temperature Sensor STS Troubleshooting Perform Pre trip P5 Corrective Action If P5 passes no further action is required If P5 fails replace the defective sensor as determined by P5 refer to TEMPERATURE SENSOR Service Section 7 24 4 39 T 362 Rev B AL56 PRIMARY RETURN SENSOR RTS Cause Invalid Return Temperature Sensor RTS reading Component Return Temperature Sensor RTS Troubleshooting Perform Pre trip P5 Corrective Action If P5 passes no further action is required If P5 fails replace the defective sensor as determined by P5 refer to TEMPERATURE SENSOR Service Section 7 24 AL57 AMBIENT SENSOR AMBS Cause Invalid Ambient Temperature Sensor AMBS reading Component Ambient Temperature Sensor AMBS Troubleshooting Test the AMBS refer to Sensor Checkout Procedure Section 7 24 1 Corrective Action Replace AMBS if defective refer to TEMPERATURE SENSOR Service Section 7 24 AL58 COMPRESSOR HIGH PRESSURE SAFETY HPS Cause High pressure safety switch remains open for at least one minute Component High Pressure Switch HPS Troubleshooting Test th
87. CONDARY SUPPLY SENSOR SRS Cause Secondary Supply Sensor SRS is out of range Component Secondary Supply Sensor SRS Troubleshooting Perform Pre trip P5 T 362 Rev B 4 2 AL70 SECONDARY SUPPLY SENSOR SRS Corrective Action If P5 passes no further action is required Corrective Action If P5 fails replace the defective sensor as determined by P5 refer to TEMPERATURE SENSOR Service Section 7 24 AL71 SECONDARY RETURN SENSOR RRS Cause Secondary Return Sensor RRS is out of range Component Secondary Retrn Sensor RRS Troubleshooting Perform Pre trip P5 Corrective Action If P5 passes no further action is required Corrective Action If P5 fails replace the defective sensor as determined by P5 refer to TEMPERATURE SENSOR Service Section 7 24 AL72 CONTROL TEMP OUT OF RANGE Cause After the unit goes in range for 30 minutes then out of range for a continuous 120 minutes Component Refrigeration System Troubleshooting Ensure unit is operating correctly Corrective Action Power cycle unit Control Temperature is in In range Any Pre trip mode resets the timers NOTICE If the controller is configured for four probes without a DataCORDER the DataCORDER alarms AL70 and AL71 will be processed as Controller alarms AL70 and AL71 Refer to
88. Cd30 the green IN RANGE light will energize When CnF26 Heat Lockout Temperature is set to 10 perishable mode is active with set points above 10 14 F When CnF26 is set to 5 C perishable mode is active with set points above 5 C 23 F 4 3 4 When the system is in Perishable Pulldown Mode the highest priority is given to bringing the container down to set point When cooling from a temperature that is more than 2 5 4 5 F above set point the system will be in perishable pulldown mode in economized operation Perishable Pulldown However pressure and current limit functions may restrict the valve if either exceeds the preset value 4 3 5 Perishable Steady State is used to maintain the control temperature near a setpoint that is above the heat lock out temperature Perishable Steady State Once set point is reached the unit will transition to per ishable steady state mode This results in unloaded operation by cycling the DUV to limit capacity and maintain steady temperature control The unit is capable of maintaining supply air tempera ture to within 0 2 0 36 F of set point Supply air temperature is controlled by positioning of the elec tronic expansion valve EEV cycling of the digital unloader valve DUV cycling of the compressor and cycling of the heaters 4 3 6 Perishable Idle Mode is used when it is unnecessary to run the compressor to maintain control temper
89. Container Refrigeration TRANSICOLD 3 United Technologies g Um OPERATIONS AND SERVICE MANUAL For 69N T40 561 200 to 299 Container Refrigeration Units 1 362 Rev B OPERATIONS AND SERVICE MANUAL For 69NT40 561 200 to 299 TABLE OF CONTENTS PARAGRAPH NUMBER SAFETY SUMMARY 2 3 1 2 3 2 2 3 3 2 3 4 2 3 5 2 3 6 2 3 7 2 3 8 2 4 1 2 4 2 2 4 3 2 4 4 2 4 5 2 4 6 2 4 7 2 4 8 2 4 9 2 4 10 2 4 11 2 4 12 2 4 13 2 4 14 2 4 15 2 4 16 2 4 17 2 4 18 2 4 19 2 4 20 2 4 21 2 4 22 2 4 23 1 1 GENERAL SAFETY NOTICES 1 2 FIRST AID 1 3 OPERATING PRECAUTIONS 1 4 MAINTENANCE PRECAUTIONS 1 5 SPECIFIC HAZARD STATEMENTS INTRODUCTION 2 1 INTRODUCTION 2 2 CONFIGURATION IDENTIFICATION 2 3 FEATURE DESCRIPTIONS Control BOX adhe Temperature Readout Pressure Readout Compressors 222155 bos ael ree e ee ics sss ve b RR ES e Ed od eR AREA Evaporator 25 Mel ded rd eerie e Evaporator Fan Operation Plate Set Judo eese ena dud ds ee x t arma 24 OPTION DESCRIPTIONS Battery iin RV EL ib iS sue s EM Deh rmldificatlori oem RR Ru e ERCH Interrogator EAE UM Remote Monitoring
90. D 6 CONTROLLER RELAY PHASE SEQUENCING 0 8 J 9 CONTROLLER RELAY HIGH SPEED EVAPORATOR FANS J 14 CONTROLLER RELAY HEATING J 15 CONTROLLER RELAY DEFROST E 7 IN RANGE RELAY J 15 CONTROLLER RELAY COOL LIGHT J 12 CONTROLLER RELAY CONDENSER FAN U 11 TEST POINT H 9 F 10 H 11 G 12 H 13 G 15 L 17 TRANSFORMER 3 AUTO TRANSFORMER 230 460 OPTION D 3 TRANSFRESH REAR CONNECTOR OPTION E 7 CONTROLLER RELAY ECONOMIZER SOLENOID VALVE E 10 CONTROLLER RELAY LOW SPEED EVAPORATOR FANS J 13 VENT POSITION SENSOR UPPER N 17 WETTING CURRENT RESISTOR OPTION J 12 WATER PRESSURE SWITCH OPTION E 12 T 362 Rev B Figure 8 5 SCHEMATIC DIAGRAM Unit With Autotransformer A
91. DC battery pack power A 12 volt bat tery pack may also be plugged into the back of the interrogation cable which is then plugged into an interrogation port No controller battery pack is required with this method 4 Real Time Clock demand the DataCORDER is equipped with a charged battery pack and AC power is not present the DataCORDER will power up when the real time clock indicates that a data recording should take place When the DataCORDER is finished recording it will power down During DataCORDER power up while using battery pack power the controller will perform a hardware volt age check on the battery If the hardware check passes the controller will energize and perform a soft ware battery voltage check before DataCORDER log ging If either test fails the real time clock battery power up will be disabled until the next AC power cycle Further DataCORDER temperature logging will be prohibited until that time An alarm will be generated when the battery voltage transitions from good to bad indicating that the battery pack needs recharging If the alarm condition persists for more than 24 hours on continuous AC power it indi cates that the battery pack needs replacement 4 8 9 Pre trip Data Recording The DataCORDER will record the initiation of a Pre trip test refer to Section 4 7 and the results of each test included in Pre trip The data is time stamped and may be extracted via the Data Retrieval program Ref
92. DTS must have insulating material placed completely over the sensor to ensure the coil metal temperature is sensed Sensor DTS Re Installation 7 24 6 Sensors ETS1 and ETS2 Re Installation The Evaporator Temperature Sensors ETS1 andETS2 are located in a tube holder under insulation as illus trated in Figure 7 21 When the combo sensor is removed and reinstalled it must be placed in a tube holder by applying thermal grease Insulating material must completely cover the sensor to ensure the correct temperature is sensed Figure 7 21 Evaporator Temperature Sensor Posi tioning 1 Wire Tie 2 ETS1 and ETS 2 3 ETS Tube Holder 4 Insulation 7 24 7 Sensor CPDS Re Installation To replace the Compressor Discharge Temperature Sensor see Figure 7 22 1 Ensure the unit is disconnected from the power source and that ST is in OFF position 2 Remove the existing sensor Clean all silicone sealer and dielectric compound from the sensor well Ensure well is clean and dry The top of the compressor where the sensor seals must also be clean and dry 7 26 Figure 7 22 Compressor Discharge Temperature Sensor Sensor ilicon Bead Sensor Well 3 Using the syringe supplied with the replacement sensor squeeze all of the dielectric compound into the sensor well 4 Place a bead of the silicone sealer supplied with the replacement sensor around the sensor seal ing ring Insert sensor in
93. EEV position in on left display Cd55 will display discharge superheat discharge temperature minus discharge satura tion temperature as calculated from discharge pressure values in C F as calculated by the discharge temperature minus the discharge saturation temperature as calculated from discharge pressure will be displayed if selection is not valid Cd58 will display CLOSE if the WPS or CFS switch contacts are closed or if these op tions are not installed is displayed when the WPS or CFS switch contacts are open When the WPS CFS Override Logic is TRUE the right display will flash on all units Discharge Superheat NOTE 1 This CLOSE OPEn state displayed in this Code Select function only applies to units Water Pressure that have the ability to detect the state of a WPS CFS This function should not be relied Switch Condenser upon to display the condition of the switch on units that don t have a WPS CFS switch Fan Switch State or connected to ECG2 exclusively Override Logic State 2 The right display will flash if the WPS CFS Override Logic is TRUE on all units This is always the case whether the unit has a WPS or CFS installed or not 3 The ability of the WPS CFS Override Logic to control the condenser fan is limited It is not possible for this logic to control the fan on units that have the WPS or CFS wired in series with the fan contactor Units wired in this configuration can indi
94. ELAY J 15 CONTROLLER RELAY COOL LIGHT J 12 CONTROLLER RELAY CONDENSER FAN 11 TEST POINT H 9 F 10 H 11 G 12 H 13 G 15 L 17 TRANSFORMER M 3 AUTO TRANSFORMER 230 460 OPTION D 3 TRANSFRESH REAR CONNECTOR OPTION E 7 CONTROLLER RELAY ECONOMIZER SOLENOID VALVE E 10 CONTROLLER RELAY LOW SPEED EVAPORATOR FANS J 13 VENT POSITION SENSOR UPPER N 17 WETTING CURRENT RESISTOR OPTION J 12 WATER PRESSURE SWITCH OPTION E 12 T 362 Rev B Figure 8 2 SCHEMATIC DIAGRAM
95. ER when the desired test code is displayed 1 Individually selected tests other than the LED Display test will perform the operations neces sary to verify the operation of the component At the conclusion PASS or FAIL will be displayed This message will remain displayed for up to three minutes during which time a user may select another test If the three minute time period expires the unit will terminate pre trip and return to control mode operation While the tests are being executed the user may terminate the pre trip diagnostics by press ing and holding the PRE TRIP key The unit will then resume normal operation If the user decides to terminate a test but remain at the test selection menu the user may press the UP ARROW key When this is done all test outputs will be de energized and the test selection menu will be displayed During Pre trip testing current limiting and pressure limiting are both active except during P 7 High Pressure Switch Testing when pres sure limiting is turned off d Pre Trip Test Results At the end of the pre trip test selection menu the mes sage P rSLts Pre trip results will be displayed Pressing the ENTER key will allow the user to see the results for all subtests i e 1 O 1 1 etc The results will be displayed as PASS or FAIL for all the tests run to completion since power up If a test has not been run since power up Will be displayed Once a
96. IGURATION NO TITLE DEFAULT OPTION dCF01 Future Use 2 Sensor Configuration 2 2 5 6 9 54 64 94 Logging Interval Minutes 60 15 30 60 120 dCF04 Thermistor Format Short Long dCFO05 Thermistor Sampling Type A A b C dCF06 Controlled Atmosphere Humidity Sampling Type A A b dCF07 Alarm Configuration USDA Sensor 1 A Auto On Off dCFO08 Alarm Configuration USDA Sensor 2 A Auto On Off dCF09 Alarm Configuration USDA Sensor 3 A Auto On Off dCF10 Alarm Configuration Cargo Sensor A Auto On Off 4 15 T 362 Rev B Figure 4 11 Standard Configuration Download Report File Reports Window lal x alale gt gt elm a Raw Data Report for ABC1234567 Jan 01 2015 to Mar 01 2015 System Configuration at the Time of Interrogation Interrogated On Mar 05 2015 Extracted by DataLINE Rev 1 0 0 Controller Software 5361 Controller Serial 04163552 Bill of Lading 1 Origin Origin Date Destination Discharge Date Comment DataLINE Tool Probe Calibration Readings USDA1 0 0 USDA2 0 0 USDA3 0 0 Temperature Units Centigrade Jan 01 2015 Setpoint 1 66 Container 9 Sensors Logged at 15 Minute Interval Sensor Format Resolution F1 Help 234567a amp dex ML2i ABC1234567 Astart as viewD ata Raw Dat W7 Microsoft Word TS ViewData Graph Report 5 File Reports Toggle Window Container ABC1234567 Serial 04163552 RetAir CAO
97. INTRODUCTION The Carrier Transicold model 69NT40 561 200 299 series units are of lightweight aluminum frame con struction designed to fit in the front of a container and serve as the container s front wall They are one piece self contained all electric units which include cooling and heating systems to provide precise temperature control The units are supplied with a complete charge of refrig erant R 134a and compressor lubricating oil and are ready for operation upon installation Forklift pockets are provided for unit installation and removal The base unit operates on nominal 380 460 volt 3 phase 50 60 hertz Hz power An optional autotrans former may be fitted to allow operation on nominal 190 230 3 phase 50 60 Hz power Control system power is provided by a transformer which steps the supply power down to 18 and 24 volts single phase The controller is a Carrier Transicold Micro Link 3 microprocessor The controller operates automatically to select cooling holding or heating as required to maintain the desired set point temperature within very close limits The unit may also be equipped with an electronic temperature recorder The controller has a keypad and display for viewing or changing operating parameters The display is also equipped with lights to indicate various modes of oper ation 2 2 CONFIGURATION IDENTIFICATION Unit identification information is provided on a plate located on the back
98. Information DataCorder 34 5 5 ARS 504 1 2 3 H Container ID Recording Interval 60 Setpoint Figure 4 14 DataCorder Probe Calibration Screen Compressor Hour Meter 17 Hours Controller Custom zoel rH Trip Header Information Controller Parameters Container ID Operator _ Change DataCorder Date Wessel Voyage Date DataCorder Date Time 07 26 2001 15 24 07 25 2007 1526 Dione Times RESET 2000525 Synchronize with Send Shipper Product Trip Functions Last Trip Start 07 20 2001 09 00 Send Comment with New Trip Start New Trip Temperature Setpoint Intermediate Destination Trip Comment 5 Air Exchange Setpoint Final Destination 50 Trip Header Humidity Setpoint Booking Close FisHelp Successfully connected with the refrigeration unit 5117 5117 di Header Comment Information Fi Help Successfully connected with the refrigeration unit 5307 T 362 Rev B 4 8 13 DataCORDER Alarms The alarm display is an independent DataCORDER function If an operating parameter is outside of the expected range or a component does not return the correct values to the DataCORDER an alarm is gener ated The DataCORDER contains a buffer of up to eight alarms A listing of the DataCORDER alarms is provided in Table 4 9 Refer to Section 4 8 7 for con figuration information To display alarm codes a Whil
99. MODULE INSTALLATION Figure 7 26 Communications Interface Installation 1 Communications GB Interface Module Units that have been factory provisioned for installation of a Communication Interface Module CIM have the required wiring installed If the unit is not factory provi sioned a provision wiring kit Carrier Transicold part number 76 00685 00 must be installed Installation instructions are packaged with the kit To install the module Installation requires wiring to the main unit circuit breaker CB1 Make sure the power to the unit is off and power plug discon nected before beginning installation CB1 is connected to the power system see wir ing schematic Ensure that the unit power is off AND that the unit power plug is disconnected Open control box see Figure 7 26 and remove low voltage shield Open high voltage shield If using factory provisioned wiring remove the circuit breaker panel with circuit breaker from the control box Locate wires CB21 CIA3 CB22 CIA5 and CB23 CIA7 that have been tied back in the wire harness Remove the protective heat shrink from the ends of the wires Refit the circuit breaker panel Fit the new CIM into
100. Off position 4 Re install the wire tie at the switch mounting Figure 5 3 Diagram of Emergency Bypass Connec tions EMERGENCY BYPASS CONNECTOR TO TO SENSORS CONTROLLER DIAGRAM SHOWS CONNECTION FOR EMERGENCY BYPASS OPERATION TO BYPASS MODULE SECTION 6 TROUBLESHOOTING Table 6 1 TROUBLESHOOTING CONDITION POSSIBLE CAUSE REMEDY REFERENCE SECTION 6 1 UNIT WILL NOT START OR STARTS THEN STOPS External power source OFF Turn on Start Stop switch OFF or defective Check No power to unit Circuit breaker tripped or OFF Check Autotransformer not connected Section 5 2 2 Circuit breaker OFF or defective Check Control transformer defective Replace Loss of control power Fuse F3A F3B blown Check Start Stop switch OFF or defective Check Evaporator fan motor internal protector open Section 7 14 Condenser fan motor internal protector open Section 7 8 Compressor internal protector open Section 7 8 Component s not operating High pressure switch open Section 6 7 Heat termination thermostat open Replace Malfunction of current sensor Replace Low line voltage Check Compressor hums but does Single phasing Check not start Shorted or grounded motor windings Section 7 8 Compressor seized Section 7 8 6 2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING Hot load Normal Container Defective box insulation or air leak Repai
101. SOFTWARE SOFTWARE AL 70 FUNCTION TO CODE Cd DISPLAY CONFIGURATION VARIABLE DataCORDER SOFTWARE KEY PAD N INTERROGATION CONNECTOR DATAREADE 11 CONFIGURATION OPERATIONAL ALARMS SOFTWARE SOFTWARE AL gt 68 t ft 4 CONFIGURATION FUNCTION TO VARIABLE DISPLAY dCF read dC BER DATA STORAGE Computer Device MEMORY With DataLINE Software OP CONFIG PCMCIA CARD TO DISPLAY DATABANK PCMCIA CARD Scrollback T 362 Rev B 4 1 1 The keypad Figure 4 2 is mounted on the control box door The keypad consists of eleven push button switches that act as the user s interface with the con troller Descriptions of the switch functions are provided in Table 4 1 Figure 4 2 Keypad CODE SELECT MANUAL DEFROST INTERVAL ALARM LIST eu et 5 RETURN SUPPLY BATTERY POWER Display Module ALT MODE 4 1 2 The display module Figure 4 3 consists of two 5 digit displays and seven indicator lights The indicator lights include 1 COOL White or Blue LED Energized when the refrigerant compressor is energized HEAT Orange LED Energized to indicate heater operation in heat mode defrost mode or dehumidification DEFROST Orange LED Energized when the unit is in defrost mode IN RANGE Green LED Energized when the controlled temperature probe is within
102. SOR ECON TXV SENSING BULB ECONOMIZER SOLENOID bos VALVE Ei LJ ECONOMIZER DISCHARGE TXV PRESSURE TRANSDUCER Dr SUCTION PRESSURE TRANSDUCER SERVICE 17 SERVICE VALVE LH ECONOMIZER EVAPORATOR PRESSURE rl TRANSDUCER COMPRESSOR T 362 Rev B 3 10 Figure 3 7 Refrigeration Circuit Schematic Economized Operation COMBO ETS1 EVAPORATOR gt AND ETS2 ELECTRONIC EXPANSION VALVE CONDENSER LIQUID LEVEL 98 MOISTURE INDICATOR LIQUID LINE ium RECEIVER SERVICE VALVE DISCHARGE UN ORDER TEMPERATURE SENSOR VALVE ECON TXV SENSING BULB Eas UH ECONOMIZER SOLENOID c VALVE Lal a DISCHARGE PRESSURE ECONOMIZER TRANSDUCER TXV EVAPORATOR PRESSURE ECONOMIZER TRANSDUCER SUCTION PRESSURE d Suction TRANSDUCER 2 SERVICE T VALVE COMPRESSOR 3 11 T 362 Rev B Figure 3 8 Refrigeration Circuit Schematic Water Cooled Condenser Operation Evaporator Temperature Sensor Evaporator ETS1 and ETS2 Electronic Expansion Valve Condenser Digital Unloader Valve DUV Discharge Temperature Sensor Economizer Solenoid Valve Economizer XV Sensing Bulb Discharge aa alve Moisture Indicator Economizer Rupture Disk Evaporator Thermal D Pressure Expansion U Transducer Valve RED Discharge Filter Dr
103. T 362 Rev B 4 46 Table 4 6 Controller Pre trip Test Codes P5 3 Evaporator Fan Direction Test With evaporator fan running on high speed measure the temperature difference between the primary supply and primary return probes Turn the heaters on for 60 seconds then measure the temperature difference between the primary supply and primary return probes for up to 120 ad ditional seconds This is a Pass Fail test The test passes if differential of STS is 0 25 C higher than RTS Test P5 0 must pass before this test is run P5 7 Primary vs Evaporator Sensor Test Secondary Temperature This is a Pass Fail test of the primary evaporator temperature sensor ETS1 and secondary evaporator temperature sensor ETS2 Test passes if secondary evaporator temperature sensor ETS2 is within 0 5 C of the primary evaporator temperature sensor ETS1 5 8 Primary Evaporator Pres sure Transducer Test This is a Pass Fail test of the Primary Evaporator Pressure Transducer Test passes if suction pressure transducer SPT is within O psi of saturation pressure at current evaporator temperature Also passes if SPT is within 1 psi of discharge pressure 6 hours after a power inter ruption Test P5 7 must pass before this test is run 5 9 Suction Evaporator Pres sure Transducer Test Units equipped with a secondary Evaporator pressure transducer Test passes if suction pressure transducer SPT
104. TER key to enter the information to the con troller the CODE SELECT key will allow modifi cation of the previous value 7 23 4 Removing and Installing a Controller a Removal 1 Disconnect all front wire harness connectors and move wiring out of way 2 The lower controller mounting is slotted loosen the top mounting screw see Figure 7 16 and lift up and out 3 Disconnect the back connectors and remove module 4 When removing the replacement module from its packaging note how it is packaged When returning the old module for service place it in the packaging in the same manner as the replacement The packaging has been designed to protect the module from both physical and electrostatic discharge damage during storage and transit b Installation Install the module by reversing the removal steps Torque values for mounting screws item 2 see Figure 7 16 are 0 23 mkg 20 inch pounds Torque value for the connectors is 0 12 mkg 10 inch pounds 7 23 5 Battery Replacement Standard Battery Location Standard Cells a b Turn unit power OFF and disconnect power sup ply Slide bracket out and remove old batteries See Figure 4 4 Item 8 Install new batteries and slide bracket into con trol box slot Use care when cutting wire ties to avoid nicking or cutting wires Standard Battery Location Rechargeable Cells a Turn unit power OFF and disconnect power sup ply Disconn
105. TOR T 11 T 13 E 14 F 14 G 14 EVAPORATOR PRESSURE TRANSDUCER H 23 EVAPORATOR FAN CONTACTOR LOW SPEED P 10 L 13 EVAPORATOR TEMPERATURE SENSOR SUCTION D 23 ECONOMIZER SOLENOID VALVE J 11 FUSE C 7 D 7 F 21 G 21 FULL LOAD AMPS HIGH PRESSURE SWITCH G 9 HEATER CONTACTOR N 7 L 15 SYMBOL DESCRIPTION HS HTT ICF ICR IRL PA PB PR PTC RM RRS RTS SPT SRS ST STS TC TCC TCP TE TH TF TL TN TP TR TRANS TRC TS VPS WCR WP HUMIDITY SENSOR OPTIONAL F 23 HEAT TERMINATION THERMOSTAT E 15 INTERROGATOR CONNECTOR FRONT T 23 INTERROGATOR CONNECTOR REAR T 24 INTERNAL PROTECTOR E 14 F 11 G 14 IN RANGE LIGHT OPTION K 15 UNIT PHASE CONTACTOR K 9 L 8 N 1 UNIT PHASE CONTACTOR K 8 L 9 N 3 USDA PROBE RECEPTACLE M 24 N 24 P 24 PTC FOR VENT POSITIONING SENSOR N 17 REMOTE MONITORING RECEPTACLE OPTION K 7 L 7 K 12 L 12 K 15 L 15 RETURN RECORDER SENSOR C 23 RETURN TEMPERATURE SENSOR B 23 SUCTION PRESSURE TRANSDUCER H 23 SUPPLY RECORDER SENSOR L 23 START STOP SWITCH K 5 SUPPLY TEMPERATURE SENSOR A 23 CONTROLLER RELAY COOLING J 9 TRANSFRESH COMMUNICATIONS CONNECTOR OPTION D 6 CONTROLLER RELAY PHASE SEQUENCING 7 8 J 9 CONTROLLER RELAY HIGH SPEED EVAPORATOR FANS J 14 CONTROLLER RELAY HEATING J 15 CONTROLLER RELAY DEFROST E 7 IN RANGE R
106. Table 4 9 ERR INTERNAL MICROPROCESSOR FAILURE Cause Internal Microprocessor Failure The controller performs self check routines If an internal failure occurs an ERR alarm will appear on the display This is an indication the controller needs to be replaced Error Description ERR 0 RAM failure Indicates that the controller working memory has failed ERR 1 Program Memory Fail ure Indicates a problem with the controller program ERR 2 Watchdog time out The controller program has entered a mode whereby the controller program has stopped executing ERR 3 N A N A ERR 4 N A N A ERR 5 A D failure The controller s Analog to Digital A D converter has failed ERR 6 IO Board failure ERR 7 Controller failure Internal program update failure Internal version firmware incompatible 4 43 T 362 Rev B ERR INTERNAL MICROPROCESSOR FAILURE ERR 8 DataCORDER failure Internal DataCORDER memory failure ERR 9 Controller failure Internal controller memory failure In the event that a failure occurs and the display cannot be updated the status LED will indicate the appro priate ERR code using Morse code as shown below ERROto 9 ENTR STPT ENTER SET POINT PRESS ARROW amp ENTER Cause The controller is prompting the operator to enter a set point LO LOW MAIN VOLTAGE FUNCTION CODES CD27 38 DISABLED AND
107. UIT FUSE F1 F2 Cause One of the 18 VAC controller fuses F1 F2 is open Refer to Cd08 Component System Sensors Troubleshooting Check system sensors for short to ground Corrective Action Replace defective sensor s Component Wiring Troubleshooting Check wiring for short to ground Corrective Action Repair as needed Component Controller Troubleshooting Controller may have an internal short Corrective Action Replace controller refer to Controller Service Section 7 23 AL22 EVAPORATOR IP Cause Evaporator motor internal protector IP is open T 362 Rev B Component Evaporator Motor 4 36 122 EVAPORATOR IP Troubleshooting Corrective Action Shut down unit disconnect power amp check Evaporator Motor IP at plug connection pins 4 amp 6 Replace defective evaporator fan motor refer to EVAPORATOR FAN MOTOR Service Section 7 14 AL23 LOSS OF PHASE B Cause Controller fails to detect current draw Component Troubleshooting Incoming Power Check incoming power source Corrective Action Correct power source as required AL24 COMPRESSOR IP Cause Compressor internal protector IP is open Component Compressor Troubleshooting Shut down unit disconnect power amp check resistance of compressor win
108. ace the filter drier if needed refer to FILTER DRIER Service Sec tion 7 12 Component Condenser Fan Troubleshooting Check Condenser Fan for proper operation Corrective Action Correct as required Component Discharge Pressure Transducer DPT Troubleshooting Confirm accurate DPT pressure readings refer to MANIFOLD GAUGE SET Section 7 2 Corrective Action Replace DPT if defective Component Non condensables in the refrigeration system Troubleshooting With the unit off allow system to stabilize to ambient temperature Check system pressure against PT Chart for 134a refer to Table 7 4 Corrective Action Correct as required refer to Refrigerant Charge Section 7 7 1 Component Refrigerant Troubleshooting Corrective Action Check refrigerant level Correct as required refer to Refrigerant Charge Section 7 7 1 AL19 DISCHARGE TEMPERATURE HIGH Cause Discharge temperature exceeds 135 275 F for 10 minutes within the last hour Component Restrictions in the refrigeration system Troubleshooting Ensure the Discharge Service Valve is fully open Corrective Action Open the Discharge Service Valve as needed Troubleshooting Check the unit for air flow restrictions Corrective Action Clean or remove any debris from coils Component Non condensables in the refrigeration system Troubles
109. al Defrost soft key is selected and conditions will NOT allow a defrost a pop up message screen appears 2 Timer The Defrost Interval Timer reaches the user selectable Interval The user selected inter vals are 3 6 9 12 24 Hours Off AUTO Pulse or AUTO2 factory default is 3 hours Refer to Defrost Interval setting on the Trip Settings screen a Automatic defrost starts with an initial defrost at three hours and then adjusts the interval to the next defrost based on the accumulation of ice on the evaporator coil Following a start up or after termination of defrost the time will not begin counting down until the DTS reading falls below 10 C 50 F If the reading of DTS rises above termination setting any time during the timer count down the interval is reset and the countdown starts over The Auto defrost time is reset to three hours start time after every PTI ini tiation or trip start interval b Fan Pulsing Logic is used to help prevent ice formation in the drain gutter and drain cup and ice buildup in supply air channel by using the evaporator fans to blow the warm air onto these areas during unit defrost When cooling at lower set points evaporator fan pulsing can be used during Defrost De ice when the Pulse option is selected for the Defrost Interval setting on the T 362 Rev B Trip Settings screen When enabled evaporator fan pulsing will occur based on the unit tempera ture set point and the Evap Fa
110. and save the compressor base mount ing bolts Discard the 4 top resilient mounts and washers Remove slide out the old compressor from the unit T 362 Rev B 7 6 gt anann UN gt O k Inspect compressor base plate for wear Replace if necessary Wire tie the compressor base plate to the com pressor and slide the new compressor into the unit Refer to Figure 7 5 Figure 7 5 Compressor Kit 3 4 2 5 1 8 i 6 11 12 Teflon Seal for Valve Connection 2 O Ring Unloader Connection Compressor Discharge Temperature Sensor O Ring Economizer Connection Base Mounting Bolts SST Washers Resilient Mount Mylar Washers Wire Ties Power Cable Gasket Ground Connection Screw Power Cable Lubricant Krytox Not Shown NOTE DO NOT add any oil to the replacement compressor Replacement compressor is shipped with full oil charge of 60 oz m Cut and discard the wire ties used to hold the base plate to the compressor n Place the new SST washers on each side of the resilient mounts and the new Mylar washer on the bottom of it as shown in Figure 7 5 Install the four base mounting bolts loosely o Place the new Teflon seals at the compressor suction and discharge ports as well as theO rings at the unloader and economizer line con nection ports Hand tighten all four connections Torque the
111. apacity Modula tion Setting PCnt and Electronic Expansion Valve EEV allows opening of the digital unloader valve and electronic expansion valve respectively to various per centages If the unit is equipped with an LIV the Liquid Valve Setting allows the LIV to be automatically con trolled or manually opened and closed The Override Timer selection is also provided to enter a time period of up to five minutes during which the override s are active If the timer is active valve override selections will take place immediately If the timer is not active changes will not take place for a few seconds after the timer is started When the timer times out the override function is automatically terminated and the valves return to normal machinery control To operate the override a Press the CODE SELECT key then press an ARROW key until Cd41 is displayed in the left window The right window will display a control ler communications code b Press the ENTER key The left display will show a test name alternating with the test setting or time remaining Use an ARROW key to scroll to the desired test Press the ENTER key SELCt will appear in the left display c Use an ARROW key to scroll to the desired set ting and then press the ENTER key Selections available for each of the tests are provided in Table 7 1 d If the timer is not operating follow the above procedure to display the timer Use an ARROW key to scrol
112. ase B Contactor PB Heater Contactor HR Controller DataCORDER Module Controller Remote Monitoring Receptacle Start Stop Switch ST NOaORWN gt 3 5 8 Controller Battery Pack Standard Location 9 Control Transformer 10 High Speed Evaporator Fan Contactor EF 11 Low Speed Evaporator Fan Contactor ES 12 Condenser Fan Contactor CF 13 Circuit Breaker 460V 14 Current Sensor Module T 362 Rev B 3 2 REFRIGERATION SYSTEM DATA Compressor Motor Model Number ZMD26KVE TFD 272 Assembly Weight With Oil 42 9 kg 95 Ib Approved Oil Uniqema Emkarate RL 32 3MAF Oil Charge 1774 ml 60 ounces Electronic Expansion Verify at 18 C 4 4 to 6 7 C 8 to 12 F Valve Superheat container box Evaporator temperature Economizer Expansion Valve Superheat Verify at 18 C container box 4 4 to 11 1 C 8 to 20 F temperature Heater Termination Opens 54 3 C 130 5 F Thermostat Closes 38 4 C 100 7 High Pressure Switch Cut Out 25 1 0 kg cm 350 10 psig Cut In 18 0 7 kg cm 250 10 psig EXPLOSION HAZARD Failure to follow this WARNING can result in death serious personal injury and or property damage Never use air or gas mixtures containing oxygen O2 for leak testing or operating the product Charge Only With R 134a Refrigerant must conform to AHRI Standard 700 specification
113. asses through the variable orifice of the EEV the pressure drops to suction pres sure In this process some of the liquid vaporizes to a gas flash gas removing heat from the remaining liq uid The liquid exits as a low pressure low tempera ture saturated mix Heat is then absorbed from the return air by the balance of the liquid causing it to vaporize in the evaporator coil The vapor then flows through the suction tube back to the compressor During the standard mode of operation the normally closed digital unloader valve DUV controls the system refrigerant flow and capacity by loading and unloading the compressor in frequent discrete time intervals If the system capacity has been decreased to the lowest allowable capacity with the DUV the unit will enter a trim heat mode of operation during which the controller will pulse the evaporator heaters in sequence with the compressor digital signal in order to absorb the excess capacity 3 9 3 5 2 In the economized mode see Figure 3 7 the frozen and pull down capacity of the unit is increased by sub cooling the liquid refrigerant entering the electronic expansion valve Overall efficiency is increased because the gas leaving the economizer enters the compressor at a higher pressure therefore requiring less energy to compress it to the required condensing conditions Economized Operation Liquid refrigerant for use in the economizer circuit is taken from the main liquid
114. ational needs of the container Cd27 Defrost Interval Hours or Automatic This is the desired period of time between defrost cycles Factory default is 3 hours Refer to Section NO TAG for information on Defrost Interval CnF11 determines whether the operator will be allowed to chose OFF as a defrost in terval option CnF64 determines whether the operator will be allowed to choose 15 as a defrost in terval option For units operating with PuLS selected defrost interval is determined by the unit temperature setpoint and the Evaporator Fan Pulsing Temperature Setting Cd60 When the unit temperature setpoint is equal to or less than the Evaporator Fan Pulsing Temperature Setting the defrost interval is set to 6 hours Otherwise the defrost interval is determined using the Automatic Defrost Interval Determination logic In either case PuLS remains displayed in this function select code After a new Defrost Interval is selected the previously selected Interval is used until the next defrost termination the next time the DTT contacts are OPEN or the next time power to the control is interrupted If the previous value or the new value is OFF the newly se lected value will be used immediately If any Auto Pretrip sequence is initiated Cd27 will be set to AUTO unless CnF49 OEM Reset is set to Custom AND CnF64 Evaporator Fan Pulsing Logic configuration vari able is set to IN in which case Cd27
115. ature If the controller has determined that cooling is not required or the controller logic determines suction pres sure is at the low pressure limit the unit will transition to Perishable Idle Mode During Perishable Idle Mode the compressor is turned off but the evaporator fans continue to run to circulate air throughout the container If temperature rises 0 2 above set point the unit will transition back to perishable steady state Perishable Idle Air Circulation 4 3 7 When it is necessary to raise the control temperature the system will enter Perishable Heating Mode If the temperature drops to 0 5 0 9 F below set point the unit will transition to Perishable Heating Mode and the heaters will be energized The unit will transition back to Perishable Idle Mode when the temperature rises to 0 2 0 4 F below the set point and the heaters will de energize Perishable Heating Figure 4 5 Controller Operation Perishable Mode Perishable Mode Controller Set Point ABOVE 10 C 14 or 5 C 23 F optionally Set Point 20 50 Falling Rising Temperature Temperature 4 3 8 Perishable Dehumidification Dehumidification is provided to reduce the humidity levels inside the container the dehumidification set point range is from 50 to 95 Dehumidification is activated when a humidity value is set at Cd33 The yellow SUPPLY LED will flash ON and OFF every sec ond to indicate that dehumidif
116. c Press the UP DOWN arrow key to access the desired mode of operation When the mode operation is displayed press the enter key to access the submenu parameters 5 4 3 eAutoFresh Modes of Operation NOTE When setting any mode of operation com plete the entire process to ensure all param eters are set a OFF A setting of OFF will disable all automatic venting oper ations The eAutoFresh vent will be driven fully closed and the eAutoFresh opening set to 0 CMH in Cd44 This is the default mode whenever a frozen mode of operation has been selected When the frozen set point is selected the current eAutoFresh setting is saved The vent position will be restored when a perishable set point is selected b USER The USER mode provides ventilation for commodities that require fresh air circulation The flow rate can be accessed through the submenu if a perishable set point has been selected To set the flow rate press the ENTER key to activate the selection mode When FLO appears in the left hand window use the UP or DOWN arrow key to scroll to the desired opening The range is from 0 to 220CM 0 to 129CF in increments of 5 Press the ENTER key to set the value and begin operation c TEST TEST mode allows the operator to test the movement of the mechanical slide air vent and calibrate the sensor tESt When tESt appears in the left window press the ENTER key to begin the test The eAutoFresh slide will ope
117. cate that the WPS CFS Override Logic is active by flashing the right display however the wiring will not al low for control of the condenser fan Configurable Functions Cd59 through Cd61 are user selectable functions The operator can change the value of these func tions to meet the operational needs of the container 4 29 362 Rev Table 4 5 Controller Function Codes Code TITLE No DESCRIPTION 59 Pump Down Logic C459 allows operation of the pump down logic control The display will flash between STArT and PrESS EnTEr Upon entering Cd59 the operator will be required to acknowledge that they want to initiate the pump down control The display will flash between STArT dN and PrESS Once the decision to continue is confirmed pump down logic will begin and will take com plete control of the unit until pump down either succeeds or fails This operation can not be halted once it begins without power cycling the unit After pump down logic has been initiated the operator will be notified to close the Liquid Line Valve the display will flash between CLOSE LLV and PrESS EnTEr Once com plete the display will read P dN to the left and the current suction pressure to the right If the automatic pump down logic succeeds within 20 minutes the unit will turn itself off and the display will notify the operator that pump down is complete by flashing between P
118. ccording to nameplate specifi cations to ensure optimal unit perfor mance Do not remove wire harnesses from con troller modules unless you are grounded to the unit frame with a static safe wrist strap Unplug all controller module wire har ness connectors before performing arc welding on any part of the container Do not attempt to use anML2i PC card in an ML3 equipped unit The PC cards are physically different and will result in damage to the controller Pre trip inspection should not be formed with critical temperature cargoes in the container When Pre Trip key is pressed economy dehumidification and bulb mode will be deactivated At the completion of Pre Trip activity economy dehumidification and bulb mode must be reactivated When condenser water flow is below 11 3 or when water cooled opera tion is not in use the CFS switch MUST be set to position 1 or the unit will not operate properly When a failure occurs during automatic testing the unit will suspend operation awaiting operator intervention When Pre Trip test Auto 2 runs to com pletion without being interrupted the unit will terminate pre trip and display Auto 2 end The unit will suspend operation until the user depresses the ENTER key The unit will remain in the full cooling mode as long as the EB switch is in the On position and the Mode Switch is in the Full Cool position If the cargo can be damage
119. chematics and wiring diagram plates The plate sets are ordered using a seven digit base part number and a two digit dash number 2 4 OPTION DESCRIPTIONS Various options may be factory or field equipped to the base unit These options are described in the following sub paragraphs 2 4 1 Battery The refrigeration controller may be fitted with standard replaceable batteries or a rechargeable battery pack Rechargeable battery packs may be fitted in the stan dard location or in a secure location 2 4 2 Dehumidification The unit may be fitted with a humidity sensor This sen sor allows setting of a humidity set point in the control ler In dehumidification mode the controller will operate to reduce internal container moisture level 2 4 3 USDA The unit may be supplied with fittings for additional temperature probes which allow recording of USDA Cold Treatment data by the integral DataCORDER function of the Micro Link refrigeration controller 2 4 4 Interrogator Units that use the DataCORDER function are fitted with interrogator receptacles for connection of equipment to download the recorded data Two receptacles may be fitted one is accessible from the front of the container and the other is mounted inside the container with the USDA receptacles T 362 Rev B 2 4 5 The unit may be fitted with a remote monitoring recep tacle This item allows connection of remote indicators for COOL DEFROST and IN RANGE Unle
120. compressor dome tempera ture is displayed Compressor Suction Pressure Reading for evaporator pressure transducer EPT is shown on the left display Press EN TER at Cd12 to show reading for compressor suction port pressure on right display Compressor Discharge Pressure Compressor discharges pressure transducer reading is displayed Digital Unloader Valve The status of the valve is displayed Open Closed Compressor Motor Hour Meter Unit Run Time Hour Meter This code displays the compressor motor hours User can view unit run time by pressing the ENTER key while in Cd16 Total hours are recorded in increments of 10 hours i e 3000 hours is displayed as 300 The Compressor Motor Hour Meter display can be reset to 0 by pressing and holding the ENTER key for 5 seconds The Unit Run Time Hour Meter cannot be reset Relative Humidity 96 Humidity sensor reading is displayed This code displays the relative humidity as a per cent value Cd19 Software Revision Battery Check The software revision number is displayed This code checks the Controller DataCORDER battery pack While the test is running ptest will flash on the right display followed by the result PASS will be displayed for battery voltages greater than 7 0 volts FAIL will be displayed for battery voltages be tween 4 5 and 7 0 volts and will be displayed for battery voltages less than 4 5 volts After
121. d ule or controller is faulty h If no voltage is present in any step the output from the controller to the drive module may be faulty Check the connections and wires from the controller to the drive module T 362 Rev B 7 26 3 b Controller Connector EC To replace the drive module disconnect all con nectors unscrew from mounting and replace with a NEW drive module in reverse order Checking the Controller Turn the unit OFF Disconnect the six pin connector to the stepper drive from the controller With a voltmeter set to read 50 volts DC attach the positive lead to outlet pin A of the six pin connector and the negative lead to pin B or TP 9 of the controller Turn ON the unit for 40 seconds and watch the voltmeter There should be approximately 24 to 32 VDC shown on pin A There should be zero volts on pin B After a short delay the reading should rise to approximately 24 to 32 VDC on pin E Pins C and D will have zero to 5 volts transistor logic TTL signals present however this can only be checked with the connector assembled as this is an open collector type circuit Checking the outputs on A B and E will verify that the controller is supplying power to the drive module To be thorough and if it is desired the signals on pins C and D can be checked as fol lows Install a jumper assembly Carrier part number 07 00408 00 to connect the drive module and controller connectors a
122. d by low temperatures the operator must monitor container temperature and manu ally cycle operation as required to main tain temperature within required limits Allowing the scroll compressor to oper ate in reverse for more than two minutes will result in internal compressor dam age Turn the start stop switch OFF immediately 1 3 To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before dis connecting The scroll compressor achieves low suc tion pressure very quickly Do not use the compressor to evacuate the system below 0 psig Never operate the compres sor with the suction or discharge service valves closed front seated Internal damage will result from operating the compressor in a deep vacuum Take necessary steps place plywood over coil or use sling on motor to prevent motor from falling into condenser coil Do not remove wire harnesses from mod ule unless you are grounded to the unit frame with a static safe wrist strap Unplug all module connectors before per forming arc welding on any part of the 5 D 5 The unit must OFF whenever a gramming card is inserted or removed from the controller programming port Use care when cutting wire ties to avoid nicking or cutting wires Do not allow moisture to enter wire splice area as this may affect sensor resistance T 362 Rev B SECTION 2 INTRODUCTION 2 1
123. d Cd37 to make the desired changes Evaporator Fan ces Speed Select Variable DTT Setting Cd37 Bulb Mode This is the desired evaporator fan speed for use during the bulb Dehumidification and Hu midification mode option Replaced by Cd48 if CnF50 Enhanced Bulb Mode is active This code is enabled only if in the dehumidification mode Cd33 and bulb mode Cd35 has been set to bulb If these conditions are not met alt will be displayed indicating that the evaporator fans will alternate their speed and the display cannot be changed If a dehumidification set point has been selected along with bulb mode then alt may be selected for alternating speed Lo for low speed evaporator fan only or Hi for high speed evaporator fan only If a setting other than alt has been selected and bulb mode is deactivated in any manner then selection reverts back to alt This is the variable defrost termination thermostat setting to be used with the optional bulb mode functionality This item is only displayed if the bulb mode option is configured on Replaced by Cd48 interface if CnF50 Enhanced Bulb Mode Interface is active T 362 Rev B 4 24 Table 4 5 Controller Function Codes Code TITLE No DESCRIPTION Display Only Functions Cd38 through Cd40 are display only functions Secondary Supply Temperature Sensor Secondary Return Temperature Sensor Container Identification Number Cd38 will
124. d for direct user interface These tests vary in length depending on the component under test T 362 Rev B 2 While tests are running P will appear on the left display the s indicate the test number and sub test The right display will show a countdown time in minutes and seconds indi cating the amount of time remaining in the test When a failure occurs during automatic testing the unit will suspend operation awaiting operator intervention When an automatic test fails it will be repeated once A repeated test failure will cause FAIL to be shown on the right display with the corresponding test number to the left The user may then press the DOWN ARROW to repeat the test the UP ARROW to skip to the next test or the PRE TRIP key to terminate testing The unit will wait indefinitely or until the user manually enters a command When Pre trip test Auto2 runs to comple tion without being interrupted the unit will terminate Pre trip and display Auto 2 end The unit will suspend operation until the user depresses the ENTER key When an Auto 1 Pre trip test runs to completion without a failure the unit will exit Pre trip mode and return to normal control operation However dehumidification and bulb mode must be reactivated manually if required c TO RUN AN INDIVIDUAL TEST Scroll through the selections by pressing the UP ARROW or DOWN ARROW keys to display an individual test code Press ing ENT
125. dN DOnE and SHUT OFF The operator must then shut off the unit If the automatic pump down logic does not complete within 20 minutes the unit will drop out of Cd59 and return to its previous control condition Evaporator Fan Cd60 Pulsing Temperature Setting Cd60 contains a selectable temperature range used to determine the engagement point of the Evaporator Fan Pulsing logic Default setting is 18 1 The user may change the temperature by pressing enter then scrolling to the desired temperature using either ar row key Press Enter to accept the change The temperature setting will be retained until either a Pretrip or Trip Start is initiated at which time the temperature will set to the default setting High Speed Cd61 Evaporator Fan Setting 461 is used to force evaporator fan speed to high while temperature control is being per formed in the perishable setpoint range When set to On evaporator fans operate in high speed regardless of any other active option that can control evaporator fan speed Following a power cycle the state of the function select code is retained at its state prior to the power cycle If On this function select code will be set to OFF when any trip start or any pretrip test is initiated will be displayed if setpoint is in frozen range or if CnF66 is configured OFF T 362 Rev B 4 30 Figure 4 16 Alarm Troubleshooting Sequence Start Troubleshooting
126. ded to DataBANK card files are accessible through an Omni PC Card Drive The files can then be viewed using the DataLINE software c Communications Interface Module The communications interface module is a slave mod ule which allows communication with a master central monitoring station The module will respond to commu nication and return information over the main power line With a communications interface module installed all functions and selectable features that are accessible at the unit may be performed at the master station Retrieval of all DataCORDER reports may also be per formed Refer to the master system technical manual for further information 4 8 11 USDA Cold Treatment Sustained cold temperature has been employed as a postharvest method for the control of fruit flies and other insect genera The commodity insect species treatment temperatures and exposure times are found in sections T107 T108 and T109 of the USDA Treat ment Manual In response to the demand to replace fumigation with this environmentally sound process Carrier has inte grated Cold Treatment capability into its microproces sor system These units have the ability to maintain T 362 Rev B supply air temperature within one quarter degree Cel sius of set point and record minute changes in product temperature within the DataCORDER memory thus meeting USDA criteria Information on USDA is pro vided in the following sub paragraphs a
127. ding and alarm functions of the DataCORDER Reprogramming to the factory installed configuration is achieved via a configuration card Changes to the unit DataCORDER configuration may be made using the DataLINE interro gation software A list of the configuration variables is provided in Table 4 2 Descriptions of DataCORDER operation for each vari able setting are provided in the following paragraphs 4 8 3 Sensor Configuration dCF02 Two modes of operation may be configured the Stan dard Mode and the Generic Mode T 362 Rev B a Standard Mode In the standard mode the user may configure the Data CORDER to record data using one of seven standard configurations The seven standard configuration vari ables with their descriptions are listed in Table 4 3 The inputs of the six thermistors supply return USDA 1 2 3 and cargo probe and the humidity sensor input will be generated by the DataCORDER See Fig ure 4 11 NOTE The DataCORDER software uses the supply and return recorder sensors SRS RRS The temperature control software uses the supply and return temperature sensors STS RTS b Generic Mode The generic recording mode allows user selection of the network data points to be recorded The user may select up to a total of eight data points for recording A list of the data points available for recording fol lows Changing the configuration to generic and select ing which data points to record ma
128. dings at contactor T1 T2 T2 T3 Corrective Action Monitor unit if alarm remains active or is repetitive replace the compres sor at the next available opportunity refer to COMPRESSOR Service Section 7 8 AL25 CONDENSER IP Cause Condenser fan motor internal protector IP is open Component Insufficient Air Flow Troubleshooting Shut down unit and check condenser fan for obstructions Corrective Action Remove obstructions Component Condenser Fan Motor Troubleshooting Corrective Action Shut down unit disconnect power amp check Condenser Fan Motor IP at plug connection pins 1 amp 2 Replace defective condenser fan motor refer to Condenser Fan Motor Assembly Service Section 7 11 AL26 ALL SENSORS FAILURE SUPPLY RETURN PROBES Cause Sensors out of range Component All sensors detected as out of range Troubleshooting Perform Pre trip P5 Corrective Action If P5 passes no further action is required T 362 Rev B AL26 ALL SENSORS FAILURE SUPPLY RETURN PROBES AL27 Corrective Action If P5 fails replace the defective sensor as determined by P5 refer to TEMPERATURE SENSOR Service Section 7 24 ANALOG TO DIGITAL ACCURACY FAILURE Cause Controller AD converter faulty Component Controller Troubleshooting Corrective Action Power cycle the
129. display the current supply recorder sensor SRS reading for units configured for four probes If the unit is configured with a DataCORDER Cd38 will display If the DataCORDER suffers a failure AL55 Cd38 will display the supply recorder sensor reading Cd39 will display the current return recorder sensor RRS reading for units configured for four probes If the unit is configured with DataCORDER Cd39 will display If the DataCORDER suffers a failure AL55 Cd39 will display the return recorder sensor read ing If a valid container id exists the default display for Cd40 will be cd40_XXXXxX where is the 5th character through the 9th character of the container id Pressing the Enter key on Cd40 will display id YYYYYYY where is the 5th character to the 11th character of the container id If no valid container id exists or the container id is blank the default display will have Cd40 on the left display and the right display will alternate between _nEEd id Press ing the enter key while on Cd40 in the state will prompt the Set Id Interface On start up if the container id is not valid Cd40 will be brought up on the display for the first minute of power up This can be left by either entering a container id or leaving the code select normally 40 is configured at commissioning to read a valid container identification number The reading will not displa
130. e ESV 1 Slotted Screw 2 Top Coil small O ring 3 Solenoid Coil Enclosing Tube and Body 4 Bottom Coil large O ring T 362 Rev B Always turn OFF the unit circuit breakers CB 1 amp CB 2 and disconnect main power supply before working on moving parts Turn unit power off and remove power from the unit Disconnect leads Remove top screw and o ring Remove coil and save mounting hardware seals and spacer for reuse See Figure 7 11 Refer to step d for valve coil replacement Removing the Solenoid Valve Pump down the compressor refer to Section 7 4 and frontseat both suction and discharge valves VALVE REMOVAL The preferred method of removing the solenoid valve is to cut the con nection between the brazed section and the valve using a small tube cutter Remove valve Alternately heat inlet and outlet connections to valve body and remove valve Clean the valve stem with mild cleaner if neces sary Installing the Solenoid Valve Fit the new solenoid valve into position and braze Use a wet rag to keep valve cool when ever brazing Installing the Solenoid Valve Coil Install the brass spacer on the valve stem Lubricate both o rings with silicone provided in the kit Install bottom coil o ring on the valve stem Install the solenoid coil on the valve stem Place the top coil o ring on the coil mounting screw and secure the coil to the valve using a torque wrench Tor
131. e HPS refer to Checking High Pressure Switch Section 7 9 1 Corrective Action Replace HPS if defective refer to Sensor Replacement Section 7 24 Component Refrigeration System Troubleshooting Check unit for air flow restrictions Corrective Action Clean or remove any debris from coils AL59 HEATER TERMINATION THERMOSTAT HTT Cause Heat Termination Thermostat HTT is open Component Heat Termination Thermostat HTT Troubleshooting Corrective Action Check for 24 volts at test point TP10 if no voltage at TP10 after unit has reached set point HTT is open Replace HTT if defective refer to Sensor Replacement Section 7 24 AL60 DEFROST TEMPERATURE SENSOR DTS Cause Failure of the Defrost Temperature Sensor DTS to open Component Defrost Temperature Sensor DTS Troubleshooting Test the DTS refer to Sensor Checkout Procedure Section 7 24 1 T 362 Rev B 4 40 AL60 DEFROST TEMPERATURE SENSOR DTS 7 24 AL61 HEATER CURRENT DRAW FAULT Cause Improper current draw during heat or defrost mode Component Heater s Troubleshooting While in heat or defrost mode check for proper current draw at heater contactors refer to ELECTRICAL DATA Section 3 3 Corrective Action Replace h
132. e all refrigerant using a refrigerant recov refrigerant container on weight scales ery system b The recommended method to evacuate and 764 Partial System dehydrate the system is to connect evacuation hoses at the compressor suction and liquid line service valve see Figure 7 4 Be sure the ser vice hoses are suited for evacuation purposes a If refrigerant charge has been removed from the low side only evacuate the low side by connect ing the evacuation set up at the compressor suction valve and the liquid service valve but leave the service valves frontseated until evacu NOTE ation is completed To prevent the area between the Econo mizer Solenoid Valve ESV and the Com pressor from being isolated during b Once evacuation has been completed and the pump has been isolated fully backseat the ser vice valves to isolate the service connections T 362 Rev B 7 4 7 7 and then continue with checking and if required adding refrigerant in accordance with normal procedures REFRIGERANT CHARGE EXPLOSION HAZARD Failure to follow this WARNING can result in death seri ous personal injury and or property damage Never use air or gases containing oxygen O2 for leak testing or operating the product Charge only with R 134a Refrigerant must conform to AHRI Standard 700 specification Checking the Refrigerant Charge NOTE Use a refrigerant recovery system whenever removing refrigerant When working with
133. e for finding leaks in a system is with a R 134a electronic leak detector Testing joints with soapsuds is satis factory only for locating large leaks If the system is without refrigerant charge the system with refrigerant 134a to build up pres sure between2 1 to 3 5 bar 30 5 to 50 8 psig To ensure complete pressurization of the sys tem refrigerant should be charged at the com pressor suction valve and the liquid line service valve Remove refrigerant cylinder and leak check all connections NOTE Only refrigerant 134a should be used to pressurize the system Any other gas or vapor will contaminate the system which will require additional purging and evacuation of the system c If required remove refrigerant using a refriger ant recovery system and repair any leaks Check for leaks d Evacuate and dehydrate the unit Refer to Sec tion 7 6 1 e Charge unit per Section 7 7 1 7 6 EVACUATION AND DEHYDRATION 7 6 1 Moisture is detrimental to refrigeration 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 General 7 6 2 Preparation a Evacuate and dehydrate only after pressure leak test refer to Section 7 5 Essential tools to properly evacuate and dehy drate any system include a vacuum pump 8m
134. e in the Default Display mode press the ALT MODE amp ALARMLIST keys This accesses the DataCORDER Alarm List Display Mode which displays any alarms stored in the alarm queue b To scroll to the end of the alarm list press the UP ARROW Depressing the DOWN ARROW key will scroll the list backward c The left display will show where is the alarms number in the queue The right display will show if the alarm is active where is the alarm number IA will show if the alarm is inactive d END is displayed to indicate the end of the alarm list if any alarms are active CLEAr is displayed if all the alarms in the list are inactive e Ilf no alarms are active the alarm queue may be cleared The exception to this rule is the Data CORDER alarm queue Full alarm AL91 which does not have to be inactive in order to clear the alarm list To clear the alarm list 1 Press the ALT MODE amp ALARM LIST keys 2 Press the UP DOWN ARROW key until CLEAr is displayed 3 Press the ENTER key The alarm list will clear and will be displayed T 362 Rev B 4 Press the ALARM LIST key AL will show on the left display and on the right dis play when there are no alarms in the list 5 Upon clearing of the alarm queue the alarm light will be turned off 4 8 14 DataLINE provides the user with an interface to view modify current settings of the ISO trip
135. e specified range P3 1 P4 Tests High Speed Evaporator Fans Current Draw High speed evaporator fans are turned on then off Current draw must fall within specified range and measured current changes must exceed spec ified ratios No other system components will change state during this test NOTE If unit configured for single evaporator fan operation and either AL11 or AL 12 is active at the start of either test then the test will fail immediately If AL11 or AL12 become active during the test then the test will fail upon conclusion of the test Evaporator fans start in the off condition current draw is measured then high speed evaporator fans will be turned on After 60 seconds the current draw is measured again The change in current draw is then re High Speed Evaporator corded Fan Motors On Test passes if change in current draw in the specified range AND mea sured current changes exceed specified ratios If the three phase motors are configured IN the change ratio test is skipped P4 0 High speed evaporator fans are then turned off After 10 seconds the High Speed Evaporator 4 1 current draw is measured The change in current draw is then recorded Fan Motors Off D jt Test passes if change in current draw test is in the specified range P5 Tests Air Stream Temperature Sensor Tests Tests the validity of the Air Stream Temperature Sensors The High Speed Evaporator Fan is turned on and r
136. e supply temperature sensor and supply recorder sensor are located to the left of the compressor Figure 3 3 Compressor Section Compressor Compressor Discharge CPDS Location Discharge Connection Suction Connection Location Compressor Terminal Box Oil Drain Location Economizer Connection Discharge Pressure Transducer DPT Temperature Sensor 10 11 12 13 14 15 16 3 3 Digital Unloader Valve DUV Suction Pressure Transducer SPT Evaporator Pressure Transducer EPT High Pressure Switch HPS Discharge Service Valve Suction Service Valve Supply Temperature Supply Recorder Sensor Assembly STS SRS Warning Label T 362 Rev B 3 1 5 Air Cooled Condenser Section The air cooled condenser section consists of the con denser fan condenser coil receiver liquid line service valve filter drier fusible plug economizer economizer expansion valve economizer solenoid valve ESV and sight glass moisture indicator The condenser fan pulls air from around the coil and discharges it horizontally through the condenser fan grille Figure 3 4 Air Cooled Condenser Section 5 4 3 9 10 7 11 00 o 12 14 s s A ist 1 Grille and Venturi Assembly 8 Fil
137. e top of the coil use a water hose with a nozzle to wash the coil from the inside out d Systematically wash across the inside top face of the coil until the water runs clean e Wash down the center section and then through the bottom of the coil continue washing until the water runs clear f Afterthe coil is clean rinse the condenser fan to remove any dirt build up from the blades g Replace the condenser fan grille ensuring that it is centered around the fan T 362 Rev B 7 8 7 10 2 Condenser Coil Removal a Using a refrigerant reclaim system remove the refrigerant charge Do not remove the condenser fan grille before turning power OFF and discon necting the power plug Remove the condenser fan grille retain all bolts and washers for reuse Remove the condenser fan Remove the infill panels to the left and right of the condenser fan shroud Remove the condenser fan shroud Unplug the condenser fan motor Remove and retain sufficient putty from around the motor wire harness to allow the harness to be slid back through the side support bracket Cut the top and bottom drain lines midway between the side support bracket and the first cable tie approx 150mm 6 from the side sup port bracket i Remove and retain sufficient putty from around the drain lines to allow the tubes to be slid back through the side support bracket Remove filter drier Unbraze the inlet connection to coil 1 Remo
138. e unit b Spray the surface with water before applying the cleaning solution This helps the cleaner work better C Liberally apply the prepared cleaner solution 5 parts water and 1 part cleaner 7 13 d Allow the cleaner to soak for 5 to 7 minutes e Assess area for rinsing Follow all local regula tions regarding disposal of waste water f Thoroughly rinse the cleaner and surrounding area floor etc When rinsing where heavy foam ing solution is present it is very important to take the time to thoroughly rinse the equipment and surroundings g Always rinse the empty coil cleaner bottle cap tightly and dispose of properly 7 16 ELECTRONIC EXPANSION VALVE The electronic expansion valve EEV is an automatic device which maintains required superheat of the refrigerant gas leaving the evaporator The valve func tions 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 7 16 4 Replacing Electronic Expansion Valve and Strainer a Removing an EEV Always turn OFF the unit circuit breakers CB 1 amp CB 2 and disconnect main power supply before working on moving parts 1 Pump down the compressor refer to Section 7 4 and frontseat both suction and discharge valves 2 Turn unit power off and remove power from the unit 3 Remove coil 4
139. e valves f Open the vacuum pump and electronic vacuum gauge valves if they are not already open Start the vacuum pump Evacuate unit until the elec tronic vacuum gauge indicates 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 g Break the vacuum with either clean dry refriger 22 0 Liquid Service Connection Economizer Solenoid Valve Receiver or Water Cooled Condenser Compressor Discharge Service Connection Suction Service Connection Vacuum Pump Electronic Vacuum Gauge Manifold Gauge Set Refrigerant Cylinder Reclaimer 7 6 3 Complete System NOTE Refer to Partial System procedure for infor mation pertaining to partial system evacua tion and dehydration ant 134a or dry nitrogen Raise system pressure to roughly 0 14 bar 2 psig monitoring it with the compound gauge If R134a was used remove refrigerant using a refrigerant recovery system If nitrogen was used relieve the pressure Repeat steps f and g one time Remove the copper tubing and change the filter drier Evacuate unit to 500 microns Close the electronic vacuum gauge and vacuum pump valves Shut off the vacuum pump Wait five minutes to see if vacuum holds This procedure 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 a Remov
140. eater s if defective refer to Section 7 13 2 Evaporator Heat er Removal and Replacement Component Contactor Troubleshooting Check voltage at heater contactor on the heater side If no voltage pres ent Corrective Action Replace heater contactor if defective AL63 CURRENT LIMIT Cause Unit operating above current limit Component Refrigeration System Troubleshooting Check unit for air flow restrictions Corrective Action Clean or remove any debris from coils Troubleshooting Check unit for proper operation Corrective Action Repair as needed Component Power supply Troubleshooting Confirm supply voltage frequency is within specification and balanced according to ELECTRICAL DATA Section 3 3 Corrective Action Correct power supply Component Current limit set too low Troubleshooting Check current limit setting Code Cd32 Corrective Action The current limit can be raised maximum of 23 amps using Cd32 AL64 DISCHARGE TEMPERATURE SENSOR CPDS Cause Discharge Temperature sensor out of range Component Discharge temperature sensor CPDS Troubleshooting Test the CPDS refer to Sensor Checkout Procedure Section 7 24 1 Corrective Action Replace the CPDS if defective refer to Sensor Replacement Section 7 24 4 41 362 Rev B AL65 DISCHARGE PRESSURE TRANSDUCER DPT Cause Compressor Discharge Transducer is out of range Component Compressor Discharge Transducer DPT Troublesho
141. eck for proper compressor rotation within the first 30 seconds If rotation is not correct the compressor will be stopped and restarted in the opposite direction If the compressor is producing unusually loud and continuous noise after the first 30 seconds of operation stop the unit and investigate 5 6 1 Starting the Unit a With power properly applied the fresh air vent in proper position place the START STOP switch to ON see Figure 3 5 b The Controller Function Codes for the container ID Cd40 software version Cd18 and unit model number Cd20 will be displayed in sequence c Continue with Start Up Inspection Section 5 7 5 6 2 To stop the unit place the START STOP switch in position 0 OFF Stopping the Unit 5 7 START UP INSPECTION 5 7 1 Check rotation of condenser and evaporator fans Physical Inspection 5 7 2 Check and if required reset controller Function Codes Cd27 through Cd39 in accordance with desired oper ating parameters Refer to Table 4 5 Check Controller Function Codes 5 7 3 DataCORDER a Check and if required set the DataCORDER Con figuration in accordance with desired recording param eter Refer to Section 4 8 3 b Enter a Trip Start To enter a Trip Start do the fol lowing 1 Depress the ALT MODE key When the left dis play shows dC depress the ENTER key 2 Scroll to Code dC30 3 Depress and hold the ENTER key for five sec
142. ect battery wire connector from control box Slide out and remove old battery and bracket See Figure 4 4 Item 8 Slide new battery pack and bracket into the con trol box slot Reconnect battery wire connector to control box and replace wire ties that were removed Secure Battery Option Rechargeable Cells Only a 7 21 Turn unit power OFF and disconnect power sup ply Open control box door and remove both the high voltage shield and clear plastic rain shield if installed Disconnect the battery wires from the KA plug positions 14 13 11 Using Driver Bit Carrier Transicold part number 07 00418 00 remove the 4 screws securing the display module to the control box Discon nect the ribbon cable and set the display module aside T 362 Rev B The battery wires must face toward the right e Remove the old battery from the bracket and clean bracket surface Remove the protective backing from the new battery and assemble to the bracket Secure battery by inserting the wire tie from the back of the bracket around the bat tery and back through the bracket f Reconnect the ribbon cable to display and re install the display g Route the battery wires from the battery along the display harness and connect the red battery wire and one end of the red jumper to KA14 the other end of the red jumper wire to KA11 and the black wire to KA13 h Replace wire ties that were remov
143. ective Component Evaporator Temperature Sensor s ETS amp ETS1 Troubleshooting Verify accuracy of temperature sensors refer to Sensor Checkout Pro cedure Section 7 24 Corrective Action Replace ETS or ETS1 if defective Component Evaporator Fans Troubleshooting Confirm fans operating properly Corrective Action Replace fan s if defective refer to EVAPORATOR FAN MOTOR AS SEMBLY Section 7 14 05 MANUAL DEFROST SWITCH FAILURE Cause Controller has detected continuous Manual Defrost Switch activity for five minutes or more Component Keypad Troubleshooting Power cycle the unit Corrective Action Resetting the unit may correct problem monitor the unit If the alarm reappears after 5 minutes replace the keypad ALO06 KEYPAD OR KEYPAD HARNESS FAIL Cause Controller has detected one of the keypad keys is continuously activity Component Keypad or Harness Troubleshooting Power cycle the unit Corrective Action Resetting the unit may correct problem monitor the unit If the alarm reappears replace the keypad and harness AL07 FRESH AIR VENT OPEN WITH FROZEN SET POINT Cause The VPS is reading greater than 0 CMH while unit is in frozen mode Component Vent Position Sensor VPS Troubleshooting Manually reposition vent and confirm using Cd45 Refer to VENT POSITION SENSOR SERVICE Section 7 25 T 362 Rev B 4 32
144. ective coil is removed from unit remove defrost heaters and install on replacement coil i Install coil assembly by reversing above steps j Leak check connections Evacuate and add refrigerant charge 7 13 2 The heaters are wired directly back to the contactor and if a heater failure occurs during a trip the heater set containing that heater may be disconnected at the contactor Evaporator Heater Replacement The next Pre trip P1 will detect that a heater set has been disconnected and indicate that the failed heater should be replaced To remove a heater do the follow ing Always turn OFF the unit circuit breakers CB 1 amp CB 2 and disconnect main power supply before working on moving parts a Before servicing unit make sure the circuit breakers CB 1 and CB 2 and start stop switch ST are in the OFF position and the power plug is disconnected b Remove the upper back panel c Determine which heater s need replacing by checking resistance of each heater set Refer to Section 3 3 for heater resistance values Once the set containing the failed heater is deter mined cut the splice connection and retest to determine the actual failed heater s d Remove hold down clamp securing heater s to Coil e Lift the bent end of the heater with the opposite end down and away from coil Move heater to the side enough to clear the heater end support and remove To replace a heater do steps a through e i
145. ed 7 24 TEMPERATURE SENSOR SERVICE Service procedures for the return recorder return tem perature supply recorder supply temperature ambi ent defrost temperature evaporator temperature and compressor discharge temperature sensors are pro vided in the following sub paragraphs 7 24 1 Sensor Checkout Procedure To verify that accuracy of a temperature sensor T 362 Rev B 7 22 Remove the sensor and place in a 0 32 F ice water bath The ice water bath is prepared by filling an insulated container of sufficient size to completely immerse bulb with ice cubes or chipped ice then filling voids between ice with water and agitating until mixture reaches 0 32 F measured on a laboratory thermometer Start unit and check sensor reading on the con trol panel The reading should be 0 C 32 F If the reading is correct reinstall sensor if it is not continue with the following Turn unit OFF and disconnect power supply Refer to Section 7 23 and remove controller to gain access to the sensor plugs Using the plug connector marked EC that is connected to the back of the controller locate the sensor wires RRS RTS SRS STS AMBS DTS or CPDS as required Follow those wires to the connector and using the pins of the plug measure the resistance Values are provided in Table 7 2 and Table 7 3 Due to the variations and inaccuracies in ohm meters thermometers or other test equipment a reading
146. ely to exit the Cd49 display Configurable Functions Cd50 through Cd53 are user selectable functions The operator can change the value of these func tions to meet the operational needs of the container Cd50 4 27 T 362 Rev B Table 4 5 Controller Function Codes Code TITLE No DESCRIPTION Cd50 CCPC Disabled OFF disabled enabled SEtPt suspended by setpoint too low CAHUM suspended by or humidity control suspended by ACT active FAIL all return temperature probe failure for CCPC PrtrP pretrip active C LIM suspended by cool limit logic PULL pulldown active ALArM suspended by shutdown alarm Press enter arrow keys and then enter to select OFF or If On is selected CCPC operation may be suspended as indicated by one of the sus pension codes listed above If CCPC is not OFF and is not suspended will be dis played Automatic Cold Cd51 Treatment Parameter Selection ACT mode 451 increments of 1 day 1hr Display default O_0 done mm dd this will be display is ACT has completed value OFF or Display Select default OFF value F on 0 1 degree increments Display Select default 0 0 DAyS value 0 99 increments of 1 Display Select default 0 ProbE value Probe positions ex 1 2 _ 4 1 3_ Disp
147. en Mode Test Pulldown Control temperature must be at least 7 2 C 45 F The setpoint is changed to 17 8 The system will then attempt to pull down the control temperature to setpoint using normal frozen mode cooling During this test the control temperature will be shown on the right display The test passes if the control temperature reaches setpoint minus 0 3 before the 180 minute timer expires Otherwise the test fails Upon fail ure and when initiated by an automatic Pre trip sequence P10 1 will auto repeat once by starting P10 0 over again P10 2 Frozen Mode Temperature Test Maintain Test P10 1 must pass for this test to execute Same as for test 8 2 except the control temperature is the return probe temperature The average error must be 1 6 C If the DataCORDER supply tem perature probe is invalid the test fails and the control probe temperature will be recorded as 50 C Upon failure and when initiated by an auto matic Pre trip sequence P10 2 will auto repeat by starting P10 0 over again T 362 Rev B Table 4 7 DataCORDER Function Code Assignments Inapplicable Functions Display NOTE To Access Press ALT MODE key then CODE SELECT key Code No TITLE DESCRIPTION dC1 Recorder Supply Temperature Current reading of the supply recorder sensor dC2 Recorder Return Temperature Current reading of the return recorder sens
148. er to below a DataCORDER is configured for USDA probes b DataCORDER is set to logging interval for 60 minutes c Sensor is set to 2 Averaged 3 USDA d The resolution is set to Normal Figure 4 12 DataCorder Configuration Screen DataCorder Configuration x Standard if Custom Configuration Option 0 Custom 2 Supply SRS Return Air RRS Cargo Humidity EA Caro Logging Interval Resolution Minutes 50 Low Normal DataCorder Sample Type Alarms 2Averaged 3 USDA USDA1 Auto 7 AllAveraged All Snapshot USDA2 Auto 7 Controller S ample Type 4 USDA3 Auto hd Averaged Cargo auto x F1 Help Successfully connected with the refrigeration unit 2 Calibrate the three USDA probes by ice bathing the probes and performing the calibration func tion with the DataLINE This calibration proce dure generates the probe offsets which are stored in the controller and applied to the USDA sensors for use in generating sensor type reports Refer to the Data Retrieval manual 62 10629 for more details Refer to Figure below Figure 4 13 DataCorder Probe Calibration Screen RFA Probe Calibration SBE Current Probe Offset Temperatures USDA1 0 0 0c 0 0 USDA2 00 Doc 00 USDA3 0 0C DoC 00 CARGO 00 00 00
149. er to Table 4 8 for a description of the data stored in the DataCORDER for each corresponding Pre trip test 4 8 10 DataCORDER Communications Data retrieval from the DataCORDER can be accom plished by using the DataLINE DataBANK Card ora communications interface module NOTE A DataLINE or a communications interface module display of Communication Failed is caused by faulty data transfer between the DataCORDER and the data retrieval device Common causes include T 362 Rev B 1 Bad cable or connection between Data CORDER and data retrieval device 2 PC communication port s unavailable or mis assigned Configuration identification for the models covered herein may be obtained on the Container Products Group Information Center by authorized Carrier Transi cold Service Centers a DataLINE The DataLINE software for a personal computer is sup plied on both floppy disks and CD This software allows interrogation configuration variable assignment screen view of the data hard copy report generation cold treatment probe calibration and file management Refer to Data Retrieval manual 62 10629 for a more detailed explanation of the DataLINE interrogation soft ware The DataLINE manual may be found on the Internet at www container carrier com b DataBANK Card The DataBANK card is a PCMCIA card that inter faces with the controller through the programming slot and can download data at a fast rate Files downloa
150. ers Resistance cold 66 8 to 77 2 ohms 20 C 68 F Type Sheath 380 VAC 3 PH 50 Hz 460 VAC 3 PH 60 Hz Full Load Amps 1 07 9 High Speed Full Load Amps 0 47 0 47 Low Speed Nominal Horsepower 0 36 0 63 High Speed e Evaporator Fan Nominal Horsepower 0 05 0 8 Motor s Low Speed Rotations Per Minute 2850 rpm 3450 rpm High Speed Rotations Per Minute 1425 rpm 1725 rpm Low Speed Voltage and Frequency 360 460 1 25 Hz 400 500 VAC 1 5 Hz Bearing Lubrication Factory lubricated additional grease not required Rotation CW when viewed from shaft end Control Circuit 7 5 amps F3A F3B f Fuses Controller DataCORDER 5 amps F1 amp F2 Emergency Bypass 10 amps FEB Electrical Output 0 5 VDC to 4 5 VDC over 90 degree range 9 Meu ac Supply Voltage 5 VDC 1096 Supply Current 5 mA typical 3 7 T 362 Rev B h Solenoid Valve Nominal Resistance Coils ESV 24 77 F 25 C 7 7 ohms 5 VDC Maximum Current Draw 0 7 amps Nominal Resistance i DUV Coils 12 VDC 77 F 20 C 14 8 ohms 596 Maximum Current Draw 929 mA Coil Feed to Ground 47 ohms Nominal Gray Wire Resistance Coil Feed to Coil Feed 95 ohms Orange wire Power Red wire Output Brown wire Ground Input voltage 5 VDC Output voltage 0 to 3 3 VDC k Humidity Sensor Output voltage readings verses relative humidity RH percentage 30 0 99 V 50 1 65 V 70 2 3
151. es of vacuum and then charge with R 134a to a slightly positive pres sure of 0 1 kg cm2 1 0 psig Frontseat both manifold gauge set valves and disconnect from cylinder The gauge set is now ready for use Figure 7 2 R 134a Manifold Gauge Hose Set To Low Side Access Valve To High Side Access Valve T 362 Rev B RED Refrigeration and or Evacuation Hose SAE J2196 R 134a Hose Fitting 0 5 16 Acme YELLOW Refrigeration and or Evacuation Hose SAE J2196 R 134a Hose Fitting with O ring M14 x 1 5 High Side Field Service Coupling Red Knob BLUE Refrigeration and or Evacuation Hose SAE J2196 R 134a Low Side Field Service Coupling Blue Knob 7 3 SERVICE CONNECTIONS The compressor suction compressor discharge and the liquid line service valves see Figure 7 3 are pro vided with a double seat and an access valve which enables servicing of the compressor and refrigerant lines Turning the valve stem clockwise all the way forward will frontseat the valve to close off the line connection and open a path to the access valve Turning the stem counterclockwise all the way out will backseat the valve to open the line connection and close off the path to the access valve With the valve stem midway between frontseat and backseat both of the service valve connections are open to the access valve path For example the valve stem is first fully backseated whe
152. et and outlet connections to valve body and remove valve 7 Clean the valve stem withmild cleaner if neces sary b Installing the Economizer Expansion Valve 1 The economizer expansion valve should be wrapped in a soaked cloth for brazing 2 Braze inlet connection to inlet line 3 Braze outlet connection to outlet line 4 Reinstall the cushion clamps on inlet and outlet lines c Replace filter drier Refer to Section 7 12 d Evacuate to 500microns by placing vacuum pump on liquid line and suction service valve e Check economizer expansion valve superheat see Section 3 2 7 19 TROUBLESHOOTING P6 7 DUV A failed digital unloader valve DUV which is normally closed or an internal seal failure of the compressor can result in the unit running continually in the fully loaded mode causing it to undershoot its set point tem perature Both of these can be checked out by running pre trip test P6 7 When running P6 7 the controller is looking for the differences in pressure and current draw between loaded mode and unloaded mode to make a judgment If there are no differences then it will show fail To confirm what caused the test to fail perform the fol lowing additional test 1 Connect manifold gauge set to discharge DSV and suction SSV service valves 2 Front seat the SSV and pump down the com pressor 3 Front seat the DSV valve to isolate the compres sor 4 Disconnect DUV from
153. fective Replace is not initiate defrost manu Keypad is defective Replace d Defrost temperature sensor open Replace Initiates but relay DR drops Low line voltage Section 3 3 out _ Heater contactor or coil defective Replace Initiates but does not defrost Heater s burned out Section 7 13 Frequent defrost Wet load Normal 6 7 ABNORMAL PRESSURES Condenser coil dirty Section 7 10 2 Condenser fan rotating backwards Section 7 10 Condenser fan inoperative Section 7 11 High discharge pressure Refrigerant overcharge or noncondensibles Section 7 3 Discharge service valve partially closed Open Electronic expansion valve EEV control malfunction Replace Incorrect software and or controller configuration Check Failed suction pressure transducer SPT or evapo Replace rator pressure transducer EPT Suction service valve partially closed Open Filter drier partially plugged Section 7 12 Low suction pressure Low refrigerant charge Section 7 3 No evaporator air flow or restricted air flow Section 7 13 Excessive frost on evaporator coil Section 6 6 Evaporator fan s rotating backwards Section 7 14 3 EEV control malfunction Replace Failed digital unloader valve DUV Replace Suction and discharge pres Compressor operating in reverse Section 6 14 sures tend to equalize when Compressor cycling stopped Check unit is operating Failed digital unloader valve DUV Replace 6 8 ABNORMAL NOISE OR VIBRATIONS Compressor start up after an extended s
154. fety devices high pressure switch motor internal protectors and heat termination thermostat to protect the system while in Emergency Bypass Mode The unit will remain in the full cooling mode as long as the EB switch is in the On position and the Mode Switch is in the Full Cool position If the cargo can be damaged by low temperatures the operator must monitor container temperature and manu ally cycle operation as required to main tain temperature within required limits T 362 Rev B When the Emergency Bypass switch is in the Bypass position the EBS will be enabled With the Mode switch in Full Cool mode the following will occur simultaneously a The EBS switch will enable EBS input b The phase detection circuit will detect the phase rotation and close to provide power to the com pressor contactor The condenser fan contact will close to energize the condenser contactor and provide power to the condenser fan motor The evaporator fan contact will close to energize the high speed evaporator contactor and pro vide power to the evaporator fan motor The EBS electronic module will operate the EEV to control superheat To return the unit to normal operation 1 2 Locate the connectors behind the compressor Disconnect the Emergency Bypass connector from the EBS module connector and reconnect it to the controller connector See Figure 5 3 T 362 Rev B 3 Inside the control box place the EB switch in the
155. four base mounting screws to 6 2 mkg 45 ft Ibs q Torque the compressor ports connections to Service Valve Connection Torque Value Suction and Discharge 108 5 to 135 5 Nm Rotalocks 80 to 100 ft Ibs Unloader connection zum 18 to 20 ft Ibs 32 5 to 35 Nm Economized connection 24 to 26 ft lbs Connect butt splice and heat shrink the new compressor dome temperature sensor with the old sensor wires removed in step h Wire tie any loose wiring as appropriate Evacuate the compressor to 1000microns if the unit was pumped down before the replaced com pressor was removed Otherwise evacuate the complete unit and charge it with R 134a refriger ant see Section 7 6 1 and Section 7 7 1 Open the compressor terminal cover and con nect the compressor power cable following the steps below 1 Liberally coat the orange gasket surfaces with the Krytox lubricant 2 Install the orange gasket part onto the com pressor fusite with the grooved or threaded side out Ensure that the gasket is seated onto the fusite base 3 Coat the inside of the power plug female connector pins with theKrytox lubricant and insert the plug onto the compressor terminal connections Make sure the orange gasket has bottomed out onto the fusite and it fits securely onto the terminal pins while fully inserted into the orange plug 4 Connect the green ground wire to the grounding tab loca
156. function codes is provided in Table 4 5 To access the function codes a Press CODE SELECT then press an arrow key until the left window displays the desired func tion code b The right window will display the selected func tion code value for five seconds before returning to normal display mode c additional time is required pressing the ENTER key will extend the display time to 30 seconds 4 3 MODES OF OPERATION General operation sequences for cooling heating and defrost are provided in the following sub paragraphs Schematic representation of controller operation is pro vided in Figure 4 5 amp Figure 4 8 Operational software responds to various inputs These inputs come from the temperature sensors and pressure transducers the temperature set point the settings of the configuration variables and the function code assignments The action taken by the operational software changes as the input values change Overall interaction of the inputs is described as a mode of operation The modes of operation include perishable chill mode and frozen mode Descriptions of the con troller interaction and modes of operation are provided in the following sub paragraphs 4 3 1 At start up the controller logic checks for proper phase sequencing and compressor rotation If incorrect sequencing is causing the compressor and three phase evaporator fan motors to rotate in the wrong direction the controller will e
157. hase Sequence 4 4 STARTING AND STOPPING INSTRUCTIONS 5 5 Starting the Unit 5 5 START UP INSPECTION 5 5 Stopping the Unit 5 5 STS 7 26 Index 2 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM 4 1 Temperature Readout 2 1 TEMPERATURE SENSOR SERVICE 7 22 Thermometer Port 2 2 TROUBLESHOOTING 6 1 TROUBLESHOOTING P6 7 DUV 7 15 U Upper Air 2 2 Upper Fresh Air Makeup Vent 5 2 USDA 2 1 UTOTRANSFORMER 7 18 V VALVE OVERRIDE CONTROLS 7 17 VAPORATOR SECTION CLEANING 7 12 VENT POSITION SENSOR 7 27 Vent Position Sensor 5 3 VPS 7 27 Water Cooling 2 2 3 362 Carrier Transicold Division Carrier Corporation A part of UTC Building amp Industrial Systems a business unit of United P O Box 4805 Technologies Corporation Stock symbol UTX Syracuse NY 13221 USA TRANSICOLD www carrier transicold com
158. heck compressor sensor wiring If display is 5 the current sensor is defective Corrective Action Replace current sensor if defective AL16 COMPRESSOR CURRENT HIGH Cause Compressor current draw is over the calculated maximum for 10 minutes Component Current Sensor T 362 Rev B between SPT AL16 COMPRESSOR CURRENT HIGH Troubleshooting Compare Cd3 to actual measured current at wire T1 T2 or going to the compressor contactor If there is a difference determine whether this is caused by current sensor or amp clamp tool Corrective Action Replace current sensor if defective Component Amperage is indeed too high Troubleshooting Confirm supply voltage frequency is within specification and balanced according to Electrical Data Section 3 3 Corrective Action Correct power supply Component Operating Conditions Troubleshooting Make sure system pressures are relevant to operating conditions Corrective Action Check air flow of condenser Check Refrigerant charge refer to REFRIGERATION SYSTEM SER VICE Section 7 3 Component Monitor Unit Troubleshooting Alarm is display only the alarm may clear itself during operation Corrective Action If alarm remains active or is repetitive replace compressor at next avail able opportunity refer to COMPRESSOR Service Section 7 8 AL17 COMPRESSOR PRESSURE DELTA FAULT Cause Compressor has attempted to start in b
159. hooting With the unit off allow system to stabilize to ambient temperature Check system pressure against PT Chart for 134a refer to Table 7 4 Corrective Action Correct as required refer to Refrigerant Charge Section 7 7 1 Component Additional Alarms such as AL 16 AL24 4 35 T 362 Rev B AL19 DISCHARGE TEMPERATURE HIGH Troubleshooting Check compressor operation Corrective Action If the alarm persists it may indicate a failing compressor replace the compressor refer to COMPRESSOR Service Section 7 8 AL20 CONTROL CONTACTOR FUSE F3 Cause Control power fuse F3A or F3B is open Component Check F3A if the fuse is open Troubleshooting Check PA PB CH coils for short to ground if short is found Corrective Action Replace the defective coil Replace the fuse Component Check F3B if the fuse is open Troubleshooting Check ESV coil resistance at TP7 to TP9 if short to ground or if resis tance is less than 4 ohms coil is defective Check CF ES EF HR coils for short to ground if short is found coil is defective Corrective Action Replace the defective coil Replace the fuse Component Check Voltage at QC1 Troubleshooting If voltage is present it indicates a defective microprocessor Corrective Action Refer to Controller Service Section 7 23 AL21 CONTROL CIRC
160. hutdown Normal Brief chattering when manually shut down Compressor operating in reverse Section 6 14 Compressor Loose mounting bolts or worn resilient mounts Tighten Replace Loose upper mounting Section 7 8 1 Loose slugging Section 7 13 Bent loose or striking venturi Check Condenser or Evaporator Fan Worn motor bearings Section 7 11 Section 7 14 Bent motor shaft Section 7 11 Section 7 14 6 3 T 362 Rev B Table 6 1 TROUBLESHOOTING Vent not opening CONDITION POSSIBLE CAUSE REMEDY REFERENCE SECTION 6 9 MICROPROCESSOR MALFUNCTION Incorrect software and or controller configuration Check Defective sensor Section 7 24 Will not control Defective wiring Check Low refrigerant charge Section 7 3 6 10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW Frost on coil Section 6 6 Evaporator coil blocked Dirty coil Section 7 13 Evaporator fan motor internal protector open Section 7 14 No or partial evaporator air Evaporator fan motor s defective Section 7 14 flow Evaporator fan s loose or defective Section 7 14 Evaporator fan contactor defective Replace 6 11 EAUTOFRESH NOT OPERATING Unit not Configured for eAutoFresh Operation No action Cd43 in Off mode Section 5 4 2 Wiring disconnected Check wiring Stepper drive defective Section 7 26 2 Stepper motor defective Section 7 26 4
161. ication is active Once dehumidification is active and the following conditions are satisfied the controller will activate the heat relay to begin dehumidification 1 The humidity sensor reading is above the humidity set point Cd33 Pull Down Only Applicable to Perishable Mode Controller Set Point ABOVE 10 C 14 or 5 C 23 F optionally 2 5 4 5 2 The unitis in perishable steady state and supply air temperature is less than 0 25 0 45 F above set point 3 The heater debounce timer three minutes has timed out 4 Heater termination thermostat HTT is closed If the above conditions are true for at least one hour the evaporator fans will switch from high speed to low speed Evaporator fan speed will then switch every hour as long as the 4 conditions are met see Bulb Mode Section 4 3 9 for different evaporator fan speed options If any condition except item 1 becomes false OR if the 4 5 T 362 Rev B relative humidity sensed is 2 below the dehumidifica tion set point the high speed evaporator fans will be energized During dehumidification power is applied to the defrost heaters This added heat load causes the controller to open the EEV to match the increased heat load while still holding the supply air temperature very close to the set point Opening the EEV reduces the temperature of the evap orator coil surface which increases the rate at which water is conden
162. ier Pressure Suction Transducer Pressure CD Economizer Transducer TR Sight Glass m Suet iquid Line CD uction Service U Service Valve NC 7 Valve Water Cooled Condenser vo Compressor DISCHARGE LIQUID SUCTION VAPOR T 362 Rev B 3 12 SECTION 4 MICROPROCESSOR 41 TEMPERATURE CONTROL MICROPROCES SOR SYSTEM The temperature control Micro Link 3 microprocessor system see Figure 4 1 consists of a keypad display module the control module controller and intercon necting wiring The controller houses the temperature control software and the DataCORDER software The temperature control software functions to operate the unit components as required to provide the desired cargo temperature and humidity The DataCORDER software functions to record unit operating parameters and cargo temperature parame ters for future retrieval Coverage of the temperature control software begins with Section 4 2 Coverage of the DataCORDER software is provided in Section 4 8 The keypad and display module serve to provide user access and readouts for both of the controller func tions temperature control and DataCORDER The functions are accessed by keypad selections and viewed on the display module The components are designed to permit ease of installation and removal Figure 4 1 Temperature Control System TEMPERATURE CONTROL SOFTWARE DISPLAY MODULE CONFIGURATION OPERATIONAL ALARMS PRE TRIP
163. indicator shows a high level of moisture the filter drier should be replaced To replace filter drier 1 Pump down the unit refer to Section 7 4 Evacuate if unit is not equipped with service valves Then replace filter drier 2 Evacuate the low side in accordance with Section 7 6 3 After unit is in operation inspect for moisture in system and check charge EVAPORATOR COIL amp HEATER ASSEMBLY The evaporator section including the evaporator coil should be cleaned regularly The preferred cleaning fluid is fresh water or steam Another recommended cleaner is Oakite 202 or similar following manufac turer s instructions The two drain pan hoses are routed behind the con denser fan motor and compressor The drain pan line s must be open to ensure adequate drainage 7 13 1 Evaporator Coil Replacement a Pump unit down Refer to Section 7 4 Always turn OFF the unit circuit breakers CB 1 amp CB 2 and disconnect main power supply before working on moving parts b With power OFF and power plug removed remove the screws securing the panel covering the evaporator section upper panel c Disconnect the defrost heater wiring d Remove the mounting hardware from the coil e Unsolder the two coil connections one at the distributor and the other at the coil header f Disconnect the defrost temperature sensor refer to Section 7 24 from the coil g Remove middle coil support h After def
164. ing instructions are provided in Section 5 8 4 8 DATACORDER 4 8 1 Carrier Transicold DataCORDER software is inte grated into the controller and serves to eliminate the temperature recorder and paper chart DataCORDER functions may be accessed by keypad selections and viewed on the display module The unit is also fitted with interrogation connections see Figure 4 1 which may be used with the Carrier Transicold DataReader to download data A personal computer with Carrier Tran sicold DataLINE software installed may also be used to download data and configure settings The DataCORDER consists of Configuration Software Description Operational Software Data Storage Memory Real Time Clock with internal battery backup Six Thermistor Inputs Interrogation Connections Power Supply battery pack The DataCORDER performs the following functions a Logs data at 15 30 60 or 120 minute intervals and stores two years of data based on one hour interval b Records and displays alarms on the display module c Records results of Pre trip testing d Records DataCORDER and temperature control software generated data and events as follows Container ID Change Software Upgrades Alarm Activity Battery Low battery pack Data Retrieval Defrost Start and End Dehumidification Start and End Power Loss with and without battery pack Power Up with and without battery pack Remote
165. ion Initially Cd48 will display current dehumidification mode bUIb bulb cargo mode dEnUM normal dehumidification or OFF off This display is steady Pressing ENTER key will take the interface down into a hierarchy of parameter selection menus mode setpoint evaporator speed DTT setting Pressing ENTER key in any pa rameter selection menu commits to selection of the currently displayed parameter and causes the interface to descend into the next parameter selection menu All parameter selection menus alternate between a blank display and the current selection in the right hand display Pressing CODE SELECT key in a selection menu cancels the current selection activity and ascends back up to the next higher selection menu or to Cd48 display mode if that is the next higher If the operator does not press any key for five seconds the interface reverts to normal sys tem display and the current selection menu is cancelled but any previously committed changes are retained Available parameters and parameter ranges are a function of configuration options and previously selected parameters as indicated above Whenever any pretrip test is initiated dehumidification mode goes to OFF Whenever dehumidification mode goes to OFF e Dehumidification control setpoint goes to0 RHinternally but will then initialize to 95 RH when dehumidification mode leaves OFF Evaporator speed select goes to Alt for units without PWM Compressor Control Cnf57
166. is measured The change in current draw is then recorded Test passes if change in current draw test is in the specified range P3 Tests Low Speed Evaporator Fan Current Draw The system must be equipped with a low speed evaporator fan as determined by CnF02 the Evaporator Fan Speed Select configuration variable Low speed evaporator fan is turned on then off Current draw must fall within specified range No other sys tem components will change state during this test NOTE If unit configured for single evaporator fan operation and either AL11 or AL 12 is active at the start of either test then the test will fail immediately If AL 11 or AL12 become active during the test then the test will fail upon conclusion of the test Low Speed Evaporator Fan Pag Motors On High speed evaporator fans will be turned on for 20 seconds the fans will be turned off for 4 seconds current draw is measured and then the low speed evaporator fans are turned on After 60 seconds the current draw is measured again The change in current draw is then recorded Test passes if change in current draw test is in the specified range 4 45 T 362 Rev B Table 4 6 Controller Pre trip Test Codes Low speed evaporator fans are then turned off After 10 seconds the Low Speed Evaporator Fan 4 current draw is measured change in current draw is then recorded Motors Off Su Test passes if change in current draw test is in th
167. is within 1 5 psi of the evaporator pressure transducer EPT Test P5 8 must pass before this test is run 5 10 Humidity Sensor Controller Configuration Verification Test This is a Pass Fail Skip test of the humidity sensor configuration Test passes if the controller configuration has humidity sensor in Test fails if the controller configuration has humidity sensor out and Vout is greater than 0 20 Volts for the humidity sensor Test is skipped if the controller configuration has the humidity sensor out and Vout is less than 0 20 Volts Test P5 9 must pass before this test is run 5 11 Humidity Sensor Installa tion Verification Test This is a Pass Fail test of humidity sensor installation sensor is pres ent Test passes if Vout is greater than 0 20 Volts for the humidity sensor Test fails if Vout is less than 0 20 Volts for the humidity sensor Test P5 10 must pass before this test is run 5 12 Humidity Sensor Check Test Range This is a Pass Fail test of the Humidity Sensor Range Test passes if Vout for the humidity sensor is between 0 33 Volts and 4 Volts Test fails if Vout is outside of this range Test P5 11 must pass before this test is run P6 Tests Refrigerant Probes Compressor and Refrigerant Valves Pass Fail testing is performed for the compressor EEV DUV LIV if equipped ESV and the refrigerant pressure and temperature sen sors P6 0 Discharge
168. isplayed NOTICE AL26 is active when none of the sensors are responding Check the connector at the back of the controller if it is loose or unplugged reconnect it then run a Pre trip test P5 to clear AL26 47 PRE TRIP DIAGNOSTICS Pre trip Diagnostics is an independent controller func tion that suspends normal refrigeration controller activi ties and provides preprogrammed test routines The test routine can be run in Auto Mode which automati cally performs a pre programmed sequence of tests or Manual Mode which allows the operator to select and run any of the individual tests Pre trip inspection should not be per formed with critical temperature cargoes in the container When the Pre trip key is pressed econ omy dehumidification and bulb mode will be deactivated At the completion of the Pre trip test economy dehumidification and bulb mode must be reactivated A Pre trip test may be initiated by use of the keypad or via communication but when initiated by communica tion the controller will execute the entire battery of tests auto mode At the end of a Pre trip test the message rSLts pretest results will be displayed Pressing ENTER will allow the user to see the results for each of the sub tests The results will be displayed as PASS or FAIL for each test run to completion A detailed description of the Pre trip tests and test codes is provided in Table 4 6 Detailed operat
169. it through the evaporator coil where it is heated or cooled and discharging it at the bottom Evaporator Section If the unit is equipped with eAutoFresh system compo nents are mounted in addition to the standard refrigera tion unit components The stepper motor component is installed in the vent the air filter sensor stepper motor drive and sensing lines are installed on the rib of the upper grill Most evaporator components are accessible by remov ing the upper rear panel as shown in the illustration or by removing the evaporator fan access panels see Figure 3 2 Figure 3 2 Evaporator Section 1 Evaporator Fan Motor 1 EM1 Return Recorder Sensor Temperature Sensor RRS RTS Humidity Sensor HS Evaporator Fan Motor 2 EM2 Evaporator Coil Heaters Underside of Coil Evaporator Coil Electronic Expansion Valve EEV NOR T 362 Rev B 8 Evaporator Temperature Sensors Location ETS1 amp ETS2 9 Interrogator Connector Rear ICR 10 USDA Probe Receptacle PR2 11 USDA Probe Receptacle PR1 12 USDA Probe Receptacle PR3 13 Cargo Probe Receptacle PR4 3 1 4 Compressor Section The compressor section includes the compressor digi tal unloader valve DUV high pressure switch dis charge pressure transducer DPT evaporator pressure transducer EPT and the suction pressure transducer SPT Th
170. ite COOL is illuminated 4 9 Figure 4 9 Frozen Mode ENERGIZED DE ENERGIZED 24 VOLT POWER NOTE The EEV and DUV are independently oper ated by the microprocessor Complete sche matics and legends are located in Section 8 4 3 20 Defrost is initiated to remove ice buildup from the evap orator coil which can obstruct air flow and reduce the cooling capacity of the unit The defrost cycle may con sist of up to three distinct operations depending upon the reason for the defrost or model number configura tion The first is de icing of the coil the second is defrost due to a probe check cycle and the third is a snap freeze process based on the unit model configu ration Defrost Defrosting the coil consists of removing power to the cooling components compressor evaporator fans and condenser fan closing the EEV and turning on the heaters which are located below the evaporator coil During normal operation de icing will continue until temperatures indicate that the ice on the coil has been removed proper air flow has been restored and the unit is ready to control tem perature efficiently If defrost was initiated by the probe check logic then the Probe Check is carried out after the com pletion of the defrost cycle A Probe Check is initi ated only when there is an inaccuracy between the controller temperature sensors For more informa tion on Probe Check
171. ith a vent positioning sensor VPS and may also be fitted with screens 2 4 19 Labels Safety Instruction and Function Code listing labels dif fer depending on the options installed Labels available with additional languages are listed in the parts list 2 4 20 Two replacement controllers are available 2 4 17 Controller 1 Re manufactured Controller is the equivalent of a new OEM controller and is supplied with a 12 month warranty 2 Repaired Controller has had previous faults repaired and upgraded with the latest software NOTE Repaired controllers are NOT to be used for warranty repairs only full OEM Re manufac tured controllers are to be used Controllers will be factory equipped with the latest ver sion of operational software but will NOT be config ured for a specific model number and will need to be configured at the time of installation or sale 2 4 21 Condenser Grille Condenser grilles are direct bolted 2 4 22 Emergency Bypass The optional Emergency Bypass switch EB functions to bypass the controller in the event of controller fail ure 2 4 23 The optional eAutoFresh venting system moderates the atmospheric level inside the container unit in response to cargo respiration eAutoFresh SECTION 3 DESCRIPTION 3 1 GENERAL DESCRIPTION 3 1 2 Fresh Air Makeup Vent 3 1 1 Refrigeration Unit Front Section The function of the upper or lower makeup air vent is to The unit is designed
172. king the Refrigerant Charge 7 5 7 7 2 Adding Refrigerant to System Full Charge 7 5 7 7 3 Adding Refrigerant to System Partial Charge 7 5 7 8 COMPRESSOR d peers meu fhe eG ee eee co Rae i gue 7 5 7 8 1 Removal and Replacement of Compressor 7 6 7 9 HIGH PRESSURE SWITCH 4 7 7 7 9 1 X Checking High Pressure Switch 7 7 7 9 2 Replacing High Pressure Switch 7 8 T 362 Rev B iv 17 10 CONDENSER dee i 7 8 7 10 1 Condenser Coil Cleaning 7 8 7 10 2 Condenser Coil Removal 7 8 7 10 3 Condenser Coil Preparation 7 8 7 10 4 Condenser Coil Installation 7 9 7 11 CONDENSER AND FAN MOTOR 7 9 7 11 1 Condenser Fan Motor Remove Replace 7 10 112 etre urere o era EA Ra E LA Ed 7 10 7 13 EVAPORATOR COIL am
173. l to the desired time interval and press ENTER to start the timer e The above described sequence may be repeated during the timer cycle to change to another override T 362 Rev B Table 7 1 Valve Override Control Displays Override Timer Left Display Controller Communications Codes Setting Codes Right Display Right Display Cd 41 SELCt tiM 0 00 0 minutes 0 Seconds In 30 second increments to 5 00 5 minutes 0 seconds PCnt 9o Setting DUV Capacity Modulation AUtO Normal Machinery Control 100 EEV Setting Electronic Expansion Valve AUtO Normal Machinery Control CLOSE Closed 0 3 6 10 25 50 100 CAP Capacity Mode 7 22 AUTOTRANSFORMER If the unit does not start check the following a T 362 Rev B Make sure the 460 VAC yellow power cable is plugged into the receptacle see Figure 7 15 and locked in place Make sure that circuit breakers CB 1 and CB 2 are in the ON position If the circuit breakers do not hold in check voltage supply There is no internal protector for this transformer design therefore no checking of the internal protector is required Using a voltmeter and with the primary supply circuit ON check the primary input voltage 460 VAC Next check the secondary output voltage 230 VAC The transformer is defective if output voltage is not available AUtO Normal Control Std UnLd Economizer Closed
174. late and gasket plate using original hardware Apply thread sealant and torque screws to 0 29 mkg 25 1 Inch pounds Mount grille assembly using original hardware Apply thread sealant and torque screws to 0 29mkg 25 1 Inch pounds Reconnect the motor connector Replace the bolts that secure the eAutoFresh Panel to the front of the unit Carry out functional test Refer to Section 5 4 3 step c T 362 Rev B 0 090 BON 10 11 12 Figure 7 25 Motor Cup Replacement Connector Tie Wrap eAutoFresh Panel Cup Motor Rail Top Plate Gasket Grille Grill Screws Rail Screws Plate Slide Rail Bottom Motor Cup Screws T 362 Rev B 7 27 MAINTENANCE OF PAINTED SURFACES The refrigeration unit is protected by a special paint system against the corrosive atmosphere in which it normally operates However should the paint system be damaged the base metal can corrode In order to protect the refrigeration unit from the highly corrosive sea atmosphere or if the protective paint system is scratched or damaged clean the area to bare metal using a wire brush emery paper or equivalent cleaning method Immediately following cleaning apply paint to the area and allow to dry Refer to the Parts List for proper paint selection 7 28 COMMUNICATIONS INTERFACE
175. lay default SPnEW value F on 0 1 increments Display Select default 10 0 Initially Cd51 will display current countdown timer increments of 1 day 1hr default 0 0 Pressing ENTER key will take the interface down into a hierarchy of parameter selection menus act treat days probe and spnew setting Pressing ENTER key in any of the parameter selection menus commits to selection of the currently displayed parameter and causes the interface to descend into the next param eter selection menu All parameter selection menus alternate between a blank display and the current selection in the right hand display Pressing CODE SELECT key in a selection menu cancels the current selection activity and ascends back up to the next higher selection menu or to Cd51 display mode if that is the next higher If the operator does not press any key for five seconds the interface reverts to normal sys tem display and the current selection menu is cancelled but any previously committed changes are retained Available parameters and parameter ranges are a function of configuration options and previously selected parameters as indicated above Parameter with the exception of Act may not be altered if Cd51 is re entered if Act is On When has completed including reaching the new setpoint done on the left dis play and the MONTH DAY of completion on the right display will be displayed as the sec ond entry in
176. lay 0 CMH CFM 7 26 EAUTOFRESH SERVICE 7 26 1 Removing the Air Sample Filter Element Servicing the eAutoFresh Air Filter The air sample filter element can be accessed in two ways 1 Through the eAutoFresh side evaporator access panel 2 Through the inside of the container by lowering the upper evaporator panel hand unscrew and remove the filter cup from the bottom of the air sample filter assembly b Remove the filter element from the filter assem bly c Install the new air sample filter element by reversing the above steps 7 26 2 Checking eAutoFresh Drive System Checking the Auto Slide a To check with an ohmmeter disconnect the four pin connector to the stepper motor With a reli able digital ohmmeter check the winding resis tance In normal ambient the motor should have 72 to 84 ohms measured on the red green a b terminals and on the white black c d terminals leads If an infinite or zero reading occurs check connections or replace the motor If near normal or normal reading occurs proceed to the follow ing sections to check out the controller b To check with a SMA 12 portable stepper drive tester TheSMA 12 portable stepper drive tester Carrier Transicold P N 07 00375 00 is a bat tery operated stepper drive which will open and close the auto slide which allows a more thor ough check of the motor Checking the Slide Motor a Turn unit OFF b Disconnect the four pin
177. le even when it is placed on the mat 7 23 2 A group of test points TP see Figure 7 16 are pro vided on the controller for troubleshooting electrical cir cuits see schematic diagram section 7 A description of the test points follows Controller Troubleshooting NOTE Use a digital voltmeter to measure AC volt age between TP s and ground TP9 except for TP8 TP 1 Not used in this application TP 2 Enables the user to check if the high pressure switch HPS is open or closed 7 19 3 Enables the user to check if the water pressure switch WP contact is open or closed TP 4 Enables the user to check if the internal protec tor for the condenser fan motor IP CM is open or closed TP 5 Enables the user to check if the internal protec tors for the evaporator fan motors IP EM1 or IP EM2 are open or closed TP 6 IF EQUIPPED Enables the user to check if the controller liquid injection valve relay TQ is open or closed TP 7 Enables the user to check if the controller econ omizer solenoid valve relay TS is open or closed TP 8 Not used in this application TP 9 The chassis unit frame ground connection TP 10 Enables the user to check if the heat termina tion thermostat HTT contact is open or closed Figure 7 16 Controller Section of the Control Box 2 1 Controller Software Prog
178. le will go blank briefly then read Pro donE when the software loading has loaded If a problem occurs while loading the software the display will blink the message Pro FAIL or bad 12V Turn start stop switch OFF and remove the card Turn unit OFF via start stop switch ST Remove the PCMCIA card from the program ming software port and return the unit to normal operation by placing the start stop switch in the ON position Turn power on and wait about 15 seconds for the new software to load into the controller memory The status LED will flash quickly and the display will remain blank as the controller loads the new software When complete the controller will reset and power up normally Wait for default display setpoint on the left and control temperature on the right Confirm software is correct using keypad code select 18 to view Cd18 XXXX Turn power off Operational software is loaded b Procedure for loading Configuration Software 1 T 362 Rev B Turn unit OFF using start stop switch ST 10 11 12 13 14 Insert software programming PCMCIA card con taining the following example files into the pro gramming software port See Figure 7 16 this file allows the user to select the file program to upload into the control ler cfYYMMDD mI 3 multi configuration file Turn unit ON using start stop switch ST Press the UP or DOWN arrow key until displa
179. line as it leaves the filter drier The flow is activated when the controller ener gizes the economizer solenoid valve ESV The liquid refrigerant flows through the ESV to the expansion valve internal passages absorbing heat from the liquid refrigerant flowing to the electronic expansion valve The resultant medium temperature pressure gas enters the compressor at the economizer port fitting When the control air temperature falls to 2 0 C 3 6 F above set point the DUV unloads the compressor s scroll and begins to reduce the capacity of the unit Percentage of the unit capacity is accessed through code select 01 Cd01 For example if Cd01 displays 70 it indicates that the compressor is operating unloaded with the DUV engaged 30 of the time 3 5 3 The microprocessor controls the superheat leaving the evaporator via the electronic expansion valve EEV based on inputs from the evaporator pressure trans ducer EPT The microprocessor transmits electronic pulses to the EEV stepper motor which opens or closes the valve orifice to maintain the superheat set point Electronic Expansion Valve T 362 Rev B Figure 3 6 Refrigeration Circuit Schematic Standard Operation COMBO ETS1 EVAPORATOR 8 ri ELECTRONIC EXPANSION VALVE CONDENSER LIQUID LEVEL SHD MOISTURE 5 INDICATOR LIQUID LINE RECEIVER SERVICE VALVE DIGITAL DISCHARGE UNLOADER TEMPERATURE VALVE SEN
180. ll Pre test activity is completed dehumidification and bulb mode must be reactivated manually if required 5 9 PROBE DIAGNOSTICS A complete temperature probe check is performed during the P5 Pre trip test A probe check is also run at the end of a defrost cycle the defrost light will remain on during this period If supply probes are within limits and return probes are within limits the unit will return to normal operation During normal operation the control ler continuously monitors and compares adjacent tem perature probe readings The probe check procedure consists of running the evaporator fans for up to eight minutes in order to com pare the readings from the adjacent temperature probes If a significant difference in temperature read ings is detected between probes a defrost cycle fol lowed by another probe check may be initiated Any continued disagreement between probes will prompt the controller to invalidate the failed temperature probe and the backup probe will be used for tempera ture control In Perishable Mode both pairs of supply and return probes are monitored for probe disagreement Probe disagreement is considered a difference of 0 5 C 0 9 F or greater between the supply air sensors and or a difference of 2 0 C 3 6 F between the return air sensors Probe disagreement found in either pair can trigger a defrost probe check In Frozen Mode only the controlling probes are consid ered Disagreement
181. ller continuously monitors supply air temperature Once the supply air temperature falls below set point the controller periodically records supply air temperature set point and time A calculation is then performed to deter mine temperature drift from set point over time If the calculation determines that cooling is no longer required contacts TC and TN are opened to de energize the compressor motor and the condenser fan motor In addition the controller will close the EEV The evaporator fan motors continue to run to cir culate air throughout the container The green IN RANGE light remains illuminated as long as the supply air temperature is within tolerance of the set point If the supply air temperature increases to 1 0 1 8 F above set point and three minutes have elapsed contacts TC and TN close to restart the compressor and condenser fan motors in stan dard mode non economized operation The white COOL light is also illuminated i If the average system capacity has risen to 100 during unloaded cooling and three minutes off time has elapsed relay TS will energize to open the ESV placing the unit in economized mode j the supply air increases more than 2 5 4 5 F above set point temperature the micro processor will transition the evaporator superheat control from modulation back to full cool control 4 3 12 Perishable Mode Heating Sequence of Operation a the supply air temperature decrease
182. n reverse Figure 7 8 Heater Arrangement Bracket Heater Element 7 14 EVAPORATOR FAN AND MOTOR ASSEMBLY The evaporator fans circulate air throughout the con tainer by pulling air in the top of the unit The air is forced through the evaporator coil where it is either Retainer heated or cooled and then discharged out the bottom of the refrigeration unit into the container The fan motor bearings are factory lubricated and do not require additional grease T 362 Rev B 7 14 4 Replacing the Evaporator Fan Assembly Always turn OFF the unit circuit breakers CB 1 amp CB 2 and disconnect main power supply before working on moving parts a Remove access panel by removing mounting bolts and TIR locking device Reach inside of unit and remove the Ty Rap securing the wire harness loop Disconnect the connector by twisting to unlock and pulling to separate b Loosen four 1 4 20 clamp bolts that are located on the underside of the fan deck at the sides of the fan assembly Slide the loosened clamps back from the fan assembly c Slide the fan assembly out from the unit and place on a sturdy work surface 7 14 2 Disassemble the Evaporator Fan Assembly a Attach a spanner wrench to the two 1 4 20 holes located in the fan hub Loosen the 5 8 18 shaft nut by holding the spanner wrench stationary and turning the 5 8 18 nut counter clockwise see Figure 7 9 b Remove the spanner wrench Use a universal wheel puller
183. n Pulsing Temp setting on the Trip Settings screen QUEST 11 also pulses the evaporator fans during Defrost De ice within a narrow perishable set point range The logic for each evaporator fan pulsing feature is described below c After a new Defrost Interval is selected the pre viously selected Interval is used until the next defrost termination the next time the DTS con tacts are OPEN or the next time power to the control is interrupted If the previous value or the new value is OFF the newly selected value will be used immediately 3 Probe Check If defrost is initiated due to Probe Check immediately following the defrost cycle the evaporation fans are started and run for eight minutes to stabilize the temperature throughout the container A probe check com parison is carried out at the end of the eight min ute period if any sensor is found out of calibration At this time its alarm set is no longer used for control reorder purposes 4 Probe Check Logic The logic determines that a Probe Check is necessary based on tempera ture values currently reported by the supply and return probes 5 Delta T Logic If the difference between return and supply air temperature Delta T becomes too great indicating possible reduced airflow over the evaporator coil caused by ice buildup requiring a defrost a In Perishable Pull Down Delta T increases to greater than 12 C and 90 minutes of compres sor run time have been rec
184. n connecting a manifold gauge to measure pres sure Then the valve is opened 1 4 to 1 2 turn to mea sure the pressure Figure 7 3 Service Valve Line Connection Access Valve Stem Cap Valve stem Compressor Or Filter Drier Inlet Connection Valve Frontseated Valve Backseated NOORWN gt Connection of the manifold gauge hose set see Fig ure 7 4 is dependent on the component being ser viced If only the compressor is being serviced the high side coupling is connected to the discharge ser vice valve For service of the low side after pump down the high side coupling is connected to the liquid line service valve The center hose connection is brought to the tool being used vacuum tank etc 362 Rev B Connecting the manifold gauge set a Remove service valve stem cap and to make sure the valve is backseated b Remove access valve cap See Figure 7 3 c Connect the field service coupling see Figure 7 2 to the access valve d Turn the field service coupling knob clockwise which will open the system to the gauge set e To read system pressures slightly midseat the service valve f Repeat the procedure to connect the other side of the gauge set To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before dis connecting Removing the Manifold Gauge Set a While the compressor is still ON backseat the high side service val
185. n fully and then return to the closed position The test may be observed by the operator to ensure proper operation of the vent After completion of the TEST the unit will return to the previous mode of operation NOTE It is recommended that the calibration proce dure only be performed during Pre trip or when the container has been fully vented CAL will attempt to calibrate the sensor When CAL is selected the display will flash CAL The oper ator is to hold the ENTER key for 5 seconds The dis play will stop flashing and read CAL for 5 seconds The microprocessor will read the value and then compare that value to a known zero value If the sensor is within the calibration parameter range the micropro cessor will determine the appropriate offset for the sen Sor If the sensor is outside of this range for example if the container is loaded or has a high level of CO2 the controller will flash NOCAL for 5 seconds then revert to the previous mode of operation d DELAY T 362 Rev B In DELAY mode the operation of the eAutoFresh sys tem will be delayed for a set amount of time This allows time for the cargo to reach set point In DELAY mode the eAutoFresh vent will open to the stored FLO value when the return air temperature sensor RTS is at or below set point plus the return offset value rtn or the delay time tIM whichever comes first The eAutoFresh vent will be fully closed when ret
186. n position 0 OFF Plug in and lock the 460VACpower plug at the receptacle on the transformer 2 Plug the 230 VAC black cable into a de ener gized 190 230 VAC 3 phase power source Energize the power source Set circuit breakers CB 1 and CB 2 to position I ON Close and secure control box door T 362 Rev B Figure 5 1 Autotransformer 1 Dual Voltage Modular Autotransformer 2 Circuit Breaker CB 2 230 Volt 3 460 VAC Power Receptacle 5 3 ADJUST FRESH AIR MAKEUP VENT The purpose of the fresh air makeup vent is to provide ventilation for commodities that require fresh air circu lation The vent must be closed when transporting fro zen foods Air exchange depends on static pressure differential which will vary depending on the container and how the container is loaded Units may be equipped with a vent position sensor VPS The VPS determines the position of the fresh air vent upper or lower as equipped and sends data to the controller display 5 3 1 Two slots and a stop are designed into the Upper Fresh Air disc for air flow adjustments The first slot allows for a 0 to30 air flow the second slot allows for a 30 to 100 air flow To adjust the percentage of air flow loosen the wing nut and rotate the disc until the desired percentage of air flow matches with the arrow Tighten the wing nut To clear the gap between the slots loosen the wing nut until the disc clears the stop Fig
187. n software is a variable listing of the com ponents available for use by the operational software This software is factory installed in accordance with the equipment fitted and options listed on the original pur chase order Changes to the configuration software are required only when a new controller has been installed or a physical change has been made to the unit such as the addition or removal of an option A configuration variable list is provided in Table 4 4 Change to the factory installed configuration software is achieved via a configuration card or by communications Figure 4 4 Control Module 3 4 5 Mounting Screw Micro Link 3 Control DataCORDER Module Connectors Test Points IO S 4 3 3 6 EN12830 1038 12 00579 00 KC SIN 0491162 REV 5147 1 KD Fuses Control Circuit Power Connection Software Programming Port Battery Pack Standard Location o 362 Rev 4 2 2 Operational Software Cd Function Codes The operational software is the actual operation pro gramming of the controller which activates or deacti vates components in accordance with current unit operating conditions and selected modes of operation The programming is divided into function codes Some of the codes are read only while the remaining codes may be user configured The value of the user configu rable codes can be assigned in accordance with user desired mode of operation A list of the
188. n the keypad The first value to be modified is the date in YYYY MM DD format The values will be entered from right to left Press the UP or DOWN ARROW key to increase or decrease the values The ENTER key will enter the infor mation for the current field and move to the next value the CODE SELECT key will allow modifi cation of the previous value Press the ENTER key on the keypad The next value to be modified is the time in HH MM format The values will be entered from right to left Press the UP or DOWN ARROW key to increase or decrease the values The ENTER key will enter the information for the current field and move to the next value the CODE SELECT key will allow modification of the previous value Press the ENTER key on the keypad The date and time will not be committed until start up pro cedures are completed on the next power up d Procedure for setting the container ID NOTE The characters will be preset to the con tainer ID already on the controller If none exist the default will be 0000000 1 Press the UP or DOWN arrow key until display reads Set ID 2 Press the ENTER key on the keypad 3 Values will be entered from right to left Press the UP or DOWN ARROW key to increase or decrease the values ENTER will enter the infor mation for the current field and move to the next value CODE SELECT will allow modification of the previous value 4 When the last value is entered press the EN
189. nd place the two small pieces of heat shrink tubing one over each wire before adding crimp fittings as shown in Figure 7 18 NOTE The P5 Pre Trip test must be run to deacti vate probe alarms refer to Section 5 8 7 25 362 Rev B 7 24 3 Sensors STS SRS Re Installation To properly position a unit supply sensor Supply Tem perature Sensor STS or Supply Recorder Sensor SRS the sensor must be fully inserted into the probe holder This positioning will give the sensor the optimum amount of exposure to the supply air stream and will allow the Controller to operate correctly Insufficient probe inser tion into the probe holder will result in poor temperature control due to the lack of air flow over the sensor It is also necessary to ensure that the probe tip does not contact the back panel The design minimum clear ance of 6 mm 1 4 inch should be maintained see Figure 7 19 Figure 7 19 Supply Sensor Positioning Sensor Wire Cap amp Grommet Assembly Evaporator Back Supply Sensor 7 24 4 Sensors RRS RTS Re Installation Reinstall the return sensor Return Temperature Sen sor RTS or Return Recorder Sensor RRS as shown in Figure 7 20 For proper placement of the return sen sor be sure to position the enlarged positioning section of the sensor against the side of the mounting clamp T 362 Rev B Figure 7 20 Return Sensor Positioning 7 24 5 The Defrost Temperature Sensor
190. nergize or de energize relay TCP as required see Figure 8 2 Relay TCP will switch its contacts energizing or de energizing relays PA and PB Relay PA is wired to energize the circuits on L1 L2 and L3 Relay PB is wired to energize the cir cuits on L3 L2 and L1 thus providing reverse rotation Start up Compressor Phase Sequence T 362 Rev B 4 3 2 At start up the controller logic will initiate a compressor bump start procedure to clear liquid refrigerant from the compressor suction and discharge pressures have equalized the compressor will perform three compres sor bump starts A compressor bump start may also occur after a defrost cycle has been completed During Bump Start the EEV will close Relays TS TQ TN TE and TV will be de energized opened The result of this action will close the ESV and shut all fans off The compressor will start for 1 second then pause for five seconds This sequence will be repeated two more times After the final bump start the unit will pre position the EEV to the correct starting position pause and start up Start up Compressor Bump Start 4 3 3 In Perishable Mode the controller maintains the supply air temperature at set point the SUPPLY indicator light is illuminated and the default reading on the display window is the supply temperature sensor reading Perishable Mode Temperature Control When the supply air temperature enters the in range temperature tolerance
191. ng on the selection of Cd46 Airflow display units Cd28 Metric Imperial or the pressing of the deg C F key Cd45 will display whenever the control detects movement via the sensor unless AL50 is active Cd45 will display for 30 seconds then time out and return to the normal display mode Cd46 Airflow Display Units Selects the airflow units to be displayed by Cd45 if configured for Vent Position Sensor or displayed by USER FLO under Cd43 if configured for Autoslide CFz Cubic Feet per Minute CM Cubic Meters per Hour bOth Displays CF or CM depending on the setting of Cd28 Metric Imperial or the press ing of the degree C F key Variable Economy adi Temperature Setting Used when Economy Mode CnF22 is set to 3 cust Display will show when the unit is not configured for Economy Mode When the unit has a perishable setpoint and Economy Mode is active at the start of each cooling or heating cycle high speed evaporator fans will run for 3 minutes After three minutes the evaporator fans will be switched to low speed any time that the supply tem perature is within 0 25 C of the setpoint and the return temperature is less than or equal to the supply temperature the user selected Cd47 values are 0 5 C 4 0 C de fault is 3 0 T 362 Rev B 4 26 Table 4 5 Controller Function Codes Code No TITLE DESCRIPTION Cd48 Dehumidification Bulb Cargo Mode Parameter Select
192. normal current draw Refer to Table 4 5 4 4 4 Generator Protection Compressor High Temperature Protection The controller continuously monitors compressor dis charge pressure and temperature and suction pres sure discharge pressure or temperature rises above the allowed limit or suction pressure falls below the allowed limit the compressor will be cycled off and on every 3 minutes Condenser and evaporator fans will continue to operate during the compressor off cycle T 362 Rev B If high compressor dome temperature occurs mea sured by the CPDS the controller will allow additional refrigerant to be released into the system in order to provide cooling to the evaporator coil and compressor dome The controller is alerted to high compressor dome temperatures via the CPDS when ambient tem perature is greater than 43 3 C return air temperature is less than 17 5 and the compressor discharge temperature is greater than 117 7 C Dome temperature control logic will disengage when return air temperature and ambient temperature return to allowed limits or when the compressor turns off 4 4 5 Compressor Low Pressure Protection If the suction pressure low limit is triggered the DUV will energize to raise the suction pressure 4 4 6 Perishable Mode System Pressure Regu lation In perishable mode system pressures may need to be regulated at ambient temperatures of 20 68 and below Once below thi
193. of the unit during routine defrost cycles However it is still highly recommended that after carry ing cargo subject to fumigation procedures that the inside of the unit be thoroughly cleansed prior to reuse Carrier Transicold has identified a fully biodegradable and environmentally safe alkaline cleaning agent Tri Pow r amp HD for the unit This will assist in helping to remove the corrosive fumigation chemicals and dis lodging of the corrosive elements This cleaner is available from the Carrier Transicold Performance Parts Group PPG and can be ordered through any of the PPG locations Part Number NU4371 88 As a general safety precaution before using this prod uct refer to and retain the Material Safety Data MSDS sheet This document can be found at www nucalgon com products coil cleaners trip ower htm Prior to Cleaning Always wear goggles gloves and work boots Avoid contact with skin and clothing and avoid breathing mists When mixing add water to the sprayer first then the cleaner ALWAYS provide for proper ventilation when cleaning indoor evaporator coils rear doors must be open Be aware of surroundings food plants etc and the potential for human exposure Always read directions and follow recommended dilution ratios More is not always better Using non diluted cleaner is not recommended Cleaning Procedure a Remove the upper evaporator access panel inside of th
194. ontinue to run until the valve opens Frontseat the liquid line service valve Place Start Stop switch in the OFF position when the suction reaches a positive pressure of 0 1 bar 1 4 psig Frontseat the suction and discharge service valves The refrigerant will be trapped between the compressor discharge service valves and the liquid line valve Before opening up any part of the system a slight positive pressure should be indicated on the pressure gauge Remove power from the unit before opening any part of the system If a vacuum is indicated emit refrigerant by cracking the liquid line valve momentarily to build up a slight positive pressure When opening up the refrigerant system certain parts may frost Allow the part to warm to ambi ent temperature before dismantling This avoids internal condensation which puts moisture in the system After repairs have been made be sure to per form a refrigerant leak check refer to Section 7 5 and evacuate and dehydrate the low side refer to Section 7 6 1 i Checkrefrigerant charge refer to Section 7 6 7 5 REFRIGERANT LEAK CHECKING EXPLOSION HAZARD Failure to follow this WARNING can result in death seri ous personal injury and or property damage Never use or gas mixtures containing oxygen 02 for leak testing or operating the product Charge only with R 134a Refrigerant 7 3 must conform to AHRI Standard 700 specification The recommended procedur
195. ontroller will fully close the eAut oFresh air vent Nine seconds after power up the con troller will check if there is a carbon dioxide CO3 sensor connected When a sensor is detected the controller will enable access to the Gas Limit mode of operation If no sensor is detected the only modes of operation available will be Test User and Delay The controller will then resume operation in the last mode of operation before power interruption 5 4 1 Pre trip testing of the eAutoFresh system is performed during Pre Trip test PO Operation of the system may be observed during this test eAutoFresh Pre Trip Inspection Upon initiation of Pre Trip PO the current state will be saved and the vent will fully close This will be followed by two sequences of opening to 10096 and returning to the closed position No other eAutoFresh mode of operation will be available until the two cycles of open ing and closing have completed Upon termination of the test the vent will open to the previous state and operation will return to the previous mode If the last mode was gASLM the vent will open to the preset FLO setting the controller will start taking new readings and control based on those readings 5 4 2 AutoFresh Start Up Procedure To start the system do the following a Press the CODE SELECT key see Figure 4 2 b Press the UP or DOWN arrow key until Cd43 is displayed then press ENTER T 362 Rev B
196. or dC3 5 USDA 1 2 3 Temperatures Current readings of the three USDA probes Network Data Points 1 8 Current values of the network data points as configured Data point dC6 13 1 Code 6 is generally the humidity sensor and its value is obtained from the controller once every minute dC14 Cargo Probe 4 Temperature Current reading of the cargo probe 4 dC15 19 Future Expansion These codes are for future expansion and are not in use atthis time Temperature Sensors 1 5 Current calibration offset values for each of the five probes supply dC20 24 Calibration return USDA 1 2 and 3 These values are entered via the in terrogation program dC25 Future Expansion This code is for future expansion and is not in use at this time S N Left 4 Right 4 The DataCORDER serial number consists of eight characters dC26 27 Function code dC26 contains the first four characters Function i code dC27 contains the last four characters This serial number is the same as the controller serial number dC28 Minimum Days Left An approximation of the number of logging days remaining until the DataCORDER starts to overwrite the existing data dC29 Days Stored Number of days of data that are currently stored in the DataCORD ER Date of Last Trip start The date when a Trip Start was initiated by the user In addition if the system goes without power for seven continuous days or longer dC30 a trip start will automatically be generated on the next AC power up Pres
197. orded b In Perishable Steady State A baseline Delta T is recorded following the first defrost cycle after steady state conditions are reached the unit is cooling and the evaporator fans and heaters must remain in a stable state for a period of five minutes Defrost will be initiated if Delta T increases to greater than 4 C above the base line and 90 minutes of compressor run time have been recorded c In Frozen Mode Defrost will be initiated if Delta T increases to greater than 16 C and 90 min utes of compressor run time have been recorded When defrost is initiated the controller closes the EEV opens contacts TC TN and TE or TV to de energize the compressor condenser fan and evaporator fans The controller then closes contacts TH to supply power to the heaters The orange DEFROST light and heat light are illuminated and the COOL light is also de energized Figure 4 10 Defrost ENERGIZED DE ENERGIZED 24 VOLT POWER The EEV and DUV are independently operated by the microprocessor Complete schematics and legends are located in Section 9 Defrost will terminate when the DTS reading rises above one of two model number configurable options selection either an upper setting of 25 6 C 78 F which is default or lower setting of 18 C 64 F When the DTS reading rises to the configured setting the de icing operation is
198. oth directions and fails to generate sufficient pressure differential Component N A Troubleshooting Corrective Action Controller will attempt restart every 20 minutes and deactivate the alarm if successful Resume normal operation Component Discharge Pressure Transducer DPT Troubleshooting Confirm accurate DPT pressure readings refer to MANIFOLD GAUGE SET Section 7 2 Corrective Action Replace DPT if defective Component Suction Pressure Transducer SPT Troubleshooting Confirm accurate SPT pressure readings refer to MANIFOLD GAUGE SET Section 7 2 Corrective Action Replace SPT if defective Component Monitor Unit Troubleshooting Alarm is display only the alarm may clear itself during operation Corrective Action If alarm remains active or is repetitive replace compressor at next avail able opportunity T 362 Rev B 4 34 AL18 DISCHARGE PRESSURE HIGH Cause Discharge pressure is over the maximum for 10 minutes within the last hour Component Restrictions in the refrigeration system Troubleshooting Ensure Liquid Line Service Valve is fully open Corrective Action Open Liquid Line Service Valve as needed Component Filter Drier Troubleshooting Check the filter drier if it is iced up or very cold it indicates that the filter drier needs replacement Corrective Action Repl
199. oting Confirm accurate DPT pressure readings refer to MANIFOLD GAUGE SET Section 7 2 Corrective Action Replace DPT if defective AL 66 SPT SUCTION PRESSURE TRANSDUCER EPT EVAPORATOR PRESSURE TRANSDUC ER Cause Suction Pressure Transducer SPT out of range Component Suction Pressure Transducer SPT Troubleshooting Corrective Action Confirm accurate EPT and SPT pressure readings refer to MANIFOLD GAUGE SET Section 7 2 Performing a Pre trip 5 9 test will also check the transducers Replace EPT SPT if defective Troubleshooting Monitor Corrective Action If the alarm persists it may indicate a failing compressor refer to COM PRESSOR Service Section 7 8 AL67 HUMIDITY SENSOR Cause Humidity Sensor HS reading out of range Component Humidity Sensor HS Troubleshooting Corrective Action Make sure the humidity sensor is properly connected in the socket Make sure the humidity sensor wires have not been damaged Monitor replace HS if alarm persists AL69 EVAPORATOR TEMP SENSOR ETS1 Cause Evaporator Temperature Sensor ETS1 out of range Component Evaporator Temperature Sensor ETS1 Troubleshooting Test the ETS1 refer to Sensor Checkout Procedure Section 7 13 2 Corrective Action Replace Evaporator Temperature Sensor ETS1 if defective AL70 SE
200. out 1 in CnF52 Oil Return Algorithm 0 out 1 in CnF53 Water Cool Oil Return Logic 0 out 1 in CnF55 TXV Boost Relay 0 out 1 in CnF56 TXV Boost Circuit 0 out 1 in CnF57 PWM Compressor Control 0 out 1 in CnF59 Electronic Evaporator Expansion Valve 0 1 EC 2 KE 3 NA CnF61 ACT ASC Control Enable 0 out 1 in CnF62 Extended Temperature Control Enable 0 1 in CnF63 CCPC Pre trip Tripstart Default State 0 1 off CnF64 Enable Fan Pulsing Logic 0 1 out CnF66 High Speed Evaporator Fan Option O off 1 on CnF67 Air Heaters 0 out 1 in CnF68 Enable Default Pulsing Temperature 0 out 1 in Note Configuration numbers not listed are not used in this application These items may appear when loading configuration software to the controller but changes will not be recognized by the controller programming 4 21 T 362 Rev B 4 10 CONTROLLER FUNCTION CODES Table 4 5 Controller Function Codes Code No TITLE DESCRIPTION Note If the function is not applicable the display will read NOTICE Display Only Functions Cd01 through Cd26 are display only functions Display Only Functions Digital Unloader Displays the DUV percent closed The right display reads 100 when the valve is fully Cd01 Valve Closed closed The valve will usually be at 10 on start up of the unit except in very high ambient temperatures The current sensor measures current draw in lines L1 amp L
201. ove power plug s before turning OFF start stop switch ST unit circuit breaker s and external power source Make sure the power plugs are clean and dry before connecting to power recepta cle Make sure that the unit circuit breaker s CB 1 amp CB 2 and the START STOP switch ST are in the O OFF position before connecting to any electrical power source Make sure power to the unit is OFF and power plug disconnected before replac ing the compressor Before disassembly of the compressor be sure to relieve the internal pressure very carefully by slightly loosening the couplings to break the seal Do not use a nitrogen cylinder without a pressure regulator Do not open the condenser fan grille before turning power OFF and discon necting power plug Oakite No 32 is an acid Be sure that the acid is slowly added to the water DO T 362 Rev B NOT PUTWATERINTOTHEACID this will cause spattering and excessive heat Wear rubber gloves and wash the solu tion from the skin immediately if acciden tal contact occurs Do not allow the solution to splash onto concrete Always turn OFF the unit circuit breakers CB 1 amp CB 2 and disconnect main power supply before working on moving parts Installation requires wiring to the main unit circuit breaker CB1 Make sure the power to the unit is off and power plug disconnected before beginning installa tion Charge water cooled condenser or receiver a
202. p HEATER ASSEMBLY 7 10 7 13 1 Evaporator Coil Replacement 7 10 7 13 2 Evaporator Heater Replacement 7 11 7 14 EVAPORATOR FAN AND MOTOR ASSEMBLY 7 11 7 14 1 Replacing the Evaporator Fan Assembly 7 12 7 14 2 Disassemble the Evaporator Fan Assembly 7 12 7 14 3 Assemble the Evaporator Fan Assembly 7 12 7 15 EVAPORATOR SECTION CLEANING 7 12 7 16 ELECTRONIC EXPANSION VALVE 7 13 7 16 1 Replacing Electronic Expansion Valve and Strainer 7 13 7 17 ECONOMIZER SOLENOID VALVE 7 14 7 18 ECONOMIZER EXPANSION VALVE 7 14 7 18 1 Economizer Expansion Replacement 7 15 7 19 TROUBLESHOOTING P6 7 DUV 7 15 7 20 DIGITAL UNLOADER VALVE 7 16 7 21 VALVE OVERRIDE CONTROLS 7 17 7 22 AUTOTRANSFORMER 7 18 1 29 CONTROLLERS
203. pressor pump down sequence At the conclusion of compressor pump down sequence the compressor will shut down and the valve test will start P6 5 Compressor Leak Test Passes if suction pressure increases a minimum of 4 psia when the P6 6 Economizer Valve Test valve opens for 15 seconds Passes if pressure and current changes are within 3 seconds of DUV P6 7 Digital Unloader Valve Test switch signal and either the pressure change or the current draw change is above 5 psi or above 1 5A respectively If equipped Test passes if change of suction pressure is greater than BME ECON AVE TAR 4 psia when the valve opens for 10 seconds Otherwise it fails The test records the suction pressure during the open valve position and passes if the suction pressure increase is above 3 psi when the valve opens for 10 seconds NOTE P7 0 amp P8 are included with Auto 2 amp Auto 3 only P9 0 through P10 are included with Auto2 only Electronic Expansion Valve Test P7 Tests High Pressure Tests Unit is run at full capacity without condenser fan running to make sure that the HPS opens and closes properly Test is skipped if sensed ambient temperature is less than 7 2 C 45 F return air temperature is less than 17 8 C 0 F or the water pressure Switch is open With the unit running the condenser fan is turned off and a 900 second 15 minute timer is started The right display shows
204. que the screw to 25 in Ibs Connect coil wires using butt splices and heat shrink tubing 7 18 ECONOMIZER EXPANSION VALVE The economizer expansion valve is an automatic 7 14 device that maintains constant superheat of the refrig erant gas leaving at the point of bulb attachment regardless of suction pressure Unless the valve is defective it seldom requires tenance other than periodic inspection to ensure that the thermal bulb is tightly secured to the suction line and wrapped with insulating compound 7 18 1 Economizer Expansion Replacement Figure 7 12 Economizer Expansion Valve Inlet Outlet a Removing the Economizer Expansion Valve NOTE The economizer expansion valve is a her metic valve it does not have adjustable superheat See Figure 7 12 1 Pump down the compressor refer to Section 7 4 and frontseat both suction and discharge valves Evacuate if unit is not equipped with ser vice valves Refer to Section 7 6 1 2 Turn unit power off and remove power from the unit 3 Remove cushion clamps located on the inlet and outlet lines 4 Remove insulation Presstite from expansion valve bulb 5 Unstrap the bulb line located on the economizer 6 VALVE REMOVAL The preferred method of removing the valve is to cut the connection between the brazed section and the valve using a small tube cutter Remove valve Alternately use a wet rag to keep valve cool Heat inl
205. r Shortage of refrigerant Section 7 3 Evaporator coil covered with ice Section 6 6 Evaporator coil plugged with debris Section 7 13 Evaporator fan s rotating backwards Section 7 13 Section 7 14 Air bypass around evaporator coil Check Controller set too low Reset Refrigeration system Compressor service valves or liquid line shutoff valve partially closed Open valves completely Dirty condenser Section 7 10 2 Compressor worn Section 7 8 Current limit function code Cd32 set to wrong value Section 4 4 3 Economizer solenoid valve malfunction Section 7 21 Digital unloader valve stuck open Replace Electronic expansion valve Replace 6 1 T 362 Rev B Table 6 1 TROUBLESHOOTING Refrigeration system CONDITION POSSIBLE CAUSE REMEDY REFERENCE SECTION 6 3 UNIT RUNS BUT HAS INSUFFICIENT COOLING Abnormal pressures Section 6 7 Abnormal temperatures Section 6 15 Abnormal currents Section 6 16 Controller malfunction Section 6 9 Evaporator fan or motor defective Section 7 14 Compressor service valves or liquid line shutoff valve partially closed Open valves completely Frost on coil Section 6 10 Digital unloader valve stuck open Replace Electronic expansion valve Replace 6 4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING Start Stop switch OFF or defective Check No operation of any kind Circuit breaker OFF or defective Check External power
206. r washers 1 Refit the side support bracket bolts 2 Refit the top support bracket bolts as well as the top grille extension support 3 Refit the bottom support bracket bolts Braze the condenser coil inlet connection Insert the receiver pipe work onto the coil outlet and loosely secure the receiver assembly to the side support bracket with the retained hardware Braze the outlet connection to the receiver assembly Install a new filter drier Replace the liquid line cushion clamps h Secure the receiver assembly to the side sup port bracket Pressure leak test the coil and filter drier con nections refer to Section 7 5 Evacuate the entire unit refer to Section 7 6 Slide the top and bottom drain lines back into place through the side support bracket Using the two supplied straight connectors and contact adhesive reconnect the drain lines Slide the condenser fan motor wiring harness back through the side support bracket and refit to condenser motor Replace all wire ties that were removed to prop erly secure the drain line and wiring o Reseal the wire harness and drain line penetra tions with the putty p Slide the condenser fan onto the motor shaft reversed but do not secure q Refit the condenser fan shroud to the unit Use the condenser fan as a guide to ensure the shroud is properly centered around the fan Remove the condenser fan and place it on the shaft facing the co
207. r 1 4 20 clamp bolts to 0 81 mkg 70 inch pounds Connect the wiring connector f Replace access the panel making sure that the panel does not leak Make sure that the TIR locking device is lockwired 7 15 EVAPORATOR SECTION CLEANING Containers and Container units that are exposed to certain fumigants may develop visible surface corro sion This corrosion will show up as a white powder found on the inside of the container and on the reefer unit evaporator stator and fan deck Analyses by Carrier Transicold environmental special ists have identified the white powder as consisting pre dominantly of aluminum oxide Aluminum oxide is a coarse crystalline deposit most likely the result of sur face corrosion on the aluminum parts within the con tainer If left untreated over time it may build up in thickness and eventually flake as a light weight white powder 7 12 The surface corrosion of aluminum is brought about by exposure to chemicals such as sulfur dioxide and pos sibly other fumigants that are commonly used for fumi gation and protection of some perishable cargo such as grapes for example Fumigation is the process by which a chemical is released into an enclosed area to eliminate infestations of insects termites rodents weeds and soil born disease Typically any aluminum oxide that becomes detached from evaporator fan stators will be blown into the wet evaporator coil where it will be caught and then flushed out
208. r mod ules Breaking the seal will void the warranty The Micro Link 3 controller is shown in Figure 4 4 It is fitted with test points harness connectors and a soft ware card programming port 4 2 CONTROLLER SOFTWARE The controller software is a custom designed program that is subdivided into configuration software and oper ational software The controller software performs the following functions a Control supply or return air temperature to required limits provide modulated refrigeration operation economized operation unloaded operation electric heat control and defrost Defrost is performed to clear buildup of frost and ice to ensure proper air flow across the evapora tor coil Provide default independent readouts of set point and supply or return air temperatures Provide ability to read and if applicable modify the configuration software variables operating software Function Codes and Alarm Code indi cations Provide a Pre trip step by step checkout of refrigeration unit performance including proper component operation electronic and refrigera tion control operation heater operation probe calibration pressure limiting and current limiting settings Provide battery powered ability to access or change selected codes and set point without AC power connected Provide the ability to reprogram the software through the use of a memory card 4 2 1 Configuration Software CnF Variables Configuratio
209. ramming Port 2 Mounting Screw 3 Controller 4 Test Points 7 23 3 Controller Programming Procedure The unit must be OFF whenever a pro gramming card is inserted or removed from the controller programming port 1 Turn unit OFF via start stop switch ST 2 Insert software programming PCMCIA card con taining the following example files into the pro gramming software port See Figure 7 16 menuDDMM ml3 this file allows the user to select a file program to upload into the control ler cfYYMMDD ml3 multi configuration file T 362 Rev B 3 Turn unit ON via start stop switch ST Programming Procedure for Software Versions 5354 and Greater amp With Updated Menu Option menu0115 ml NOTE Units must be loaded with software version 5354 or higher See the label in the control box door for factory installed software ver sion The updated menu option allows the operational soft ware to be loaded and time and container identification to be set a Procedure for loading Operational Software 1 10 11 12 13 The display module will display the message SetUP Press the UP or DOWN arrow key until the dis play reads LOAd 53XX for Scroll Press the ENTER key on the keypad The display will alternate to between PrESS EntR and rEV XXXX Press the ENTER key on the keypad The display will show the message Pro SoFt This message will last for up to one minute The display modu
210. ration Software CnF Variables 4 3 4 2 2 Operational Software Cd Function Codes 4 4 4 3 MODES OF OPERATION 0 4 4 4 3 4 Start up Compressor Phase Sequence 4 4 4 3 2 Start up Compressor Bump Start 4 4 4 3 3 Perishable Mode Temperature Control 4 4 43 4 Perishable PulldoWwn 2 2 s e 4 4 4 3 5 Perishable Steady State sisse ga a RR bee 4 4 4 3 6 Perishable Idle Air Circulation 4 5 4 3 7 Perishable Heating 4 5 4 3 8 Perishable Dehumidification 4 5 4 3 9 Perishable Dehumidification Bulb Mode 4 6 4 3 10 Perishable ECONOMY 2 xn iR LIRE A DEEE URE 4 6 4 3 11 Perishable Mode Cooling Sequence of Operation 4 6 4 3 12 Perishable Mode Heating Sequence of Operation 4 7 4 3 13 Perishable Mode Heat 4 7 4 3 14 Frozen Mode Temperature Control 4 8 43
211. re Gauge Discharge Pressure Gauge Discharge Pressure Valve shown frontseated High Side Connection Utility Connection to a Refrigerant cylinder b Vacuum Pump c Oil Container Low Side Connection og 7 1 When the Suction Pressure Valve 1 is frontseated turned all the way in the suction low pressure can be checked at the Suction Pressure Gauge 2 When the Discharge Pressure Valve 4 is frontseated the discharge high pressure can be checked at the Discharge Pressure Gauge 3 When both valves are backseated all the way out high pressure vapor will flow into the low side When the Suction Pressure Valve 1 is open and the Discharge Pressure Valve 4 shut the system can be charged through the Utility Connection 6 Oil can also be added to the system A R 134a manifold gauge hose set with self sealing hoses see Figure 7 2 is required for service of the models covered within this manual The manifold gauge hose set is available from Carrier Transicold Carrier Transicold part number 07 00294 00 which includes items 1 through 6 Figure 7 2 If the manifold gauge hose set is new or was exposed to the atmosphere it will need to be evacuated to remove contaminants and air as follows 1 Backseat turn counterclockwise both field ser vice couplings see Figure 7 2 and midseat both hand valves Connect the yellow hose to a vacuum pump and refrigerant 134a cylinder Evacuate to 10 inch
212. re installed In the test mode the setpoint will be temporarily set to 196 allowing the test of dehumidification After 5minutes the normal setpoint is restored If unit is configured for HUMIDIFICATIONMODE then selection of a setpoint greater than 75 will activate humidification and a setpoint less than or equal to 75 will activate dehumidification If the unit is configured for dehumidification only then the entire setpoint range will apply to dehumidification If Pretrip is initiated this value will be set to OFF automatically Replaced by Cd48 interface if CnF50 Enhanced Bulb Mode Interface is active Cd34 Economy Mode On Off The current state of the economy mode option On or CnF22 determines whether economy mode offered Economy mode is a user selectable mode of operation provided for power saving purposes Cd35 Bulb Mode The current state of the bulb mode option nOr or bULb Replaced by Cd48 if CnF50 Enhanced Bulb Mode is active Bulb mode is an extension of dehumidification control Cd33 If dehumidification CnF04 is set to Off Cd35 will display Nor and the user will be unable to change it CnF28 de termines whether the bulb mode selection is offered After a dehumidification set point has been selected and entered for code Cd33 the user may then change Cd35 to bulb After Bulb Mode has been selected and entered the user may then utilize function codes Cd36 an
213. refrigerants you must comply with all local government environmental laws In the U S A refer to EPA Section 608 Connect the gauge manifold to the compressor discharge and suction service valves For units operating on a water cooled condenser change over to air cooled operation Bring the container temperature to approxi mately 0 32 F or below Then set the con troller set point to 25 C 13 F Partially block the condenser coil inlet air If cov ering the lower portion of the coil is not suffi cient remove the left hand infill panel and cover the left side of the coil Increase the area blocked until the compressor discharge pres sure is raised to approximately 12 8 bar 185 psig On units equipped with a receiver the level should be between the glasses On units equipped with a watercooled condenser the level should be at the center of the glass If the refrigerant level is not correct continue with the following paragraphs to add or remove refriger ant as required Adding Refrigerant to System Full Charge Evacuate unit and leave in deep vacuum Refer to Section 7 6 1 7 5 7 8 Place cylinder of R 134a on scale and connect charging line from cylinder to liquid line valve Purge charging line at liquid line valve and then note weight of cylinder and refrigerant Open liquid valve on cylinder Open liquid line valve half way and allow liquid refrigerant to flow into the unit until the co
214. ressing of the deg C F key CFM is displayed as CF CMH is dis played as CM is the time delay prior to the door opening The time range is from 1 to 72 hrs in 1 hr increments CO2LM is the maximum level of CO that is allowed for the cargo The range is from 0 to 19 in 196 incre ments the default setting is 10 O2LM is the minimum level of Os that is allowed for the cargo The range is from 296 to 20 in 1 increments the default setting is 10 Rtn is an offset value used to expand the return air temperature value to compensate for the fresh air entering the container The allowable range is from 0 6 C to 2 8 C or 1 0 F to 5 0 F in 0 1 increments the default setting is 2 8 C 5 F 5 5 CONNECT REMOTE MONITORING RECEPTA CLE If remote monitoring is required connect the remote monitor plug at the unit receptacle see Figure 3 5 When the remote monitor plug is connected to the remote monitoring receptacle the following remote cir cuits are energized CIRCUIT Sockets B toA Sockets C toA Sockets D toA FUNCTION Energizes remote cool light Energizes remote defrost light Energizes remote in range light 5 6 STARTING AND STOPPING INSTRUCTIONS Make sure that the unit circuit breaker s CB 1 amp CB 2 and the START STOP switch ST are in the OFF position before connecting to any electrical power source NOTE The electronic phase detection system will ch
215. rost 4 9 4 10 Defrost Temperature Sensor 4 10 defrost temperature sensor 4 11 Defrost Timer 4 11 Dehumidification 2 1 DESCRIPTION 3 1 DIGITAL UNLOADER VALVE 7 16 Display Module 4 2 E eAutoFresh 2 2 7 27 eAutoFresh Modes of Operation 5 4 eAutoFresh OPERATION 5 3 eAutoFresh Pre Trip Inspection 5 3 Economized Operation 3 9 ECONOMIZER EXPANSION VALVE 7 14 ECONOMIZER SOLENOID VALVE 7 14 Electrical Data 3 7 ELECTRONIC EXPANSION VALVE 7 13 Electronic Expansion Valve 3 9 Emergency Bypass 2 2 EMERGENCY BYPASS OPERATION option 5 7 ETS1 7 26 ETS2 7 26 EVACUATION AND DEHYDRATION 7 3 Evaporator 2 1 EVAPORATOR COIL 7 10 Evaporator Coil Replacement 7 10 EVAPORATOR FAN 7 11 Evaporator Fan Assembly 7 12 Evaporator Fan Operation 2 1 4 11 Evaporator Heater Replacement 7 11 Evaporator Section 3 2 EVAPORATOR SECTION CLEANING 7 12 F Failure Action 4 11 FILTER DRIER 7 10 First Aid 1 1 Fresh Air Make Up 2 2 Fresh Air Makeup Vent 3 1 T 362 Rev B Front Section 3 1 Frozen Heat Mode 4 8 Frozen Economy Mode 4 8 Frozen Idle Mode 4 8 Frozen Mode Temperature Control 4 8 Frozen Mode Cooling Sequence of Operation 4 9 Frozen Steady State 4 8 G GENERAL DESCRIPTION 3 1 Gutters 2 2 H Handles 2 2 Handling Modules 7 19 HEATER ASSEMBLY 7 10 INSPECTION 5 1 Interrogator 2 1 INTRODUCTION 2 1 K Keypad 4 2 L Labels 2 2 Lower Air 2 2
216. rrect direction Adjust the fan to the correct position 37mm 1 5 from the fan shroud see Figure 7 7 Figure 7 7 Condenser Fan Position 37mm 1 5 gt Shroud S Use Loctite H on the fan set screws and tighten t Refitleft and right infill panels u Refit the condenser fan grille ensuring the grille is properly centered around the condenser fan v Evacuate the entire unit refer to Section 7 6 w Recharge the unit with the charge shown on the unit serial plate refer to Section 7 7 It is import ant for proper unit operation that the charge is weighed into the unit 7 11 CONDENSER FAN AND FAN MOTOR The condenser fan rotates counter clockwise viewed from front of unit The fan pulls air through the con denser coil and discharges the air horizontally through the front of the unit 7 9 T 362 Rev B 7 11 1 362 Rev Condenser Fan Motor Remove Replace Do not remove the condenser fan grille before turning power OFF and discon necting the power plug Remove the condenser fan grille retain all bolts and washers for reuse Remove the condenser fan by loosening the two Set screws Disconnect the condenser fan motor wiring Take necessary steps place plywood over coil or use sling on motor to pre vent motor from falling into condenser coil Note the number of shims on each side of the motor as the same configuration will be required to refit the new motor Remove
217. rrect weight of refrigerant refer to Section 3 2 has been added as indi cated by scales NOTE It may be necessary to finish charging unit through suction service valve in gas form due to pressure rise in high side of the sys tem Backseat manual liquid line valve to close off gauge port Close liquid valve on cylinder Start unit in cooling mode Run for approxi mately 10 minutes and check the refrigerant charge Adding Refrigerant to System Partial Charge Examine refrigerant system for any evidence of leaks repair as necessary Refer to Section 7 5 Maintain the conditions outlined in Section 7 7 1 Fully backseat the suction service valve and remove the service port cap Connect charging line between suction service valve port and cylinder of refrigerant R 134a Open VAPOR valve Partially frontseat turn clockwise the suction service valve and slowly add charge until the refrigerant appears at the proper level Be care ful not to frontseat the suction valve fully if the compressor is operated in a vacuum internal damage may result COMPRESSOR Make sure power to the unit is OFF and power plug disconnected before replac ing the compressor Before disassembly of the compressor be sure to relieve the internal pressure very carefully by slightly loosening the couplings to break the seal 362 Rev B 7 8 1 0 The scroll compressor achieves low suc tion pressure very quickly Do no
218. s Bulb mode is active when Cd35 is set to Bulb Once bulb mode is activated the user may then change dehumidification evaporator fan operation from the default speed alternates from low to high each hour to constant low or constant high speed This is done by toggling Cd36 from its default of alt to Lo or as desired If low speed evaporator fan operation is selected this gives the user the additional capability of selecting dehumidification set points from 50 to 9596 In addition if bulb mode is active Cd37 may be set to override the previous defrost termination thermostat DTT settings The temperature at which the DTT will be considered open may be changed in 0 1 C 0 2 F increments to any value between 25 6 C 78 F and 4 C 39 2 F The temperature at which the is considered closed for interval timer start or demand T 362 Rev B defrost is 10 C 50 F for open values from 25 6 C 78 F down toa10 C 50 F setting For open values lower than 10 C the closed values will decrease to the same value as the open setting Bulb mode is ter minated when 1 Bulb mode code Cd35 is set to Nor 2 Dehumidification code Cd33 is set to Off 3 The user changes the set point to one that is in the frozen range When bulb mode is disabled by any of the above condi tions evaporator fan operation for dehumidification reverts to alt and the DTS termination se
219. s 0 5 C 0 9 F below set point the system enters the heating mode See Figure 4 5 The controller closes contacts TH see Figure 4 7 to allow power flow through the heat termination thermo stat HTT to energize the heaters HR The orange HEAT light is also illuminated The evap orator fans continue to run to circulate air throughout the container b When the supply air temperature rises to 0 2 C 0 4 F below set point contact TH opens to de energize the heaters The orange HEAT light is also de energized The evaporator fans con tinue to run to circulate air throughout the con tainer c The safety heater termination thermostat HTT is attached to an evaporator coil circuit and will open the heating circuit if overheating occurs Figure 4 7 Perishable Mode Heating ENERGIZED DE ENERGIZED NOTE The EEV and DUV are independently oper ated by the microprocessor For full dia grams and legend see Section 8 4 3 13 Perishable Mode Trim Heat If the system capacity has been decreased to the low est allowable capacity and conditions exist that warrant maximum temperature stability the controller will pulse the HR relay to energize the evaporator heaters in sequence with the compressor digital signal 4 7 T 362 Rev B 4 3 14 In Frozen Mode the controller maintains the return air temperature at set point the yellow RETURN indicator ligh
220. s ambient temperature the con denser fan may cycle on and off based on limits imposed for discharge pressure For extremely cold ambient temperatures 18 C 0 F heater cycling may occur within normal system operation based on dis charge pressure limits 4 4 7 Condenser Fan Override When CnF17 Discharge Temperature Sensor is set to In and CnF48 Condenser Fan Switch Override is set to the condenser fan switch override logic is activated If condenser cooling water pressure is suffi cient to open the water pressure switch de energizing the condenser fan when water flow or pressure condi tions are not maintaining discharge temperature the logic will energize the condenser fan as follows 1 Ifthe DUV is less than 80 open when the troller calls for it to be100 open the condenser fan is energized When the DUV is 100 open the fan will de energize 2 If DPT reading is invalid or out of range AL65 the condenser fan is energized and will remain energized until system power is cycled 3 If the system is running on condenser fan over ride and the high pressure switch opens the condenser fan is energized and will remain energized until the system power is cycled 45 QUEST CCPC Compressor Cycle Perishable Cooling CCPC is a method of temperature control used during steady state perishable cooling that cycles the compressor on and off according to return air temperature To be eligible
221. s and hold ENTER key for five seconds to initiate a Trip Start Battery Test Results Shows the current status of the optional battery pack dC31 PASS Battery pack is fully charged FAIL Battery pack voltage is low dC32 Time Hour Minute Current time on the real time clock RTC in the DataCORDER dC33 Date Month Day Current date month and day on the RTC in the DataCORDER dC34 Date Year Current year on the RTC in the DataCORDER dC35 Cargo Probe 4 Calibration Current calibration value for the Cargo Probe This value is an input via the interrogation program 4 51 T 362 Rev B Table 4 8 DataCORDER Pre trip Result Records Test No TITLE DATA 1 0 Heater On Pass Fail Skip Result Change in current for Phase A B and C 1 1 Heater Off Pass Fail Skip Result Change in currents for Phase A B and C Condenser Fan On Pass Fail Skip Result Water pressure switch WPS Open Closed Change in currents for Phase A B and C Condenser Fan Off Pass Fail Skip Result Change in currents for Phase A B and C Low Speed Evaporator Fan On Pass Fail Skip Result Change in currents for Phase A B and C Low Speed Evaporator Fan Off Pass Fail Skip Result Change in currents for Phase A B and C High Speed Evaporator Fan On Pass Fail Skip Result Change in currents for Phase A B and C High Speed Evaporator Fan Off Supply Return Probe Test Pass Fail Skip Result Change in currents for Phase A B
222. s in heat 10 1 Frozen Mode Pulldown Test Pass Fail Skip Result STS time to pull down unit to 17 8 C 0 F 10 2 Frozen Mode Maintain Test Pass Fail Skip Result Averaged DataCORDER return temperature RRS over last recording interval T 362 Rev B 4 52 Table 4 9 DataCORDER Alarm Indications To Access Press ALT MODE key then ALARM LIST key Code No TITLE DESCRIPTION Recorder Supply Temperature The supply recorder sensor reading is outside of the range of 50 C Out of Range to 70 58 F to 158 or the probe check logic has determined 70 there is a fault with this sensor NOTE The P5 Pre trip test must be run to inactivate the alarm Recorder Return Temperature The return recorder sensor reading is outside of the range of 50 C Out of Range to 70 C 58 F to 158 F or the probe check logic has determined dAL71 there is a fault with this sensor NOTE The P5 Pre trip test must be run to inactivate the alarm dAL72 74 USDA Temperatures 1 2 3 The USDA probe temperature reading is outside of 50 C to 70 C Out of Range 58 F to 158 F range Cargo Probe 4 Out of Range The cargo probe temperature reading is outside of 50 C to 70 C dAL75 o 58 F to 158 F range dAL76 77 Future Expansion These alarms are for future expansion and are not in use atthis time Network Data Point 1 8 Out of The network data point is outside of its specified range The Da
223. s shown in Figure 7 24 Connect the positive lead of the voltmeter to test connector socket C and negative lead to socket B and run as before by resetting unit Repeat for sockets D and B Figure 7 24 Jumper Assembly Drive Module Connector SD There should be approximately five volts DC on sock ets C and 51 andS2 when measured as above If not the connections or controller is faulty If any of 7 28 these pins are not consistent the connections or the controller is suspect Check and replace as required 7 26 4 Servicing the eAutoFresh Drive System To replace the Drive Motor Assembly a Remove the bolts that secure the eAutoFresh Panel 3 Figure 7 25 to the front of the unit Reach in cut tie wrap 2 and disconnect the motor connector 1 Bring panel to work area Remove four screws 8 fastening the grille 7 Remove six screws 9 fastening the rails 5 and 11 the slide plate 10 and the gasket plate 6 Set components aside for reassembly Remove the four screws 12 fastening the motor cup 4 to the panel Cut sealer on outside and inside of motor cup assembly Push out the motor cup assembly from the rear of the panel Mount the replacement motor cup assembly in the panel using original screws Torque screws to 0 29 mkg 25 1 Inch pounds 7 29 Reapply sealer to the inside and the outside of the motor cup assembly Mount the upper amp lower rails slide p
224. sed and removes water from the pass ing air Removing water from the air reduces the rela tive humidity When the relative humidity sensed is 296 below set point the controller de energizes the heat relay The controller will continue to cycle heating to maintain relative humidity below the selected set point If dehumidification is terminated by a condition other than the humidity sensor e g an out of range or com pressor shutdown condition the heat relay is de ener gized immediately Two timers are activated during dehumidification to prevent rapid cycling and consequent contactor wear 1 Heater debounce timer three minutes The heater debounce timer is started whenever the heater contactor status is changed The heat contactor remains energized or de energized for at least three minutes even if the set point criteria are satisfied 2 Out of range timer five minutes The out of range timer is started to maintain heater opera tion during a temporary out of range condition If supply air temperature remains outside of the user selected in range setting for more than five minutes the heaters will be de energized to allow the system to recover The out of range timer starts as soon as temperature exceeds in range tolerance value set by Cd30 4 3 9 Perishable Dehumidification Bulb Mode Bulb mode is an extension of dehumidification which allows changes to the evaporator fan speed and or defrost termination set point
225. sed over and no alarm will be necessary If the best return probe is greater than 1 2 C 2 2 F difference with respect to its supply probes then the best return probe is also invalidated If the unit is in perishable mode a probe alarm will be triggered for both return probes 5 10 EMERGENCY BYPASS OPERATION OPTION Emergency Bypass operation is used to override the con troller in the case of a controller malfunction to keep the unit cooling When Emergency Bypass is installed and turned on the unit will remain in a continuous state of full cool until the Emergency Bypass switch is turned off To place the unit in the Emergency Bypass Operation a Locate the connection diagram and connectors for the emergency bypass EB sensors behind the top left side of the compressor Disconnect the emergency bypass connector from the controller connector and attach it to the emer gency bypass module connector See Figure 5 3 Locate the wire tire located at the EB switch in the control box Cut the wire tie then place the EB switch in the On position Place the Mode Switch MS in the Full Cool position to enable the system for cooling Manually control container air temperature by cycling the Mode switch between Full Cool and evaporator Fans Only To operate the fans only the MODE switch must be in the FANS ONLY position and the EMERGENCY BYPASS switch must be in the Bypass position The EBS module uses the system s sa
226. sor The vent position will display for 30 seconds whenever motion corresponding to 5 CMH 3 CFM or greater is detected It will scroll in intervals of 5 CMH 3 CFM Scrolling toCd45 will display the Fresh Air Vent Position The position of the vent will be recorded in the Data CORDER whenever the unit is running under AC power and any of the following Trip start On every power cycle Midnight Manual changes greater than 5 CMH 3 CFM remaining in the new position for at least four minutes NOTE The user has four minutes to make necessary adjustments to the vent setting This time cal culation begins on the initial movement of the sensor The vent can be moved to any posi tion within the four minutes On completion of the first four minutes the vent is required to remain stable for the next four minutes If vent position changes are detected during the four minute stability period AL50 will be gen erated This provides the user with the ability to change the vent setting without generating multiple events in the DataCORDER 5 4 EAUTOFRESH OPERATION The eAutoFresh system allows the opening and clos ing of the mechanical air vent slide The opening and closing of the slide is determined by the mode selected through Cd43 The modes of operation are OFF USER TEST DELAY and GASLIMIT Each mode of operation has submenus with selectable parameters Not all parameters are available in each submenu Upon power up the c
227. ss other wise indicated the receptacle is mounted at the control box location 2 4 6 Quest CCPC Compressor Cycle Perishable Cooling CCPC is a method of temperature control used during steady state perishable cooling that cycles the compressor on and off according to supply return air temperature conditions 2 4 7 The unit may be fitted with a communications interface module The communications interface module is a slave module which allows communication with a mas ter central monitoring station The module will respond to communication and return information over the main power line Refer to the ship master system technical manual for further information 2 4 8 An autotransformer may be provided to allow operation on 190 230 3 phase 50 60 Hz power The autotrans former raises the supply voltage to the nominal 380 460 volt power required by the base unit The auto transformer may also be fitted with an individual circuit breaker for the 230 volt power If the unit is equipped with an autotransformer and communications module the autotransformer will be fitted with a transformer bridge unit TBU to assist in communications 2 4 9 Rain gutters may be fitted over the control box and recorder section to divert rain away from the controls 2 4 10 The unit may be equipped with handles to facilitate access to stacked containers These fixed handles are located on either side of the unit 2 4 11 The uni
228. t connection to valve body and remove valve Figure 7 14 View of Digital Unloader Valve DUV Assembly 2 4 Sleeve O ring hidden Screen Valve Strainer Tube Solenoid Valve Body Hex Nut 1 2 OD T Examine compressor and service valves Ensure that the o ring is not stuck in the gland of the valve Discard the o ring on the o ring face seal con nection Installing the DUV Lubricate the gland shoulder area and o ring with refrigerant oil Fit new valve in position and hand tighten the o ring nut Use a wet rag to keep valve cool while brazing Braze DUV to service valve connection 4 Reinstall and tighten the brackets that secure the valve body to the discharge line 5 Torque o ring face seal connections to 18 to 20 ft Ibs 6 Install the coil onto the valve body and tighten the attachment bolt NOTE Confirm that the small spacer tube is inserted into the coil prior to attaching it to the valve body The valve will not function correctly without it T Leak check and evacuate low side of unit as applicable Refer to Section 7 6 1 8 Open service valves 7 21 VALVE OVERRIDE CONTROLS Controller function code Cd41 is a configurable code that allows timed operation of the automatic valves for troubleshooting Test sequences are provided in Table 7 1 Capacity mode CAP allows alignment of the economizer solenoid valve in the standard and econo mized operating configurations DUV C
229. t is illuminated and the default reading on the display window is the return temperature sensor RTS reading When the return air temperature enters the in range temperature tolerance Cd30 the green light will energize When CnF26 Heat Lockout Temperature is set to 10 frozen mode is active with set points below 10 14 F When CnF26 is set to 5 C frozen mode is active with set points below 5 C 23 F When the system is in Frozen Mode the highest prior ity is given to bringing the container down to set point the system will remain in economized operation Frozen Mode Temperature Control 4 3 15 Frozen cargos are not sensitive to minor temperature changes and the frozen temperature control system takes advantage of this to greatly improve the energy efficiency of the unit Frozen range temperature control is accomplished by cycling the compressor on and off as the load demand requires Once the frozen set point is reached the unit will tran sition to frozen steady state economized operation Frozen Steady State 4 3 16 When temperature drops to set point minus 0 2 0 4 F and the compressor has run for at least five min utes the unit will transition to the frozen idle mode The compressor is turned off and the evaporator fans con tinue to run to circulate air throughout the container If temperature rises above set point 0 2 0 4 F the unit will transition back
230. t may be fitted with ports in the front of the frame for insertion of a thermometer to measure supply and or return air temperature If fitted the port s will require a cap and chain 2 4 12 The refrigeration system may be provisioned for a water cooled condenser 2 4 13 Aluminum back panels may have access doors and or hinge mounting 2 4 14 460 Volt Cable Various power cable and plug designs are available for the main 460 volt supply The plug options tailor the cables to each customer s requirements Remote Monitoring Communications Interface Module Autotransformer Gutters Handles Thermometer Port Water Cooling Back Panels 362 Rev B 2 4 15 230 Volt Cable Units equipped with an autotransformer require an additional power cable for connection to the 230 volt Source Various power cable and plug designs are available The plug options tailor the cables to each customer s requirements 2 4 16 Cable Restraint Various designs are available for storage of the power cables These options are variations of the compressor section cable guard Upper Air Fresh Air Make Up The unit may be fitted with an upper fresh air makeup assembly The fresh air makeup assembly is available with a vent positioning sensor VPS and may also be fitted with screens 2 4 18 Lower Air Fresh Air Make Up The unit may be fitted with a lower fresh air makeup assembly The fresh air makeup assembly is available w
231. t use the compressor to evacuate the system below 0 psig Never operate the compres sor with the suction or discharge service valves closed frontseated Internal dam age will result from operating the com pressor in a deep vacuum Removal and Replacement of Compressor Turn the unit ON and run it in full cool mode for 10 minutes NOTE If the compressor is not operational front seat the suction and discharge service valves and go to step e below Frontseat the manual liquid line valve and allow the unit to pull down to 0 1 kg cm2 1 psig Turn the unit start stop switch ST and unit cir cuit breaker CB 1 OFF and disconnect power to the unit Frontseat the discharge and suction service valves Remove all remaining refrigerant from the com pressor using a refrigerant recovery system Remove the compressor terminal cover discon nect the ground wire and pull the cable plug from the compressor terminals Install the termi nal cover back after removing the power cable NOTE Inspect the power cable plug terminals to ensure they are not deformed or have any signs of heat or arcing If any damage is noted replace the power cable Remove the Rotalock fittings from the suction and discharge service connections and uncou ple the unloader and economizer lines from the compressor Cut the dome temperature sensor CPDS wires The replacement compressor comes with a CPDS already assembled Remove
232. ta Range CORDER is configured by default to record the supply and return re corder sensors The DataCORDER may be configured to record up dAL78 85 to eight additional network data points An alarm number AL78 to AL85 is assigned to each configured point When an alarm occurs the DataCORDER must be interrogated to identify the data point as signed When a humidity sensor is installed it is usually assigned to AL78 RTC Battery Low The real time clock RTC backup battery is too low to adequately maintain the RTC reading A real time clock failure is critical to the operation of the unit If this alarm occurs replace the RTC battery at the next available opportu dAL86 nity After replacing the battery the following actions are required Update the RTC setting Update the unit s software configuration Update the operational software Update all user selectable function code settings defrost setpoint etc RTC Failure An invalid time has been detected Either the DataCORDER run time hour and minute have not changed at the start of the hour or the real dAL87 time clock RTC time has gained or lost more than 2 minutes in the hour This situation may be corrected by cycling the power setting the clock or meeting the above criteria for an hour dAL88 DataCORDER EEPROM write of critical DataCORDER information to the EEPROM has ure failed Flash Memory Error An error has been detected in the process of writing daily data to the
233. ted inside the terminal box of the compressor using the self tap ping grounding screw Close the compressor terminal box using the terminal cover removed in step t u Backseat all service valves connect the power to the unit and run it for at least 20 minutes v Perform a leak check of the system 7 7 7 9 HIGH PRESSURE SWITCH 7 9 1 gt Checking High Pressure Switch Do not use a nitrogen cylinder without a pressure regulator NOTE The high pressure switch is non adjustable a Remove switch as outlined in Figure 7 9 2 Connect ohmmeter or continuity light across Switch terminals Ohm meter will indicate no resistance or continuity light will be illuminated if the switch closed after relieving compressor pressure Connect hose to a cylinder of dry nitrogen See Figure 7 6 Figure 7 6 High Pressure Switch Testing Cylinder Valve and Gauge Pressure Regulator Nitrogen Cylinder Pressure Gauge 0 to 36 kg cm2 0 to 400 psig Bleed Off Valve 1 4 inch Connection d Set nitrogen pressure regulator at 26 4 kg cm 375 psig with bleed off valve closed Close valve on cylinder and open bleed off valve Open oylinder valve Slowly close bleed off valve to increase pressure on switch The switch should open at a static pressure up to 25 kg cm 350 psig If a light is used the light will go out If an ohmmeter is used the meter will indicate open circuit Slowly open bleed off
234. ter Drier 2 Condenser Fan 9 Economizer 3 Condenser Coil Cover 10 Economizer Solenoid Valve ESV 4 Condenser Coil 11 Economizer Expansion Valve 5 Condenser Fan Motor 12 Warning Label location 6 Receiver 13 Service Access Valve 7 Sight Glass 14 Liquid Level Moisture Indicator T 362 Rev B 3 4 3 1 6 The control box Figure 3 5 includes the manual operation switches circuit breaker CB 1 compressor fan and heater contactors control power transformer fuses key pad display module current sensor module controller module and the communications interface module Control Box Section 3 1 7 The communications interface module is a slave mod ule which allows communication between the refrigera tion unit and a ship system master central monitoring station The module will respond to communication and return information over the ships main power line Refer to the master system technical manual for further information Communications Interface Module Figure 3 5 Control Box Section 2 3 4 1 rs ln Ps ar 415 n i MIS MIN 12 lt gt 14 f Compressor Contactor CH Compressor Phase A Contactor PA Compressor Ph
235. terminated 4 3 22 Defrost Related Settings DTS Failure When the return air temperature falls to 7 C 45 F the controller ensures that the defrost temperature sensor DTS reading has dropped to 10 or below If it has not it indicates a failed DTS a DTS failure alarm is trig gered and the defrost mode is operated by the return temperature sensor RTS Defrost will terminate after 1 hour If the DTS fails to reach is termination setting the defrost terminate after 2 hours of operation Defrost Timer If CnF23 is configured to SAv save then the value of the defrost interval timer will be saved at power down and restored at power up This option prevents short power interruptions from resetting an almost expired defrost interval and possibly delaying a needed defrost cycle If the save option is not selected the defrost timer will re initiate and begin recounting If CnF11 is model number configured to OFF the oper ator will be allowed to choose OFF as a defrost inter val option If CnF64 is configured in the operator will be allowed to choose PuLS as a defrost interval option For units operating with PuLS selected defrost interval is determined by the unit temperature set point and the Evap Fan Pulsing Temp setting on the Trip Settings screen When the unit temperature set point is equal to or less than the Evaporator Fan Pulsing Temperature Setting the defrost interval is set to 6 hours Other wise
236. th the compressor and it should be changed at the earliest opportunity 7 20 a 1 T 362 Rev B DIGITAL UNLOADER VALVE Removing the DUV Pump down the compressor refer to Section 7 4 and frontseat both suction and discharge valves In the event the DUV is stuck open and compressor cannot pump down remove charge The scroll compressor achieves low suc tion pressure very quickly Do not use the compressor to evacuate the system below 0 psig Never operate the compres sor with the suction or discharge service valves closed frontseated Internal dam age will result from operating the com pressor in a deep vacuum Turn unit power off and remove power from the unit Loosen bolt on top of the DUV and remove coil assembly There is small spacer tube between the top of the valve and the 12 VDC coil that needs to be reinstalled into the solenoid valve coil When removing the coil it may fall out when lifted from the valve body Take care that the spacer is not lost the valve will not function correctly without it Remove clamps holding the DUV to the dis charge line Loosen the nuts attaching the DUV to the top of the compressor VALVE REMOVAL The preferred method of removing the solenoid valve is to cut the con nection between the brazed section and the valve using a small tube cutter Remove valve See Figure 7 14 Alternately use a wet rag to keep valve cool Heat outle
237. the 0 95 to 1 05 Vdc range If the voltage is not within this range sen sor calibration fails Perishable Mode Maintain ds Temperature Test Test P8 1 must pass for P8 2 to execute A fifteen minute timer is started and the system will attempt to minimize control temperature error supply temperature minus setpoint until the timer expires The control temperature will be sampled each minute starting at the beginning of P8 2 During P8 2 the left display will read P8 2 and the right display will show the supply air temperature When the test is completed the average control temperature error will be compared to the pass fail criteria Test passes if the average temperature error is within 1 0 Test fails if the average temperature error is greater than 1 0 C or if the DataCORDER supply temperature probe is invalid If the test fails the control probe temperature will be recorded as 50 0 C P9 Test DTT Close and Open Test The DTT in this control is not a physical device with actual metal lic contacts it is a software function that acts similar to a thermostat Using various temperature inputs the DTT function determines whether a thermostat mounted on the Evaporator Coil would have OPEN or CLOSED contacts Primarily the DTT function operates based on the temperature reading from the Defrost Termination Sensor 4 49 T 362 Rev B Table 4 6 Controller Pre trip Test Codes P9 0 DTT
238. the top of compressor and install a 1 2 to 1 4 flared adapter Oring pn 40 50076 005 Figure 7 13 Adapter and O Ring 1 2 1 4 5 Using R134a or Nitrogen pressurize the line to 50 psi 3 5 bar at the adapter connection and close supply at the tank Pressure should hold as the valve is normally closed If pressure drops check for leaks at the installed fitting 40 50076 00sv repair and retest If pressure increases at the suction service valve and T 362 Rev B decreases at the pressure supply the valve is leaking and should be replaced If no leak pro ceed to step 6 Energize DUV by removing coil and placing a magnet on the valve stem opening the valve If the pressure does not increase at the SSV and decrease at the supply replace the valve as it did not open If a magnet is not available a jumper procedure can be used as follows 1 Remove all 4 controller fuses F1 F2 F3a F3b Remove the KA6 wire from KA controller con nector on the front of the controller Disconnect the X1 wire from the 24VAC side of transformer black wire and locate it away from the transformer Jumper between the black transformer wires to the KA6 wire removed from the connector Connect power to unit and turn circuit breaker on DUV coil is now energized Pressure should drop Power circuit breaker off reconnect wires and reinstall fuses If the valve opens and closes properly the failure mode is wi
239. the unit Attach three wires CB21 CIA3 CB22 CIA5 and CB23 CIA7 to the CIM at connection CIA Locate connectors CIA and CIB remove plugs if required and attach to the module Replace the low voltage shield Table 7 4 R 134a Temperature Pressure Chart Temperature F 40 40 14 6 35 37 12 3 30 34 9 7 25 32 6 7 20 29 3 5 18 28 2 1 16 27 0 6 Temperature F C psig 14 26 0 4 12 24 1 2 10 23 2 0 8 22 2 9 6 21 3 7 Vacuum cm hg kg cm bar 49 4 37 08 0 49 41 6 31 25 0 42 32 8 24 64 0 33 22 7 17 00 0 23 11 9 8 89 0 12 7 1 5 33 0 07 2 0 1 52 0 02 Pressure kPa kg cm bar 1 1 0 03 0 03 8 3 0 08 0 08 13 8 0 14 0 14 20 0 0 20 0 20 25 5 0 26 0 26 T 362 Rev B 362 Rev Table 7 4 R 134a Temperature Pressure Chart Temperature Vacuum 4 20 4 6 31 7 0 32 0 32 2 19 5 6 36 6 0 39 0 39 0 18 6 5 44 8 0 46 0 45 2 17 7 6 524 0 53 0 52 4 16 8 6 59 3 0 60 0 59 6 14 9 7 66 9 0 68 0 67 8 13 10 8 74 5 0 76 0 74 10 12 12 0 82 7 0 84 0 83 12 11 13 2 91 0 0 93 0 91 14 10 14 5 100 0 1 02 1 00 16 9 15 8 108 9 1 11 1 09 18 8 17 1 117 9 1 20 1 18 20 7 18 5 127 6 1 30 1 28 22 6 19 9 137 2 1 40 1 37 24 4 21 4 147 6 1 50 1 48 26 3 22 9 157 9 1 61 1 58 28 2 24 5 168 9 1 72 1 69 30 1 26 1 180 0 1 84 1 80 32 0 27 8 191 7 1 9
240. tments The first slot allows for a 0 to 25 air flow the second slot allows for a 25 to 10096 air flow To adjust the percentage of air flow loosen the hex nut and rotate the disc until the desired percentage of air flow matches with the arrow Tighten the hex nut To clear the gap between the slots loosen the hex nut until the disc clears the stop On some models the air slide is supplied with two adjustable air control discs The fresh air makeup can be adjusted for 15 35 50 or 75 cubic meters per hour CMH The air flow has been established at 60 Hz power and 2 1 2 inch T bar and with 15 mm 0 6 inch H20 external static above free blow Loosen the hex nut adjust each disc to the required air flow then tighten hex nut NOTE The main air slide is in the fully closed posi tion during reduced air flow operation when equipped with air control discs c Air Sampling for Carbon Dioxide CO3 Level Loosen hex nuts and move the cover until the arrow on the cover is aligned with the atmo sphere sampling port label Tighten the hex nuts and attach a 3 8 in hose to the sampling port If the internal atmosphere content has reached an unacceptable level the operator may adjust the disc opening to meet the required air flow volume to ventilate the container 5 3 3 The VPS allows the user to determine the position of the fresh air vent via Cd45 This function code is acces sible via the Code Select key Vent Position Sen
241. to the well with the leads parallel to the suction fitting 5 Reconnect the sensor see Figure 7 18 and run Pre trip P5 7 25 VENT POSITION SENSOR VPS The vent position sensor VPS determines the position of the fresh air vent in near real time via the Cd55 The fresh air vent position sensor alarm AL50 will occur if the sensor reading is not stable for four min utes or if the sensor is outside of its valid range shorted or open This can occur if the vent is loose or the panel is defective To confirm a defective panel assure that the wing nut is secure and then power cycle the unit If the alarm immediately reappears as active the panel should be replaced The alarm should immediately go inactive check the 4 minute stability requirement If the alarm reoccurs after the four minutes and the panel was known to have been stable then the sensor should be replaced Upper VPS In order to replace the Upper VPS the panel must be removed and replaced with another upper fresh air panel equipped with VPS Upon installation a new VPS assembly requires cali bration as follows 1 Rotate the vent to the 0 CMH CFM position 7 27 2 Cd45 will automatically display Press the Enter key and hold for five seconds 3 After the enter key has been pressed the display will read CAL for calibration 4 Press the ALT MODE key and hold for five sec onds 5 After the calibration has been completed Cd45 will disp
242. tor lights behave as described below P1 Tests Heaters Current Draw Heater is turned on then off Current draw must fall within specified range No other system components will change state during this test P1 0 Heaters Turned On Heater starts in the off condition current draw is measured and then the heater is turned on After 15 seconds the current draw is measured again The change in current draw is then recorded Test passes if the change in current draw test is in the range specified P1 1 Heaters Turned Off Heater starts in the off condition current draw is measured and then the heater is turned on After 15 seconds the current draw is measured again The change in current draw is then recorded Test passes if the change in current draw test is in the range specified P2 Tests Condenser Fan Current Draw Condenser fan is turned on then off Current draw must fall within specified range No other system components will change state during this test If the Water Pres sure Switch is open this test will be skipped P2 0 Condenser Fan On Condenser fan starts in the off condition current draw is measured and condenser fan is then turned on After 15 seconds the current draw is measured again The change in current draw is then recorded Test passes if change in current draw test is in the specified range P2 1 Condenser Fan Off Condenser fan is then turned off After 10 seconds the current draw
243. tting resets to the value determined by CnF41 4 3 10 Economy fan mode is an extension of the Perishable Mode and is provided for power saving purposes Economy fan mode is activated when Cd34 also used for Frozen Economy Mode is set to ON Economy fan mode is used in the transportation of temperature tolerant cargo or non respiration items which do not require high airflow for removing respiration heat Perishable Economy There is no active display that indicates that economy fan mode has been initiated To check for economy fan mode perform a manual display of Cd34 In order to initiate economy fan mode a perishable set point must be selected prior to activation When econ omy fan mode is active the evaporator fans will be controlled as follows At the start of each cooling or heating cycle the evaporator fans will run in high speed for three minutes They will then be switched to low speed any time the supply air temperature is within 0 2 C 0 36 F of the set point and the return air temperature is less than or equal to the supply air temperature 3 C 5 4 F The fans will continue to run in low speed for one hour At the end of the hour the evaporator fans will switch back to high speed and the cycle will be repeated If bulb mode is active economy fan mode will be overridden 4 3 11 Perishable Mode Cooling Sequence of Operation NOTE In Standard Perishable Mode the evapora tor motors run in
244. un for eight minutes with all other outputs de energized A temperature comparison is made between the return and supply probes Test passes if temperature comparison falls within the specified range NOTE If this test fails 5 0 and FAIL will be displayed If both Probe tests this test and the PRIMARY SECONDARY pass display will read P5 PASS P5 0 Supply Return Probe Test This test if for units equipped with secondary supply probe only The temperature difference between primary supply probe and second ary supply probe is compared Test passes if temperature comparison falls within the specified range P5 1 Supply Probe Test NOTE If this test fails 5 1 and FAIL will be displayed If both Probe tests this and the SUPPLY RETURN TEST pass because of the multiple tests the display will read P5 PASS For units equipped with secondary return probe only The temperature difference between return temperature sensor RTS and return temperature sensor RRS probe is compared Test passes if temperature comparison falls within the specified range NOTES P5 2 Return Probe Test 1 If this test fails P5 2 and FAIL will be displayed If both Probe tests this test and the SUPPLY RETURN pass because of the multiple tests the display will read 5 PASS 2 The results of Pre trip tests 5 0 5 1 and 5 2 will be used to activate or clear control probe alarms
245. ure 5 2 gives air exchange values for an empty container Higher values can be expected for a fully loaded con tainer Upper Fresh Air Makeup Vent T 362 Rev B 5 2 Figure 5 2 Upper Fresh Air Make Up Flow Chart AIR FLOW CMH 50HZ 250 TBAR 11 2 25 8 TBAR 3 10 20 30 40 50 60 70 80 90 100 PERCENT OPEN 0 AIR FLOW CMH 300 60HZ TBAR 250 11 2 d 4 7 TBAR 10 20 30 40 50 60 PERCENT OPEN 70 80 90 100 5 3 2 Lower Fresh Air Makeup Vent a Full Open or Closed Positions Maximum air flow is achieved by loosening the wing nuts and moving the cover to the maximum open posi tion 10096 position The closed position is 0 air flow position The operator may also adjust the opening to increase or decrease the air flow volume to meet the required air flow b Reduced Flow for Lower Fresh Air Makeup NOTE In order to prevent inaccurate display read ings on units equipped with a Vent Position Sensor VPS ensure that the rack and pin ion drive of the VPS is not disrupted when adjusting the air makeup vent Do not loosen the hex nut beyond its stop Doing so may cause inaccurate display readings and errors in DataCORDER reports Similar to the Upper Fresh Air Makeup vent two slots and a stop are designed into the Lower Fresh Air slide for air flow adjus
246. urn air temperature is greater than the set point plus the offset temperature rtn To set the unit in Delay mode scroll until DELAY appears in the left window press ENTER to activate the submenu The first selection is the amount of time tIM for the delay Select the amount of time for the delay by using the UP and DOWN arrow keys The range is from 1 to 72 hours in 1 hour increments Press the ENTER key to set the value and move to the FLO rate Use the UP or DOWN arrow key to scroll to the desired FLO rate The range is from 0 to 220CM 0 to 129CF in increments of 5 and 3 respectively Press the ENTER key to set the value and move to the return temperature offset Use the UP or DOWN arrow key to scroll to the desired rtn rate The range of offset is from 0 6 C to2 8 C 1 0 F to 2 8 F in 0 1 increments Press ENTER to set the value and begin operation e GAS LIMIT gASLM In GAS LIMIT mode access to the submenu is avail able provided a perishable set point has been selected and a valid reading is detected from the sensor Gas limit mode the microprocessor will monitor and limit the level of CO in the container by opening and closing the eAutoFresh vent The vent will open to the FLO setting once the unit has completed initial tem perature pull down or if the cargo temperature is within 5 C of set point and the level has reached the max limit or if the level has reached the lower limit
247. valve to decrease the pressure The switch should close at 18 kg cm 250 psig T 362 Rev B 7 9 2 Replacing High Pressure Switch Remove the refrigerant charge Disconnect wiring from defective switch The high pressure switch is located on the discharge connection or line and is removed by turning counterclockwise Install a new high pressure switch after verifying switch settings Evacuate dehydrate and recharge the system Start the unit verify refrigeration charge and oil level 7 10 CONDENSER COIL The condenser coil consists of a series of parallel cop per tubes expanded into copper fins and formed into a C shape with the fourth side of the square formed by the side support bracket 7 10 1 To ensure optimal efficiency of the unit the condenser coil must be clean The condenser coil should be cleaned at least once a year but more frequent clean ing may be required depending on operating condi tions The coil is cleaned with fresh water sprayed in the reverse direction of the air flow to remove any debris from the coil A high pressure washer is not required mains water pressure is sufficient To clean the condenser coil perform the following procedure Condenser Coil Cleaning Do not remove the condenser fan grille before turning power OFF and discon necting the power plug a Make sure the unit is powered off and the plug is disconnected b Remove the condenser fan grille c Starting from th
248. ve b Midseat both hand valves on the manifold gauge set and allow the pressure in the mani fold 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 c Backseat the low side service valve Backseat both field service couplings and frontseat both manifold hand valves Remove couplings from access valves d Install both service valve stem caps and service port caps finger tight only 7 4 PUMP DOWN THE UNIT To service the filter drier economizer expansion valves economizer solenoid valve digital unloader valve or evaporator coil pump the refrigerant into the high side as follows The scroll compressor achieves low suc tion pressure very quickly Do not use the compressor to evacuate the system below 0 psig Never operate the compres sor with the suction or discharge service valves closed frontseated Internal dam age will result from operating the com pressor in a deep vacuum Automatic Pump Down To perform an Automatic Pump Down using Cd59Pump Down Logic refer to Table 4 5 Controller Function Codes Manual Pump Down a Attach manifold gauge set to the compressor suction and discharge service valves Refer to Section 7 2 Start the unit and run in the frozen mode control ler set below 10 C 14 F for 10 to 15 minutes Check function code Cd21 refer to Section 4 2 2 The economizer solenoid valve should be open If not c
249. ve the cushion clamps securing the liquid line to the top and bottom receiver brackets retain all clamps and securing hardware Place a support under the condenser coil before releasing the coil from the frame Remove the lower mounting bracket bolts from the inside of the coil Remove the top mounting bracket bolts and grille extension mount from inside the coil p Remove the side support bracket mounting bolts q Slide the condenser assembly with receiver out of the unit 7 10 3 Condenser Coil Preparation Before installing the new condenser coil the receiver assembly and mounting hardware must be removed from the old coil assembly 7 10 4 From the old coil unbolt the receiver assembly from side support bracket Unbraze the receiver assembly from the coil outlet line and remove from the coil assembly Unbolt the side support bracket from the top and bottom coil supports and remove from old coil Refit the side support bracket to the new coil ensuring that the top and bottom are flush mounted with the coil support Condenser Coil Installation Once the side support bracket has been secured to the new condenser coil the entire assembly is ready to be installed into the unit a Slide the new condenser coil into place ensuring the coil inlet connection ismated to the pipework and that the coil is fully supported Secure the condenser coil into the unit using the retained hardware refit the mylar and fende
250. wall of the condenser section The plate provides the unit model number the unit serial number and the unit parts identification number PID The model number identifies the overall unit configura tion while the PID number provides information on specific optional equipment factory provisioned to allow for field installation of optional equipment and dif ferences in detailed parts 2 3 FEATURE DESCRIPTIONS 2 3 1 Units are equipped with an aluminum control box and may be fitted with a lockable door Control Box 2 3 2 The unit is fitted with suction and discharge refrigerant temperature sensors The sensor readings may be viewed on the controller display Temperature Readout 2 3 3 The unit is fitted with evaporator suction and dis charge pressure transducers The transducer readings may be viewed on the controller display Pressure Readout 2 3 4 The unit is fitted with a scroll compressor equipped with suction and discharge service connections Compressor 2 3 5 The unit is fitted with a two row square formed con denser coil using 7mm tubing Condenser Coil 2 3 6 The evaporator section is equipped with an electronic expansion valve EEV Evaporator 2 3 7 Units are equipped with three phase evaporator fan motors Opening of an evaporator fan internal protector will shut down the unit Evaporator Fan Operation 2 3 8 Plate Set Each unit is equipped with a tethered set of wiring s
251. where in the manual follows the general safety notices 1 2 FIRST AID An injury no matter how slight should never go unat tended Always obtain first aid or medical attention immediately 1 3 OPERATING PRECAUTIONS Always wear safety glasses Keep hands clothing and tools clear of the evaporator and condenser fans Wear appropriate personal protective equipment for the work being undertaken No work should be performed on the unit until all circuit breakers and start stop switches are turned off and power supply is disconnected In case of severe vibration or unusual noise stop the unit and investigate 1 4 MAINTENANCE PRECAUTIONS Beware of unannounced starting of the evaporator and condenser fans Do not open the condenser fan grille or evaporator access panels before turning power off disconnecting and securing the power plug Be sure power is turned off before working on motors controllers solenoid valves and electrical control switches Tag circuit breaker and power supply to pre vent accidental energizing of circuit 1 1 Do not bypass any electrical safety devices e g bridg ing 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 con tainer disconnect all wire harness connectors from the modules in control boxes Do not remove wire harness from
252. will be set to PuLS Cd28 Temperature Units Degrees C or Degrees F This code determines the temperature units C or F that will be used for all temperature displays The user selects C or F by selecting function code Cd28 and pushing the EN TER key The factory default value is Celsius units This function code will display if CnF34 is set to F Cd29 Failure Action Mode If all of the control sensors are out of range alarm code AL26 or there is a probe circuit calibration failure alarm code AL27 the unit will enter the shutdown state defined by this setting The user selects one of four possible actions as follows A Full Cooling Compressor is on economized operation b Partial Cooling Compressor is on standard operation C Evaporator Fan Only Evaporator fans on high speed not applicable with frozen set points d Full System Shutdown Factory Default Shut down every component in the unit 4 23 362 Rev B Table 4 5 Controller Function Codes Code TITLE No DESCRIPTION Cd30 In Range Tolerance The in range tolerance will determine the temperature band around the set point which will be designated as in range For normal temperature control control temperature is considered in range if it is within setpoint in range Tolerance There are four possible values 1 0 5 C 0 9 F 2 1 0 1 8 F 3 1 5 2 7 F 4 2 0
253. within 296 of the chart value would indi cate a good sensor If a sensor is defective the resistance reading will usually be much higher or lower than the resistance values given Table 7 2 Sensor Resistance r DTS ETS hial 5 SRS STS Ohms Ohms 9 760 2 697 8 862 2 188 8 057 62 2 Ohms 49 060 46 230 E 41 100 336 500 7 8 312 600 6 7 270 300 4 4 2 2 1 RS 9 37 8 36 7 35 6 34 4 33 3 32 2 a 1 36 600 32 650 5 6 234 200 203 400 2 2 177 000 34 4 27 8 154 300 26 100 7 E Eni 25 6 134 800 6 6 23 390 9 23 3 10 118 100 8 9 20 990 411 43 3 3 3 5 5 7 8 n 0 52 2 54 4 23 170 27 590 af a oa eel eres 1 2 390 2 297 7394 644 6 684 1 855 1537 4 665 EE 2275 205 5 923 7 215 am 2o SEIN 2 124 68 3 E 98 6 099 73 9 ms 5571 79 4 1281 106 85 0 110 90 6 6 1 3 603 107 2 225 sspe s 3313 2 8 sata be 130 2 042 5 095 185 1 072 4 874 6 103 600 18 870 4 97 070 17 900 2 91 030 16 980 0 85 400 16 120 3 049 2 926 2 4 75 270 166 70 720 177 em 2122 62500 200 sep psu 2 14 55330 222 elt 14 540 13 820 12 490 11 310 80 160 BH 15 310 7 23 T 362 Rev B Table 7 3 Sensor Resistance CPDS
254. y reads Set UP Press the ENTER key on the keypad Press the UP or DOWN arrow key until display reads XXXX the message ruN COnFG If a defective card is being used the display will blink the message bAd CArd Turn start stop switch OFF and remove the card Press the ENTER key on the keypad The display module will go blank briefly and then display 551 00 based on the operational soft ware installed Press the UP or DOWN ARROW key to scroll through the list to obtain the proper model dash number If a defective card is being used the display will blink the message bAd Turn start stop switch OFF and remove the card Press the ENTER key on the keypad When software loading has successfully com pleted the display will show themessage donE If a problem occurs while load ing the software the display will blink the mes sage Pro FAIL or bad 12V Turn start stop switch OFF and remove the card Turn unit OFF using start stop switch ST Remove the PCMCIA card from the program ming software port and return the unit to normal operation by placing the start stop switch in the ON position Confirm correct model configuration using the keypad to choose code 20 CD20 The model displayed should match the unit serial number plate c Procedure for setting the date and time 1 7 20 Press the UP or DOWN arrow key until display reads Set TIM Press the ENTER key o
255. y alpha characters only the numeric portion of the number will dis play Valve Override SERVICE FUNCTION This code is used for troubleshooting and allows manual posi tioning of the economizer solenoid valve electronic expansion valve and digital unloader valve Provides readings such as Percent Capacity EEV Capacity Mode LIV and DUV Refer to Section 7 21 for operating instructions Configurable Functions Cd43 is a user selectable function The operator can change the value of this function to meet the operational needs of the container Cd43 eAutoFresh Mode Cd43 is a user selectable mode of operation that allows the opening and closing of a me chanical air vent door via a stepper motor These selection modes are as follows OFF Air makeup vent will remain closed USER Allows for manual selection of the setting DELAY The opening of the door is based on selected time return temperature and flow rate percent opened gASLM The opening is based percent open and and selectable limits LM This selection is only active if the unit has a sensor TEST CAL sensor option units only The door will fully open and close to allow the user to inspect its operation If CAL is selected the controller will zero calibrate the CO sensor input If the unit is not configured with AutoFresh the Cd43 will display Refer to Section 5 4 3 for description of operational parameters
256. y be done using the Carrier Transicold Data Retrieval Program 1 Control mode Control temperature Frequency Humidity Phase A current Phase B current Phase C current Main voltage Evaporator expansion valve percentage 2 DWN 0 Discrete outputs Bit mapped require special handling if used 11 Discrete inputs Bit mapped require special handling if used 12 Ambient sensor 13 Evaporator temperature sensor 14 Compressor discharge sensor 15 Return temperature sensor RTS 16 Supply temperature sensor STS 17 Defrost temperature sensor 18 Discharge pressure transducer 19 Suction pressure transducer 20 Condenser pressure transducer 21 Vent position sensor VPS 4 8 4 Logging Interval dCF03 4 8 5 Thermistor Format dCF04 The user may select four different time intervals user may configure the format in which the therm between data recordings Data is logged at exact inter istor readings are recorded The short resolution is a 1 vals in accordance with the real time clock The clock is byte format and the long resolution is a 2 byte format factory set at Greenwich Mean Time GMT The short requires less memory and records tempera ture with variable resolutions depending on tempera ture range The long records temperature in 0 01 0 02 F steps for the entire range Table 4 2 DataCORDER Configuration Variables CONF

OPERATIONS AND SERVICE MANUAL 69NT40

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