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1. 4 11 4 7 3 Adding A Partial Charge 4 12 4 8 REPLACING THE COMPRESSOR 4 13 49 COMPRESSOR OIL LEVEN 4 13 4 9 1 Checking Oil Level ooooccooocccconnrnn ented 4 13 4 9 2 Adding Oil with Compressor in System unnn 4 13 4 9 3 Adding Oil to Service Replacement Compressor unn 4 14 4 10 COMPRESSOR UNLOADER VALVE sssssssssess es n eens 4 15 4 11 CHECKING AND REPLACING FILTER DRIER 000 000 ccc eee nn 4 15 4 12 CHECKING AND REPLACING HIGH PRESSURE SWITCH 4 15 4 12 1 Replacing High Pressure Switch 4 15 4 12 2 Checking High Pressure Switch 4 16 4 13 CHECKING CALIBRATION OF THE DEFROST AIR SWITCH 4 16 4 14 CHECKING AND REPLACING EVAPORATOR FAN MOTOR BRUSHES amp COMMUTATOR 4 17 4 15 EVAPORATOR COIL CLEANING sssssssee eee nmn 4 17 4 16 CONDENSER COIL CLEANING ete 4 17 4 17 SOFENCID VALVES x ii A an AA te 4 17 4 17 1 Supra 550 650 750 850 3 Way Valve 4 17 4 17 2 Hot Gas Valve HGS2 and 3 Way Valve for Supra 950 HGS2 not used on 950 4 18 4 18 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE CPR 4 18 4 19 THERMOSTATIC EXPANSION VALVE 000 cece e mn 4 19 4 20 MICROPROCESSOR CONTROLLER 000 cece
2. Do not turn on Do not turn on Do not turn on Do not turn on 4 23 62 10828 4 23 SUCTION PRESSURE TRANSDUCER Table 4 5 Sensor Resistance Micro Units Before installing a new suction pressure transducer it ATS CDT BAS SAS SWTS must be calibrated RAS SAS amp The calibration will not be performed if the run relay is WTS Resistance Resistance energized This prevents the operator from calibrating In Ohms i In Ohms the unit with the sensor in the system The reading of the sensor must be at atmospheric pressure 0 psig or 14 7 psi If the sensor reading is greater than 20 psig 34 7 117 800 1 178 000 psi or less than 6 7 psig 8 psi it can not be calibrated Oncethe micro is calibrated the display will readout the actual value S 62 400 624 000 a Turn power off and remove starter solenoid wire then let unit fail to start This will de energize run relay b Connect wiring to new suction pressure transducer 32 700 327 000 Before installing suction pressure transducer into unit display the suction pressure via the unit status display While the suction pressure is being displayed 19 900 199 000 press Enter Key forthree seconds the display should read 0 If display reads 0 install suction pressure transducer into unit i 11 900 119 000 10 000 100 000 73 000 62 10828 4 24 Table 4 6 R 404A Temperature Pressure Chart 4 25 62 10828 SECTION 5 TROUBLESHOOTING
3. ES wo Ki J 8 M 4 F 4 0 12 A em a des ch SP18 o 0 5 M 12 Q 4 J B M 4 ot Gm OL 95 6 1 Eds SEE NOTE 9 REISS SP19 1 3 0 3 L 2 L 10 EFMR1 NJ Jo a gt gt N IN a ul o SEE NOTE 9 crc noris HES TO 000000 SP11 AT B EN NJ CO O SP19 i NOTE 10 conf EFMR3 u GJ i X io re EHC Cn N SUPRA 950 ONLY un NAE GP SEE NOTE 5 1 08 HGS1 mg r T gt T0 DKF N emm emm a em em em em em em em CJ ER O 9 SP17 HGS2 NJ C KA gt TO SP15 pq Ces UFR SUPRA 5 6 7 850 ONLY NJ N TP10 N A oca la SG BI L SP11 SEE NOTE 8 C2 SEE NOTE 3 Ge CCR TP11 Ce em um eum eum eum o GP Se DDR TP12 SEE NOTE 10 NJ SYMBOL ALT ATS 8 BTY CC CCR CDT DA DER DDS DDR DK DPS DSR DS OT OTT EFM1 2 3 EFMR1 2 3 EHC EHR Fl F2 F11 F3 F7 F4 FS FS FB F9 F10 F12 FH FHR FHTH FP GP GPR HCR H651 2 HP1 HP2 HRI MP MC1 OL oP P1 P2 850 950 DESCRIPTION ALTERNATOR AMBIEN
4. f is a number corresponding to the number of the failed test ERROR CAUSE ERR 1 Processor failure ERR 2 Check chip installation or Replace ERR 3 microprocessor Display board to logic board com munication failure This can be caused by a defective ribbon cable or ribbon cable not plugged in properly ERR 4 or Display 2 4 OPERATION 2 4 1 Pre Trip Inspection a Pre Trip Inspection Before Starting Before starting engine check the following points 1 Drain water and sediment from fuel tank sump Then fill tank with diesel fuel 2 Drain water from fuel filter separator if applicable 3 Check radiator coolant level Antifreeze should be adjusted for climate conditions minimum 50 50 mix ture maximum 60 40 mixture 4 Check condenser radiator coil for cleanliness 5 Check air cleaner and hoses 6 Check Defrost Air Switch and hoses 7 Check engine oil level 8 Check condition and tension of all belts 9 Check all fan and idler bearings 10 Check door latches and hinges 11 Check condition of condenser fan blades 12 Check battery fluid level if applicable 13 Check battery cables and terminals 14 Check evaporator coil for cleanliness 15 Check evaporator fan 16 Check air chute if applicable 17 Check bulkhead and return air screens if applicable 18 Check defrost water drains 19 Check glow plugs b Pre Trip Inspection Starting Start the unit in continuous run Refer to Sections 2 4 2
5. Do not mix standard coolant antifreeze and extended life coolant antifreeze Verify coolant prior to adding any make up coolant antifreeze i 2 Clean radiator and condenser 13 Check refrigerant level Change fan motor brushes 2 Check and rebuild alternator 9 Check engine speed 550 850 High 2300 to 2350 Low 1800 to 1850 650 750 950 High 2200 2250 Low 1800 1850 Check all belt tension pulley bear i ings 2 Change antifreeze and flush cooling i system 13 Check bearings in clutch and electric i motors Clean and adjust fuel injectors Hefer to the engine manual for correct procedure and settings 4 8 62 10828 4 1 SERVICING ENGINE RELATED COMPONENTS 4 1 1 Cooling System The condenser and radiator can be cleaned atthe same time The radiator must be cleaned internally as well as externally to maintain adequate cooling See Figure 4 1 The condenser and radiator are incorporated into a single assembly The condenser fans draw the air through the condenser and radiator coil To provide maximum air flow the condenser fan belt should be checked periodically and adjusted if necessary to pre vent slippage Use only ethylene glycol anti freeze with inhibitors in system as glycol by itself will damage the cooling system Always add pre mixed 50 50 anti freeze and water to radiator engine Never exceed more than a 50 concentration of anti freeze
6. Q2 Truck Refrigeration OPERATION amp SERVICE for SUPRA 550 650 750 850 amp 950 Truck Refrigeration Units 62 10828 Rev D TRANSICOLD OPERATION AND SERVICE MANUAL FOR Supra 550 650 750 850 950 TRUCK REFRIGERATION UNITS TABLE OF CONTENTS PARAGRAPH NUMBER Page GENERAL SAFETY NOTICES unto IA KA KIA ae as Safety 1 FIRSTAID Safety 1 OPERATING PRECAUTIONS 00000 cece nh rmn Safety 1 MAINTENANCE PRECAUTIONS ii ia MS A A E A mne Safety 1 SPECIFIC WARNING AND CAUTION GIATEMENTG Safety 1 DESCRIPTION 1 1 T INTRODUCTION A a ES 1 1 1 2 GENERAL DESCRIPTION esis ete o pc rpm Reo xp an e e e etal ew denies 1 6 1 37 SGONDENSING SECTION ier EE d gea AER eds netted 1 6 123 1 Dive Equipment EE 1 6 1 3 2 Condensing Section Refrigeration System 1 7 1 4 EVAPORATOR SECTION sims sarria Ua 1 10 1 4 1 Thermal Expansion Valve 1 10 1 4 2 HeatiEXCHaNger sonic oia ad ND 1 10 1 4 3 Evaporator Cola e eU MPEG ME put beu E EM pie 1 10 1 4 4 Electric and Water Heat ec css RR Abe Aet tA UR Wastes ea 1 10 15 SYSTEM OPERATING CONTROLS ANDCOMPONENTS 1 11 1 5 1 Switches And Controls oii ia arn ie iae i aai pa nee ene eens 1 11 L UNIT SPECIFICATIONS cio rar bte nam Ye densa kWa 1 12 1 6 1 Enginie Dala IIIA AA DERI te elected ia meee cele ected 1 12 1 6 2
7. 2 8 Engine Compressor V Belts 4 9 Evacuation And Dehydration 4 10 Evaporator 1 10 Evaporator Coil Cleaning 4 17 Evaporator Fan Motors 1 15 F Fail Safe Defrost Termination 3 2 Filter Drier 1 10 Fuel Circuit 4 6 Fuel Filter 3 2 4 6 Fuel Heater Thermostat 1 12 Functional Parameters 2 6 Fuse Alarm 2 10 Fuse Identification 1 5 G Glow Plug 1 12 4 7 62 10828 INDEX H Heat And Defrost 1 9 1 17 Heat Exchanger 1 10 High Battery Voltage Alarm 2 10 High Coolant Temperature Alarm 2 10 High Pressure Alarm 2 10 High Pressure Cutout Switches 1 14 Horsepower 1 12 Hot Gas Bypass Solenoid Valve 1 9 Hour Meters 4 20 K Keypad 2 2 L Loaded Operation 1 8 Low Battery Voltage Alarm 2 10 Low Oil Pressure Alarm 2 10 Lubrication System 1 12 Maintenance Hour Meter 1 2 9 Maintenance Hour Meter 1 Alarm 2 11 Maintenance Hour Meter 2 2 9 Maintenance Hour Meter 2 Alarm 2 11 Manual Defrost Initiation 3 2 Manual Glow Override 2 7 Manual Start 2 4 Maximum Off Time 2 6 Microprocessor Components 2 2 Microprocessor Configuration 2 2 Microprocessor Controller 4 20 Microprocessor Controller 2 1 Minimum Off Time 2 6 Minimum On Time 2 6 Model Chart 1 1 Modes Of Operation 3 1 Index 2 N No Power for Standby Alarm 2 11 Null Mode Overrides 3 1 O Oil Pressure Switch 1 12 Operation 2 3 Out Of Range Alarm 2 11 Out Of Range Tolerance 2 7 P Pre Tri
8. 2 8 Suction Pressure Transducer 4 24 Superheat 4 19 Supply Air Sensor Alarm 2 10 Supply Air Temperature 2 8 Switch On Hour Meter 2 9 Switches And Controls 1 11 System Check Alarm 2 11 System Operating Controls And Components 1 11 62 10828 T Thermal Expansion Valve 1 10 4 19 Thermostatic Expansion Valve Superheat 1 14 Torque Values 1 15 62 10828 INDEX U Unit Data 2 7 Unloaded Operation 1 7 Unloading In Temperature Mode 3 3 W Water Pump Belt Tensioner 4 8 Weight 1 12 Index 4 TRANSICOLD VA North America Central America Carrier Transicold and Mexico 700 Olympic Drive Ejercito Nacional No 418 Athens GA 30601 USA Piso 9 Torre Yumal Tel 1 706 357 7223 Col Chapultepec Morales Fax 1 706 355 5435 11570 Mexico D F Tel 5255 9126 0300 Fax 5255 9126 0373 A member of the United Technologies Corporation family Stock symbol UTX 2008 Carrier Corporation e Printed in U S A 0608 Carrier A United Technologies Company Carrier Transicold Division Carrier Corporation Truck Trailer Products Group P O Box 4805 Syracuse N Y 13221 U S A www carrier transicold com
9. 3 Replace Valve Assembly 4 Install coil assembly voltage plate and cap 5 Leak check evacuate and dehydrate the unit 6 Install a complete refrigerant charge 7 Start unit and check operation 62 10828 4 17 2 Hot Gas Valve HGS2 and 3 Way Valve for Supra 950 HGS2 not used on 950 1 Snap cap 2 Voltage plate 3 Coil assembly 4 Enclosing tube 5 Plunger assembly 6 Valve body assembly Figure 4 18 HOT GAS VALVE HGS2 and Supra 950 3 Way Valve HGS2 Shown a Replacing solenoid coil 1 Remove coil snap cap voltage plate and coil assem bly Disconnect leads and remove coil junction box if necessary 2 Verify coil type voltage and frequency This informa tion appears on the coil voltage plate and the coil housing 3 Place new coil over enclosing tube and then install voltage plate and snap cap Do not damage or over tighten the enclos ing tube assembly Also make sure all parts are placed on the enclosing tube in proper sequence to avoid premature coil burnout 62 10828 4 18 b Replacing solenoid valve internal parts If the valve is to be replaced or the internal parts serviced the refrigerant charge must be removed 1 Remove and store the refrigerant charge in an evac uated container Refer to Section 4 4 2 Remove coil snap cap voltage cover and coil as sembly Remove the valve body head 3 Check for foreign material in valve body 4 Check for damaged plunger and o ring I
10. C 2 0 F 1 1 C 0 5 F 0 3 C Perishable setpoint 0 5 F gt 12C 0 3 C 1 4 F 0 8 C 2 7 F 1 5 C 3 6 F 2 C 3 6 F 2C 3 6 F 2 C 2 5 F 1 4 C 0 5 F 1 2 C 2 0 F 1 1 C Frozen setpoint gt 10 4 F 12 C SUPRA 950 STANDBY Heat 4 cyl Heat 6 cyl START Cool 6 cyl Figure 3 5 TEMPERATURE CONTROL SEQUENCE START STOP MODE 62 10828 SECTION 4 SERVICE Beware of V belts and belt driven components as the unit may start automatically Before servicing unit make sure the RUN STOP Switch is in the STOP position Also disconnect the negative battery cable Unit with R404A and POE oil the use of inert gas brazing procedures is mandatory otherwise compressor failure will occur For more information see Technical Procedure 98 50553 00 In ert Gas Brazing NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing re frigerant When working with refrigerants you must comply with all local government environmental laws U S A EPA section 608 MAINTENANCE SCHEDULE Supra 550 see Table 4 1 for description of required service FILTER TYPE REQUIRED SERVICE Petroleum Oil With Bypass Oil Filter 4 1 62 10828 MAINTENANCE SCHEDULE Supra 650 750 850 see Table 4 1 for description of required service etroleum OII Withou Bypass Oil Filter Petroleum Oil With Bypass Oil Filter ynthet
11. b Connect the refrigeration hose see Figure 4 8 to the access valve c Read system pressures d Repeat the procedure to connect the other side of the gauge set 4 3 3 Removing the Manifold Gauge Set 1 While the compressor is still ON backseat the high side service valve 2 Midseat both hand valves on the manifold gauge set and allow the pressure in the manifold gauge set to be drawn down to low side pressure This returns any liquid that may be in the high side hose to the system To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before disconnecting 3 Backseat the low side service valve Frontseat both manifold set hand valves Remove the refrigeration hoses from the access valves 4 Install both service valve stem caps finger tight only High Pressure Backseated Hand Valve Frontseated Hand Valve To Low Side To High Side 3 BLUE 3 RED 3 YELLOW 4 1 Manifold Gauge Set 2 Hose Fitting 3 Refrigeration and or Evacuation Hose 4 Hose Fitting w core depressor Figure 4 8 Manifold Gauge Set 62 10828 4 4 PUMPING THE UNIT DOWN OR REMOVING THE REFRIGERANT CHARGE NOTE To avoid damage to the earth s ozone layer use arefrigerant recovery system whenever remov ing refrigerant a Pumping the Unit Down To service the filter drier expansion valve CPR valve or evaporator coil pump most of refr
12. 1 3 Null Mode Overrides AA mh 3 1 3 1 4 Dual Probe Operation 3 2 3 1 5 Fuel Heater Operation 3 2 3 1 6 Defrost Mode eoe eene AE Duct akut esee ded pas RE eer 3 2 3 1 7 Suction Pressure Control Mode 3 2 3 1 8 Auto Diesel Restart Option unanenanannunnannn 3 3 39 2 SEQUENCE OF OPERATION wis fag eves opm eg Parker epe OD Pax eee DOE DP eR PUER 3 3 3 2 1 ENGINE DIV cara Se eee hec es Cac os EO nt Ba eee ina be ays DERE ER 3 3 3 2 2 3 4 3 2 3 Auto Start Sequence eet EE A peek ike 3 4 SERVICE 0 A dean os ete ka 4 1 MAINTENANCE SCHEDULE Supra 550 4 1 MAINTENANCE SCHEDULE Supra 650 750 850 4 2 MAINTENANCE SCHEDULE Supra op 4 2 OIEGHANGE INTERVALS steer nia die ieee EE EE ER Ce ERAS Un ac 4 2 4 1 SERVICING ENGINE RELATED COMPONENTS sssssses es nen 4 4 ATA Gooling System ioo ame hia Aa Diode 4 4 4 1 2 Changing Lube Oil and Lube Oil Filters 4 4 4 1 8 Replacing the Speed and Run Control Solenoids 4 5 4 1 4 Engine Air Cleaner coii UII E DRE eee ime wee balk aa ERE 4 5 4 1 5 Fuel Filter and Fuel Circuit ui AA KIA RII hn 4 6 4 1 6 Servicing Glow Plugs gt EE Me Aa E NEEN a Rae Th 4 7 41 6 CARO A KA BATA BATI MALE ERS Ee EG BA Re EUM DEVE 4 7
13. 1 C To startthe unit in manual start mode the unit must be in continuous run mode and the Auto Manual Start Opera tion function parameter set to MAN OP FN10 OFF NOTE When configuration CNF11 is ON and set point is 32 to 42 F 0to 5 5 C the unit is locked into continuous run The AUTO START STOP key is disabled NOTE Auto Start Stop operation may be tied to the setpoint ranges for frozen and perishable loads and the AUTO START STOP key may be locked out 2 4 8 Continuous Run Operation After start up observe the AUTO START STOP indica tor If it is illuminated the unit is in the Auto Start Stop mode If Continuous Run operation unit will operate continuously after starting is desired press the Auto obio key to change the operation to Continuous un In the Continuous Run mode the diesel engine will run continuously providing constant air flow and temperature control to the product Continuous Run operation is normally used for perishable loads Continuous operation may be tied to the setpoint ranges for frozen and perishable loads and the AUTO START STOP key may be locked out The unit will remain in low speed for 10 minutes after engine start up when the Continuous Run setpoint is below 10 F 12 C Enter Set Point and change Functional Parameters to match the requirements of the load 2 4 9 Defrost Cycle Defrost is an independent cycle overriding cooling and heating functions to de ice t
14. ATTEMPT 15 Seconds STOP MAXIMUM 10 Seconds Checked at 2 Seconds FIRST ATTEMPT kee VARIABLE 0 to 85 SECONDS GEM Figure 3 1 Auto Start Sequence The second and third start attempts have a glow time that is five seconds greater than the table amount If the Manual Glow Override Function Parameter is set to ADD GLOW the additional time will be added to the first attempt Actual time added to the second and third attempts will vary with ambient temperature After the glow time has expired the starter solenoid SS is energized to crank the engine The engine will crank for 10 seconds 20 seconds if engine coolant temperature is below 32 F 0 C or until engine opera tion is sensed by the microprocessor at alternator signal input at terminal L3 If the engine has not started a 15 second null cycle will elapse before subsequent start attempts The run relay will remain energized during the null cycle Before the next starting sequence the oil pressure and alternator auxiliary input is checked to insure that the en gine is not running For the second and third start attempts the glow time is increased by five seconds over the glow time of the first attempt The control allows three consecu tive start attempts before starting is locked out and the start failure alarm is activated If battery voltage drops below 10 volts at any point dur ing the Auto Start Sequence the sequence will be stopped and the start
15. F 0 3 C i j Perishable 12 19 STOP o setpoint DaF setpoint 0 5 F 510 49F 0 3 C 10 4F 12 C LS Heat 03 C ago 2 2 F 1 2 C 3 6 F 2 C 2 7 F 1 5 C HS Heat 36 2 C 3 6 F 2 C 3 6 F 2 C 0 5 F 1 2 C Frozen f setpoint 0 5 F 0 3 C ee gt 10 4 F 12 C Frozen setpoint gt 10 4 F 12 C SUPRA 550 650 750 850 Figure 3 3 TEMPERATURE CONTROL SEQUENCE START STOP MODE 3 9 62 10828 CONTINUOUS MODE DIESEL STANDBY HS Cool 6 cyl Col i 2 7 F 1 5 C all 0 55 1 220 0 5 F 0 3 C LS Cool 4 cyl Perishable Ce Perishable 0 5 F setpoint z setpoint 0 3 C gt 10 4 F 12 C 0 5 F gt 10 4 F 12 C LS Heat 4 cyl 0 3 C 1 4 F 0 8 C 2 5 F 1 4 C 2 2 F 1 2 C HS Heat 6 cyl 2 7 F 1 5 C 3 6 F 2 C Cool 6 cyl o o 1 4 F 0 8 C 2 5 F 1 4 C Eeer 05 1 2 C 999 2 0 F 1 1 C F Frozen roden setpoint setpoint lt 12 C gt 10 4 F 12 C Cool 4 cyl SUPRA 950 Figure 3 4 TEMPERATURE CONTROL SEQUENCE CONTINUOUS MODE 62 10828 DIESEL 2 7 F 1 5 C 0 5 F 0 3 C Perishable setpoint gt 10 4 F 12 C 2 2 F 1 2 C LS Heat 4 cyl HS Heat 6 cyl START 3 6 F 2 C 2 5 F 1 4 C LS Cool 0 5 F 0 3 C Frozen setpoint gt 10 4 F 12 C START STOP MODE 3 6 F 2 C 3 6 F 2 C 0 5 F 1 2
16. Measures return air to the evaporator SAS optional Measures supply air to the evapora tor and is also used in heat option kits as an overtem perature safety sensor 62 10828 1 6 UNIT SPECIFICATIONS 1 6 1 Engine Data Lubrication System Lube Oil Viscosity API Classification CD Outdoor Temperature gt Delvac 1 Below 32 Below 0 C 10W or 10W30 32 to 77 F 0 to 25 C 15W40 Over 77 F Over 25 C 30W or 15W40 Table 1 6 Engine Data For Supra 550 CT2 29TV Z482 29 2 in 479 cc 8 5 hp 6 3 kW 2400rpm Weight 117 lbs 53 Kg 4 0 quarts 3 8 liters Without EWHS 4 5 guarts 4 3 liters With EWHS Use 50 50 to 60 40 ethylene glycol water mix standard or Shell Dexcool extended life antifreeze i f 6 0 quarts 5 7 liters Without Bypass Oil Capacity 7 7 0 quarts 6 6 liters With Bypass Operating High 2300 2350 rpm Speeds 1800 to 1850 rpm Injection Setting 1991 to 2133 psig 135 to 145 Bars Oil Pressure Switch Closes at 18 3 psig 1 2 0 2 Bar 0 9 ohms at 11 volts Fuel Heater Thermostat Closes on temperature falls at 45 6 5 F 7 2 1 17 C Opens on temperature rise at 7522 6 5 F 24 1 17 C Coolant Capacity 62 10828 1 12 Table 1 7 Engine Data For Supra 650 750 850 43 9 in3 719 cc 15 5 hp 11 6 kW 2400rpm Weight 139 Ibs 63 kg 3 9 quarts 3 7 liters Without EWHS Coolant Capacity 4 5 quarts 4 3 liters With EWHS Use 50 50 to 60 40 et
17. Motor Contactor MC Fuel Heater Relay FHR Option Located in plug box on 950 Main Fuse F1 80 amp 10 Microprocessor Module Note See Figure 2 1 for Cab Command Figure 1 4 Electrical Box 10828 1 4 TP11 CCR Gi AOA NAE b Figure 1 5 Relay Fuse Board With All Optional Components Table 1 3 Fuse Identification lem Amps Man Fuse See Figure 1 1 80A RORFue 5A Run Relay Fuse 15A Feat Relay Fuso 3A Unloader Fuse 850 8 950 5A OA A 5A A A Defrost Damper Relay Fuse OA 0A OA A 5A Fuel Heater Fuse Option 8 5 1 3 5 1 5 Desig F7 I Option 950 Only SA 1 5 Table 1 4 Relay Identification Desig Starter Solenoid Relay Electric Fan Motor Relay Electric Fan Motor Relay Electric Fan Motor Relay DOR Defrost Damper Solenoid Relay Option sel Be 62 10828 Table 1 5 Test Point Identification Pi TP2 TPS TP4 TPS TP TP TP TPS 1 2 GENERAL DESCRIPTION T
18. Probe SUP Controlling Probe FN4 b PROBE Supply Air FN5 Degrees Temperature Unit ForC Cor F FN6 ON ME Maximum Off time 30 Min TEMP Temperature Based MOP STD Unloader control FN10 ON AUTO OP Auto Start Operation FN10 MAN OP Manual Start Operation OFF 1 T RANGE Out of Range Tolerance Code vs English Code or English display format Manual Glow Override Normal or Add 30sec Alarm RST Alarm Reset Required Alarm CLR No Alarm Active 62 10828 TABLE 2 2 UNIT DATA CODES Ge Ge CDA CDs CDs CD Ars oe ap 9 CD10 CDTI CDi2 CD13 CDi CDiS 6016 6017 6018 CD19 Codes 5 amp 6 are variable SAS is displayed when the SUP Probe Function is selected REM is dis played when the REM Probe Function is selected Suction Pressure The English display for Suction Pressure is SUCT the code display is CD1 The English units are designated by a P psig following the reading while the metric are designated by a B bars English readings below 0 are in inches of mercury The display range is 0 7 to 29 4 Bar 20 hg to 420 psig Engine Hours The English display for Engine Hours is ENG the code display is CD2 The data is displayed with units desig nator H i e ENG 5040H or CD2 5040H The display range is 0 to 99999 Engine Temperature The English display for Engine Temperature is WT the code display is CD3 The English units ar
19. SYSTEM LOCATION MID FRAME CONDENSER CONTROL BOX COMPRESSOR CONTROL BOX COMPRESSOR FRAME CONTROL BOX EVAPORATOR CONTROL BOX CONTROL BOX CONTROL BOX OPTION OPTION CONTROL BOX EVAPORATOR EVAPORATOR CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX ENGINE CONTROL BOX ENGINE FUEL TANK ENGINE CONTROL BOX FRAME FRAME COMPRESSOR COMPRESSOR CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX ENGINE CONTROL BOX CONTROL BOX EVAPORATOR ENGINE CONTROL BOX ENGINE CONTROL BOX EVAPORATOR FRAME ENGINE ENGINE CONTROL BOX COMPRESSOR CONTROL BOX STARTER STARTER CONTROL BOX CONTROL BOX CONTROL BOX COMPRESSOR ENGINE ole COMPONENT CONNECTION NUMBER OR LETTER SWITCH SYMBOL INDICATES MOMENTARY CONTACTS INDICATES A WIRE GROUND INDICATES A CHASSIS GROUND NO WIRE INDICATES STANDARD OPTIONS INDICATES A CONNECTION WIRE LUG ETC INSULATING PLUG INDICATES DIODE NI NJ n ts NJ mes O Eh N OUTPUT MODULE O A W D1 TO SP16 lt lt pH FHTH FHR ie o FUEL HEATER OPTION DOOR SWITCH OPTION TO 553 DS 289 NOTE 14 RELAY PRESENT WITH DOOR SWITCH OPTION ONLY ALTERNATOR WIRING SUPRA 650 amp 750 ONLY em emm e TO MPS2 SP15 9 L T0
20. Se 550 650 750 850 ONLY ACCUMULATOR Im VALVE mmm Discharge 3 Liquid AA mua Suction Inactive COMPRESSOR COOLING CYCLE FILTER DRIER HOT GAS BYPASS RECEIVER VALVE SOLENOID VALVE A HGS2 o Ha m DRAIN PAN HEATER 0 INLET CHECK VALVE i RECEIVER HEAT EXCHANGER SUBCOOLER COMPRESSOR PRESSURE DISCHARGE REGULATOR SERVICE VALVE CONDENSER METERING 850 ONLY ORIFICE SUCTION KI ACCUMULATOR SE 550 650 750 850 E s E Liquid COMPRESSOR ma Suction HEAT AND DEFROST CYCLE Inactive Figure 1 13 Refrigeration Circuit 62 10828 1 18 SECTION 2 OPERATION 2 1 MICROPROCESSOR CONTROLLER 2 1 1 Introduction 44 CAUTION Under no circumstances should anyone at tempt to repairthe Logic or Display Boards Should a problem develop with these com ponents contact your nearest Carrier Tran sicold dealer for replacement The Microprocessor System consists of the micropro cessor module Item 10 Figure 1 4 relay fuse board Item 7 Figure 1 4 Cab Command Figure 2 1 and in terconnecting wiring a The Microprocessor Module includes the tempera ture control software and necessary input out
21. Service 62 10299 Compressor 056 82 1053 Compressor 05G Twinport 62 02756 Compressor 05G Operation and Service 1 1 62 10828 o lt Le M os 35 F 6 E UNIT DATA SETPOINT BOX TEMPERATURE LJ FUNCTION AUTO START STOP O o KE n PRETRIP 1 4 DI Ed El C3 Ca EA CITY MAN ROAD SPEED DEFROST BUZZER OFF STANDBY CAB COMMAND 1 Muffler 9 Compressor Pressure Regulating Valve CPR 2 Thermal Expansion Valve Location 10 Accumulator 3 Engine Refer toTable 1 1 11 Filter Drier 4 Heat Exchanger Location 12 Receiver 5 Compressor 13 Hot Gas Bypass Solenoid HGS2 6 Alternator 14 Hot Gas Valve Three Way HGS1 7 Electric Standby Motor 15 Condenser 8 Defrost Air Switch 16 Radiator Overflow Reservoir Figure 1 1 Condensing Section Top View Cab Command 62 10828 1 2 1 Fuel Filter 4 Oil Filter 2 Model Serial Number Plate 5 Air Cleaner 3 Speed and Run Solenoids Figure 1 2 Unit Curbside View 1 Receiver Sight Glasses 5 Standby Board 2 Electrical Box See Figure 1 4 6 Manual Glow Crank Switch MGC If Equipped 3 Evaporator 7 RUN STOP Switch RSS 4 Relay Fuse Board Figure 1 3 Unit Roadside View 1 3 62 10828 OO Po 62 Manual RUN STOP Switch 7 Relay Fuse Board See Table 1 9 8 Manual Glow Crank Switch If Equipped Figure 1 5 Warning Buzzer 8 Motor Overload Relay MOL Summer Winter Switch EWHS Only 9 Standby
22. atau seb 5 4 5 39 62 Heating zie uA e RAT T ret A e A Re RA 5 5 5 3 7 Abnormal NoISG c reb Rp a bem EE 5 5 5 3 8 Control System Malfunction 5 5 5 3 9 No Evaporator Air Flow or Restricted Air Flow 5 5 5 3 10 Expansion Valve Malfunction ananena 5 6 5 3 11 Hot Gas Three Way Valve Malfunction 5 6 5 4 Standby Motor Malfunction ehh 5 6 SCHEMATIC DIAGRAMS 222 eee eee eee eee nnn 6 1 64 INTRODUCTION escisiones 6 1 M 62 10828 Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Figure 1 11 Figure 1 12 Figure 1 13 Figure 2 1 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 Figure 4 10 Figure 4 11 Figure 4 12 Figure 4 13 Figure 4 14 Figure 4 15 Figure 4 16 Figure 4 17 Figure 4 18 Figure 4 19 Figure 4 20 Figure 4 21 Figure 6 1 FIGURE NUMBER Page Condensing Section Top View Cab Command 1 2 Unit e Dias EA IA AA eir red
23. close OP The unit will start in High Speed Heat with unloaders energized 850 and 950 and fans de energized After 30 seconds the unit will revert to normal temperature control Once the engine has started the microprocessor will complete the Defrost Transistor DT circuit to energize the Electric Fan Motor Relays EFMR 1 through 3 which close contacts to energize the Electric Evapora tor Fan Motors EFM1 through 3 The microprocessor continues to monitor inputs to de termine required modes of operation The inputs include the Suction Pressure Transducer SPT Water temper ature Sensor Supply Air Sensor SAS and the Com pressor Discharge Transducer CDT As required the microprocessor will take the following actions On Supra 850 and 950 units when in the low speed mode the microprocessor also energizes the Unloader Front Relay UFR Energizing UFR closes a set of contacts to energize the compressor unloader UF de activating two cylinders For high ambient protection on Supra 850 units the unloader is controlled through the Compressor Clutch Relay CCR CCR is energized through a second dis charge pressure switch HP2 If high pressure is below 367 psig 25 bar the compressor is in 4 cylinder opera tion 2 cylinder for 950 If pressure is above 440 psig 30 Bar the compressor is in 4 or 6 cylinder operation On call for heat the Heater Relay HR1 is energized to close a set of contacts and energize
24. dry nitrogen See Figure 4 14 Set nitrogen pressure regulator higher than cutout point on switch being tested Pressure switch cutout and cut in points are shown in section 1 6 2 e Close valve on cylinder and open bleed off valve f Openoylinder valve Slowly close bleed off valve and increase pressure until the switch opens If light is used light will go out and if an ohmmeter is used the meter will indicate open Open pressure on gauge Slowly open bleed off valve to decrease pressure until switch closes light will light or ohmmeter will move cp CH o 62 10828 4 16 4 13 CHECKING CALIBRATION OF THE DEFROST AIR SWITCH a Make sure magnehelic gauge is in proper calibration NOTE The magnehelic gauge may be used in any position but must be re zeroed if position of gauge is changed from vertical to horizontal or vice versa USE ONLY IN POSITION FOR WHICH IT IS CALIBRATED b With air switch in vertical position connect high pres sure side of magnehelic gauge to high side connec tion of air switch See Figure 4 15 c Install tee in pressure line to high side connection Tee should be approximately half way between gauge and air switch or an improper reading may result d Attach an ohmmeter to the air switch electrical con tacts to check switch action NOTE Use a hand aspirator P N 07 00177 01 since blowing into tube by mouth may cause an incor rect reading e With the gauge reading
25. each time the timer expires The defrost timer runs only when the defrost termination thermostat is closed also it does not accumulate time when the unit is in the null mode The defrost timer is resetto zero when ever a defrost cycle is initiated b Defrost Air Switch Initiation The Defrost Air switch is of the diaphragm type and it measures the change in air pressure across the evapo rator coil When the pressure differential is increased to set point due to the formation of ice on the coil surface the switch closes to signal the microprocessor to place the unit in the defrost mode c Manual Defrost Initiation Defrost may be initiated manually by pressing the MANUAL DEFROST key d Fail safe Defrost Termination Should the defrost cycle not complete within 45 minutes or if the external defrost signal does not clear at defrost termination the microprocessor places the unit in the defrost override mode and the defrost cycle is termi nated The internal timer is reset for 1 5 hours the Func tional Parameter setting and Defrost Air switch signal is ignored for defrost initiation The manual defrost switch will override this mode and start a new 45 minute cycle When defrost override is active the appropriate alarm will be indicated 3 1 7 Unloading in Temperature Mode NOTE The unloader relay is locked in for a minimum of 2 minutes once it is energized due to suction pressure There are two modes of unloader operation
26. illuminated by this alarm Out Of Range Alarm The English display for the Out Of Range alarm is OUT RANGE The code display is AL20 This alarm is generated when the main compartment temperature is outside the designated range from set point When this alarm is generated the fault light will illuminate 2 11 Remote Compartment 2 Out of range Alarm The English display for the Remote Compartment 2 alarm is 2RAS OUT The code display is AL21 This alarm is generated when the second compartment tem perature is outside the designated range from set point When this alarm is generated the fault light will illumi nate Remote Compartment 3 Out of range Alarm The English display for the Remote Compartment 3 alarm is 3RAS OUT The code display is AL22 This alarm is generated when the second compartment tem perature is outside the designated range from set point When this alarm is generated the fault light will illumi nate No Power for Standby Alarm The display for the No Power alarm is NO POWER This alarm is generated when the unit is placed in the Standby mode and there is no power to the power sup ply detector 2 4 13 Stopping Instructions To stop the unit from any operating mode place the I O Cab Command or RUN STOP Switch in the OFF posi tion 62 10828 SECTION 3 CONTROL LOGIC AND TEMPERATURE CONTROL 3 1 MODES OF OPERATION The operational software responds to various
27. keypad Figure 2 1 has 12 keys which allow the operator to initiate various functions display operating data and change operating parameters Arrow Keys The up and down ARROW keys are used ES to modify increment or decrement the displayed data If the unit is in the default display these keys are pressed to change the setpoint selection The ENTER key is used to accept a change in function codes or a change in setpoint m 3 e cC S c o lt Manual Defrost Key f The MANUAL DEFROST key is used to A initiate a defrost cycle If the predeter mined conditions for defrost are not met the unit will not enter defrost and the dis play will return to the default screen Pretrip Check Key The PRETRIP key is used to initiate a pre trip test cycle If the predetermined condi tions for pretrip are not met the unit will not enter pretrip and the display will return to the default screen v A Auto Start Stop Auto Start Continuous Run Key The AUTO START STOP key is used to change the operating mode from Continu ous Run to Auto Start Stop Each push of the key will alternate the operating modes The micro processor retains the last entered setpoint in memory even if the unit is shut down or a power failure occures The Auto Start Stop indicator on the display will illumi nate when Auto Stop Start is enabled If the indicator is not illuminated the unit is in the Continuous Run Mode To start the unit in man
28. method to evacuate and dehy drate the system is to connect three evacuation hoses Do not use standard service hoses as they are not suited for evacuation purposes as shown in Figure 4 9 to the vacuum pump and refrigeration unit Also as shown connect a evacuation manifold with evacuation hoses only to the vacuum pump elec tronic vacuum gauge and refrigerant recovery sys tem 4 11 CH 2 y With the unit service valves closed back seated and the vacuum pump and electronic vacuum gauge valves open start the pump and draw a deep vac uum Shut off the pump and check to see if the vac uum holds This operation is to test the evacuation setup for leaks repair if necessary Midseat the refrigerant system service valves Then open the vacuum pump and electronic vacuum gauge valves if they are not already open Start the vacuum pump Evacuate unit until the electronic vac uum gauge indicates 2000 microns Close the elec tronic vacuum gauge and vacuum pump valves Shut off the vacuum pump Wait a few minutes to be sure the vacuum holds Break the vacuum with clean dry refrigerant Use re frigerant that the unit calls for Raise system pressure to approximately 2 psig Remove refrigerant using a refrigerant recovery sys tem Repeat steps e through g one time Evacuate unit to 500 microns Close off vacuum pump valve and stop pump Wait five minutes to see if vacuum holds Th
29. microprocessor senses coolant temperature above 230 F 110 C When this alarm is generated the fault light will illuminate and the engine will shut down High Pressure Alarm The English display for the High Pressure alarm is HI PRESS The code display is AL2 This alarm is gener ated if the high pressure switch opens When this alarm is generated the fault light will illuminate and the engine will shut down Start Failure Alarm The English display for the Start Failure alarm is STARTFAIL The code display is AL3 This alarm is generated if the start sequence has completed and the engine has failed to start When this alarm is generated the fault light will illuminate If function parameter MAN OP FN10 OFF is selected the start failure alarm will be generated if the engine is not started in five minutes Low Battery Voltage Alarm The English display for the Low Battery Voltage alarm is LOW BATT The code display is AL4 This alarm is generated if the battery voltage falls below 10 VDC When this alarm is generated the fault light will illumi nate High Battery Voltage Alarm The English display for the High Battery Voltage alarm is HIBAT T The code display is AL5 This alarm is gen erated if the battery voltage rises to 17 VDC When this alarm is generated the fault light will illuminate and the engine will shut down Defrost Override Alarm The English display for the Defrost Override a
30. or down ARROW keys The displayed choice will then flash to indicate that the choice has not been entered Depress the ENTER key to activate the new choice The display will stop flashing to indicate that the choice has been entered Ifthe new choice is not entered in 5 seconds the display will revert back to the last entered choice All function parameters are retained in memory Descriptions of the function parameters and operator choices are provided in the following paragraphs A function parameter listing is also provided in Table 2 1 Defrost Interval The English display for Defrost Interval is DEFR the code display is FNO The choices are displayed with one decimal place and then the capital letter H for hours i e DEFR 12 0H The defrost choices are 1 5 3 6 or 12 hours Speed Control The Speed Control parameter overrides the normal mi croprocessor speed control solenoid operation Param eter English displays are CITY SPD or HIGH SPD The code displays are FN1 ON or FN1 OFF With CITY SPD or FN1 ON displayed the unit is locked into low speed With HIGH SPD or FN1 OFF dis played speed is under normal microprocessor control Minimum Off Time The auto start mode Minimum Off Time parameter En glish display is OFF T the code display is FN2 The choice for the off time is displayed with two digits and then the capital letter M for minutes i e OFF T 20M or FN2 20M The off t
31. return line is about 1 32 Gal 5 liters per hour b Changing the fuel filter When changing fuel filter the new filter should be filled with clean fuel 1 Remove cover gasket and filter 2 Wash filter in cleaning solvent and blow out with air pressure Clean cover 3 To Install reverse above steps 4 After changing fuel filter operate the electrical pump to bleed the fuel circuit properly before starting the engine 62 10828 4 6 C 1 Bowl 2 Gasket 3 Filter 4 Connector Figure 4 4 Electric Fuel Pump Verify fuel pump capability 1 Remove fuel pump from the system Connect a ma nometer to pump outlet Energize fuel pump with a small quantity of fuel At zero flow the fuel pump should provide about 10 30 psig 0 7 Bar of pressure at the pump outlet Pulsation frequency high fuel circuit has low pres sure drop high flow Pulsation frequency low or null high pressure drop inside the circuit low or zero flow Check for re striction inside the circuit 4 1 6 Servicing Glow Plugs When servicing the glow plug is to be fitted carefully into the cylinder head to prevent damage to glow plug Torque value for the glow plug is 6 to 11 ft lb 0 8 to 1 5 mkg Checking for a Defective Glow Plug a One method is to place an ammeter or clip on am meter in series with each glow plug and energize the plugs Each plug if good should show amperage draw of 8 to 10 amps b Asecon
32. second thermistor This thermistor is installed in the supply air stream and activated using Function Code FN4 With Function Code FN4 set to FN4 ON or REM PROBE the microprocessor is set for dual probe con trol With the microprocessor set for dual probe control the microprocessor will select the supply air probe for con trol when in Perishable Range operation and the return air probe when in Frozen Range operation Operating on the supply air probe in the Perishable Range mini mizes top freezing while operating on the return air probe in the Frozen Range keeps the product at or slightly below setpoint In the event of a probe failure on a single probe unit the unit will be shut down if operating in the Perishable Range or switched to low speed cooling if operating in the Frozen Range When operating inthe Frozen Range and on standby the unit continues to operate in cooling An alarm will be generated to advise the operator of the probe failure With dual probe control the microprocessor will switch over to the other probe in the event of an active probe failure This allows continued normal operation The appropriate alarm will be generated to advise the opera tor of the probe failure 3 1 5 Fuel Heater Operation Energizing the heater relay provides a circuit to the fuel heater thermostat FHT A thermostat FHT internal to the fuel filter bowl closes to energizes the fuel heater FH at temperatures below th
33. side by connecting at the suction and discharge service valve Refer to sections 4 5 amp 4 6 for general procedure 7 Re check superheat 62 10828 4 20 MICROPROCESSOR CONTROLLER NOTE The erasable programmable read only memory EEPROM chip component U3 on the microprocessor logic board has a label on it listing the revision level of the software Under no circumstances should a technician electrically probe the processor at any point other than the connector terminals where the harness attaches Microprocessor components operate at different voltage levels and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could permanently damage the processor As mentioned above some microprocessor inputs operate at voltage levels other than the conventional 12 vdc Connector points and the associated approximate voltage levels are listed below for reference only Under no circumstances should 12 vdc be applied at these connection points Grounded wrist cuffs are available from Carrier P N 07 00304 00 It is recommended that these be worn whenever handling a microprocessor Most electronic components are susceptible to damage caused by electrical static discharge ESD In certain cases the human body can have enough static electricity to cause resultant damage to the components by touch This is especially true of the integrated circuits found on the truc
34. standard defrost cycle Pre Trip is terminated and unit returns to normal operation 2 4 6 Setpoint 33 F to 50 F 1 C to 10 C 51 F to 77 F 11 C to 25 C Greater than 78 F 26 C NOTE If configuration CNF3 is ON maximum set point is increased to 90 F Setpoints of 22 F to 86 F 30 C to 30 C may be entered via the keypad With the default screen showing on the display the up or down ARROW key may be pressed to bring the set point tothe desired reading The display will flash to indicate that the reading being displayed is a non entered value Depress the ENTER key to activate the new setting If the ENTER key is not pressed within five seconds after the last key stroke the display will revert to the previous active setting The microprocessor retains the last entered setpoint in memory even if the unit is shut down or a power failure occurs 2 4 7 Start Stop Operation After start up observe the AUTO START STOP indica tor If it is illuminated the unit is in the Auto Start Stop mode If not press the Auto Start Stop key to toggle the unit into Auto Start Stop mode Automatic start stop is provided to permit starting restarting of the diesel driven compressor as reguired This gives the microprocessor automatic control of starting and stopping the diesel engine The main function of automatic start stop is to turn off the refrigeration system near the setpoint to provide a fuel efficient temper
35. tempera ture control and suction pressure control 950 Only Temperature Control a Temperature Control Within 1 4 F 0 8 C of Setpoint 1 Coollight CL or heat light HL illuminated de pending on mode of operation 2 If in low speed cooling unloader relays UFR may energize to unload compressor banks Refer to Table 3 1 3 In low speed heating front unloader relay UFR energizes to unload compressor bank Table 3 1 Unloading in Temperature Mode SETPOINT BELOW 10 F 12 C SETPOINT ABOVE 10 F 12 C Cylinder Supra 922 944 ool High Speed IC Cool High Speed Cool Low Speed Heat Low Speed Cool Low Speed Cool Low Speed Heat Low Speed Heat High Speed DES Cylinder 4 b Perishable Cooling Unloader Control Diesel During perishable cooling the unloader is energized when the temperature approaches setpoint If a supply probe is present the unloader is energized when the supply temperature decreases 5 4 F 3 C below set point It will stay unloaded until the supply temperature rises above setpoint If a supply probe is not present the unloader is energized when the return temperature decreases more than 9 F 5 C above setpoint It will stay unloaded until the return temperature rises more than 14 4 F 8 C above setpoint The return probe log ic is disabled for ambient temperature higher than 90 F 32 2 C Standby During perishable cooling the unloader is energ
36. the hot gas bypass solenoid valve HGS2 and the hot gas valve HGS1 placing the unit in the heat mode If the unit is equipped with hot water heat the contactor will open the hot water heat solenoid valve Units equipped with electric heat will energize the heater elements On call for defrost the microprocessor energizes the hot gas bypass valve HGS2 and the hot gas valve HGS1 in the same manner as in heat Also DT is de ener gized stopping the evaporator fan motors 62 10828 3 2 2 Standby Refer to SECTION 6 for a schematic diagram of the unit controls To facilitate location of the components re ferred to in the written text the schematic has map coordinates added to the margins These locations have also been added to the legend In order to provide complete information the following description is writ ten as if all options are installed Indications of specific unit applicability and optional equipment are provided onthe schematic diagram The microprocessor controls operation of the various relays and components by com pleting or by breaking the circuit to ground To start the unit place the RUN STOP Switch RSS in the RUN position and the cab command I O Switch in the ON position With the switches positioned the STANDBY key is pressed to begin the start process When the STANDBY key is pressed the microprocessor provides a ground path to energize the Diesel Electric Relay DER Ener gizing DER opens a se
37. this key the buzzer is activated whenever the alarm fault indicator is illuminated The buzzer off indicator on the display will illuminate when the buzzer is disabled s Road Key The ROAD key selects the diesel engine operating mode The microprocessor retains the last entered setpoint in memory even if the unit is shut down or a power failure occures NOTE When functional parameter FN10 is set for time start the unit optional auto diesel restart is active and the Road key will be flashing Stand by Key The STAND BY key selects the electric ES motor operating mode The microproces sor retains the last entered setpoint in memory even if the unit is shut down or a power failure occures NO POWER will be displayed if unit is switched to standby and power is not available 2 3 2 Digital Display The digital display see Figure 2 1 has nine positions The default display is setpoint on the left and actual supply or return air temperature on the right The read out may be set to read in Degrees F or Degrees C The display also has symbol type indicators for the fol lowing modes Cool Heat Defrost Road diesel Opera tion Auto Start Stop mode Stand By mode City Speed mode and Out Of Range operation The indicator is illumi nated to indicate the mode or condition is active On each power up the microprocessor will perform a self test Errors if any will be indicated on the display as an EER where
38. unit When CNF 25 is ON the CNF1 A setting is not used SD 4560 50 850 56 26 850 2 CNF9allows selection of how the unit wil react under an Out Of Range condition EL WALA SENE Se SHORE AN Out Ore Range condition is de Max Set Point 90 F Modified function lock SE Ss Ee Se a Aue from setpoint With this CNF in the OFF units i position once the box temperature has SES L been Out Of Range for 15 minutes the ALARM light will be turned on and the aa Ga GEN O SF alarm display OUT RANGE will be dis i played alternately with the default dis erer play of the setpoint and box temperature ns q __ um With this CNE in the ON position once Units with unloaders 950 Only the box temperature p has been SB TTSS Out Of Range for 45 minutes the uni will shut down and the same alarms as described above will be displayed CNF3 amp CNF11 Standard Function Lock allows the Func High Speed Start i tion Key and the Start Stop Continuous Run EE Key to be locked so that no changes can be i Low speed only engine warm up Not re i made i commended Max Set Point 86 F All functions locked Modified Function Lock is the same as ETT re Standard Function Lock except that with the 950 Only i setpoint at or between 32 and 42 F 0 and A NT 5 6 C the unit will always operate in Co
39. up of metering devices by free water and formation of acids resulting in metal corrosion 4 6 2 Preparation a Evacuate and dehydrate only after pressure leak test Refer to section 4 5 b Essential tools to properly evacuate and dehydrate any system include a good vacuum pump 5 cfm 8m3H volume displacement P N 07 00176 01 anda good vacuum indicator such as a thermocouple vacu um gauge vacuum indicator Carrier p n 0700414 00 NOTE Use of a compound gauge is not recommended because of its inherent inaccuracy CH Keep the ambient temperature above 60 F 15 6 C to speed evaporation of moisture If ambient temper ature is lower than 60 F 15 6 C ice might form be fore moisture removal is complete Heat lamps or al ternate sources of heat may be used to raise system temperature Gre Er d N b e a 11 10 Refrigerant Recovery Unit Refrigerant Cylinder Evacuation Manifold Valve Vacuum Pump Electronic Vacuum Gauge Evaporator Coil Receiver Outlet King Valve Condenser Coil Suction Service Valve Discharge Service Valve Figure 4 9 Vacuum Pump Connection TO Ogouoongom m m 4 6 3 Procedure for Evacuation and Dehydrating System a Remove refrigerant using a refrigerant recovery sys tem b The recommended
40. 1 1 TO 550 B DATALINK OPTION DK TO FIA TO RSS3 COLOR GREEN DC CONTROL CIRCUITS BLACK DC GROUNDS RED AC CIRCUITS GREEN YELLOW AC GROUNDS ADDRESS SYSTEM EXAMPLE HCD2 MPW2 INDICATES A WIRE BETWEEN PLUG HC PIN D2 AND MICROPROCESSOR MP AND PIN W2 VOLTAGE BELOW 12 VOLTS REFER TO OWNERS MANUAL FOR TROUBLESHODTING PROCEDURE ENGINE CT2 29 2 GLOW PLUGS ENGINE CT3 44 3 GLOW PLUGS NO CONNECTION OF STANDBY PANEL COL MC AND DPS ONLY FOR VERSIONS 550 650 750 AND 350 HGS2 ONLY FOR VERSIONS 550 650 750 850 HP2 CCR AND SUFR ONLY FOR SUPRA 850 FOR CCR REFERENCE AS UFR2 Based on Drawing 62 04094 Rev A 10 2 INDEX A Accumulator 1 8 Additional Support Manuals 1 1 Adjusting The Compressor Pressure Regulating Valve CPR 4 18 Alarm Display 2 9 Alarm Reset 2 7 Alternator 1 15 4 7 5 2 Alternator Auxiliary Alarm 2 10 Alternator V Belt 4 8 Alternator Regulator 1 6 Ambient Temperature 2 8 Auto Diesel Restart 3 5 Auto Start Sequence 3 6 Auto Manual Start Operation 2 6 B Battery Voltage 2 8 Belt Tension Gauge 4 8 Brushes 4 7 C Changing Lube Oil and Lube Oil Filters 4 4 Charging The Refrigeration System 4 11 Checking And Replacing Evaporator Fan Motor Brushes 8 Commutator 4 17 Checking And Replacing Filter Drier 4 15 Checking And Replacing High pressure Switch 4 15 Checking Calibratio
41. 108 lbs 49 kg 137109 62 kg Oil Charge 4 0 pints 1 9 L 5 5 pts 2 6 L 6 75 pts 3 2 APPROVED COMPRESSOR OIL 056 05K R 404A Mobile Arctic EAL 68 i Castrol Icematic SW 68C a High Pressure Cutout Switches 1 6 3 Refrigeration System Data HP1 a Defrost Timer Cutout at 465 10 psig 32 7 0 7 kg cm2 1 1 2 3 6 or 12 hours Cut in at 350 10 psig 24 6 0 7 kg cm2 b Defrost Thermostat HP2 850 Only Opens at 47 5 F 8 3 C t 37 5F o 209 Cutout at 367 12 psig 25 0 8 kg cm Closes at 37 5 F 3 3 C 3 c Defrost Air Switch Setting Cut in at 440 10 psig 29 9 0 7 kg cm2 p Y 550 650 750 Initiates at 1 00 4 07 inch b 50 Discharge Temperature Sensor 25 4 1 8 mm wg CDT P Fa This is athermistor type sensor located when installed 850 950 Initiates at 0 70 07 inch on the compressor discharge cover 17 8 1 8 mm wg Unit shuts down d Refrigerant Charge elf ambient is less than 120 F 50 C AND Refer to Table 1 1 Temperature exceeds 310 F 154 C for 3 min e Compressor Pressure Regulating Valve CPR Temperature exceeds 340 F 171 C for 3 min elf ambient is greater than 120 F 50 C AND g 50 C NOBEL CPR Setting CPR Setting elmmediately shuts down in all ambients SUPRA 550 34 1 2 3 0 07 If temperature exceeds 350 F 177 C SUPRA 650 28 1 1 91 0 07 SUPRA 750 32 1 2 18 0 07 SUPRA
42. 4 2 SERVICING AND ADJUSTING V BELTS 000 ccc eee eens 4 8 4 2 1 Belt Tension Gauge 0 cece sh hh 4 8 4 2 2 Alternator VBa distant ERR eL e e ode doe e RR A 4 8 4 2 3 Water Pump Belt Tensioner WAWA AUWAWA Eaa a 4 8 4 2 4 Standby Motor Compressor V Belt 4 9 4 2 5 Engine Compressor V Belts 4 9 43 INSTALLING MANIFOLD GUAGE GET 4 9 4 3 1 Preparing Manifold Gauge Hose Set For Use 4 9 4 3 2 Connecting Manifold Gauge Hose Get 4 9 4 3 8 Removing the Manifold Gauge Set 4 9 4 4 PUMPING THE UNIT DOWN sssseee RR IH mr mn 4 10 45 REFRIGERANT LEAK CHECKING mns 4 10 4 6 EVACUATION AND DEHYDRATION muananasunnanawannananana 4 10 O A A 4 10 4 6 2 Preparation i io it an ka 4 10 4 6 3 Procedure for Evacuation and Dehydrating System 4 11 iji 62 10828 TABLE OF CONTENTS TABLE OF CONTENTS PARAGRAPH NUMBER Page SERVICE Continued eed sale Sete ale AA aa 4 1 4 7 CHARGING THE REFRIGERATION SYSTEM 0000 cece ee n 4 11 4 7 1 Checking the Refrigerant Charge 4 11 4 7 2 Installing a Complete Charge
43. 44 CAUTION DO NOT attempt to service the microprocessor or the logic or display boards Should a problem develop with the microprocessor contact your nearest Carrier Transicold dealer for replacement INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 1 DIESEL ENGINE 5 1 1 Engine Will Not Start Starter motor will not crank or low cranking speed Starter motor cranks but engine fails to start Starter cranks engages Engine lube oil too heavy but dies after a few seconds Voltage drop in starter cable s Battery insufficiently charged Battery terminal post dirty or defective Bad electrical connections at starter Starter motor malfunctions Starter motor solenoid defective Open starting circuit Incorrect grade of lubricating oil No fuel in tank Air in fuel system Water in fuel system Plugged fuel filters Plugged fuel lines to injector s Fuel control operation erratic Glow plug s defective Run solenoid defective Fuel pump FP malfunction Check Check Check 5 1 3 Engine Manual 5 1 4 1 6 Check Check Drain Sump Replace Check Engine Manual 4 1 6 4 1 3 4 1 5 1 6 Check 5 1 2 Engine Starts Then Stops Engine stops after several rotations Fuel supply restricted No fuel in tank Leak in fuel system Faulty fuel control operation Fuel filter restricted Injector nozzle s defective Injection pump defective Air cleaner or hose restricted Safety device open Open wiring circuit to run solenoi
44. 5 amps run control relay 5 Excessive current draw by Fuse F3 Opens at 15 amps run relay F4 6 Excessive current draw heat relay Opens at 5 amps 7 Excessive current draw by speed Fuse F5 Opens at 10 amps relay 7 Excessive current draw by unload Fuse F6 850 and 950 Only Opens at 5 amps er 8 Excessive current draw by Fuse F7 950 Only Opens at 15 amps defrost damper relay 8 Excessive current draw by Fuse F8 F9 F10 Opens at 20 amps evaporator fan motors 9 Excessive current draw by fuel Fuse F11 Opens at 5 amps pump 10 Excessive compressor High pressure cutout switch HP au Refer to Section 1 6 3 a discharge pressure tomatic reset 11 Excessive compressor Compressor discharge Shuts unit down above discharge temperature temperature sensor CDT 310 F 154 C for 3 minutes or 350 F 177 C 12 Excessive current draw by fuel Fuse F12 Opens at 25 amps heater circuit option 62 10828 1 16 1 8 REFRIGERANT CIRCUIT 1 8 1 Cooling See Figure 1 13 When cooling the unit operates as a vapor compression refrigeration system The main components of the system are the reciprocating compressor air cooled condenser thermostatic expansion valve direct expansion evapora tor and hot gas valve In the cooling mode the hot gas valve is de energized With the hot gas valve de energized flow through the valve is from the side discharge connection to the bot tom condenser connection The compre
45. 850 950 29 1 1 97 0 07 f Thermostatic Expansion Valve Superheat Setting at O F 17 8 C box temperature 8 10 F 13 3 to 12 2 C 62 10828 1 14 1 6 4 Electrical Data a Evaporator Fan Motors Bearing Lubrication Factory lubricated additional grease not required Operatin 0 13hp 100W 10 8 amps 2000 mn 12 vdc b Standby Motors Bearing Lubrication Factory lubricated additional grease not required Rotation Speed 1760 rom 60Hz 1500 rom 50Hz e REMITE Connection Type H Full Load Amps SUPRA 550 20 SUPRA 650 750 SUPRA 850 SUPRA 950 c Alternator 70 amps d Standby Motor Overload MODEL KAA coa 550 850 950 1 6 5 TORQUE VALUES 1 15 62 10828 1 7 SAFETY DEVICES System components are protected from damage caused by unsafe operating conditions by automatically shutting down the unit when such conditions occur This is accomplished by the safety devices listed in Table 1 9 Table 1 9 Safety Devices Microprocessor Controller Unsafe Conditions Safety Device Device Setting 1 Low engine lubricating oil Oil pressure safety switch OP Opens below 18 4 3 psig pressure automatic reset 1 2 0 2 Bar 2 High engine coolant temperature Water temperature sensor Opens above 230 5 F microprocessor 110 3 C 3 Excessive current draw by glow Fuse F1 Opens at 80 amps plug circuit control circuit or starter solenoid SS 4 Excessive current draw by Fuse F2 Opens at
46. Compressor Data EE UNE ENNEN NEE YR Re E Re RS e bee RAD e MER UR 1 14 1 6 3 Refrigeration System Data nananannn 1 14 1 6 4 Electrical Data 5 25 abt a noD mre 1 15 1 6 5 TORQUE VALUES er RR UE TS RUE EH ue RE eens 1 15 T SAFETY DEVICES este se elie ic ad ENDS ta ein 1 16 1 8 REFRIGERANT GIRGUIT EIA 1 17 1 8 1 Cooling See Figure 1 13 ooooooccccoccccccr e rm 1 17 1 8 2 Heat And Defrost See Figure 1 13 uanann 1 17 i 62 10828 TABLE OF CONTENTS PARAGRAPH NUMBER Page OPERATION ii e aa 2 1 2 1 MICROPROCESSOR CONTROLLER anneanne 2 1 SL AU serge e A ade A A vatem 2 1 2 2 MICROPROCESSOR CONFIGURATION 0occcccccccccc mn 2 2 2 3 DESCRIPTION OF MICROPROCESSOR COMPONENTS 2 2 2 3 Keypad mm A 2 2 2 3 2 00 NI TEE 2 3 2 4 OPERATION dic Ede eu E pe eso x eo c tigate 2 3 2 4 1 Pre Trip INSPECHON eri deer rupe RR ved RRRUt enira ee ver 2 3 2 4 2 Starting Road Operation uaannasunnnnnn 2 4 2 4 8 Starting Standby Motor Drive 2 4 244 Manual Start eoo opis neces entcePEO PERO adie op Fares epp Re e 3 2 4 E E e EE 2 4 Ee 2 4 EE E ele el le EE 2 5 2 4 8 Continuous Run Operation 2 5 EC HEES 2 5 2 4 10 Functional Parameters oriye KUA AA RA 2 6 2411 Unit Data t
47. E CAUSES SECTION 5 3 6 2 Heating High discharge pressure Overcharged system Condenser fan defective V belts broken or loose Noncondensibles in system Low discharge pressure Compressor valve s worn or broken Hot Gas three way valve malfunction Low refrigerant charge Low suction pressure Refrigerant shortage Compressor pressure regulating valve malfunction Suction service valve partially closed 5 3 7 Abnormal Noise Compressor Loose mounting bolts Worn bearings Worn or broken valves Liquid slugging Insufficient oil Condenser or Loose or striking shroud evaporator fan Bearings defective Bent shaft V belts Cracked or worn 5 3 8 Control System Malfunction Will not control Sensor defective Relay s defective Microprocessor controller malfunction Solid State controller malfunction 5 3 9 No Evaporator Air Flow or Restricted Air Flow Evaporator coil blocked Frost on coil Dirty coil Fan motor s malfunction No or partial evaporator V belt broken or loose air flow Clutch defective Evaporator fan loose or defective Evaporator fan rotating backwards Evaporator air flow blocked in trailer box Fan motor s malfunction 5 5 62 10828 INDICATION REFERENCE TROUBLE BOSS REE 66955 SECTION 5 3 10 Expansion Valve Malfunction Low suction pressure with Low refrigerant charge high superheat External equalizer line plugged Ice formation at valve seat Wax oil or dirt plugging valve or orifice Broken capillary Power ass
48. ESD In certain cases the human body can have enough static electricity to cause resultant damage to the components by touch This is especially true of the integrated circuits found on the truck trailer microprocessor 6 1 62 10828 SERIAL PORT 006000 E N op m 10 E E E 8 E 2 e E E e DICATES AN OUTPUT TEST POINT INDICATES A SOLDERED SPLICE POINT PIN CONNECTION 1 LIGHT LINES INDICATES WIRES IN THE SYSTEM NORMALLY CLOSED CONTACTS NORMALLY OPEN CONTACTS INDICATES CONNECTION 13 MULTIPLE PLUG CONNECTION NUMBER Y SUP L R M a FS Lager DSR CONTROL PANEL OPTION CAB COMMAND o w LO NJ c ul gt o 6060006 NJ J 15A eO P A H RS CIC SUPRA 550 650 LOCATION A 8 m CT SP13 SUPRA 950 ONLY AN ft 85 FHR 85
49. Heat Exchanger The heat exchanger is of the tube in tube type con nected in the main suction line and liquid line Within the heat exchanger the cold suction gas is used to cool the warm liquid refrigerant This results in greater system capacity and efficiency 1 4 8 Evaporator Coil The evaporator coil is a tube and fin type The operation of the compressor maintains a reduced pressure with the the coil At this reduced pressure the liquid refriger ant evaporates at a temperature sufficiently low enough to absorb heat from the air Air movement over the condenser is provided by two or three electric fans 1 4 4 Electric and Water Heat The unit can be equipped with Electric Heat Water Heat and Electric Water heat See Figure 1 12 When the controller calls for heat the heater contactor will close or valve will open and engage the heat system Water Heat Coil Electric 62 10828 Heat Elements ELECTRIC HEAT CONTROL BOX HOT WATER HEAT COMPONENTS 1 Water Valve 2 Water Tube HWH 3 Hose HWH 4 Harness HWH 1 5 SYSTEM OPERATING CONTROLS AND COMPONENTS The unit is furnished with a microprocessor control system Once the set point is entered at the controller the unit will operate automatically to maintain the de sired temperature within very close limits The control system automatically selects high and low speed cool ing o
50. N To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before disconnecting Safety 3 62 10828 A CAUTION Refrigerant R404a is a blend Charging as a vapor will change the properties of the refrigerant Only liquid charging through the king valve is acceptable 44 CAUTION Extreme care must be taken to ensure the manifold common connection remains immersed in oil at all times Otherwise air and moisture will be drawn into the compressor 44 CAUTION Do not damage or over tighten the enclosing tube assembly Also make sure all parts are placed in the enclosing tube in proper sequence to avoid premature coil burn out 44 CAUTION Under no circumstances should atechnician electrically probe the microprocessor at any point oth er than the connector terminals where the harness attaches Microprocessor components operate at different voltage levels and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could permanently damage the microprocessor 44 CAUTION Most electronic components are susceptible to damage caused by electrical static discharge ESD In certain cases the human body can have enough static electricity to cause resultant damage to the components by touch This is especially true of the integrated circuits found on the microprocessor 44 CAUTION Under no circumstances should anyone attempt to service the micropr
51. R 4 6 70 Amp Alternator sineseztrureci c ied ben dd ENDA teu ede ped 4 7 M Belt Arrangement o uoo RR RE RURSUS CYRUS Rea S PN RS 4 8 Belt Tensi n Gauge gt ciio EUM Ded uade rasa s 4 8 Manifold Gauge Get 4 9 Vacuum Pump Connection 4 11 Procedure for Adding A Complete Charge 4 12 Procedure for Adding A Partial Charge 4 12 COITipreSSOFr u ter core ewe pota Sessa Aedes a Dieser pore her ee se esp e d 4 14 Unloader Solenoid Valve unananaanan 4 15 Typical Setup for Testing High Pressure Switch 4 16 Defrost Air Switch Test Gen 4 16 Fan Motor Brushes i c ape TET ep TRUE atch MAUA a Fert SANI 4 17 Hot Gas Three Way Valve Supra 550 650 750 850 4 17 Hot Gas Valve HGS2 and Supra 950 3 Way Valve HGS2 Shown 4 18 Compressor Pressure Regulating Valve 4 18 Thermostatic Expansion Valve sssssssssseeseee e mm 4 19 Thermostatic Expansion Valve Bulb and Thermocouple 4 19 Electrical Schematic Wiring Diagram 6 2 62 10828 LIST OF ILLUSTRATIONS vi LIST OF TABLES TABLE NUMBER Page Table 1 71 Oe ER TEE 1 1 Table 1 2 Additional Support Manuals 1 1 Table 1 3 Fuse Identi
52. T TEMPERATURE SENSOR BUZZER BATTERY COMPRESSOR CLUTCH COMPRESSOR CLUTCH RELAY COMPRESSOR DISCHARGE TEMPERATURE SENSOR DEFROST AIR SWITCH DIESEL ELECTRIC RELAY DEFROST DAMPER SOLENOID OPTION DEFROST DAMPER RELAY OPTION DATALINK CONNECTOR DETECTOR POWER SUPPLY DOOR SWITCH RELAY DOOR SWITCH DEFROST TRANSISTOR DEFROST THERMOSTAT ELECTRIC FAN MOTOR ELECTRIC FAN MOTOR RELAY EVAPORATOR HEAT CONTACTOR EVAPORATOR HEAT RELAY FUSE 80A FUSE SA FUSE 15A FUSE 5A FUSE 10A FUSE 5A FUSE 20A FUSE 25A FUEL HEATER OPTION FUEL HEATER RELAY OPTION FUEL HEATER THERMOSTAT COPTION FUEL PUMP GLOW PLUG GLOW PLUG RELAY HIGH CURRENT RELAY HOT GAS SOLENOID HIGH PRESSURE CUT OUT SWITCH HIGH PRESSURE CUT OUT SWITCH HEAT RELAY 1 MICROPROCESSOR BOARD MOTOR CONTACTOR SEE 62 04083 OVERLOAD PROTECTOR SEE 62 04083 OIL PRESSURE SAFETY SWITCH NO CAB COMMAND PLUG CONNECTOR MICROPROCESSOR CAB COMMAND PLUG CONNECTOR POWER SUPPLY RECEPTACLE SEE 62 04083 RETURN AIR SENSOR RUN CONTROL RELAY RUN RELAY RUN SOLENOID RUN STOP SWITCH SUPPLY AIR SENSOR OPTION STANDBY MOTOR SEE 62 04083 SPEED CONTROL SOLENOID STARTER MOTOR SERIAL PORT RS232 SUCTION PRESSURE TRANSDUCER SPEED RELAY STARTER SOLENOID STARTER SOLENOID CONTACTOR STARTER SOLENOID RELAY STANDBY UNLOADER FRONT RELAY UNLOADER FRONT RELAY UNLOADER FRONT WATER TEMPERATURE SENSOR NOTES UNIT SHOWN OFF POSITION WIRE IDENTIFICATION
53. TE If configuration CNF9 is ON the unit will shut down if an out of tolerance condition exists for over 45 minutes If configuration CNF9 is OFF and an out oftolerance condition exists the unit will continue to operate but generate Alarm 20 RAS OUT The English display for Out Of Range Temperature Tol erance is T RANGE The code display is FN11 The choices are A B or C A 3 6 F 2 C B 5 4 F 3 C and C 7 2 F 4 C When the out of range temperature is configured ON the microprocessor indicates out of range when the temperature has been within the tolerance band at least once and then goes outside the tolerance band for 45 minutes Also the unit will shut down When the out of range temperature is configured OFF the microprocessor indicates out of range when the temperature has been within the tolerance band at least once and then goes outside the tolerance band for 15 minutes Also the unit will continue to operate For set points at or below 10 F 12 2 C frozen range the unit is only considered out of range for tempera tures above set point Code Vs English Messages The function descriptions unit status and alarms can be displayed in English or codes through this function selection The choices are displayed as ENGLISH or CODES Refer to Table 2 1 for a listing of the display readings when the English or Code choice is activated Manual Glow Override The auto start glow time can
54. The English dis play is MOD V The code display is CD12 Software Revision The English display for the Eeprom Software Revision is REV The code display is CD13 The actual Eeprom software revision number is displayed on the right If the ENTER key is depressed for three seconds while the Eeprom Software Revision is displayed the display will revert to the Board Mounted Software display The En glish display will change to REV U2 on the left and the actual board mounted software revision number will be displayed on the right Serial Number Low The English display for the Low Serial Number of the Eeprom is SERL The code display is CD14 The lower 3 digits of the Eeprom serial number will be dis played on the left i e SERL 504 or CD14 504 Serial Number Upper The English display for the Upper Serial Number of the Eeprom is SERU The code display is CD15 The upper 3 digits of the Eeprom serial number will be dis played on the left i e SERH 001 or CD14 001 Compartment 2 Air Temperature N A The English display for the Second Compartment Air Temperature is 2RA the code display is CD16 Compartment 3 Air Temperature The English display for the Third Compartment Air Tem perature is 3RA the code display is CD17 Maintenance Hour Meter 1 The English display for the Maintenance Hour Meter 1 is MHR 1 the code display is CD18 The data is dis played with un
55. Use a low silicate anti freeze Water Thermostat Temperature Coolant inlet cold side Remove all foreign material from the radiator con denser coil by reversing the normal air flow Air is pulled in through the front and discharges over the standby motor Compressed air or water may be used as a cleaning agent It may be necessary to use warm water mixed with any good commercial dish washer detergent Rinse coil with fresh water if a de tergent is used Drain coolant by removing lower radiator hose and ra diator cap Install hose and fill system with clean untreated wa ter to which three to five percent of an alkaline based radiator cleaner should be added six ounces dry 151 grams to one gallon 3 78 liters of water Run engine 6 to 12 hours and drain system while warm Rinse system three times after it has cooled down Refill system with water Run engine to operating temperature Drain system again and fill with treated water anti freeze see Cau tion and refer to section 1 2 NEVER POUR COLD WATER INTO A HOT ENGINE however hot water can always be added to a cold engine Oo o Coolant outlet hot side Figure 4 1 Coolant System When changing oil filters the new filters should be primed with clean oil If the filters are not primed the engine may operate fora period with no oil supplied to the bearings 62 10828 After warming up the engine stop engine remove drain plug f
56. aporator Fan Motors EFM1 through 3 The microprocessor continues to monitor inputs to de termine required modes of operation The inputs include the Suction Pressure Transducer SPT Return Air Sensor RAS Supply Air Sensor SAS and the Com pressor Discharge Transducer CDT 62 10828 As required the microprocessor will take the following actions On call for heat the Heat Relay HR is energized to close a set of contacts and energize the hot gas bypass solenoid valve HGS2 and the hot gas valve HGS1 placing the unit in the heat mode In the heat mode the microprocessor also energizes the Evaporator Heat Relay EHR Energizing EHR closes a set of contacts to energize the Evaporator heat Contactor EHC which closes it s contacts to energize the Evaporator Heaters On call for defrost the microprocessor energizes the hot gas bypass solenoid valve HGS2 and the hot gas valve HGS1 inthe same manner as in heat Also DT is de energized stopping the evaporator fan motors 3 2 3 Auto Start Sequence Refer to SECTION 6 for a schematic diagram of the unit controls To facilitate location of the components re ferred to in the written text the schematic has map coordinates added to the margins These locations have also been added to the legend In order to provide complete information the following description is writ ten as if all options are installed Indications of specific unit applicability and optional equ
57. aria ai tee aia eae da aa ach deep ante AEs 2 7 2 412 2 9 2 4 13 Stopping Instructions 2 11 CONTROL LOGIC AND TEMPERATURE CONTROL 22 222 nnn nn nnn 2 1 34 MODES OF OPERATION iets ELE uo Rs 3 1 3 1 1 Startup and Pull Down Engine Operation 3 1 3 1 2 Startup and Pull Down Standby Operation 3 1 3 130 Null Mode Oveirides resp EEN ee eh A WR M epe bn 3 1 3 1 4 Dual Probe Operation uaanaanannananannannn 3 2 3 1 5 Fuel Heater Operation 3 2 31 6 Defrost Mode mi uu gs ais 3 2 3 1 7 Unloading in Temperature MOJA wwa srra aa AAA eens 3 3 3 1 8 Auto Diesel Restart Option ananaananannannn 3 5 3 2 SEQUENCE OF OPERATION a g aiaa KE hn mnn 3 5 3 2 1 Engine Drive o coco Dy aser rev encode epu eges eoo eund ses eo epu e E d 3 5 9 2 2 amp Standby 5 nm oec a O a fee o S e EE 3 6 3 2 8 Auto Start Sequence suser rr vr ese 3 6 62 10828 ii PARAGRAPH NUMBER Page CONTROL LOGIC AND TEMPERATURE CONTROL 222 22 nnn nnn nnn 3 1 3 1 MOIES GE OPERATION 2 peres repertis nete re ctr Ree ette tap Ros dace UE ok 3 1 3 1 1 Startup and Pull Down Engine Operation 3 1 3 1 2 Startup and Pull Down Standby Operation 3 1 3
58. at zero apply air pressure very slowly to the air switch An ohmmeter will indi cate continuity when switch actuates f Refer to section 1 6 3 for switch settings If switch fails to actuate at correct gauge reading adjust switch by turning adjusting screw clockwise to increase set ting or counterclockwise to decrease setting g Repeat checkout procedure until switch actuates at correct gauge reading 2 After switch is adjusted place a small amount of paint or glycerol onthe adjusting screw so that vibration will not change switch setting Ohmmeter or Continuity Device Adjustment Screw 0 050 socket head size Low Side Connection Pressure Line or Aspirator Bulb P N 07 00177 01 Magnehelic Gauge P N 07 00177 High Side Connection Figure 4 15 Defrost Air Switch Test Setup DN BR NDT 4 14 CHECKING AND REPLACING EVAPORATOR FAN MOTOR BRUSHES 4 COMMUTATOR The fan motor commutator and brushes should be checked periodically for cleanliness and wear to main tain proper operation of the the fan motors 1 Brush Cap 2 Brush Figure 4 16 Fan Motor Brushes To check brushes proceed as follows a With unit off and battery disconnected remove brush cap item 1 2 per motor See Figure 4 16 b Remove brushes item 2 2 per motor and check the length of the brush If the length is less than 1 4 inch the brushes should be replaced after checking com mutator c Blow out the brush holder with low p
59. ature control system and then restart the engine when needed Start Stop operation is normally used for frozen loads Enter Set Point and change Functional Parameters to match the requirements of the load Whenever the unit starts in Auto Start Stop it will run until elt has run for the predetermined minimum run time The engine coolant temperature is above 122 F 50 C The box temperature is at setpoint The controller will not shut off the engine if the battery voltage is not sufficient to restart it Battery voltage above approximately 13 4 volts is required for shutdown This varies depending on ambient Look at battery voltage in data list to find out whether shutdown voltage has been reached If there is a in front of the number the voltage is enough to shutdown and restart If only the number appears the voltage is still too low for shutdown The controller will restart the engine if any of the following criteria have been met eBox temperature has changed by 11 F 6 1 C for setpoints in the perishable range and 4117 F 6 1 C for setpoints in the frozen range DURING minimum off time Box temperature has moved away from setpoint by 3 6 F 2 0 C AFTER minimum off time for setpoints in the perishable range or 0 5 F 0 3 C for setpoints in the frozen range The battery voltage drops below 12 2 VDC Refer to Table 2 2 for unit data The engine coolant temperature drops below 34 F
60. b Compressor Unloader 850 and 950 Only Refer to Section 3 1 7 for detailed information on unloader temperature control The Supra 850 and 950 unit compressors are fitted with one electric unloader valve The capacity controlled cyl inder is easily identified by the solenoid which extends from the side of the cylinder head When the solenoid is energized two cylinders are unloaded The unloaded cylinders operate with little or no pressure differential consuming very little power A description of unloader operation is provided in the following steps Unloaded Operation Pressure from the discharge manifold Figure 1 7 item 15 passes through the strainer 9 and bleed orifice 8 to the back of the piston bypass valve 7 Unless bled away this pressure would tend to close the piston 6 against the piston spring 5 pressure With the solenoid valve 1 energized the solenoid valve stem 2 will open the gas bypass port 3 Refrigerant pressure will be bled to the suction manifold 10 through the opened gas bypass port A reduction in pressure on the piston bypass valve will take place be cause the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice 8 When the pressure behind the piston has been reduced sufficiently the valve spring will force the piston bypass valve back opening the gas bypass from the discharge manifold to the suction manifold Discharge pressure in t
61. be manually overridden through this function The choices are displayed as NORM GLOW or ADD GLOW If the ADD GLOW selection is entered the control will add additional glow time Alarm Reset Alarms can be reset through this function The mes sages are displayed as ALARM RST or ALARM CLR If the ALARM RST is displayed then there is at least one alarm present Pressing the ENTER key will clear all the alarms If ALARM CLR is displayed then there are no alarms present 2 4 11 Unit Data The UNIT DATA key can be used to display the micro processor input data values The display will show the description of the input on the left side with the actual data on the right side The unit data list can be scrolled through by pressing the UNIT DATA key With each successive key push the list is advanced one If the UNIT DATA or an ARROW key is held for one second the list will scroll at a rate of one item every 0 5 seconds Oncethe end ofthe list is reached the list will scroll back to the first entry The display will revert back to the default display if no keys are pressed for 5 seconds If the ENTER key is pressed the display time will be increased to 30 seconds A description of the unit data readings is provided in the following paragraphs A Unit Data listing is provided in Table 2 2 2 7 Table 2 1 Functional Parameters CODE ENGLISH DATA DEFR Defrost Interval F 0 REM Controlling
62. bient temperatures of 90 F or higher the un loading suction pressure settings relative to ambient temperatures are a straight line Refer to chart below STANDBY OPERATION SUCTION PRESSURES UNLOADING SUCTION PRESSURE PSIG 80 90 100 110 120 130 AMBIENT TEMPERATURE F High Ambient Control 850 Only The refrigeration system will control discharge pressure in both diesel and standby and will control the unloader in the following manner Diesel At discharge pressures of 440 10 PSIG 30 0 7 Bar and higher the refrigeration system will be forced into unloaded operation until the discharge pressure is re duced to 367 12 PSIG 25 0 8 Bar Standby The refrigeration system is controlled by the Standby Unloader Front Relay SUFR and is always forced into unloaded operation 3 1 8 Auto Diesel Restart Option IfAC power is lost for five minutes or more configuration 10 is active and TIME START is enabled the diesel engine will start and run until AC power is restored and applied forfive minutes When the five minute shutdown timer expires and AC power is present the unit will shut down the diesel engine and restart the standby motor If AC power is NOT present the diesel engine will operate as required Once the unit has cycled off it will remain off for the minimum off time of five minutes This prevents rapid cycling due to changes in air temperature Air tempera ture in the box changes
63. burns Do not remove the cap from a hot radiator if the cap must be removed do so very slowly in order to release the pressure without spray REFRIGERANTS The refrigerant contained in your unit can cause frostbite severe burns or blindness when in direct contact with the skin or eyes For this reason and because of legislation regarding the handling of refrigerants during system service we recommend that you contact your nearest Carrier Transicold authorized repair facility whenever your unit requires refrigeration system service Safety 1 62 10828 BATTERY This unit is equipped with a lead acid type battery The battery normally vents small amounts of flammable hydrogen gas Do not smoke when checking the battery A battery explosion can cause serious physical harm and or blindness SPECIFIC WARNING AND CAUTION STATEMENTS To help identify the label hazards on the unit and explain the level of awareness each one carries an explanation is given with the appropriate consequences DANGER means an immediate hazard which WILL result in severe personal injury or death WARNING means to warn against hazards or unsafe conditions which COULD result in severe personal injury or death CAUTION means to warn against potential hazard or unsafe practice which could result in minor personal injury product or property damage The statements listed below are specifically applicable to this refrigeration unit and appear elsewhere in this
64. cedure operate the unit in high speed cooling until the box tempera ture is below 20 F 6 7 C Partially block off air flow to condenser coil to raise discharge pressure to 210 psig 14 8 kg cm Bring the setting to greater than 10 degrees below box temperature to ensure the unit remains in high speed cool with the unload ers de energized 6 Note the average temperature of the suction gas at the expansion valve bulb and average pressure on the gauge 7 From the temperature pressure chart Table 4 6 determine the saturation temperature correspond ing to the suction pressure 8 Subtract the saturation temperature determined in step 7 from the average temperature measured in step 6 The difference is the superheat of the suction gas Refer to section 1 6 3 for required setting 4 19 4 TXV Bulb 5 Thermocouple 1 Suction Line 2 TXV Bulb Clamp 3 Nut and Bolt Figure 4 21 Thermostatic Expansion Valve Bulb and Thermocouple b Adjusting Superheat See Figure 4 20 Check superheat refer to preceding step 2 If superheat is too low increase superheat by turning adjustment screw see Figure 4 20 clockwise Ad just in 1 4 turn increments one complete turn equals approximately a seven degree change in superheat and re check superheat repeating readings until they are consistent Ensure maximum tolerance has not been exceeded 3 If superheat is too high decrease by turning adjust ment screw see Figu
65. closed If the high pressure switch is open power will not be ap plied to microprocessor terminal M1 and operation will not be allowed Energizing RR closes a set of contacts to supply power to the alternator ALT Run Solenoid RS Fuel Pump FP and Fuel Heater Relay FHR RS energizes to open the engine fuel rack FP energizes to pump fuel to the injection pump and FHR energizes to close a set of contacts supplying power to the fuel heater thermostat The fuel heater thermostat closes to energize the fuel heater at temperatures below the option setting The engine is thus prepared for start up The microprocessor will now run the Auto Start Se quence refer to Section 3 2 3 to start the engine The Glow Plug Relay GPR is energized to close a set of contacts SSC and provide power to the Glow Plugs GP as required to preheat the engine cylinders The Starter Solenoid Relay SSR will then be energized to close a set of contacts and energize the Starter Sole noid SS Energizing SS closes a set of contacts to energize the Starter Motor SM and crank the engine During cranking a signal is also supplied to microproces sor terminal L2 Once the engine starts and and the alternator begins to produce power the microprocessor senses the power at terminal L3 and the start sequence is terminated The microprocessor ignores the Oil Pres sure Switch OP signal for 15 seconds to allow the engine time to develop sufficient pressure to
66. d Fuel pump FP malfunction Check Fill Tank Repair Engine Manual 4 1 5 Engine Manual Engine Manual 4 1 4 1 7 4 1 3 4 1 5 5 1 3 Starter Motor Malfunction Starter motor will not crank or turns slowly Battery insufficiently charged Battery cable connections loose or oxidized Battery cables defective Starter brushes shorted out Starter brushes hang up or have no contact Starter solenoid damaged I O or START RUN Switch defective Engine lube oil too heavy Check Check Replace Engine Manual Engine Manual Engine Manual Replace 1 6 62 10828 INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 1 3 Starter Motor Malfunction CONTINUED Starter motor turns but pinion does not engage Clean both remove burrs or replace apply grease Pinion or ring gear obstructed or worn Starter motor does not disengage I O or START RUN Switch defective Replace after switch was depressed Starter motor solenoid defective Engine Manual Pinion does not disengage after engine is running Defective starter Engine Manual 5 1 4 Malfunction In the Engine Starting Circuit No power to starter motor solenoid SS Run solenoid does not energize or does not remain energized Battery defective Loose electrical connections Battery defective Loose electrical connections Oil pressure safety switch OP defective Run relay RR defective Water temperature safety switch open Water temperature sensor WTS d
67. d method is to disconnect the wire connection to the plug and test the resistance from the plug toa ground on the engine block 4 1 7 Alternator Observe proper polarity reverse polarity will destroy the diodes As a precaution disconnect positive terminal when charg ing Positive Output Terminal Regulator 12vdc Test Lamp Terminal Ground Terminal The alternator and regulator are housed in a single as sembly A diagram for alternator troubleshooting or re placement is provided below See Figure 4 5 a Inspection Verify tightness of connections If excitation wire is dis connected the unit will display ALT AUX and battery will not recharge during unit operation b Brushes Maintenance Schedule and Table 4 1 1 Make sure battery terminals and alternator exciter cable are disconnected 2 Remove the two screws holding the regulator 3 Replace the brushes 4 Reassemble the regulator c Voltage control 1 Power up the unit 2 Press UNIT DATA until voltage measurement output is displayed Figure 4 5 70 Amp Alternator P N 30 60050 04 62 10828 4 2 SERVICING AND ADJUSTING V BELTS Beware of V belts and belt driven compo nents as the unit may start automatically 4 2 1 Belt Tension Gauge Use a belt tension gauge Carrier P N 07 00203 see Figure 4 7 when replacing or adjusting V belts The belt tension gauge provides an accurate and easy method of adjusting belts to the
68. e Air Cleaner a Inspection The air cleaner hose and connections should be in spected for leaks A damaged air cleaner or hose can seriously affect the performance and life of the engine If housing has been dented or damaged check all con nections immediately Stop engine remove air filter Install new air filter When inspecting air cleaner housing and hoses check the connections for mechanical tightness and look for fractures in the inlet and outlet hoses When leakage occurs and adjustment does not correct the problem replace necessary parts or gaskets Swelled or dis torted gaskets must always be replaced 62 10828 4 1 5 Fuel Filter and Fuel Circuit Resirictor fitting Return tube lt E Injection pump Bleed port Fuel filter Fuel pump Injectors Supply line gt Return line Figure 4 3 Fuel System a Checking fuel circuit 1 The engine must run with bleed port slightly un screwed This indicates that the injection pump pres sure is greater than 1 47 psig 0 1 Bar Check for air leakages and clean fuel lines if pressure isn t correct 2 The electrical pump is designed to deliver 10 30 psig 0 7 Bar The fuel circuit flow rate in the
69. e cut in setting 62 10828 3 1 6 Defrost Mode Defrost is an independent cycle overriding cooling and heating functions to de ice the evaporator as required The controller displays DF during defrost mode on the right hand temperature display The left hand display will continue to display the setpoint Defrost may only be initiated if the defrost termination thermostat DTT is closed The DTT closes on a tem perature fall at 37 F 3 C to signal the microprocessor that the coil temperature is low enough to allow the build up of frost Defrost is terminated when the DTT opens again on a temperature rise at 47 F 8 C signaling the microprocessor that the coil has been warmed to the point that the frost buildup should have been removed During defrost the unit enters the heat mode and the evaporator fans are de energized This will prevent the circulation of warm air to the load If the unit is shut down for any reason during a defrost cycle run relay is de en ergized the microprocessor defrost cycle is terminated and the unit will restart normally For 950 units only the defrost damper if provided is closed at defrost start and is kept closed for 90 seconds with heat on for 60 seconds after defrost has terminated a Defrost Timer Initiation Timed defrost is controlled by the setting of Functional Parameter FNO and may be set for 1 5 3 6 or 12 hours The microprocessor will place the unit into the defrost mode
70. e designated by an F following the reading i e WT 185 0F or CD3 185 0F while the metric are designated by a C i e WT 85 0C or CD3 85 0C The display range is 10 F to 266 F 12 C to 130 C Return Air Temperature The English display for Return Air Temperature is RAS the code display is CD4 The English units are designated by an F following the reading i e RAS 35 0F or CD4 35 0F while the metric are designated by a C i e RAS 1 7C or CD4 1 7C The display range is 10 F to 266 F 12 C to 130 C 62 10828 2 8 Supply Air Temperature The English display for Supply Air Temperature is SAS the code display is CD5 The English units are designated by an F following the reading i e SAS 35 0F or CD5 35 0F while the metric are designated by a C i e SAS 1 7C or CD5 1 70 The display range is 36 F to 158 F 38 C to 70 C The data will be dis played only if the SUP PROBE is selected in the control ling probe functional parameter Remote Air Temperature The English display for Remote Air Temperature is REM the code display is CD6 The English units are designated by an F following the reading i e REM 35 0F or CD6 35 0F while the metric are designated by a C i e REM 1 7C or CD6 1 70 The display range is 36 F to 158 F 38 C to 70 C The data will be dis played only ifthe REM PROBE is selected in the control ling probe functio
71. e engine is OFF and negative battery cable is discon nected before replacing the compressor a Removing If compressor is inoperative and unit still has refrigerant pressure frontseat suction and discharge service valves to trap most of the refrigerant in the unit If compressor runs pump down the unit Refer to sec tion 4 4 a 1 Slowly release compressor pressure to a recovery system 2 Remove bolts from suction and discharge service valve flanges 3 Disconnect wiring to compressor discharge temper ature sensor CDT suction pressure transducer SPT and the wiring to the high pressure switch HP 4 Release idler pulleys and remove belts Removethe four bolts holding the compressor to the power tray Remove the compressor from chassis Remove the pulley from the compressor Drainoil from defective compressor before shipping Installing To install the compressor reverse the procedure out lined when removing the compressor Refer to sec tion 1 6 5 for torque values NOTE The service replacement compressor is sold without shutoff valves but with valve pads Customer should retain the original capacity control valves for use on replacement compres sor Check oil level in service replacement com pressor Refer to sections 1 6 2 and 4 9 OND 2 Attach two lines with hand valves near vacuum pump to the suction and discharge service valves Dehydrate and evacuate compressor to 500 m
72. e is disconnected before replacing the compressor 62 10828 Safety 2 A CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded Re verse polarity will destroy the rectifier diodes in alternator As a precautionary measure disconnect positive battery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator 44 CAUTION Underno circumstances should anyone attemptto repairthe microprocessor orthe Logic or Display Boards Should a problem develop with these components contact your nearest Carrier Transicold dealer for replacement 44 CAUTION Unit with R404A and POE oil the use of inert gas brazing procedures is mandatory otherwise com pressor failure will occur For more information see Technical Procedure 98 50553 00 Inert Gas Braz ing 44 CAUTION Use only ethylene glycol anti freeze with inhibitors in system as glycol by itself will damage the cooling system Always add pre mixed 50 50 anti freeze and water to radiator engine Never exceed more than a 50 concentration of anti freeze Use a low silicate anti freeze A CAUTION When changing oil filters the new filters should be primed with clean oil If the filters are not primed the engine may operate for a period with no oil supplied to the bearings 44 CAUTION When changing fuel filter the new filter should be filled with clean fuel 44 CAUTIO
73. ecessary a Remove rubber check valves Kazoo from drain lines b Spray coil with a mild detergent solution such as Oakite 164 or any good commercial grade automatic dish washer detergent such as Electrosol or Cascade and let the solution stand for a few minutes and re 4 17 verse flush opposite normal air flow with clean water at mild pressure A garden hose with spray nozzle is usually sufficient Make sure drain lines are clean c Run unit until defrost mode can be initiated to check for proper draining from drain pan 4 16 CONDENSER COIL CLEANING Refer to section 4 1 1 4 17 SOLENOID VALVES 4 17 1 Supra 550 650 750 850 3 Way Valve 1 Snap cap 2 Voltage plate 3 Coil assembly 4 Valve body assembly Figure 4 17 HOT GAS Three Way VALVE Supra 550 650 750 850 a Replacing solenoid coil It is not necessary to pump the unit down to replace the coil See Figure 4 17 a Remove snap cap to remove coil Disconnect from harness b Verify coil type voltage and frequency This informa tion appears on the coil voltage plate and the coil housing c Place new coil over enclosing tube and then install voltage plate and snap cap d Replacing solenoid valve internal parts Remove and store the refrigerant charge in an evac uated container Refer to Section 4 4 2 Remove snap cap to remove coil
74. ection 4 6 62 10828 4 10 b Removing the Refrigerant Charge Connect a refrigerant recovery system Carrier p n MVS 115 F L CT 115V or MVS 240 F L CT 240V to the unit to remove refrigerant charge Refer to instruction provided by the manufacture of the refrig erant recovery system 4 5 REFRIGERANT LEAK CHECKING If system was opened and repairs completed leak check the unit a The recommended procedure for finding leaks in a system is with an electronic leak detector Carrier p n 07 00295 00 Testing joints with soapsuds is satis factory only for locating large leaks If system is without refrigerant charge system with refrigerantto build up pressure between 2 1 to 3 5 kg cm 30 to 50 psig Remove refrigerant cylinder and leak check all connections NOTE Use only the correct refrigerant to pressurize the system Any other gas or vapor will contami nate the system which will require additional purging and evacuation of the high side dis charge of the system on c Remove refrigerant using a refrigerant recovery sys tem and repair any leaks Evacuate and dehydrate theunit Refer to section 4 6 Charge unit with refrig erant Refer to section 4 7 4 6 EVACUATION AND DEHYDRATION 4 6 1 General Moisture can seriously damage refrigerant systems The presence of moisture in a refrigeration system can have many undesirable effects The most common are copper plating acid sludge formation freezing
75. ectronic transistorized device No mechanical contacts or relays are used to perform the voltage regulation of the alternator system The electronic circuitry should never require adjustment and the solid state active elements used have proved reli able enough to warrant a sealed unit The regulator is an electronic switching device It senses the voltage appearing at the auxiliary terminal of the alternator and supplies the necessary field current for maintaining the system voltage at the output termi nal The output current is determined by the load Positive Output Terminal Regulator 12vdc Test Lamp Terminal Ground Terminal Figure 1 6 70 Amp Alternator P N 30 60050 04 1 3 2 Condensing Section Refrigeration System The condensing section mounted refrigeration system equipment includes the compressor condenser sub cooler accumulator defrost air switch filter drier re ceiver hot gas three way valve hot gas bypass valve except for 950 and compressor pressure regulating valve a Compressor The compressor assembly includes the refrigerant com pressor suction and discharge service valves high pressure switch unloader s 850 and 950 only andthe suction pressure transducer The compressor draws refrigerant gas from the evaporator and delivers it tothe condenser at an increased pressure The pressure is such that refrigerant heat can be absorbed by the sur rounding air at ordinary temperatures
76. eects 4 20 4 21 MICROPROCESSOR REPLACEMENT and CONFIGURATION 4 20 4 21 1 To Remove and Replace Microprocessor Logic Board 4 20 4 21 2 To Reach The Configuration Fields From The Keypad 4 21 4 22 CONTROLLER SENSOR CHECKOUT sssssssses ees mn 4 21 4 28 SUCTION PRESSURE TRANSDUCER 0 0000 ees m 4 24 62 10828 iv TABLE OF CONTENTS PARAGRAPH NUMBER Page TROUBLESHOOTING at da 5 1 ba DIESEL ENGINE cuatri rd AE ai 5 1 5 1 1 Engine Will Not Start oocccccccccccocccn er 5 1 5 12 Engine Starts Ther SOS mi AE M epist Th 5 1 5 1 3 Starter Motor Malfunction 5 1 5 1 4 Malfunction In the Engine Starting Circuit 5 2 5 2 sAETERNATOR A EE roh 5 2 5 3 REFRIGERATION ue xp eb rix pu ERI Rx qan 5 3 3 1 Unit Will NOEGOOl 7 ee cece pices pete ids re da ded 5 3 5 3 2 Unit Runs But Has Insufficient Cooling 5 3 5 3 3 Unit Operates Long or Continuously in Cooling 5 3 5 3 4 Unit Will Not Heat or Has Insufficient Heating 5 3 5 3 5 Defrost Cycle Malfunction ann 5 4 538 Abnormal Pressure II rete ette id A eae eid er 5 4 5 9 6 1 Cooling 1 cie eph Le E ME eT b ERR ME eee bir PM
77. eed Mode 5 Buzzer Off Key 12 Cool Mode 19 Out of range 6 Enter Key 13 Heat Mode 20 Fault Light Figure 2 1 Cab Command 2 1 62 10828 g A Pre Trip checkout of refrigeration unit operation h An optional RS232 communication port to communi cate unit operating data to a mobile satellite transmit ter This information will then be relayed back to the office via a modem to a computer There are presently three 3 protocols supported The protocol for the QualComm transmitter the pro tocol for the HUGHES transmitter and the Carrier Communication Protocol The microprocessor will transmit a HUGHES protocol packet every hour Transmission with the Carrier or QualComm protocol is by request 2 2 MICROPROCESSOR CONFIGURATION The microprocessor is configured in accordance with the equipment supplied on an individual unit and the requirements of the original purchase order The config urations do not require change unless the unit has an equipment change or a change is required by the owner Although the configurations may not be modified using the keypad operational differences will be noted throughout the following descriptions and operating pro cedures See NO TAG for list of microprocessor config urations Some microprocessor settings such as setpoint and functional parameters may be changed at the keypad and are described in the following sections 2 3 DESCRIPTION OF MICROPROCESSOR COMPONENTS 2 3 4 Keypad The
78. efective Run solenoid defective I O or START RUN Switch defective Check Tighten Check Tighten Replace Replace 1 6 Replace 4 1 3 Replace 5 2 ALTERNATOR AUTOMOTIVE TYPE Alternator fails to charge Low or unsteady charging rate Excessive charging rate as evidenced by battery requiring too frequent refilling or charge indicator shows constant charge with engine idling Noisy alternator 62 10828 Limited charging system operating time Battery condition Alternator belt loose broken Loose dirty corroded terminals or broken leads Excessively worn open or defective brushes Open blocking diode Regulator faulty Open isolation diode Open rotor field coil Alternator belt loose Loose dirty corroded terminals or broken leads Excessively worn sticky or intermittent brushes Faulty regulator Grounded or shorted turns in rotor Open grounded or shorted turns in stator Regulator leads loose dirty corroded terminals or wires broken Defective regulator Defective or badly worn V belt Worn bearing s Misaligned belt or pulley Loose pulley 5 2 4 2 Check Repair Check Check Check Check Replace 4 2 Check Repair Check Check Check Replace Clean Repair Check INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 3 REFRIGERATION 5 3 1 Unit Will Not Cool Diesel engine Malfunction s 5 1 Compressor malfunction Compressor drive defective 4 8 Compressor defective 4 8 Refri
79. embly failure or partial Replace Loss of element bulb charge Replace Superheat setting too high Low superheat and liquid Superheat setting too low slugging in compressor External equalizer line plugged Ice holding valve open Foreign material in valve Pin and seat of expansion valve eroded or held open by foreign material Fluctuating suction Improper bulb location or installation pressure Low superheat setting 5 3 11 Hot Gas Three Way Valve Malfunction Valve does not function properly No power to valve Improper wiring or loose connections Coil defective Valve improperly assembled Coil or coil sleeve improperly assembled Temperature controller malfunction Replace Movement of plunger restricted due to a Corroded or worn parts b Foreign material lodged in valve c Bent or dented enclosing tube Valve shifts but refrigerant Foreign material lodged under seat 4 17 continues to flow Defective seat 4 17 5 4 Standby Motor Malfunction Standby motor fails to start Motor contactor MC defective Replace Motor Overload OL open Replace motor Improper power supply 1 6 Oil pressure switch OPS open Cab Command defective Standby motor starts then stops Motor Overload OL open High amperage draw 62 10828 5 6 SECTION 6 ELECTRICAL SCHEMATIC WIRING DIAGRAM INTRODUCTION This section contains Electrical Schematic Wiring Diagram covering the Models listed in Table 1 1 The following general safety notices supplement the
80. ensor WTS The microprocessor will stop the unit when this sensor signals a high water temperature condition The sensor is located on the engine cylinder head 5 High Pressure Cutout Switch HP1 This switch will automatically stop the engine when compressor discharge pressure exceeds the set point The switch is located on the compressor cylinder head 6 High Pressure Cutout Switch HP2 850 Only This switch is used to unload the compressor in high ambient conditions 7 Compressor Discharge Temperature Sensor CDT except for 850 The microprocessor will stop the unit when this sensor signals a high discharge temperature condition The sensor is located on the compressor center head 8 Compressor Suction Pressure Transducer SPT The Compressor Suction Pressure Transducer signal is used by the microprocessor in the compressor protec tion logic to protect the compressor under excessive suction pressure conditions and under excessively low suction pressure conditions The sensor is located on the compressor body for all units except 850 It is lo cated in the suction line for 850 units 9 Ambient Temperature Sensor ATS 950 Only The Ambient Temperature Sensor signal is used by the microprocessor in the compressor protection logic to determine expected conditions It is located between the condenser and the front grille 10 Temperature control sensors Boxtemperature is controlled by one or two sensors RAS
81. et then replace drier b Check refrigerant level Refer to section 4 7 1 4 12 CHECKING AND REPLACING HIGH PRESSURE SWITCH 4 12 1 Replacing High Pressure Switch a Pump down the unit Refer to section 4 4 a Frontseat both suction and discharge service valves to isolate compressor b Slowly release compressor pressure through the ser vice valve gauge ports to refrigerant recovery device c Disconnect wiring from defective switch The high pressure switch is located near the top of the com pressor See Figure 4 12 d Install new cutout switch after verifying switch set tings Refer to section 1 6 2 e Evacuate and dehydrate the compressor Refer to section 4 8 62 10828 4 12 2 Checking High Pressure Switch Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 psi 165 kg cm2 Do not use oxygen in or near a refrigerant system as an explosion may occur See Figure 4 14 Oylinder Valve and Gauge Pressure Regulator Nitrogen Cylinder Pressure Gauge 0 to 400 psig O to 28 kg cm Bleed Off Valve 1 4 inch Connection Figure 4 14 Typical Setup for Testing High Pressure Switch Remove switch as outlined in section 4 12 1 Connect ohmmeter or continuity light across switch terminals Ohmmeter will indicate resistance and continuity light will be lighted if switch closed after re lieving pressure Connect switch to a cylinder of
82. f o ring isto be replaced always put refrigerant oil on o rings be fore installing Tighten enclosing tube assembly If the valve has not been removed from the unit leak check the valve Install coil assembly voltage cover and cap Evacuate and dehydrate the unit Install a complete refrigerant charge Start unit and check operation Oo ON OD 4 18 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE CPR The CPR valve is factory pre set and should not need adjustment If it is necessary to adjust the valve for any reason proceed with the following outline When adjusting the CPR valve the unit must be running in the high speed heat or defrost This will ensure a suction pressure above the proper CPR setting EX N Er www b www Kl AS 1 Cap 2 Jam Nut 3 Setting Screw Figure 4 19 Compressor Pressure Regulating Valve To adjust the CPR valve proceed as follows a Install a manifold gauge set b Remove cap item 1 from CPR valve c With an 8 mm Allen wrench loosen the jam nut Figure 4 19 item 2 d Using the 8 mm Allen wrench adjust the setting Screw To raise the suction pressure turn the setting screw item 3 clockwise to lower the suction pres sure turn the setting screw counterclockwise Refer to section 1 6 3 for CPR valve setting e When the setting has been adjusted tighten the jam nut securely against the setting screw item 3 This will prevent any movement of the settin
83. failure alarm is activated The system is configured for cooling mode for engine or standby start default mode Once unit is considered running it will maintain setpoint temperature by switch ing between heat and cool When in the null mode two conditions will override nor mal microprocessor off time and or temperature control If the unit is in the Engine Drive or Standby mode and battery voltage falls below 11 volts the engine or motor will be restarted to allow the alternator to recharge the battery If the unit is in the Engine Drive mode and the engine coolant temperature drops below 34 F 1 C the engine will be restarted General operation sequences for cooling null and heating are provided in the following paragraphs The microprocessor automatically selects the mode neces sary to maintain box temperature at setpoint 62 10828 CONTINUOUS MODE DIESEL STANDBY 3 3 HS Cool 2 7 F 1 5 C 29 Wee 0 5 F 0 3 C 0 5 F 0 3 C Perishable Perishable setpoint ose 0 3 00 Setpoint gt 10 4 F 12 C LS Heat SES gt 10 4 F 12 C 0 5 F 0 3 C 2 2 F 1 2 C 2 7 F 1 50 3 6 F 2 C He 66 2 2 F 1 2 C Frozen Frozen setpoint setpoint gt 10 4 F 12 C gt 10 4 F 12 C SUPRA 550 650 750 850 Figure 3 2 TEMPERATURE CONTROL SEQUENCE CONTINUOUS MODE 62 10828 3 8 START STOP MODE DIESEL STANDBY 3 3 6 F 2 C 2 7 F 1 5 C 0 5 1 2 C EE SE 0 5
84. fication 1 5 Table 1 4 Relay Identification 1 5 Table 1 5 Test Point Identification 1 6 Table 1 9 Safety Devices Microprocessor Controller 1 16 Table 2 1 Manual Glow Time 2 4 Table 2 1 Functional Parameter 2 7 Table2 2 Unit Data Codes 1r ee e dee bree ed OD LPRR GIR Dex 2 8 Jable 2 3 Alarm Display 2 reser A pe A A ete eR REA T abe 2 9 Table 3 1 Unloading in Temperature Mode 3 3 Table 4 1 Service Category Descriptions 4 3 Table 4 2 Belt Tension See Figure 4 7 o o oocococcccccocnr e rnt 4 8 Table 4 3 Connection Point Voltage 4 20 Table 4 5 Sensor Resistance Micro Units ATS CDT RAS SAS amp WTS 4 24 Table 4 6 R 404A Temperature Pressure Chart nanannun 4 25 vii 62 10828 SAFETY SUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual They are recommended precautions that must be understood and applied during operation and maintenance of the equi
85. g screw due to vibrations in the unit Replace the cap 4 19 THERMOSTATIC EKPANSION VALVE The thermal expansion valve see Figure 4 20 is an automatic device which maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure The valve functions are a auto matic response of refrigerant flow to match the evapora tor load and b prevention of liquid refrigerant entering the compressor During normal operation the valve should not require any maintenance If service is re quired it should be performed only by trained person nel 1 Orifice 2 Strainer 3 Protective Cap 4 Adjustment Figure 4 20 Thermostatic Expansion Valve a To Measure Superheat NOTE The expansion valve and bulb location are located on the road side of the evaporator 1 Ensure charge level is correct refer to section 4 7 1 and ensure CPR setting is correct refer to section 4 18 2 Remove insulation from expansion valve bulb and suction line Ensure bulb and attachment area on suction line are clean 3 Place thermocouple above parallel to TXV bulb and then secure clamps making sure both the bulb and thermocouple are firmly secured to suction line as shown in Figure 4 21 Reinstall insulation cover ing both bulb and sensor 4 Connect an accurate gauge to the 1 4 port on the suction service valve 5 n order to ensure the pressure at the expansion valve is stable enough for this pro
86. g tube retainer and con nect wiring c Replacing Solenoid Valve Internal Parts 1 Pump down the unit Frontseat both service valves to isolate the compressor 2 Remove coil retainer see Figure 4 13 and coil 3 Remove enclosing tube collar item 4 using installa tion removal tool supplied with repair kit item 3 4 Check plunger for restriction due to a Corroded or worn parts b Foreign material lodged in valve c Bent or dented enclosing tube 5 Install new parts Do not overtighten enclosing tube assembly Torque to a value of 100 inch pounds 1 15 mkg 6 Remove supplied installation removal tool Install coil voltage plate and retainer 7 Evacuate and dehydrate the compressor 4 15 8 Start unit and check unloader operation Refer to section 4 10 a 1 amp 1 Retainer 7 Plunger Spring 2 Coil Assembly 8 Plunger Assembly 3 Installation Removal 9 Gasket Tool 10 Valve Body 4 Enclosing Tube 11 Gasket Collar 12 Bolt 5 O Ring 13 Gasket Bolt 6 Enclosing Tube 14 Piston Ring Figure 4 13 Unloader Solenoid Valve 4 11 CHECKING AND REPLACING FILTER DRIER To Check Filter Check for a restricted or plugged filter drier by feeling the liquid line inlet and outlet connections of the drier cartridge If the outlet side feels cooler than the inlet side then the filter drier should be changed To Replace Filter Drier a Pump down the unit per section 4 4 Remove brack
87. geration system Defrost cycle did not terminate 5 3 Abnormal pressure 5 3 Hot Gas three way valve malfunction 5 3 1 5 3 2 Unit Runs But Has Insufficient Cooling Compressor Compressor valves defective 8 Unloader malfunction 0 3 6 3 10 4 4 1 Refrigeration system Abnormal pressure 5 3 Expansion valve malfunction 5 8 No or restricted evaporator airflow 5 3 Unloader malfunction 4 1 1 Engine does not Speed control linkage 4 1 develop full rpm Engine malfunction 5 1 5 3 3 Unit Operates Long or Continuously in Cooling Container Hot Load Allow time to pull down Defective box insulation or air leak Correct Refrigeration system Abnormal pressure 5 3 6 Temperature controller malfunction 5 3 8 5 3 4 Unit Will Not Heat or Has Insufficient Heating Refrigeration Abnormal pressure 5 3 6 Temperature controller malfunction 5 3 8 Hot Gas three way valve malfunction 5 3 1 Compressor Compressor drive defective 4 8 Compressor defective 4 8 Engine does not develop Speed control linkage 4 1 3 full rpm Engine malfunction 5 1 5 3 62 10828 INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 3 5 Defrost Cycle Malfunction Will not initiate defrost automatically Will not initiate defrost manually Initiates but does not defrost Freguent defrost Does not terminate or cycles on defrost 5 3 6 Abnormal Pressure 5 3 6 1 Cooling High discharge pressure Low discharge pressure High suction pressure Low s
88. he Supra models are self contained one piece refrig eration heating units designed for truck applications The units consist of a condenser section located out side the truck body and an evaporator section which extends inside the body Two types of drives may be included Road Operation Both the TDB and TDS model units are equipped with an engine In the Road Operation mode the compressor and alternator are driven by the engine TDB units do not have standby motors A standby motor shell is installed without the motor winding to allow the same belt ar rangement for both units Standby Operation TDS units are equipped with an internal combustion diesel engine and an electric standby motor In Standby Operation the compressor and alternator are driven by the electric standby motor 1 3 CONDENSING SECTION The condensing section see Figure 1 1 Figure 1 2 amp Figure 1 3 contains the drive equipment alternator and the high side refrigeration system equipment The en gine radiator and refrigerant condenser are incorpo rated into a single condenser radiator assembly 62 10828 1 3 1 Drive Equipment The drive equipment includes the engine engine mounted clutch air cleaner muffler coolant overflow bottle drive belts and standby motor a Engine The engine Figure 1 1 item 3 is a TriVortex diesel manufactured by Kubota Engine operation is controlled by a Run Solenoid and a Speed Solenoid The engine is co
89. he discharge manifold will close the discharge piston check valve assembly 14 isolat ing the compressor discharge manifold from the individ ual cylinder bank manifold The unloaded cylinder bank will continue to operate fully unloaded until the solenoid valve control device is de energized and the gas bypass port is closed 1 Solenoid Valve 11 Oylinder Discharge 2 Valve Stem Valve 3 Gas Bypass Port 12 Valve Plate 4 Spring Guide 13 Oylinder Suction 5 Spring Valve 6 Piston 14 Discharge Piston 7 Piston Bypass Valve Check Valve 8 Bleed Orifice Assembly 9 Strainer 15 Discharge Manifold 10 Suction Manifold Figure 1 7 Cylinder Head Unloaded 62 10828 Loaded Operation Discharge pressure bleeds from the discharge manifold Figure 1 8 item 15 through the strainer 9 and 8 bleed orifice to the solenoid valve stem 2 chamber and the back of the piston bypass valve 7 With the solenoid valve 1 de energized the solenoid valve stem will close the gas bypass port 3 Refrigerant pressure will overcome the bypass valve spring 5 tension and force the piston 6 forward clos ing the gas bypass from the discharge manifold to the suction manifold 10 Cylinder discharge pressure will force open the dis charge piston check valve assembly 14 Refrigerant gas will pass into the compressor discharge manifold The loaded cylinder bank will continue to operate fully loaded until the solenoid valve con
90. he evaporator as required For manual initiation check that the box temperature is 40 F 4 4 C or lower and press the MANUAL DE FROST key The microprocessor will displays DF on the right of the display during defrost mode The left display will contin ue to display the setpoint Defrost may be terminated in any of three ways timer initiation air switch initiation and manually Refer to Section 3 1 6 for a more detailed description of the defrost cycle 62 10828 2 4 10 Functional Parameters NOTE If configuration CNF11 is ON functional pa rameters are locked out and the ability to change functional parameters from keypad is disabled The Function Parameters control selected operating features of the unit These parameters can be displayed by pressing the FUNCTION CHANGE key When multi ple choices are available the display will show the func tion description on the left side with the corresponding function choice on the right side The list can be scrolled through by pressing the FUNCTION CHANGE key or by using the ARROW keys With each FUNCTION CHANGE key push the list is advanced one If the FUNCTION CHANGE key is pressed and held for one second the list will scroll at a rate of one item every 0 5 seconds Once the end of the list is reached the list will scroll back to the first entry With a function parameter displayed the data choice can be changed by pressing ENTER then pressing ei ther the up
91. her configurations as required When finished turn the RUN STOP Switch to the STOP position then back to the RUN position to start the unit 4 21 4 22 CONTROLLER SENSOR CHECKOUT An accurate ohmmeter must be used to check resis tance values shown in Table 4 5 Dueto variations and inaccuracies in ohmmeters ther mometers or other test equipment a reading within 296 of the chart value would indicate a good sensor If a sensor is bad the resistance reading will usually be much higher or lower than the resistance values given in Table 4 5 At least one lead from the sensor RAS terminals D1 and E1 or SAS terminals D2 and E2 must be discon nected from the unit electrical system before any read ing is taken Not doing so will result in a false reading Two preferred methods of determining the actual test temperature at the sensor is an ice bath at 32 F 0 C or a calibrated temperature tester 62 10828 CONFIGU RATION Short glow cycle 650 750 850 and 950 Prior to S N YY0000 i These settings are optional and can be set to cus i tomer specifications or left at default values All oth er settings not marked with MUST be set as shown for proper unit operation Long glow cycle All other units 1 CNF1 determines the length ofthe glow cycle SA AA AA EF EF EF EF which varies depending on the type of engine CDT not used 850 Only i in the
92. hylene glycol water mix standard or extended life antifreeze Oli c 7 8 U S quarts 7 4 liters Without Bypass il Capaci ii 8 8 U S quarts 8 3 liters With Bypass 650 2200 to 2250 rpm Operating 750 Prior to Serial Number KFW90913748 2200 2250 Beginning with Serial Number KFW90913748 2400 2450 Speeds 850 2300 to 2350 rpm 1800 to 1850 rpm Injection Setting 1991 to 2133 psi 135 to 145 Bars ORO Closes at 18 3 psig 1 22 0 2 Bar Glow Plug 1 4 ohms at 11 volts Fuel Heater Ther Closes on temperature falls at 45 6 5 F 7 2_ 1 17 C mostat Opens on temperature rise at 75 6 5 F 24 1 17 C Table 1 8 Engine Data For Supra 950 CT3 69TV D1105 68 5 in 1123 cc No Cylinders 20hp 14 9kW 9 2400rpm Weight 214 Ibs 97 kg 4 5 quarts 4 3 liters Use 50 50 to 60 40 ethylene glycol water mix standard or extended life antifreeze Oil Capacity 10 quarts 9 46 liters Operating 2200 to 2250 rpm Speeds 1800 to 1850 rpm Injection Setting 1991 to 2133 psi 135 to 145 Bars pa cei Closes at 18 3 psig 1 2 0 2 Bar Glow ig 0 9 ohms at 11 volts Fuel Heater Closes on temperature falls at 45 6 5 F 7 2 1 17 C Thermostat Opens on temperature rise at 75 6 5 F 24 1 17 C Coolant Capacity 1 13 62 10828 1 6 2 Compressor Data Displacement 12 2 in 200 cc 24 4 in 400 cc 37 in 600 cc No Cylinders No Unloaders 84 lbs 38 kg
93. ic Ol Without Bypass Oil Filter ynthetic Oil With By ass Oil Filter Bypass Oil Filter Bypass Oil Filter OIL CHANGE INTERVALS Unit Model Maximum oil drain interval is one year 12 months Mobil Delvac1 is the only approved synthetic oil Maximum oil drain interval is two years Oil filter change required once a year every 12 months 62 10828 4 2 Service C Check the engine cooling system i 2 Check and clean air filter i 3 Check all belts 4 Check all hardware and unit mount ng bolts for tightness Change lube oil and filter s Check engine cooling system Check and clean air filter Check all belts Check fuel pump filter 2 Replace air filter cartridge 3 Check battery terminals and fluid i level 4 Check compressor oil level Use i polyol ester oil POE approved by i CARRIER i9 Check alternator brushes Check in i accordance with diesel hours PLUS i standby hours 16 Check engine thermostat for proper operation i7 Check defrost Check timer setting and function e Check refrigerant control valves for proper operation Check that fans stop Check defrost ends automatically Check water drainage from evaporator 8 Check fan motor brushes i 9 Check and adjust rocker arms i 10 Replace belts as necessary i Service F1 Std i Coolant F2 Ext Life Cool rant NOTES
94. ice valve and gauge valve to vent a small amount of refrigerant through the common connection and the oil to purge the lines of air Close the gauge manifold valve Withthe unit running frontseat the suction service valve and pull a vacuum in the compressor crankcase SLOWLY crackthe suction gauge manifold valve and oil will flow through the suction service valve into the com pressor Add oil as necessary 4 9 3 Adding Oil to Service Replacement Com pressor Service replacement compressors may or may not be shipped with oil If compressor is without oil Add correct oil charge Refer to section 1 6 2 by removing the oil fill plug See Figure 4 12 4 9 4 To remove oil from the compressor 1 Close suction service valve frontseat and pump unit down to 2 to 4 psig 0 1 to 0 3 kg cm Frontseat discharge service valve and slowly bleed remaining refrigerant 2 Remove the oil drain plug from compressor and drain the proper amount of oil from the compressor Replace the plug securely back into the compressor 3 Open service valves and run unit to check oil level repeat as required to ensure proper oil level 6 CYLINDER 1 Suction Service Valve 2 Discharge Service Valve 3 OilLevel Sight Glass 4 Oil Drain Plug 5 Oil Fill Plug 6 Unloader Assembly Figure 4 12 C
95. icrons 29 90 Hg vacuum 75 9 cm Hg vacuum Turn off valves on both lines to pump 4 13 3 Fully open backseat both suction and discharge service valves 4 Remove vacuum pump lines and install manifold gauges 5 Check refrigerant level Refer to section 4 7 1 NOTE It is important to check the compressor oil level of the new compressor and fill if necessary 6 Check compressor oil level Refer to section 4 9 Add oil if necessary 7 Check refrigerant cycles 4 9 COMPRESSOR OIL LEVEL 4 9 1 Checking Oil Level 1 Operate the unit in high speed cooling for at least 20 minutes 2 Check the oil sight glass on the compressor to en sure that no foaming of the oil is present after 20 min utes of operation If the oil is foaming excessively af ter 20 minutes of operation check the refrigerant system for flood back of liquid refrigerant Correct this situation before performing step 3 3 Check the level of the oil in the sight glass with the compressor operating The correct level should be between bottom and 1 4 of the sight glass If the level is above 1 4 oil must be removed from the compres sor To remove oil from the compressor follow step 4 9 4 If the level is below sight glass add oil to the compressor following 4 9 2 4 9 2 Adding Oil with Compressor in System Two methods for adding oil are the oil pump method and closed system method Oil Pump Method One compressor oil pump that may be pu
96. ier The drier is cylinder shell containing a drying agent and screen It is installed in the liquid line and functions to keep the system clean and remove moisture from the refrigerant A sight glass may also be installed down stream of the drier The sight glass is fitted with a paper element that changes color to indicate moisture content i Receiver Liquid refrigerant from the condenser drains into the receiver The receiver serves as a liquid reservoir when there are surges due to load changes in the system asa storage space when pumping down the system and as a liquid seal against the entrance of refrigerant gas into the liquid line Thereceiver is provided with two bullseye sight glasses for the observation of liquid level and a pressure relief valve 1 4 EVAPORATOR SECTION The evaporator section contains the evaporator coil expansion valve TXV heat exchanger defrost ter mination thermostat s and electrical evaporator fan motors 1 4 1 Thermal Expansion Valve The thermal expansion valve is an automatic device which controls the flow of liquid to the evaporator ac cording to changes in superheat to the refrigerant leav ing the evaporator The thermal expansion valve main tains arelatively constant degree of superheat in the gas leaving the evaporator regardless of suction pressure Thus the valve has a dual function automatic expan sion control and prevention of liquid return to the com pressor 1 4 2
97. igerant into condens er coil and receiver as follows 1 Backseat suction and discharge service valve turn counterclockwise to close off gauge connection and attach manifold gauges to valves 2 Open valves two turns clockwise Purge gauge line 3 Close the receiver outlet king valve by turning clockwise Start unit and run in high speed cooling Place RUN STOP Switch in the STOP position when unit reaches 0 1 kg cm 1 psig 4 Frontseat close suction service valve and the re frigerant will be trapped between the compressor suction service valve and the manual shutoff King valve 5 Before opening up any part of the system a slight positive pressure should be indicated on the pres sure gauge 6 When opening up the refrigerant system certain parts may frost Allow the part to warm to ambient temperature before dismantling This avoids internal condensation which puts moisture in the system 7 When service has been completed Open back seat King valve and midseat suction service valve 8 Leak check connections with a leak detector Refer to section 4 5 9 Start the unit in cooling and check for nonconden sibles 10 Check the refrigerant charge Refer to section 4 7 1 NOTE Store the refrigerant charge in an evacuated container if the system must be opened be tween the compressor discharge valve and re ceiver NOTE Whenever the system is opened it must be eva cuated and dehydrated Refer to s
98. ime choices are 10 20 30 45 or 90 minutes Minimum On Time The auto start mode Minimum On Time parameter En glish display is ON T The code display is FN3 The choice for the on time is displayed with two digits and then the capital letter M for minutes i e ON T4 M The on time choices are 1 or 4 minutes 62 10828 2 6 Controlling Probe The Controlling Probe parameter English displays are REM PROBE or SUP PROBE The code displays are FN4 A or FN4 B With REM PROBE or FN4 A displayed the microprocessor is set for operation with a single probe sensing return air temperature With SUP PROBE or FN4 B displayed the microprocessor is set for dual probe supply air or return air control Standard Units Select The Standard Unit Select parameter allows selection of English or metric data display The English display is DE GREES F or C The code display is FN5 The choices are C and F This parameter will also convert pressure readings to psig or bars Maximum Off Time The auto start mode Maximum Off Time English display is TIME START or TEMP START the code display is FNG ON or ENG OFF With TIME START or FNG ON displayed the engine will be started 30 minutes after shutdown With TEMP START or ENG OFF displayed the engine will be under normal microproces sor temperature control Diesel Backup Feature If the unit is in standby mode and AC
99. ing The microprocessor has 2 programmable maintenance hourmeter which are set via the serial port These maintenance hourmeter are compared to one of the hour meters diesel standby or switch on If the hour meter is greater than the maintenance hourmeter then the proper service alarm is triggered 4 21 MICROPROCESSOR REPLACEMENT and CONFIGURATION 4 21 1 To Remove and Replace Microprocessor Logic Board 1 Before removing the microprocessor disconnect the negative battery cable and attach a grounded wrist strap 07 00304 00 to your wrist and ground it to a good unit frame ground 2 Openthe roadside side door of the unit and loosen the 4 bolts holding the cover microprocessor onto the front of the control box 3 Unplug the ribbon cable from the logic board but leave it connected to the cab command cable 4 Take the new microprocessor from the anti static bag and install in the control box following steps 2 6 in reverse order 5 Place the removed microprocessor back into the anti static bag and part box for return NOTE BEFORE STARTING THE UNIT When replac ing a microprocessor it is important to check that the configurations are compatible with the unit into which it will be installed 4 21 2 To Reach The Configuration Fields From 1 2 The Keypad Place the unit RUN STOP Switch to the STOP position and the I O Switch in the OFF position With the unit off locate the serial port plug behind the co
100. inputs These inputs come from the temperature and pressure sensors the temperature set point the settings of the configuration variables and the function code assign ments The action taken by the operational software will change if any one of the inputs changes Overall interac tion of the inputs is described as a mode of operation The modes of operation include cooling heat and de frost Refer to Section 1 8 for a description of the refriger ant circuit If the unit is operating in AUTO START STOP a fourth mode is added This is the null mode In the null mode the unit shuts down until further cooling or heating is required The cooling mode is further divided into the perishable chill range operation and frozen range operation At setpoints above 10 F 12 C the unit will operate in the perishable range In perishable range all modes of op eration are available to the microprocessor At a set point of 10 F 12 C or below the unit will operate in the frozen range In frozen range heat is locked out and only the cool and defrost modes are available to the microprocessor Heat lockout can be overridden by set ting CNF4 to ON See Table 4 4 3 1 1 Startup and Pull Down Engine Operation At startup the unit operates in high speed heat with unloaders energized for 850 and 950 units After 45 seconds the microprocessor checks to see if City Speed is activated If City Speed is activated high speed is
101. into the receiver as outlined in step d In this case vapor charge remaining refrigerant through the suction service valve e When refrigerant cylinder weight scale indicates that the correct charge has been added close liguid line valve on cylinder and backseat the king valve Suction Valve Low Side Manifold Gauge Set Discharge Valve High Side Refrigerant Cylinder Dead Head Port Figure 4 10 Procedure for Adding A Complete Charge MAN 4 7 3 Adding A Partial Charge See Figure 4 11 Refrigerant R404a is a blend Charging as a vapor will change the properties of the refrigerant Only liquid charging through the king valve is acceptable NOTE The ambient air entering the condenser air temperature should be above 40 F 4 4 C 62 10828 a o Suction Valve Low Side Discharge Valve High Side Manifold Gauge Set Refrigerant Cylinder Dead Head Port AROS Figure 4 11 Procedure for Adding A Partial Charge Place drum of refrigerant on scale and note weight Backseat discharge and suction service valves and install a manifold gauge set in order to monitor sys tem Purge lines Connect the discharge gauge of a second manifold test set to the king val
102. ipment are provided onthe schematic diagram The microprocessor controls operation of the various relays and components by com pleting or by breaking the circuit to ground The Auto Start Sequence will begin once conditions for engine starting have been established and the Run Relay RR has been energized to provide power to the Run Solenoid RS Fuel Pump FP and Fuel Heater FH Refer to Section 3 2 1 for control circuit operation The sequence consists of three start attempts each including a predetermined period with the glow plugs energized and operation of the starter motor see Figure 3 1 Five seconds after the run relay is energized the micro processor will start the sequence by energizing the glow plug relay GPR to supply power to the glow plugs See Table 3 2 for glow times If the Manual Glow Override Function Parameter is set to NORMAL the glow time for the first start attempt will vary in duration based on engine coolant temperature as follows Table 3 2 Default Manual Glow Time Glow Time in Seconds 15 Less than 32 F 0 C 15 Engine Coolant Temperature 33 F to 50 F 1 C to 10 C 51 F to 77 F 11 C to 25 C Greater than 78 F 26 C 0 REPEAT FIRST 5 Seconds O THIRD 15 Seconds ATTEMPT STOP REPEAT FIRST 4 five seconds GLOW GLOW Starter engagement time is increased to 20 seconds when the water temperature sensor is at 32 F 0 C or below SECOND A ae
103. ir proper tension Properly adjusted belts give long lasting and efficient service Too much ten sion shortens belt and bearing life and too little tension causes slippage and excessive belt wear It is also impor tant to keep belts and sheaves free of any foreign material which may cause the belts to slip The belt tension gauge can be used to adjust all belts The readings which we specify for Carrier Transicold units are applicable only for our belts and application as the tension is dependent on the size of the belt and distance between sheaves When using this gauge it should be placed as close as possible to the midpoint between two sheaves See Figure 4 6 Standby Supra 850 amp 950 Standby Motor Supra 550 650 and 750 1 Engine to Compressor V belt 2 Alternator V belt 3 Standby Motor to Compressor V belt Figure 4 6 V Belt Arrangement The V belts must be kept in good condition with the proper tension to provide adequate air movement across the coils 62 10828 When installing any new belts preset the tension to the setting specified in the New Install Tension column After initial run in check the tension it should settle out to the setting specified in the Running Tension column If the run tension is below the Running Tension range re tighten the belt to a value within this range Refer to Table 4 2 Table 4 2 Belt Tension See Figure 4 7 X BELTS New Install Running Tension Tensio
104. is checks for residual moisture and or leaks With a vacuum still in the unit the refrigerant charge may be drawn into the system from a refrigerant con tainer on weight scales The correct amount of refrig erant may be added by observing the scales Refer to section 4 7 4 7 CHARGING THE REFRIGERATION SYSTEM Refrigerant R404A must be charged as aliq uid Refrigerant R404A is a blend Charging as a vapor will change the properties of the refrigerant 4 7 1 Checking the Refrigerant Charge D 4 7 2 Installing a b Start unit in cooling mode and run approximately ten minutes Partially block off air flow to condenser coil so dis charge pressure rises to 210 psig 14 8 kg cm2 The unit is correctly charged when the lower receiver sight glass is full and no refrigerant is in the upper receiver sight glass a Complete Charge See Figure 4 10 Dehydrate unit and leave in deep vacuum Refer to section 4 6 Place refrigerant cylinder on scale and connect charging line from cylinder to receiver outlet king valve Purge charging line at outlet valve Note weight of refrigerant cylinder Open liquid valve on refrigerant cylinder Open king valve half way and allow the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added as indicated by scales Correct charge will be found in section 1 3 62 10828 NOTE Itis possible that all liguid may notbe pulled
105. ischarge connection This difference in pressure across the piston assembly results in the pis ton assembly being shifted upward shutting the heat and defrost port opening the condenser port and allow ing refrigerant to flow to the condenser TO COMPRESSOR SUCTION SOLENOID DE ENERGIZED FROM COMPRESSOR TO CONDENSER Figure 1 10 Hot Gas Valve Cooling Flow 1 9 Heat and Defrost Operation See Figure 1 11 When the hot gas solenoid coil is energized discharge gas flows to the evaporator for heating or defrost When energized the solenoid plunger is lifted allowing dis charge gas to fill the volume above the piston assembly Discharge gas is also allowed to fill the volume below the piston assembly through the compressor discharge connection The pressure on both sides of the piston assembly is now equal and the piston spring exerts a force on top of the piston assembly and shifts it down ward The condenser port is now closed and the evapo rator port is open In both the energized and de ener gized positions the bypass of discharge gas to the suc tion port is prevented Solenoid energized compressor Figure 1 11 Hot Gas Valve Heat and Defrost Flow g Hot Gas Bypass Solenoid Valve except 950 The hot gas bypass solenoid valve HGS2 opens dur ing heating and allows the compressor to draw vapor from the top of the receiver resulting in increased heat ing capacity 62 10828 h Filter Dr
106. its designator H i e MHR 1 5040H OR CD18 5040H The display range is O to 99999 The maintenance hour meter is compared to one of the hour meters diesel standby or switch on determined by its mode If the hour meter is greater than the maintenance hour meter an alarm will be generated Maintenance Hour Meter 2 The English display for the Maintenance Hour Meter 2 is MHR 2 the code display is CD19 The data is dis played with units designator H i e MHR 2 5040H OR CD19 5040H The display range is 0 to 99999 The maintenance hour meter is compared to one of the hour meters diesel standby or switch on determined by its mode If the hour meter is greater than the maintenance hour meter an alarm will be generated Switch On Hour Meter The Switch On Hour Meter displays the total operating hours engine amp standby on the unit The English dis play for the Switch On Hour Meter is SON the code display is CD20 The data is displayed with units desig nator H i e SON 5040H OR CD20 5040H The display range is O to 99999 2 4 12 Alarm Display When an alarm is generated the display will alternate between the default display setpoint air temperature andthe active alarm s Each item will be displayed for 3 to 10 seconds and the display will continue to scroll through the items until the alarms are cleared Refer to Section 2 4 10 Alarm Reset for the procedure on reset ting alarms The fault light FL wil
107. ized when the control temperature reaches less than 2 F 1 1 C above setpoint The unloader stay energized until the control temperature reaches 2 5 F 1 4 C above setpoint c Perishable Heating Unloader Control Diesel During perishable heating the front unloader is energized when the control temperature increases to 0 9 F 0 5 C below setpoint The unloader will stay energized until the control temperature decreases to 1 5 F 0 8 C below setpoint NOTE These switch points may vary slightly depend ing on the amount of overshoot around set point Standby During perishable heating the unloader is energized when the control temperature increases to 1 5 F 0 8 C below setpoint The unloader will stay ener gized until the control temperature decreases to 2 F 1 1 C below setpoint d Frozen Unloader Control Diesel During frozen mode heating is not allowed The front unloader is energized when the control tempera ture decreases to 1 5 F 0 8 C above setpoint The unloader will stay energized until the control tempera ture reaches 2 F 1 1 C above setpoint Standby During frozen mode heating is not allowed The front unloader is energized when the control tempera ture decreases to 2 F 1 1 C above setpoint The unloader will stay energized until the control tempera ture reaches 2 5 F 1 4 C above setpoint 62 10828 Suction Pressure Control 950 Only Diesel The microprocessor will monitor sucti
108. k trailer microprocessor Although there is less danger of electrical static discharge ESD damage in the outdoor environment where the processor is likely to be handled proper board handling techniques should always be stressed Boards should always be handled by their edges in much the same way one would handle a photograph This not only precludes the possibility of ESD damage but also lowers the possibility of physical damage to the electronic components Although the microprocessor boards are fairly rugged when assembled they are more fragile when separated and should always be handled carefully 62 10828 4 20 When welding is required on the unit frame or on the front area of the trailer ALL wiring to the microprocessor MUST be disconnected When welding is performed on other areas of the trailer the welder ground connection MUST be in close proximity to the area being welded It is also a good practice to remove both battery cables before welding on either the unit frame or the truck to prevent possible damage to other components such as the alternator and voltage regulator a Replacing Key Board Should damage to the Key Board of the microprocessor occur it is possible to replace only the Key Board b Hour Meters The hour meter can be set to any value via the serial port ifthe meter has less then 5 hours on it This allows a replacement microprocessor to be set to the same hours as the microprocessor it is replac
109. l be illuminated when selected alarms are generated An alarm listing with indication of which alarms are accompanied by the fault light is pro vided in Table 2 2 A description of the alarms is pro vided in the following paragraphs Table 2 3 Alarm Display A A A ALT AUX Y No Alternator Auxiliary Output AL6 AL7 STARTER d Starter Motor Fault RA Y Return Air Sensor Fault SENSOR SA Supply Air Sensor Fault SENSOR CD A E o A A A WT Coolant Temperature Sensor SENSOR HIGH CDT Y High Discharge Temperature Discharge Temperature Sen SENSOR sor Fault SBY MOTOR Y Standby Motor Fault RAS OUT Y Main Compartment Out of Range 2RA OUT Y Remote Compartment 2 Out of Range 3RA OUT Y Remote Compartment 3 Out of Range NO POWER A AL14 BEER E AL15 AL16 AL17 AL18 AL19 AL20 A A LO L4 L5 L8 L9 L L11 L12 3 21 22 23 L L AL No AC Power When Unit Is In Standby 62 10828 Low Oil Pressure Alarm The English display for the Low Oil Pressure alarm is ENG OIL The code display is ALO This alarm is generated if the microprocessor senses low oil pressure any time after a short delay allowed at startup When this alarm is generated the fault light will illuminate and the engine will shut down High Coolant Temperature Alarm The English display for the High Coolant Temperature alarm is ENG HOT The code display is AL1 This alarm is generated ifthe
110. larm is DEFR FAIL The code display is AL6 This alarm is generated if the defrost has been terminated by the 45 minute timer The fault light will not be illuminated by this alarm Alternator Auxiliary Alarm The English display for the Alternator Auxiliary alarm is ALT AUX The code display is AL7 This alarm is generated if the alternator auxiliary signal is not present with the engine running When this alarm is generated the fault light will illuminate Starter Motor Alarm The English display for the Starter Motor alarm is STARTER The code display is AL8 This alarm is generated if the starter motor input signal is not present with starter solenoid energized When this alarm is gen erated the fault light will illuminate 62 10828 2 10 Return Air Sensor Alarm The English display for the Return Air Sensor alarm is RA SENSOR The code display is AL9 This alarm is generated if the return air sensor is open or shorted If the microprocessor is set to allow operation on a sec ond sensor it will switch control to that sensor If the unit is not fitted with a second sensor or if the microproces sor is not set to allow control on the second sensor one of two actions will be taken 1 If the unit is operating in the perishable range the unit will shut down Ifthe unit is operating in the frozen range the unit will Switch to low speed cool When this alarm is generated the fault light wi
111. ll illumi nate Supply Air Sensor Alarm The English display for the Supply Air Sensor alarm is SA SENSOR The code display is AL10 This alarm is generated if the supply air sensor is open or shorted This alarm will be disabled ifthe REM PROBE FN4 A is selected in the controlling probe functional parameter The fault light will not be illuminated by this alarm Coolant Temperature Sensor Alarm The English display for the Coolant Temperature Sen sor alarm is WT SENSOR The code display is AL 11 This alarm is generated if the coolant temperature sen Sor is open or shorted The fault light will not be illumi nated by this alarm Compressor Discharge Temperature Alarm The English display for the Compressor Discharge Tem perature alarm is HIGH CDT The code display is AL12 This alarm is generated if the microprocessor senses discharge temperature above 310 F 155 C for 3 minutes When this alarm is generated the fault light will illuminate If the discharge temperature exceeds 350 F 177 C the fault light will illuminate and the engine will be shut down immediately Compressor Discharge Temperature Sensor Alarm The English display for the Compressor Discharge Tem perature Sensor alarm is CD SENSOR The code dis play is AL13 This alarm is generated if the sensor is open or shorted The fault light will not be illuminated by this alarm Standby Motor Overload Alarm The English display f
112. locked out The unit will be brought to low speed and the following operations will all take place in low speed Also the unit is locked in cooling during the oil pressure delay If heating is required the unit will switch to heating after the oil pressure delay time has expired If City Speed is not activated the unit will remain in high speed heat or cool for the selected minimum run time Function Code FN3 As box temperature is reduced the microprocessor will switch to low speed at 2 2 F 1 2 C above set point The microprocessor will switch from cool to heat at set point If box temperature rises when in low speed pull down the microprocessor will switch back to high speed at 2 7 F 1 5 C above set point After completing the pulldown switching points are no longer at a fixed temperature point The microprocessor will monitor the rate of temperature reduction or in crease and switch operation as required to limit over shoot This greatly increases the accuracy of the micro processor The microprocessor will continue to monitor changes in temperature and switch the unit between high speed cool low speed cool low speed heat and high speed heat as required to maintain desired temperature If AUTO START STOP is activated the microprocessor will add a null mode at or near setpoint and shut down the unit when conditions allow See Figure 3 3 The microprocessor will monitor temperature while in the null mode and restar
113. manual These recommended precautions must be understood and applied during operation and maintenance of the equip ment covered herein A WARNING Beware of unannounced starting of the engine standby motor evaporator fan or condenser fan The unit may cycle the engine standby motor or fans unexpectedly as control requirements dictate A WARNING Under no circumstances should ether or any other starting aids be used to start engine A WARNING Make sure the power plug is clean and dry before connecting to any power source Do not attempt to connect or remove power plug or perform service and or maintenance before en suring the unit RUN STOP Switch is in the STOP position and the I O switch is in the O position A WARNING Beware of V belts and belt driven components as the unit may start automatically Before servicing unit make sure the Run Stop switch is in the STOP position Also disconnect the negative battery cable A WARNING Do notuseanitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 psi 160 bar Do not use oxygen in or near a refrigerant system as an explosion may occur A WARNING Since refrigerant traps a certain guantity of oil to avoid oil loss during maintenance add 50 cc of POE oil to the refrigeration system when any evacuation is performed A WARNING Ensure powerto the unitis OFF and power plug is disconnected or vehicle engine is OFF and nega tive battery cabl
114. mulation of oil within the tank To Comp esson suction From evaporator gt Oil return orifice Figure 1 9 Accumulator e Compressor Pressure Regulating Valve CPR This adjustable regulating valve regulates the suction pressure entering the compressor The suction pres sure is controlled to avoid overloading the electric motor or engine during high box temperature operation f Hot Gas Solenoid Valve Three Way Valve The Hot Gas Valve HGS1 directs flow of refrigerant through the system With the solenoid coil de energized the valve is in the cool mode and the compressor dis charge gas is delivered to the condenser In the cool mode heat is removed from the air inside the truck body and rejected to the surrounding air With the solenoid coil energized the valve is in the heat mode and the compressor discharge gas is diverted to the evaporator In the heat mode heat is removed from the air surround ing the truck body and rejected to the air inside the truck body A description of valve operation is provided in the following sub paragraphs Cooling Operation See Figure 1 10 With the solenoid coil de energized the valve is in the cool operating mode and the refrigerant gas is diverted to the condenser The volume directly above the piston assembly is open to suction pressure through the exter nal pilot connection and the volume underneath the pis ton assembly is open to discharge pressure through the compressor d
115. n ft Ibs ft Ibs i Standby Motor to i Compressor 80 to 90 Figure 4 7 Belt Tension Gauge Part No 07 00203 4 2 2 Alternator V Belt a Make sure negative battery terminal is disconnected b Place V belt on alternator sheave and driving pulley C Pivot alternator to place tension on belt using hand force only Do not use pry bar or excessive force as it may cause bearing failure For correct belt tension see Table 4 2 Tighten pivot and adjustment bolts 4 2 3 Water Pump Belt Tensioner Water pump belt is driven by the diesel engine crank shaft pulley The automatic belt tensioner ensures the correct tension To change the water pump belt proceed as follows a To compress the tensioner spring place a threaded bolt or rod into hole and turn clockwise This will draw the spring up and slacken V belt for easy removal b After replacing V belt remove the bolt to release the spring to return the idler to it s correct tension 4 2 4 Standby Motor Compressor V Belt a Remove alternator V belt Refer to Section 4 2 2 b Loosen the V belt idler securing bolt 22mm c Replace V belt and alternator V belt Position the idler to correct belt tension Tighten the idler retaining bolt 4 2 5 Engine Compressor V Belts a To allow for easy removal installation and adjustment of the V belts it is recommended that the muffler be dis connected from the muffler bracket and moved b Remove alternator V belt Refe
116. n Of The Defrost Air Switch 4 16 Checking Compressor Oil Level 4 13 Checking the Refrigerant Charge 4 11 Clutch Assembly 1 6 Code vs English Messages 2 7 Compartment 2 Air Temperature 2 9 Compartment 2 Setpoint 2 6 Compartment 3 Air Temperature 2 9 Index 1 Compartment 3 Setpoint 2 6 Compressor 1 7 Compressor Data 1 14 Compressor Discharge Temperature 2 8 Compressor Discharge Temperature Alarm 2 10 Compressor Discharge Temperature Sensor Alarm 2 10 Compressor Pressure Regulating Valve CPR 1 8 1 14 4 18 Compressor Unloader 1 7 4 15 Condenser Subcooler 1 8 Condensing Section 1 6 Condensing Section Refrigeration System 1 7 Configuration Of Microprocessor 4 20 Control Logic 3 1 Controller 4 20 Controller Sensor Checkout 4 21 Controlling Probe 2 6 Coolant Temperature Sensor Alarm 2 10 Cooling Operation 1 9 Cooling System 4 4 D Defective Glow Plug 4 7 Defrost Air Switch Initiation 3 2 Defrost Air Switch Setting 1 14 Defrost Cycle 2 5 Defrost Interval 2 6 Defrost Override Alarm 2 10 Defrost Thermostat 1 14 Defrost Timer 1 14 Defrost Timer Initiation 3 2 Diesel Engine 5 1 Digital Display 2 3 Display Alarm 2 11 Drive Equipment 1 6 Dual Probe Operation 3 2 62 10828 E Electric And Water Heat 1 10 Electrical Box 1 4 Electrical Data 1 15 Engine Air Cleaner 4 5 Engine Data 1 12 Engine Drive 3 5 Engine Hours 2 8 Engine Temperature
117. nal parameter Ambient Temperature The English display for Ambient Air Temperature is ATS the code display is CD7 The English units are designated by an F following the reading i e ATS 85 0F or CD7 85 0F while the metric are designated by a C i e ATS 29 4C or CD7 29 4C The display range is 36 F to 158 F 38 C to 70 C EVP Future Expansion This unit data is not used at this time The English dis play is EVP The code display is CD8 Compressor Discharge Temperature The English display for Compressor Discharge Temper ature is CDT the code display is CD9 The English units are designated by an F following the reading i e CDT 185 0F or CD9 185 0F while the metric are desig nated by a C i e CDT 85 0C or CD9 85 0C The display range is 40 F to 392 F 40 C to 200 C Battery Voltage The English display for Battery Voltage is BATT the code display is CD10 The reading is displayed the capital letter V for volts i e BATT 12 2V or CD10 12 2V The voltage reading is displayed with a 4 plus sign ifthe battery status is acceptable for shut down and auto start mode Standby Hours The English display for Standby Motor Hours is SBY the code display is CD11 The data is displayed with units designator H i e SBY 5040H OR CD11 5040H The display range is O to 99999 MOD V Future Expansion This unit data is not used at this time
118. ng aids be used to start en gine 3 Use the MANUAL GLOW CRANK Switch to start the unit Refer to Table 2 1 for required glow times 62 10828 2 4 Table 2 1 Manual Glow Time Engine Coolant Temperature ud za Less than 32 F 0 C e Enter Set Point and change Functional Parameters to match the requirements of the load 2 4 5 Pre Trip Pre Trip is atest sequence that the operator may initiate to check unit operation During Pre Trip the micropro cessor operates the unit in various modes allowing eval uation of unit operation If a failure occurs during Pre Trip the microprocessor will generate an alarm The following steps detail the sequence a The unitis operated to bring box temperature below 40 F 4 4 C b The operator presses the PRETRIP key If the de frost thermostat DTT is closed the microprocessor will display PPPP and the test is started If DTT is open the test will end c After 30 seconds in high speed cool unit cycles to low speed loaded cool d After 30 seconds unit cycles to low speed unloaded cool e After 30 seconds unit cycles to low speed unloaded heat f After 30 seconds unit cycles to low speed loaded heat After 30 seconds unit cycles to high speed heat and displays coolant temperature h After 30 seconds unit cycles to high speed cool and displays the defrost interval selection for 30 seconds then unit cycles to defrost if DTT is closed i After
119. nnect linkage rod item 8 from solenoid Remove mounting hard ware and solenoid 3 Attach linkage to new solenoid and install the clip item 5 to the linkage rod Install the replacement solenoid and mounting hardware loosely Connect the ground wire and spring 4 Energize the solenoid with a jumper wire connected to a battery Slide the solenoid far enough back on the bracket to set the engine speed lever against the stop Tighten solenoid mounting hardware 5 Check engine speed Speed may be verified using a strobe Carrier Transicold P N 07 00206 6 Disconnectthe jumper wire and start the engine The engine is in low speed Refer to section 1 6 for engine speed Reconnect the jumper wire to ener gize the solenoid The engine should increase to high speed If engine speed is not correct engine le ver against stop stop engine and move the solenoid forward slightly Repeat procedure if adjustments need to be made 7 When operating correctly tighten solenoid mounting hardware and reconnect the positive wire 8 If adjustment is not achieved by doing step 6 stop engine and remove linkage from solenoid Remove boot item 10 from solenoid and pull solenoid shaft out far enough to loosen jam nut on solenoid shaft Energize solenoid for maximum force pull and then turn shaft clockwise to shorten 9 De energize solenoid tighten shaft jam nut and re place boot Connect linkage and repeat steps 5 and 6 4 1 4 Engin
120. ns to increase heat transfer therefore heat is removed from the air circulated through the evaporator This cold air is circu lated throughout the truck to maintain the cargo at the desired temperature The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize This low temperature low pressure vapor passes through the suction line liquid line heat exchanger where it absorbs more heat from the high pressure high temperature liquid and then returns to the accumulator The compressor draws this vapor out of the accumula tor through a pick up tube which is equipped with a metering orifice This orifice prevents the accumulation of oil in the accumulator tank The metering orifice is calibrated to control the rate of oil flowing back to the compressor The vapor refrigerant then enters the compressor pres sure regulating valve CPR which regulates refrigerant pressure entering the compressor where the cycle starts over 1 8 2 Heat And Defrost See Figure 1 13 When refrigerant vapor is compressed to a high pres sure and temperature in a reciprocating compressor the mechanical energy necessary to operate the com pressor is transferred to the gas as it is being com pressed This energy is referred to as the heat of com pression and is used as the source of heat during the heating cycle When the controller calls for heating or defrost the hot gas valve solenoid energizes cl
121. ntinu ous Run If the setpoint is outside this range either Start Stop or Continuous Run can be selected The maximum setpoint and function lock are controlled via a combination of CNF3 and CNF11 550 650 750 and 850 Out of range alarm only Out of range alarm and unit shut down CNF11 OFF CNF3 OFF Maximum se point 86 F 30 C No function lock Standby Diesel Backup is disabled CNF11 ON CNF3 OFF Maximum se point 86 F 30 C Standard function lock Enables Standby Diesel Backup Functions changes normal i CNF11 OFF CNF3 ON Maximum se A m point 90 F 32 2 C EN No function lock Functions amp Start Stop locked CNF11 ON CNF3 ON Maximum se point 90 F 32 2 C Modified function lock 550 650 750 and 850 Only 950 Only All units i4 CNF20 allows the Fahrenheit Celsius func i tion to be locked In order to change the units setting CNF20 must be OFF The units set al h ting can then be changed in the functional pa Do Not Turn On rameters list If CNF20 is ON the units setting E WA EE i cannot be changed from the functional pa i rameters list Do Not Turn On 62 10828 4 22 It Aux alarm shuts unit down Rev 3 20 and higher only Rev 3 20 and higher only Rev 3 23 and higher only Rev 3 29 and i Rev 3 29 and higher only CNF6 Must be ON
122. ntrol panel Remove the protective cap to gain access to the wire terminals Place an insulated jumper wire between wires SPA and SPB at the serial port plug Caution Do not allow this wire to touch any ground Place the unit RUN STOP Switch to the RUN position and the I O Switch in the ON position The FAULT light will come on and the micro display will read CNF1 TV or CNF1 DI Remove the jumper wire from the serial port and reinstall the protective cap The configuration screen will now remain available for five minutes Scroll through the configuration list using the FUNCTION key and compare the settings with those shown in the table on the following page If any of the configurations need to be changed continue with step 4 below To change the configuration selection refer to Table 4 4 A Bring the configuration to be changed onto the display Press the ENTER key to allow change access to the displayed configuration Press either the UP or DOWN keys to display available selections for that configuration Leave the correct selection on the screen The selection display will flash warning the operator that the displayed value has not been entered Press the ENTER key to enter the new selection into memory The display will revert to the original selection if no further action is taken for the next five seconds Continue to scroll through the configuration list by pressing the FUNCTION key Change any ot
123. ocessor Should a problem develop with the microprocessor contact your nearest Carrier Transicold dealer for replacement 44 CAUTION Refrigerant R404A must be charged as a liquid Refrigerant R404A is a blend Charging as a vapor will change the properties of the refrigerant 62 10828 Safety 4 SECTION 1 DESCRIPTION 1 1 INTRODUCTION This manualcontains operating data electrical data and service instructions for the Carrier Transicold Supra model truck refrigeration units listed in Table 1 1 4h WARNING Additional Supra support manuals are listed in Table 1 2 Beware of unannounced starting of the The model serial number plate is located inside the unit engine standby motor evaporator fan or on the frame as shown in Figure 1 2 condenser fan The unit may cycle the engine standby motor or fans unexpectedly as control requirements dictate Table 1 1 Model Chart REFRIGERANT STANDBY R 404A COMPRESSOR MOTOR 5 9h CT2 29TV 4 4 kW 05K 012 2 Cylinder 76h 5 7 kW CT3 44TV 05K24 8 3 hp 4 Cylinder 6 2 kW 05637 14 8 hp CT3 69TV 6 Cylinder 11 kw Table 1 2 Additional Support Manuals Equipment Covered Supra 550 Supra 650 750 MODEL Supra 550 TDB 13 Supra 550 TDS 13 Supra 650 TDB 16 Supra 650 TDS 16 Supra 750 TDB 19 Supra 750 TDS 19 Supra 850 TDB 24 Supra 850 TDS 24 Supra 950 TDB 36 Supra 950 TDS 36 3 4 5 9 5 9 3 _ r e D 62 11052 Compressor 05G Twinport Operation and
124. oled by a radiator which is integral with the refrigerant condenser The cooling system is fitted with a coolant overflow reservoir Engine air cleaners are dry type b Clutch Assembly The clutch assembly is mounted on the engine crank shaft All units have centrifugal type clutches c Standby Motor The standby motor operates on nominal 460v 3ph 60Hz or 230v 3ph 60Hz power An overload and short cycle protection is provided along with auto matic reset Units are also equipped with a remote mounted power receptacle d Alternator Regulator 44 CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precau tionary measure disconnect positive bat tery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator The alternator supplies power for operation of the sys tem controls evaporator fan motors and for charging of the unit battery if equipped The alternator converts mechanical and magnetic ener gy to alternating current AC and voltage by the rota tion of an electromagnetic field rotor inside a three phase stator assembly The alternating current and volt age is changed to direct current and voltage by passing AC energy through a three phase full wave rectifier system Six silicon rectifier diodes are used The regulator is an all el
125. ompressor 62 10828 4 14 4 10 COMPRESSOR UNLOADER VALVE 850 and 950 only The compressor unloader located on the compressor cylinder head is controlled by relay UFR and the tem perature controller a Checkout Procedure 1 Connect manifold gauges to the compressor suction and discharge service valves and start unit in cooling with the trailer temperature at least 5 F 2 8 C above set point and the compressor will be fully loaded unloader coil de energized Note suction pressure 2 Remove wiring from the unloader coil Place electri cal tape over wire terminals 3 Set controller upscale cooler to warmer This me chanically simulates falling temperature Approxi mately 2 F 1 1 C below box temperature the un loader coil will energize Note suction pressure a rise of approximately 3 psig 0 2 Bar will be noted on the suction pressure gauge 4 Reconnect wiring on the unloader 5 Reversethe above procedure to check out compres sor loading Suction pressure will drop with this test NOTE If any unloader coil energizes and the suction pressure does not change the unloader as sembly must be checked b Solenoid Coil Replacement NOTE The coil may be removed without pumping the unit down 1 Disconnect leads Remove retainer Lift off coil See Figure 4 13 2 Verify coiltype voltage and frequency of old and new coil This information appears on the coil housing 3 Place new coil over enclosin
126. on pressure of the refrigeration system and ambient temperature and con trol the unloader to maintain a maximum operating pres sure based on these two values via a pressure trans ducer For each operating mode high speed engine low speed engine standby a specific varipower equation exists For a given ambient temperature if the suction pressure is below the equation value the compressor will run on all cylinders If not two cylinders will be unloaded The unloader is energized during engine or standby motor start a At ambient temperatures of 90 F 32 2 C or below When the system is operating at high speed andthe suction pressure drops below 33 psig the front bank is loaded When the system is operating at low speed and the suction pressure drops below 35 psig the front bank is loaded b At ambient temperatures of 90 F 32 2 C or higher At ambient temperatures of 90 F or higher the un loading suction pressure settings relative to ambient temperatures are a straight line Refer to chart below DIESEL OPERATION SUCTION PRESSURES UNLOADING 40 LOW SPEED UF 35 30 SUCTION PRESSURE PSIG 25 AMBIENT TEMPERATURE CF UF FRONT UNLOADER ENERGIZED 62 10828 Standby At ambient temperatures of 90 F 32 2 C or below When the system is operating and the suction pres sure drops below 26 psig the front bank is loaded At ambient temperatures of 90 F 32 2 C or higher At am
127. or 2 4 4 c Pre Trip Inspection After Starting After starting engine check the following points Check electric fuel pump Check fuel lines and filters for leaks Check oil lines and filters for leaks Check coolant hoses for leaks Check exhaust system for leaks Check condenser and evaporator fans for proper air flow Initiate Pre Trip and monitor all operating modes Check unloader operation 850 and 950 After operating unit 15 minutes or more Check water temperature Should be 160 to 175 F 72 to 80 C 9 Check refrigerant level Refer to section 4 7 10 Check compressor oil level Refer to section 4 9 11 Put unit into manual defrost and monitor Allow unit to terminate defrost automatically 12 Change over to desired operating mode enter set point and change functional parameters as required to match the requirements of the load oak WN d 8 62 10828 2 4 2 Starting Road Operation Place the I O Switch in the I position If the unit has been used previously in the standby mode press the road operation button Under normal circumstances this is all that is required to start the unit The unit will then perform a complete diagnostic check on the micropro cessor controller pre heat for the required amount of time based on the engine temperature and start auto matically 2 4 3 Starting Standby Motor Drive 44 WARNING Make sure the power plug is clean and dry before connecting
128. or the Standby Motor Overload alarm is SBY MOTOR The code display is AL14 This alarm is generated if the MOL is open and the diesel electric relay is energized indicating standby mode Fuse Alarm The English display for the Fuse alarm is FUSE BAD The code display is AL15 This alarm is generated when the FUSE input is sensed low When this alarm is generated the fault light will illuminate 2 System Check Alarm The English display for the System Check alarm is SYSTEM CK The code display is AL 16 This alarm is generated when refrigerant system pressure is low The fault light will be illuminated by this alarm Display Alarm The English display for the Display alarm is DISPLAY The code display is AL17 This alarm is generated when no communications exist between the main board and the display The fault light will not be illuminated by this alarm Maintenance Hour Meter 1 Alarm The English display for the Maintenance Hour Meter 1 alarm is SERVICE 1 The code display is AL18 This alarm is generated when the designated hour meter is greater than maintenance hour meter 1 The fault light will not be illuminated by this alarm Maintenance Hour Meter 2 Alarm The English display for the Maintenance Hour Meter 2 alarm is SERVICE 2 The code display is AL19 This alarm is generated when the designated hour meter is greater than maintenance hour meter 2 The fault light will not be
129. osing the port to the condenser and opening a port which allows heated re frigerant vapor to flow through the drainpan heater tube to the evaporator coil The hot gas bypass solenoid valve not on 950 also opens during heating to provide additional refrigerant to the compressor from the receiver This increases the amount of refrigerant in circulation increasing heating capacity The main difference between heating and defrosting is that when in heating all the evaporator fans continue to run blowing the air over the heated coils to heat the product When defrosting the evaporator fans stop allowing the heated vapor to defrost any ice build up there maybe The bypass line draws refrigerant from the receiver and injects it through a metered valve into the suction line past the compressor pressure regulator valve This will raise the discharge pressure and temperature 62 10828 FILTER DRIER HOT GAS BYPASS SOLENOID VALVE HGS2 DRAIN PAN HEATER o D RECEIVER VALVE CHECK VALVE RECEIVER HEAT HOT GAS EXCHANGER VALVE HGS1 SUBCOOLER COMPRESSOR PRESSURE DISCHARGE REGULATOR SERVICE VALVE VALVE LO Sie CONDENSER METERING 850 ONLY ORIFICE d rc i
130. p 2 4 Pre Trip Inspection 2 3 Pre Trip Inspection Starting 2 3 Pre Trip Inspection Before Starting 2 3 Pumping The Unit Down 4 10 R Receiver 1 10 Refrigerant Charge 1 14 Refrigerant Circuit 1 17 Refrigerant Leak Checking 4 10 Refrigeration 5 3 Refrigeration System Data 1 14 Relay Identification 1 5 Remote Air Temperature 2 8 Remote Compartment 2 Out Of Range Alarm 2 11 Remote Compartment 3 Out Of Range Alarm 2 11 Removing The Refrigerant Charge 4 10 Replacing Key Board 4 20 Replacing The Compressor 4 13 Replacing The Speed And Run Control Solenoids 4 5 Return Air Sensor Alarm 2 10 Return Air Temperature 2 8 Road Operation 1 6 Index 3 INDEX S Safety Precautions Safety 1 Safety Devices 1 16 Safety Summary Safety 1 Sensor Resistance 4 24 Sequence Of Operation 3 5 Serial Number Low 2 9 Serial Number Upper 2 9 Servicing And Adjusting V Belts 4 8 Setpoint 2 4 Software Revision 2 9 Speed Control 2 6 Standard Units Select 2 6 Standby 3 6 Standby Hours 2 8 Standby Motor 1 6 1 15 Standby Motor Overload 1 15 Standby Motor Overload Alarm 2 10 Standby Motor Compressor V Belt 4 9 Standby Operation 1 6 Start Failure Alarm 2 10 Start Stop Operation 2 5 Starter Motor Alarm 2 10 Starting Standby Motor Drive 2 4 Startup And Pull Down 3 1 Startup And Pull Down Engine Operation 3 1 Stopping Instructions 2 11 Suction Pressure
131. pment covered herein The general safety notices are presented in the following three sections labeled First Aid Operating Precautions and Maintenance Precautions A listing of the specific warnings and cautions appearing elsewhere in the manual follows the general safety notices SAFETY PRECAUTIONS Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind During normal operation all moving parts are fully enclosed to help prevent injury During all pre trip inspections daily inspections and problem troubleshooting you may be exposed to moving parts Stay clear of all moving parts when the unit is in operation and when the unit RUN STOP Switch RSS is in the START RUN position FIRST AID An injury no matter how slight should never go unattended Always obtain first aid or medical attention immediately OPERATING PRECAUTIONS Always wear safety glasses Wear hearing protection as required Keep hands clothing and tools clear of the evaporator and condenser fans No work should be performed on the unit until all circuit breakers and the RUN STOP Switch are turned off and battery power supply is disconnected Always work in pairs Never work on the equipment alone In case of severe vibration or unusual noise stop the unit and investigate MAINTENANCE PRECAUTIONS Beware of unannounced starting ofthe unit This unit is equipped with Auto Start in both the road and standby modes os unit ma
132. power is lost for five minutes or more the diesel engine will start and run until AC power is restored and applied for five minutes The ROAD icon will blink once every second while the PLUG icon will stay on constantly to indicate that this feature is active When the five minute shutdown timer expires and AC power is present the unit will shut down the diesel en gine and restart the standby motor If AC power is NOT present the diesel engine will operate If the unit is set to TEMP START the standby diesel back up feature will be turned off and the unit will operate in normal standby mode MOP STD Future Expansion Used to add or subtract 5psig 0 34 Bar to unloader equations English display is MOP STD The code display is FN7 Compartment 2 Setpoint N A English display is 2SET The code display is FN8 Compartment 3 Setpoint N A English display is 3SET The code display is FN9 Auto Manual Start Operation The English displays for Auto Manual Start Operation are AUTO OP and MAN OP The code displays are FN10 ON and FN10 OFF With AUTO OP or FN10 ON displayed the unit will be in the Auto Start Stop Operation mode With MAN OP or FN10 OFF dis played the unit will be in the Manual Start mode To start the unit in manual start mode the Auto Start Stop Continuous Run selection must be in continuous run mode Out of Range Tolerance NO
133. put cir cuitry to interface with the unit controls b The Relay Board contains replaceable relays diodes and fuses 12 13 14 15 SETPOINT FUNCTION c The Cab Command is remote mounted in the truck The Cab Command includes the LCD display and keypad The keypad and display serve to provide user access and readouts of microprocessor infor mation The information is accessed by keypad selections and viewed on the display The Carrier Transicold Microprocessor System incorpo rates the following features a Control supply or return air temperature to tight limits by providing refrigeration control heat and defrost to ensure conditioned air delivery to the load b Default independent readouts of set point at the left of the display and actual supply or return air temper ature at the right Digital readout of unit data points such as pressures temperatures and other microprocessor inputs d Digital readout of selectable operating parameters Function Codes and the ability to change those set tings e Digital display of Alarm Indications f A self test check on program memory and data memory at start up Oo BOX TEMPERATURE ENTER STANDBY 1 Unit Data Key 7 Manual Defrost Key 14 Defrost Mode 2 Auto Start Stop 8 City Speed Key 15 Road Mode Continuous Run Key 9 Road Key 16 Auto Start Stop Mode 3 Pretrip Key 10 Function Key 17 Stand by Mode 4 Stand by Key 11 1 0 Switch 18 City Sp
134. r high and low speed heating as necessary to main tain the desired temperature Units also have a auto start stop feature Auto start stop operation provides automatic cycling of the diesel en gine or standby motor which in turn offers an energy efficient alternative to continuous operation 1 5 1 Switches And Controls Manual control switches are located on the side of the electrical box Components required for monitoring and controlling the diesel engine and refrigeration system are located on the engine compressor or system piping 1 RUN STOP Switch RSS This switch controls the supply of power to the micropro cessor and cab command The switch is placed in the ON position to allow manual or automatic unit operation With the switch in the OFF position the unit will be shut down and neither manual or automatic starting is al lowed 2 Manual Glow Crank Switch MGC If Equipped Ifthe unit is equipped with a Manual Glow Crank Switch it is a three position switch This switch is held in the GLOW position to energize the glow plugs and pre heat the combustion chamber The switch is moved to the CRANK position to manually engage the engine starter When the switch is released it returns to the middle position to de energize both components 3 Oil Pressure Safety Switch OP This switch will automatically stop the engine upon loss of oil pressure The switch is located on the side of the engine 4 Water Temperature S
135. r to Section 4 2 2 c Remove the standby motor compressor V belt Refer to Section 4 2 4 d Loosen belt idler bolt 24 mm Move idler to remove V belts e Replace V belts Position the idler to the correct belt tension Tighten the idler retaining bolt 4 3 INSTALLING MANIFOLD GUAGE SET A manifold gauge hose set is required for service of models covered within this manual The manifold gauge hose set is available from Carrier Transicold Carrier Transicold P N 07 00314 00 which includes items 1 through 4 Figure 4 8 To perform service using the manifold gauge hose set do the following 4 3 1 Preparing Manifold Gauge Hose Set For Use a If the manifold gauge hose set is new or was exposed to the atmosphere it will need to be eva cuated to remove contaminants and air as follows b Connect high and low side hoses to blank connec tions on back of manifold gauge set and midseat both hand valves c Connect the yellow hose to a vacuum pump and an R 404a cylinder d Evacuate to 10 inHg 254mmHg and then charge with R 404a to a slightly positive pressure of 1 0 psig 0 07 Bar e Front seat both manifold gauge set hand valves and disconnect from cylinder The gauge set is now ready for use 4 3 2 Connecting Manifold Gauge Hose Set To connect the manifold gauge hose set for reading pressures do the following a Remove service valve stem cap and check to make sure it is backseated Remove access valve cap
136. rapidly but it takes time for the product temperature to change 3 2 SEQUENCE OF OPERATION 3 2 4 Engine Drive Refer to SECTION 6 for a schematic diagram of the unit controls To facilitate location of the components re ferred to in the written text the schematic has map coordinates added to the margins These locations have also been added to the legend In order to provide complete information the following description is writ ten as if all options are installed Indications of specific unit applicability and optional equipment are provided onthe schematic diagram The microprocessor controls operation of the various relays and components by com pleting or by breaking the circuit to ground Tostartthe unit place the the RUN STOP Switch RSS in the RUN position and the cab command 1 0 Switch in the ON position Operation of the control circuit is the same for microprocessor or manual start except on units equipped with a Manual Glow Crank Switch MGC the operator may use that switch to energize the glow plugs and crank the engine With the switches positioned the ROAD key is pressed to begin the start process Power flows from RSS through fuse F2 to the Run Control Relay RCR RCR is grounded by the microprocessor through the Door Switch Relay DSR and cab command to energize RCR The RCR contacts close to provide power to the control relays Power to the Run Relay RR is depen dent on the High Pressure Switch HPS being
137. rchased is a Robinair part no 14388 This oil pump adapts to a one U S gallon 3 785 liters metal refrigeration oil container and pumps 2 1 2 ounces 0 0725 liters per stroke when connected to the suction service valve port Also there is no need to remove pump from can after each use When the compressor is in operation the pump check valve prevents the loss of refrigerant while allowing servicemen to develop sufficient pressure to overcome the operating suction pressure to add oil as necessary Backseat suction service valve and connect oil charging hose to port Crack the service valve and purge the oil hose at oil pump Add oil as necessary 62 10828 Closed System Method In an emergency where an oil pump is not available oil may be drawn into the compressor through the suction i i service valve Since refrigerant traps a certain quantity of oil to avoid oil loss during maintenance add 50 cc of POE oil to the refrigeration sys tem when any evacuation is performed Extreme care must be taken to ensure the manifold common connection remains im mersed in oil at all times Otherwise air and moisture will be drawn into the compressor Connectthe suction connection ofthe gauge manifoldto the compressor suction service valve port and immerse the common connection of the gauge manifold in an open container of refrigeration oil Crack the suction serv
138. re 4 20 counterclockwise Ad just in 1 4 turn increments one complete turn equals approximately a seven degree change in superheat and re check superheat repeating readings until they areconsistent Ensure superheatis above mini mum tolerance 4 Replace valve if superheat cannot be adjusted to re quired setting c Replacing Expansion Valve 1 Check superheat and adjust valve if adjustable in accordance with the preceding steps If valve re quires replacement pump down the unit Refer to section 4 4 a 2 Slowly loosen the nut at the base of the valve to re lieve any remaining pressure Pull the line away from the valve sufficient to remove the orifice and strainer refer to Figure 4 20 Check condition of orifice and strainer clean as necessary If no foreign material is found then proceed with replacing the valve Retain orifice for reassembly 3 Remove insulation from expansion valve bulb and then remove bulb from suction line 4 Using inert gas brazing procedures refer to Techni cal Procedure 98 50553 00 unbraze the equalizer line and if required distributor Remove the strainer from the replacement valve and wrap in damp rags to prepare for brazing Braze replacement valve in place Install nut s orifice and strainer 5 Strap thermal bulb to suction line and insulate both It is recommended that the thermocouple required to check superheat be reinstalled at this time 6 Leak check and evacuate low
139. ressure air to re move any carbon dust in the holder This dust could prevent a good contact between the brushes and commutator d Remove the back cover of the motor and inspect the commutator If the commutator is heavily grooved polish it using fine sandpaper do not use emery cloth Wipe out any accumulation of greasy material using a clean rag dampened with solvent Reassemble the motor install new brushes and replace cap 4 15 EVAPORATOR COIL CLEANING The use of recycled cardboard cartons is increasing across the country The recycled cardboard cartons create much more fiber dust during transport than new cartons The fiber dust and particles are drawn into the evaporator where they lodge between the evaporator fins If the coil is not cleaned on a regular basis some times as often as after each trip the accumulation can be great enough to restrict air flow cause coil icing repetitive defrosts and loss of unit capacity Due to the washing action of normal defrost the fiber dust and particles may not be visible on the face of the coil but may accumulate deep within It is recommended to clean the evaporator coil on a regular basis not only to remove cardboard dust but to remove any grease or oil film which sometimes coats the fins and prevents water from draining into the drain pan Cardboard fiber particles after being wetted and dried several times can be very hard to remove Therefore several washings may be n
140. rom oil reservoir and drain engine lube oil Replace filter s lightly oil gasket on filter before instal ling and add lube oil Refer to section 1 6 1 Warm up engine and check for leaks 4 1 3 Replacing the Speed and Run Control Solenoids a Run Solenoid see Figure 4 2 Remove spring item 2 from the engine run lever 2 Disconnect wiring to solenoid Remove clip item 5 from linkage rod item 4 Remove mounting hard ware and solenoid 3 Attach linkage to new solenoid and install the clip to the linkage rod Install the replacement solenoid and mounting hardware loosely Connect the ground wire and spring 4 Energize the solenoid with a jumper wire connected to a battery Slide the solenoid far enough back on the bracket to set the engine run lever item 3 against the stop Tighten solenoid mounting hard ware 5 De energizethe solenoid Ifthe engine does not shut off repeat step 4 and adjust the solenoid forward slightly When operating correctly tighten solenoid mounting hardware and reconnect the positive wire 1 Run Solenoid 7 Spring 2 Spring Run Control Speed Control 3 Engine Run Lever 8 Linkage Rod 4 Linkage Rod Run Speed 5 Clip 9 Engine Speed Lever 6 Speed Solenoid 10 Boot Figure 4 2 Speed and Run Control Solenoids b Speed Control Solenoid see Figure 4 2 1 Remove spring item 7 from the engine speed lever item 9 2 Disconnect wiring to solenoid Disco
141. s 1 3 Unit Roadside VIEW o rras heet A A A Deets Pa OA He DR ORE a 1 3 Electrical BOX ooo A ita KE o 1 4 Relay Fuse Board With All Optional Components 1 5 70 Amp Alternator P N 30 60050 04 ae 1 7 Cylinder Head Unloaded 1 7 Cylinder Kleed Loaded se esoo LESER ine tad rd HERR ER fees 1 8 Accumulator 2 ber RR nb AED meii pb ea RR 1 8 Hot Gas Valve Cooling Flow 1 9 Hot Gas Valve Heat and Defrost Flow 1 9 Water and Electric Heat Components 000 cece nn 1 10 Refrigeration Circuit eiecti rep UD DEBDSUROLULRRSE Lenbr EP ERE HS 1 18 ERT KEE 2 1 Auto Start Sequence wannaasananansananannana 3 7 Temperature Control Sequence Continuous Mode 3 8 Temperature Control Sequence Start Stop Mode 3 9 Temperature Control Sequence Continuous Mode 3 10 Temperature Control Sequence Start Stop Mode 3 11 Coolant System i is RU Re RE RA Re seed ee eio a ecce A 4 4 Speed and Run Control Solenoids 4 5 Fuel SYSIOM roris I DELL plc LED pda e EC ELM E LEE D EAD 4 6 Electric Fuel PUMP sac tne horn Saale dah ce Eee etn Ge i eee S D
142. specific warnings and cautions appearing elsewhere in this manual They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein 44 WARNING Beware of unannounced starting ofthe fans and V belts caused by the thermostat and the start stop cycling of the unit A WARNING Under no circumstances should ether or any other starting aids be used to start engine A CAUTION Under no circumstances should anyone attempt to repair the Logic or Display Boards Should a problem develop with these components contact your nearest Carrier Transicold dealer for replacement A CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precautionary measure disconnect positive battery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator 44 CAUTION Under no circumstances should a technician electrically probe the processor at any point other than the connector terminals where the harness attaches Microprocessor components operate at different voltage levels and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could permanently damage the processor 44 CAUTION Most electronic components are susceptible to damage caused by electrical static discharge
143. ssor raises the pressure and temperature of the refrigerant and forces it into the condenser tubes The condenser fan circulates surrounding air over the outside of the condenser tubes Heat transfer is thus established from the refrigerant gas inside the tubes to the condenser air flowing over the tubes The con denser tubes have fins designed to improve the transfer of heat This removal of heat causes the refrigerant to liquefy liquid refrigerant flows from the condenser and except for the 950 through a check valveto the receiver The receiver stores the additional charge necessary for low ambient operation and for heating and defrost modes The refrigerant leaves the receiver and flows through a manual receiver shutoff valve king valve to the sub cooler The subcooler occupies a portion of the main condensing coil surface and gives off further heat to the passing air Therefrigerant then flows through a filter drier where an absorbent keeps the refrigerant clean and dry The refrigerant then flows to the Liquid suction heat exchanger Here the liquid is further reduced in temper ature by giving off some of its heat to the suction gas The liquid then flows to an externally equalized thermo static expansion valve TXV which reduces the pres sure ofthe liquid and meters the flow of liquid refrigerant to the evaporator to obtain maximum use of the evapo rator heat transfer surface The evaporator tubes have aluminum fi
144. t the unit following the same procedures used to prevent overshoot when switching to other modes The length of time the unit will remain in the null mode is also dependent on Function Code set tings Function Code FN2 will control the minimum off time after shut down Code FN3 will control the mini mum on time before the null mode can be entered again Code ENG will control the maximum off time or allow temperature based restarting Refer to Section 2 4 10 for Functional Parameter descriptions 3 1 2 Startup and Pull Down Standby Operation Operation in standby follows the same sequence as operation on the engine except the standby motor oper ates at a single speed The microprocessor will monitor changes in temperature and switch the unit between the cool mode null mode and heat mode The microproces sor will add the null mode at or near setpoint and de en ergize the motor when conditions allow 3 1 3 Null Mode Overrides When in the null mode two conditions will override nor mal microprocessor off time and or temperature control If the unit is in the Engine Drive or Standby mode and battery voltage falls below 11 volts the engine or motor will be restarted to allow the alternator to recharge the battery If the unit is in the Engine Drive mode and the engine coolant temperature drops below 34 F 1 C the engine will be restarted 62 10828 3 1 4 Dual Probe Operation The microprocessor is fitted with a connection for a
145. t to contacts to break the circuit to the engine drive controls and closes a set of contacts to allow power to the electric drive controls Power flows from RSS through fuse F2 to the Run Con trol Relay RCR RCR is grounded by the microproces sor through the Door Switch Relay DSR and cab com mand to energize RCR The RCR contacts close to provide power to the control relays Power to the Run Relay RR is dependent on the High Pressure Switch HP1 being closed If the high pressure switch is open power will not be applied to microprocessor terminal M1 and operation will not be allowed Energizing RR closes a set of contacts to supply power through the motor Overload OL to the Motor Contactor MC1 Energizing MC1 closes it s contacts to start the Standby Motor SBM On Supra 850 units power is also supplied from the DER contacts to energize the Standby Unloader Front Relay SUFR Energizing SUFR opens a set of normal ly closed contacts in the power line to the unloader preventing unloaded operation The unit will start in High Speed Heat with unloaders on and fans off After 30 seconds the unit will revert to normal temperature control Once the motor starts the alternator begins to produce power The microprocessor senses the power at termi nal L3 and it will complete the Defrost Transistor DT circuit to energize the Electric Fan Motor Relays EFMR 1 through 3 The relays close contacts to energize the Electric Ev
146. to any power source Do not attempt to connect or remove power plug or perform service and or mainte nance before ensuring the unit RUN STOP Switch is in the STOP position and the 1 0 Switch is in the O position Place the I O Cab Command and unit RUN STOP Switches in the ON position and press the STAND BY key The microprocessor will perform a self test all display messages will appear in display window Thensetpoint and boxtemperature will be displayed NO POWER will be displayed if unit is switched to STANDBY and power is not available b Enter Set Point and change Functional Parameters to match the requirements of the load 2 4 4 Manual Start a To start a unit equipped with a Manual Glow Crank Switch place the unit RUN STOP Switch in the RUN position and the I O Switch Cab Command to I position Manual operation will only function if unit is in Contin uous Mode If the AUTO START STOP indicator on the cab command is illuminated press the AUTO START STOP key to place the unit in continuous run mode indicator will not be illuminated Press the FUNCTION key until AUTO OP or MAN OP appears on the display If MAN OP appears pro ceed to step d If AUTO OP appears 1 Press the Enter key 2 Press the Up Or Down Arrow key to bring MAN OP on the display Press the Enter key To place the unit in the MANUAL START mode 44 WARNING Under no circumstances should ether or any other starti
147. trol device is ener gized and the gas bypass port is opened 1 Solenoid Valve 11 Cylinder Discharge 2 Valve Stem Valve 3 Gas Bypass Port 12 Valve Plate 4 Spring Guide 13 Cylinder Suction 5 Spring Valve 6 Piston 14 Discharge Piston 7 Piston Bypass Valve Check Valve 8 Bleed Orifice Assembly 9 Strainer 15 Discharge Manifold 10 Suction Manifold Figure 1 8 Cylinder Head Loaded 62 10828 1 8 c Condenser Subcooler The condenser is of the tube and fin type and acts as a heat exchanger in which the compressed refrigerant gas is condensed into a liquid and lowered in tempera ture Air movement over the condenser is provided by a fan mounted on the standby motor motor shell shaft A portion of the condenser is occupied by the subcooler Refrigerant leaving the receiver is passed through the subcooler where additional heat is removed Removal of this additional heat helps to ensure that only liquid refrigerant enters the thermal expansion valve d Accumulator The accumulator is a refrigerant holding tank located in the suction line between the evaporator and compres sor The purpose of the accumulator is to prevent entry of any liquid refrigerant into the compressor Refrigerant vapor leaves the accumulator outlet pipe at a point well above any liquid level thus preventing the en trance of liquid The outlet pipe is equipped with an orifice that controls oil return to the compressor and prevents accu
148. ual start mode the auto start stop continuous selection must be in continuous run mode and the Auto Manual Start Operation function parameter set to MAN OP FN10 OFF NOTE When configuration CNF11 is ON and set point is 32 to 42 F 0to5 5 C the unit is locked into continuous run The AUTO START STOP key is disabled Function Change Key The FUNCTION CHANGE key is used to display the function codes Each time this key is pressed the display will advance to the next code This key in conjunction with the ARROW and ENTER keys will allow the user to change the Function Parameters See Section 2 4 10 for more de tailed information Unit Data Key The UNIT DATA key is used to display the unit operating data This key in conjunction with the ARROW keys will allow the user to display the unit s operating data values i e coolant tem perature battery voltage etc See Section 2 4 11 for more detailed information d B City Speed Key The CITY SPEED key enables the city speed mode of operation In the city speed mode the unit will operate in low speed Each push of the key toggles the operating mode The microprocessor retains the last entered setpoint in memory even if the unit is shut down or a power failure occures The city speed indicator on the display will illuminate when the city speed mode is enabled Buzzer Off Key X The BUZZER OFF key will disable the cab Berg command buzzer When not disabled by use of
149. uction pressure Suction and discharge pressures tend to egualize when unit is operating 62 10828 Defrost air switch DA out of calibration Defrost thermostat DTT open or defective Defrost air switch DA defective Loose terminal connections Air sensing tubes defective or disconnected Microprocessor defective Loose terminal connections Defrost thermostat DTT open or defective Hot Gas three way valve malfunction Defrost relay DR defective Evaporator Clutch defective Defrost air switch DA out of adjustment Wet load Defrost thermostat DTT shorted closed Defrost air switch DA out of adjustment Quench valve malfunction Condenser coil dirty Condenser fan defective V belt broken or loose Discharge check valve restricted Noncondensibles or refrigerant overcharge Compressor valves s worn or broken Hot Gas three way valve malfunction Compressor valves s worn or broken Compressor gasket s defective Hot Gas three way valve malfunction Suction service valve partially closed King valve partially closed Filter drier partially plugged Low refrigerant charge Expansion valve malfunction No evaporator air flow or restricted air flow Excessive frost on coil Compressor valves defective Hot Gas three way valve malfunction 4 13 Replace 4 13 Tighten Check Replace Tighten Replace 5 3 11 Replace Replace 4 13 Normal Replace 4 13 Replace INDICATION REFERENCE TROUBLE POSSIBL
150. ve Connect the suction pressure hose to manifold dead head port Connect a charging line between the center tap of the second gauge set and refrigerant drum Mid seat discharge knob Open the liquid valve on drum and purge all hoses Frontseat discharge knob See Figure 4 11 Start the unit with the road compressor turning at 2400 rpm Check the sight glass to determine charge See Sec tion 4 7 1 If undercharged proceed with step d Front seat the king valve Monitor the second set of manifold gauges When the king valve pressure drops below the pressure in the refrigerant drum mid seat the manifold gauge set discharge valve and al low liquid refrigerant to flow into the system While monitoring the sight glass carefully weigh re frigerant into the system It is not possible to accu rately determine when the system is full because unit is in discharge state therefore never allow more than 1 Ib 0 45 kg of refrigerant into system at a time f After monitoring 1 Ib 0 45 kg of refrigerant into the system close the valve of the manifold gauge set connected to the king valve Open the king valve and allow the system to balance out to determine charge g Follow the procedures of Section 4 7 1 and repeat above procedure as required to clear the sight glass h Start unit and check for noncondensables 4 8 REPLACING THE COMPRESSOR Ensure power to the unit is OFF and power plug is disconnected or vehicl
151. y start at any time When performing any check of the system make certain the Emergency Switch is inthe FF position Be sure power is turned off before working on motors controllers solenoid valves and electrical control switches Tag circuit breaker and vehicle ignition to prevent accidental energizing of circuit Do not bypass any electrical safety devices e g bridging an overload or using any sort of jumper wires Problems with the system should be diagnosed and any necessary repairs performed by qualified service personnel When performing any arc welding on the unit or container disconnect all wire harness connectors from the microprocessor Do not remove wire harness from the modules unless you are grounded to the unit frame with a static safe wrist strap In case of electrical fire open circuit switch and extinguish with CO never use water AUTO START Your refrigeration unit is equipped with Auto Start in both Start Stop and Continuous Run modes The unit may start at any time A buzzer will sound for 5 seconds before the unit is started When performing any check of the refrigeration unit e g checking the belts checking the oil make certain that the RUN STOP Switch is in the OFF 0 position ENGINE COOLANT The engine is equipped with a pressurized cooling system Under normal operating conditions the coolant in the engine and radiator is under high pressure and is very hot Contact with hot coolant can cause severe

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